CEMENT AND CONCRETE WITH REINFORCED MATERIAL

• US 20150031799A1
• Filed: 10/06/2014
• Published: 01/29/2015
• Est. Priority Date: 12/31/2009
• Status: Abandoned Application

• Current Assignee: Calera Corporation
• Original Assignee: Calera Corporation
• Inventors: CONSTANTZ, BRENT R., Self, Kyle, CHEN, IRVIN, MONTEIRO, PAULO J. M.
• Application Number:
  US14/506,953
• Publication Number:
  US 20150031799A1
• Time in Patent Office: Days
• US Class Current: 524/4
• CPC Class Codes: C04B 11/00 Calcium sulfate cements
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 16/0641 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 18/248 from specific plants, e.g. hemp fibres
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 24/26 obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 32/02 with reinforcements contains no documents; reinforcing elements E04C5/00
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 264/43 Processes of curing clay and concrete materials

Abstract

Provided are compositions, methods and systems including cementitious compositions and reinforcing materials wherein the cementitious composition comprises a metastable component.

Claims

1. A composition comprising:

a cementitious composition wherein the cementitious composition comprises a metastable component selected from the group consisting of vaterite, amorphous calcium carbonate, and combination thereof, and

a reinforcing material wherein the reinforcing material is selected from the group consisting of aluminum, glass fiber, carbon fiber, ceramics, polymer, grass, grass product, wood product, fiber-reinforced plastic, epoxy coated rebar, titanium cladding treated rebar, chrome plated/coated rebar, nickel plated/coated rebar, cobalt-chromium coated rebar, polycarbonate reinforcing members, polycarbonate fiber, poly(vinyl chloride) (PVC) reinforcing members, PVC fiber, polypropylene, cellulose, polyvinyl alcohol, bamboo, and combination thereof,

wherein the cementitious composition has a wet paste pH of less than 12.

3. The composition of claim 1, wherein the cementitious composition has a δ

¹³C value less than −

12.0%.

4. The composition of claim 1, wherein the cementitious composition comprises at least 50 wt % vaterite.

5. The composition of claim 1, wherein the composition comprises more than 0.15% water-soluble chloride ion by weight of cement in the composition.

6. The composition of claim 1, wherein the reinforcing material does not exhibit changes in mechanical properties selected from the group consisting of elastic modulus, tensile strength, and yield strength, when exposed to water soluble chloride repeatedly or for an extended period of time.

11. The composition of claim 1, wherein at least 1% by volume of the reinforcing material is aligned in the same direction.

12. The composition of claim 1, wherein the cementitious composition comprises carbonate mineral wherein the carbon in the carbonate mineral is derived in whole or in part from carbon dioxide removed from an industrial waste stream.

13. The composition of claim 1, wherein the composition meets the requirements for durability, strength, serviceability, flexure and axial loads, and/or shear and torsion, in accordance with structural concrete building code.

14. The composition of claim 1, wherein the reinforcing material has a yield strength of at least 420 MPa.

15. The composition of claim 1, wherein the reinforcing material has an elastic modulus of 25 GPa to 250 GPa.

16. The composition of claim 1, wherein the composition is suitable for use in structural building applications.

17. The composition of claim 1, further comprising an aggregate.

31. The composition of claim 1, wherein the cementitious composition is a particulate composition with an average particle size of 0.1-100 microns.

32. The composition of claim 1, wherein the composition comprises between 0.1-10 wt % reinforced material.

33. The composition of claim 1, wherein the reinforced material is in a shape of bars or rebars, wires, threads, grids, plates, fibers, metal meshes, cages, whiskers, or combinations thereof.

34. The composition of claim 1, wherein the composition after setting and hardening forms a formed building material selected from the group consisting of masonry unit, brick, blocks, tile, construction panel, conduit, basin, beam, column, slab, acoustic barrier, insulation material, and combination thereof.

35. The composition of claim 1, wherein the composition after setting, and hardening has a compressive strength of at least 14 MPa.

2. (canceled)

7-10. -10. (canceled)

18-30. -30. (canceled)