Rapid set lightweight cement product

• US 4,501,830 A
• Filed: 01/05/1984
• Issued: 02/26/1985
• Est. Priority Date: 01/05/1984
• Status: Expired due to Fees

• Current Assignee: Cemcom Corporation
• Original Assignee: Research One Limited Partnership
• Inventors: Miller, Richard, Rizer, Janine M.
• Primary Examiner(s): Griffin, Ronald W.
• Application Number:
  US06/568,358
• Time in Patent Office: 418 Days
• Field of Search: 523/401, 106/90, 106/97, 106/98
• US Class Current: 523/401
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 18/082 Cenospheres
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 22/002 Water
• CPC Class Codes: C04B 24/281 Polyepoxides
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A lightweight cement product formed from a mixture comprising cement, condensed silica fume, flyash, cenospheres, finely divided crystalline silica particles, epoxy emulsion, curing agent, accelerator and water which hardens in less than one hour to produce articles with a density less than 90 pounds per cubic foot and a tensile strength of at least 600 psi and a compressive strength of at least 6000 psi after curing for 1 day at 60° C.

Claims

1. A rapid set lightweight cement product which hardens in less than one hour and which then exhibits a density of less than 90 pounds per cubic foot and which has been poured from a mixture comprising in % by weight:

space="preserve" listing-type="tabular">______________________________________ Class H Portland Cement 35 to 45 mixture of Condensed Silica 38 to 50 Fume, Flyash, Cenospheres and finely divided Crystalline Silica Particles;

Epoxy emulsion, Curing Agent, Accelerator 10 to 15 and Water 5.5 to 15. ______________________________________

2. The product of claim 1 in which the ratio of water/cement in the mixture is between 0.23 and 0.35.

3. The product of claim 1 in which the ratio of epoxy solids to cement is between 0.05 and 0.16.

4. The product of claim 1 in which the ratio of condensed silica fume plus finely divided crystalline silica to cement is between 0.475 and 0.757.

5. The product of claim 1 in which the proportions of aggregate to cement is about 1.07.

6. The product of claim 1 in which the mixture from which it is poured comprises in % by weight:

space="preserve" listing-type="tabular">______________________________________ Portland Cement 39.41 Silica Fume 5.37 Finely Divided Silica Particles 19.19 Flyash Cenospheres 17.91 Epoxy Emulsion plus Curing 10.88 Agent and Curing Accelerator Defoamer 0.064 Superplasticizer 0.77 Water 6.4 and in which the following ratio exists;

Water/Cement .255 Resin/Cement .0975 Aggregate/Cement 1.07 ______________________________________

7. The product of claim 6 in which the mixture was made with distilled or deionized water.

8. The product of claim 1 in which the mixture after pouring sets to a product with a tensile strength of at least 600 psi and a compressive strength of at least 6000 psi after one day at 60°

C.