Construction products and method of making same

• US 20070062143A1
• Filed: 09/21/2005
• Published: 03/22/2007
• Est. Priority Date: 09/21/2005
• Status: Abandoned Application

• Current Assignee: Rafie Noushad
• Original Assignee: Rafie Noushad
• Inventors: Noushad, Rafie
• Application Number:
  US11/231,506
• Publication Number:
  US 20070062143A1
• Time in Patent Office: Days
• US Class Current: 52/426
• CPC Class Codes: B32B 13/00 Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/04 comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/104 Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/306 Resistant to heat
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: C04B 14/06 : Quartz; Sand
• CPC Class Codes: C04B 18/08 : Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 : Silica fume
• CPC Class Codes: C04B 20/0048 : Fibrous materials
• CPC Class Codes: C04B 2103/302 : Water reducers
• CPC Class Codes: C04B 2111/00586 : Roofing materials
• CPC Class Codes: C04B 2111/00603 : Ceiling materials
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/0075 : for road construction
• CPC Class Codes: C04B 2111/60 : Flooring materials
• CPC Class Codes: C04B 22/04 : Metals, e.g. aluminium used as blowing agent
• CPC Class Codes: C04B 24/16 : Sulfur-containing compounds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 38/02 : by adding chemical blowing agents
• CPC Class Codes: E04C 2/049 : completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: E04C 2/521 : serving for locating conduits; for ventilating, heating or cooling
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A highly durable and easy to use prefabricated construction product is disclosed having a cellular concrete component sandwiched between two cement boards, wherein the cellular concrete component comprises cement, fly ash, an activating agent and water, and the cement boards comprise cement, fly ash, an activating agent, sand, silica fume, a water reducer agent, a reinforcing fiber, and water.

Claims

1. A prefabricated construction product comprising a cellular concrete component sandwiched between two cement boards, wherein the cellular concrete component comprises cement, fly ash, an activating agent and water, and the cement boards comprise cement, fly ash, an activating agent, sand, silica fume, a water reducer agent, a reinforcing fiber, and water.

2. The prefabricated construction product of claim 1, wherein the activating agent comprises aerating agents, foaming agents, or both.

3. The prefabricated construction product of claim 2, wherein the activating agent comprises metal agents, non-metal agents, surfactants, or a combination thereof.

4. The prefabricated construction product of claim 3, wherein the activating agent comprises aluminum powder, polyoxyethylene alkyl ether sulfates, polyoxyethylene alkly phenyl ether sulfates or salts thereof, polyoxyethylene alkyl ether phosphates or polyoxyethylene alklyl phenyl ether phosphates or salts thereof, alkylbenzenesulfonic acids or salts thereof, alpha-olefinic-sulfonic acids or salts thereof, fatty acids or salts thereof, polyoxyethylene polyalcohol fatty acid esters, polyethylene glycol fatty acid esters, polyoxyethylene pentaerythryritol fatty acid esters and polyoxyethylene sorbitan fatty acid esters or salts thereof, ethylene glycol, hexylene glycol, ferrous sulfate heptahydrate, 2-butoxyethanol, vinsol resins, sodium lauryl sulfates, nonylphenol polyethylene glycol ether, or a combination thereof.

5. The prefabricated construction product of claim 1, wherein the cellular concrete additionally comprises a reinforcing fiber.

6. The prefabricated construction product of claim 5, wherein the reinforcing fiber comprises polypropylene, alkali-resistant glass, fiberglass, nylon, aramid, acrylic, polyethylene, polyvinyl alcohol, polyolefin, or a combination thereof.

7. The prefabricated construction product of claim 1, wherein the cement boards comprise Portland cement in an amount of from about 18% to about 40%, the fly ash in an amount of from about 40% to about 50%, the silica fume in the amount of about 3% to about 7%, the activating agent in an amount of from about 0.012% to about 40%, the sand in an amount of from about 0% to about 40%, the reinforcing fiber in an amount of from about 0.4% to about 3.2%, and the water in the amount of from about 0.005% to about 60% weight based on a combined weight of non-aqueous components.

8. The prefabricated construction product of claim 7, wherein the cement boards comprise the Portland cement in the amount of about 20%, the fly ash in the amount of about 40%, the silica fume in the amount of about 5%, the activating agent in the amount of about 30%, the sand in the amount of about 5%, the reinforcing fiber comprises polypropylene in the amount of about 1 pound/M³ and two layers of fiberglass mesh, the water reducing agent comprises a super plasticizer in an amount of from about 0.02% to about 0.6%, and the water in the amount of about 20% to about 27% weight based on a combined weight of non-aqueous components.

9. The prefabricated construction product of claim 1, wherein the cellular concrete component comprises fly ash in the amount of about 60%, cement in the amount of about 15%, the activating agent in the amount of about 21%, and water in the amount of about 20% to about 60% weight based on a combined weight of non-aqueous components.

10. The prefabricated construction product of claim 1, wherein the cellular concrete, the cement boards, or both contain additional materials to reduce cure time and increase product strength, the materials comprising lime, gypsum, plaster of Paris, sodium silicate, accelerators, and polymers in an amount of about trace to about 4% weight based on a combined weight of non-aqueous components.

11. The prefabricated construction product of claim 1, wherein the cellular concrete is a fiber reinforced cellular concrete additionally comprising a reinforcing fiber in an amount of from about 0.001% to about 2.00%.

12. The prefabricated construction product of claim 1 made into external and internal wall systems, floor systems, ceiling systems and roof systems.

15. The prefabricated construction product of claim 12, wherein the roof system comprises floor systems comprise floor pavers, roadways, parking lots, playing field, residential and industrial floors.

13. The prefabricated construction product of claim 13, wherein the wall system comprises retainer walls, load-bearing walls, partition walls, external walls, internal walls, window walls, and tilt up walls.

14. The prefabricated construction product of claim 13, wherein the floor systems comprise floor pavers, roadways, parking lots, playing field, residential and industrial low rise and high rise floor systems.

16. A cementitous construction product comprising micronized polystyrene foam particles sandwiched between two cement boards, wherein the cement boards comprise cement, fly ash, an activating agent, sand, silica fume, a water reducer agent, a reinforcing fiber, and water.

17. A cementitous construction product of claim 16 wherein the micronizeed polystyrene foam particles have irregular surfaces.

18. The cementitious construction product of claim 16, wherein the micronized polystyrene foam particles are a coarse powder.

19. The cementitious construction product of claim 16, wherein the micronized polystyrene foam particles have an average diameter f about 50 to 5000 microns.