Methods of manufacture and use for hydraulically bonded cement

• US 5,358,676 A
• Filed: 11/25/1992
• Issued: 10/25/1994
• Est. Priority Date: 05/18/1990
• Status: Expired due to Fees

• Current Assignee: E. Khashoggi Industries, LLC
• Original Assignee: E. Khashoggi Industries, LLC
• Inventors: Hodson, Simon K., Jennings, Hamlin M., Andersen, Per J.
• Primary Examiner(s): AFTERGUT, KAREN K
• Application Number:
  US07/981,615
• Time in Patent Office: 699 Days
• Field of Search: 264/333, 264/69-72, 264/42, 264/28, 264/256, 264/82, 264/85, 264/109, 264/128, 264/86, 264/87, 264/101, 264/102, 264/301-302, 264/240, 264/31, 264/DIG. 43, 264/44 , 264/49, 264/344, 264/345, 264/234, 264/237, 264/348, 264/336, 264/104, 264/122
• US Class Current: 264/71
• CPC Class Codes: B28B 1/00 Producing shaped prefabricated articles from the material using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 ; producing articles with embedded elements B28B23/00
• CPC Class Codes: B28B 11/24 for curing, setting or hardening processes for influencing or modifying the setting or hardening ability of mortars, concrete or artificial stone compositions, in general C04B40/00
• CPC Class Codes: B28B 11/245 Curing concrete articles B28B11/242 takes precedence
• CPC Class Codes: B28B 23/0087 Lightweight aggregates for making lightweight articles
• CPC Class Codes: B28B 3/00 Producing shaped articles from the material by using presses shaping on moving conveyors B28B5/00; Presses specially adapted therefor presses in general B30B
• CPC Class Codes: B28B 7/342 which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2111/94 Electrically conducting materials
• CPC Class Codes: C04B 22/0046 Waste slurries or solutions used as gauging water
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 28/06 Aluminous cements monolithic refractories or refractory mortars C04B35/66
• CPC Class Codes: C04B 28/34 containing cold phosphate binders
• CPC Class Codes: C04B 40/0035 Processes characterised by the absence of a mechanical mixing step, e.g. "no-mix" processes
• CPC Class Codes: C04B 40/0071 making use of a rise in pressure
• CPC Class Codes: C04B 40/0089 making use of vacuum or reduced pressure
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: C04B 40/0277 Hardening promoted by using additional water, e.g. by spraying water on the green concrete element steam hardening C04B40/024
• CPC Class Codes: C04B 40/0281 Hardening in an atmosphere of increased relative humidity
• CPC Class Codes: C04B 40/0616 preformed, e.g. bandages
• CPC Class Codes: Y10S 264/43 : Processes of curing clay and concrete materials

Abstract

The present invention relates to hydraulically bonded cement compositions and methods of manufacture. Hydraulically bonded cement compositions and methods of manufacture include materials prepared by manipulating under pressure powdered hydraulic cement compositions using known or novel powder packing, casting, or expanding techniques, such that air within the powdered hydraulic cement is successfully removed while the cement is formed into a self-supporting near net final position. Thereafter, the formed hydraulic cement article is hydrated without mechanical mixing of the cement and water.

Claims

1. A method for preparing a cementitious article from a hydraulic cement composition, the method comprising the steps of:

(a) applying pressure to a powdered hydraulic cement composition within a mold such that air within the powdered hydraulic cement composition is substantially removed and the powdered hydraulic cement composition is formed into a mechanically self-supporting structure of a near net final position substantially corresponding to a desired article shape;

(b) removing the mechanically self-supporting structure from the mold; and

(c) hydrating the mechanically self-supporting structure by contacting the structure with an aqueous solution without substantial mechanical mixing of the cement composition and aqueous solution, thereby forming the cementitious article.

2. A method for preparing a cementitious article from a hydraulic cement composition as defined in claim 1, wherein the aqueous solution is extracted from cement paste.

