LIGHTWEIGHT CEMENTITIOUS COMPOSITIONS AND BUILDING PRODUCTS AND METHODS FOR MAKING SAME

• US 20090011207A1
• Filed: 07/05/2007
• Published: 01/08/2009
• Est. Priority Date: 07/05/2007
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: DUBEY, Ashish
• Granted Patent: US 8,070,878 B2
• Time in Patent Office: Days
• US Class Current: 428/219
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 20/1051 Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 2111/40 Porous or lightweight materials
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 22/147 Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/122 Hydroxy amines
• CPC Class Codes: C04B 24/226 : Sulfonated naphtalene-formaldehyde condensation products
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 38/0074 : expressed as porosity percentage
• CPC Class Codes: C04B 38/10 : by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 40/0082 : making use of a rise in temperature, e.g. caused by an exothermic reaction
• CPC Class Codes: C04B 7/32 : Aluminous cements
• CPC Class Codes: E04C 2/049 : completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/02 : Perlite
• CPC Class Codes: Y10T 442/10 : Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Abstract

Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.

Claims

1. A method of providing a lightweight cementitious slurry comprising:

forming a mixture of;

35 to 60 wt. %, on a wet basis, cementitious reactive powder comprising Portland cement,

2 to 10 wt. %, on a wet basis, expanded and chemically coated water tight and water repellant perlite filler,

20 to 40 wt. % water,

0 to 25 wt. %, on a wet basis, secondary filler;

10 to 50 vol. %, on a wet basis, entrained air; and

optional additive selected from at least one member of the group consisting of water reducing agents, chemical set-accelerators, chemical set-retarders, air-entraining agents, and foaming agents;

under conditions which provide an initial slurry temperature of at least about 40°

F. (4.4°

C.).

2. The method of claim 1, wherein the perlite filler is coated with a member of the group consisting of silane, siloxane, silicone and mixtures thereof.

3. The method of claim 1, wherein the perlite filler is coated with a silane.

4. The method of claim 1, wherein the perlite filler is coated with an alkyl alkoxy silane.

5. The method of claim 1, wherein the perlite filler is coated with an octyltriethoxy silane.

6. The method of claim 1, further comprising setting the slurry to form a product having a product density of 40 to 85 pcf (0.64 to 1.36 g/cc).

7. The method of claim 1, further comprising setting the slurry to form a product having a product density of 45 to 65 pcf (0.72 to 1.04 g/cc).

8. The method of claim 1, wherein the perlite filler has a mean particle diameter between 20-150 microns.

9. The method of claim 1, wherein the perlite filler has a mean particle diameter between 20-90 microns.

10. The method of claim 1, wherein the perlite filler has a mean particle diameter between 20-60 microns.

11. The method of claim 1, wherein the perlite filler has an effective particle density less than 0.50 g/cc.

12. The method of claim 1, wherein the perlite filler has an effective particle density less than 0.40 g/cc.

13. The method of claim 1, wherein the perlite filler has an effective particle density less than 0.30 g/cc.

14. The method of claim 1, wherein the slurry has an initial temperature of about 90-150°

F. (32-66°

C.).

15. The method of claim 1, wherein the cementitious reactive powder further comprises a mineral additive.

16. A method of claim 15, wherein the mineral additive comprises at least one member of the group consisting of pumice, diatomaceous earth, silica fume, tuft, trass, rice husk, metakaolin, ground granulated blast furnace slag, and fly ash, calcium carbonate, mica and talc.

17. The method of claim 15, wherein the mineral additive comprises fly ash.

18. The method of claim 15, wherein the mineral additive comprises Class C fly ash.

19. The method of claim 1, wherein the mixture comprises at least one additive selected from the group consisting of water reducing agents, chemical set-accelerators, chemical set-retarders, air-entraining agents, and foaming agents.

20. The method of claim 1, wherein the mixture further comprises at least one member of the group consisting of high alumina cement and calcium sulfate.

21. The method of claim 1, wherein the cementitious reactive powder comprises, on a dry basis, about 40 to 90 wt. % Portland cement and 10 to 60 wt. % fly ash based on the sum of the Portland cement and fly ash.

22. The method of claim 1, wherein the cementitious reactive powder comprises, on a dry basis, about 40 to 80 wt. % Portland cement, 0 to 20 wt. % high alumina cement, 0 to 7 wt. % calcium sulfate, 0 to 55 wt. % fly ash, based on the sum of the Portland cement, high alumina cement, calcium sulfate and fly ash.

23. The method of claim 1, wherein the cementitious reactive powder comprises:

35-60 wt. %, on a wet basis, cementitious reactive powder comprising Portland cement and optionally a pozzolanic material,

2-10 wt. %, on a wet basis, expanded and chemically coated water tight and water repellant perlite filler,

20-40 wt. % water,

10-50 vol. %, on a wet basis, entrained air,

optional additive selected from at least one member of the group consisting of water reducing agents, chemical set-accelerators, chemical set-retarders, air-entraining agents, and foaming agents;

10-25 wt. % secondary fillers selected from at least one member of the group consisting of expanded clay, shale aggregate and pumice;

wherein the total of expanded and chemically coated perlite filler and secondary fillers is at least 20 wt. %.

