Lightweight cellular cement compositions and methods of casting the same

• US 3,979,217 A
• Filed: 05/05/1975
• Issued: 09/07/1976
• Est. Priority Date: 06/01/1973
• Status: Expired due to Term

• Current Assignee: Halliburton Company
• Original Assignee: Halliburton Company
• Inventors: Sutton, David L.
• Primary Examiner(s): Poer, J.
• Application Number:
  US05/574,226
• Time in Patent Office: 491 Days
• Field of Search: 106/86, 106/87, 106/88, 106/90, 264/101
• US Class Current: 106/675
• CPC Class Codes: B28B 1/008 made from two or more materials having different characteristics or properties casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00
• CPC Class Codes: B28B 1/50 specially adapted for producing articles of expanded material, e.g. cellular concrete chemical aspects or making expanded aggregate C04B
• CPC Class Codes: B28C 5/388 Methods
• CPC Class Codes: C04B 14/02 Granular materials , e.g. microballoons
• CPC Class Codes: C04B 24/00 Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• 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 40/00 Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02

Abstract

The present invention relates to novel lightweight cellular cement compositions, methods of preparing such compositions and methods of casting the compositions into lightweight high strength structural members.

Claims

1. A method of producing an integral lightweight high strength cement composition having at least one high strength densified layer adjacent at least on lightweight cellular layer comprising mixing hydraulic cement;

water added in an amount of about 23-80% by weight of said dry cement;

a foam stabilizer added in an amount 0.25-5% by weight of dry cement selected from organic surfactants, inorganic lamellar particulate and mixtures thereof;

a dispersing agent selected and added to facilitate formation of a high strength densified layer prior to setting of said composition; and

air added in an amount sufficient to reduce density to less than about 80 pounds per cubic foot;

forming said cement composition into the desired shape;

positioning an air and water permeable material adjacent the cement composition;

promoting and controlling formation of said high strength densified layer by establishing a pressure differential across said permeable material causing air and water to flow from the layer to be densified and allowing said composition to set.

2. A method of claim 1 for producing an integral lightweight high strength cement composition having at least two high strength densified layers adjacent at least one lightweight cellular layer, wherein said cement composition is formed into the desired shape by at least two walls of said air and water permeable material.