Mineral binder and compositions employing the same

• US 4,642,137 A
• Filed: 03/06/1985
• Issued: 02/10/1987
• Est. Priority Date: 03/06/1985
• Status: Expired due to Term

• Current Assignee: Lone Star Industries, Inc. (Pennsylvania) (Buzzi Unicem SPA)
• Original Assignee: Lone Star Industries, Inc. (Pennsylvania) (Buzzi Unicem SPA)
• Inventors: Fitzgerald, Mark, Heitzmann, Richard F., Sawyer, James L.
• Primary Examiner(s): NOT, DEFINED
• Assistant Examiner(s): Capella, Steven
• Application Number:
  US06/708,689
• Time in Patent Office: 706 Days
• Field of Search: 106/76, 106/85, 106/89, 106/315, 106/84
• US Class Current: 106/607
• CPC Class Codes: C04B 12/005 Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 18/023 Fired or melted materials
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/14 from metallurgical processes treatment of molten slag C04B5/00
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 22/062 of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 28/00 Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
• CPC Class Codes: C04B 28/006 containing mineral polymers, e.g. geopolymers of the Davidovits type
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 40/06 Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: Y02P 40/10 Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A binder composition for Portland cement is disclosed, said composition including 100 parts by weight metakaolin and, based upon said metakaolin, from 20 to 70 parts by weight slag; from 85 to 130 parts by weight of at least 1 material selected from the class consisting of fly ash, calcined shale, and calcined clay; from 70 to 215 parts by weight finely divided silica, preferably amorphous silica; and from 55 to 145 parts by weight of a mixture of potassium silicate and potassium hydroxide, wherein at least 55 parts by weight is potassium silicate. The binder composition can be mixed with Portland cement or with a combination of Portland cement and fly ash to provide a composition curable to a material having a high early strength and a high ultimate strength.

Claims

1. A binder composition for Portland cement comprising 100 parts, by weight, metakaolin and, based upon said metakaolin:

20 to 70 parts by weight slag

85 to 130 parts by weight of at least one material selected from the class consisting of fly ash, calcined shale, and calcined clay

70 to 215 parts amorphous silica

55 to 145 parts of a material selected from the class consisting of potassium silicate and potassium hydroxide, at least 55 parts being potassium silicate.

2. The binder of claim 1 wherein the amorphous silica is silica fume.

3. The binder composition of claim 1 wherein the amount of amorphous silica is from 85 to 160 parts, by weight.

4. The binder composition of claim 3 wherein the amount is from 85 to 115 parts, by weight.

5. The binder composition of claim 1 wherein said slag is contained in an amount of from 30 to 50 parts by weight.

6. The binder composition of claim 1 wherein the material selected from the class consisting of fly ash, calcined shale, and calcined clay is fly ash.

7. The binder composition of claim 1 wherein the amount of potassium silicate and potassium hydroxide is from 65 to 115 parts by weight.

8. A cement composition comprising, on a weight basis, from 40 to 70 parts Portland cement and from 60 to 30 parts of the binder composition of claim 1.

9. The cement composition of claim 8 wherein said Portland cement is contained in an amount of from 55 to 65 parts by weight and said binder composition in an amount of from 45 to 35 parts by weight.

10. The cement composition of claim 9 having, in addition, 20 parts, by weight, fly ash.

11. A binder composition for Portland cement comprising 100 parts, by weight, metakaolin and, based upon said metakaolin:

20 to 70 parts by weight slag

85 to 130 parts by weight of at least one material selected from the class consisting of fly ash, calcined shale, and calcined clay

70 to 215 parts amorphous silica

55 to 145 parts of a material selected from the class consisting of potassium silicate and sodium hydroxide, at least 55 parts being potassium silicate.

12. A binder composition for Portland cement comprising 100 parts, by weight, metakaolin and, based upon said metakaolin:

20 to 70 parts by weight slag

85 to 130 parts by weight of at least one material selected from the class consisting of fly ash, calcined shale, and calcined clay

70 to 215 parts amorphous silica

55 to 145 parts of a material selected from the class consisting of sodium silicate and sodium hydroxide, at least 55 parts being sodium silicate.