24. The method of claim 1, wherein the cementitious reactive powder comprises, 100 parts Portland cement;

30 parts fly ash;

3 parts land plaster;

2-10 wt. % expanded and chemically coated perlite filler.

25. The method of claim 1, wherein the secondary filler is selected from at least one member of the group consisting of blast furnace slag, volcanic tuft, pumice, expanded forms of clay, shale, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads, and the like.

26. The method of claim 1, wherein the secondary filler is selected from at least one member of the group consisting of expanded clay, shale aggregate, and pumice.

27. The method of claim 1, wherein the chemical set-accelerator comprises an alkanolamine selected from the group consisting of triethanolamine, diethanolamine, monoethanolamine and mixtures thereof.

28. The method of claim 27, wherein the amount of the alkanolamine is about 0.03 to 4 wt. % based on the weight of the cementitious reactive powder on a dry basis.

29. The method of claim 1, wherein the slurry further comprises a set retarder.

30. The method of claim 1, wherein the slurry further comprises a foaming agent.

31. The method of claim 1, wherein the slurry further comprises an inorganic secondary set accelerator.

32. The method of claim 1, wherein the slurry further comprises a superplasticizer water reducing agent.

33. The composition of claim 1, comprising 10 to 50 volume % entrained air.

34. A composition for preparing a cement board comprising a slurry comprising a mixture of the following components:

to 60 wt. % cementitious reactive powder comprising Portland cement,

2 to 10 wt. %, on a wet basis, expanded and chemically coated water tight and water repellant perlite filler,

20 to 40 wt. % water,

0 to 25 wt. %, on a wet basis, secondary filler;

10 to 50 volume %, on a wet basis, entrained air, and

optional additive selected from at least one member of the group consisting of water reducing agents, chemical set-accelerators, and chemical set-retarders;

the slurry being at a temperature of at least about 40°

F. (4.4°

C.) when the components are mixed to form the composition.

35. The composition of claim 34, the slurry being at a temperature of at least 90°

F. (32°

C.) when the components are mixed to form the composition.

36. The composition of claim 34, comprising 10 to 30 volume % entrained air on a wet basis.

37. A cement board, having a density of about 45 to 85 pounds per cubic foot (0.72 to 1.36 g/cc), made from the composition of claim 34.

38. A cement board having a density of about 45 to 85 pounds per cubic foot (0.72 to 1.36 g/cc) and having a continuous phase resulting from the curing of an aqueous mixture comprising:

35-60 parts by weight Portland cement-based binder,

2-10 parts by weight expanded and chemically coated perlite filler,

10-50 volume % entrained air, and

optional additives selected from one or more members of the group consisting of water reducing agents, chemical set-accelerators, chemical set-retarders; and

0-25 parts by weight from one or more members of the group consisting of expanded clay, shale aggregate, and pumice as secondary fillers.

39. The board of claim 38, wherein the board has top and bottom surfaces reinforced with reinforcing mesh.

40. The board of claim 38, wherein the reinforcing mesh comprises inorganic material.

41. The board of claim 38, wherein the reinforcing mesh comprises organic material.

42. The board of claim 38, wherein the reinforcing mesh comprises an alkali resistant fiberglass.

43. The board of claim 38, wherein the board has a thickness of about ¼

to 1 inches (6.3 to 25.4 mm).

44. The board of claim 38, wherein the board has nail pull strength of at least 90 lbs (40.8 kg) per ASTM D1037.

45. The board of claim 38, wherein the board has nail pull strength of greater than 125 lbs (56.7 kg) per ASTM D1037.

46. The board of claim 38, wherein the board has flexural strength of at least 400 psi (2.76 MPa) per ASTM C947.

47. The board of claim 38, wherein the board has flexural strength of greater than 750 psi (5.17 MPa) per ASTM C947.

48. The board of claim 38, wherein the board has flexural strength of greater than 1000 psi (6.89 MPa) per ASTM C947.

49. The board of claim 38, wherein the board has shear strength to ceramic tile and cement mortar of at least 50 psi (0.34 MPa) per ANSI A118.10.

50. The board of claim 38, wherein the board has shear strength to ceramic tile and cement mortar of greater than 100 psi (0.69 MPa) per ANSI A118.10.

51. The board of claim 38, wherein the board has shear strength to ceramic tile and cement mortar of greater than 200 psi (1.38 MPa) per ANSI A118.10.

52. The board of claim 38, wherein the board shows no evidence of wetness or formation of water droplets on the bottom panel surface when the top panel surface is subjected to a hydrostatic pressure of 24 (61 cm) inches for 48-hours per ANSI A118.10.

53. A floor system comprising cement boards of claim 38, which pass a minimum of first three cycles of the test per ASTM C627 for structural durability.