3. A method for preparing a cementitious article from a hydraulic cement composition as defined in claim 1, wherein the aqueous solution is gaseous water.

4. A method for preparing a cementitious article from a hydraulic cement composition as defined in claim 1, wherein the powdered hydraulic cement composition has an initial density and is deliberately positioned by increasing the initial density of the powdered hydraulic cement composition.

5. A method for preparing a cementitious article from a hydraulic cement composition as defined in claim 1, wherein the powdered hydraulic cement composition is deliberately positioned into the near net final position by compressing the powdered hydraulic cement composition into a confined area substantially corresponding to the desired article shape.

6. A method for preparing a cementitious article from a hydraulic cement composition as defined in claim 1, further comprising the step of mixing an aggregate with the powdered hydraulic cement composition prior to hydrating the cement composition.

7. A method for preparing a cementitious article from a hydraulic cement composition as defined in claim 1, further comprising the step of exposing the powdered hydraulic cement composition to carbon dioxide.

8. A method for preparing a cementitious article from a hydraulically bonded cement composition as defined in claim 1, wherein the powdered hydraulic cement composition is hydrated in a partial vacuum environment.

9. A method for preparing a cementitious article from a hydraulically bonded cement composition as defined in claim 1, wherein the air within the powdered hydraulic cement composition is substantially removed by compressing the powdered hydraulic cement composition in a vacuum environment.

10. A method for preparing a cementitious article from a hydraulically bonded cement composition as defined in claim 1, wherein the air within the powdered hydraulic cement composition is substantially removed by compressing the powdered hydraulic cement composition by means of porous dies.

11. A method for preparing a cementitious article from a hydraulically bonded cement composition as defined in claim 10, wherein the porous dies exert a pressure of at least 10,000 psi during the compressing step.

12. A method for preparing a hydraulically bonded composite article comprising the steps of:

(a) applying pressure to a powdered hydraulic cement composition within a mold such that air within the powdered hydraulic cement composition is substantially removed and the powdered hydraulic cement composition is positioned into a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the composite article, the powdered hydraulic cement composition being capable of forming a continuous matrix having powdered hydraulic cement particles and aggregate particles dispersed therein, the powdered hydraulic cement particles and the aggregate particles having a density and a particle size distribution;

(b) removing the mechanically self-supporting structure from the mold; and

(c) hydrating the mechanically self-supporting structure by contacting the structure with an aqueous solution without substantial mixing of the cement particles and the aqueous solution, thereby forming the hydraulically bonded composite article.

13. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is deliberately positioned to a density in a range from about 75% to about 100% of the maximum achievable density for the given particle size distribution of the powdered hydraulic cement particles and the aggregate particles.

14. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition has a predetermined polynary size distribution.

15. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is deliberately positioned under pressure into the mechanically self-supporting structure of a predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded composite article by compressing the powdered hydraulic cement composition into the mold.

16. A method for preparing a hydraulically bonded composite article as defined in claim 15, wherein the powdered hydraulic cement composition is compressed into the mold under a pressure in a range from about 1000 psi to about 200,000 psi.

17. A method for preparing a hydraulically bonded composite article as defined in claim 15, wherein the powdered hydraulic cement composition is compressed into the mold using an isostatic press.

18. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is deliberately positioned under pressure into the mechanically self-supporting structure of a predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded composite article by the process of dry pressing the powdered hydraulic cement composition between die faces.

19. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is deliberately positioned under pressure into the mechanically self-supporting structure of a predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded composite article by the process of vibrational compaction of the powdered hydraulic cement composition within the mold.

20. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition includes a mixture of chemically different hydraulic cements.

21. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition includes a portland cement.

22. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition includes a calcium aluminate cement.

23. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition includes dicalcium silicate.

24. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition includes tricalcium silicate.

25. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition includes a phosphate cement.

26. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution is gaseous water.

27. A method for preparing a hydraulically bonded composite article as defined in claim 26, wherein the gaseous water has a vapor pressure in a range from about 0.1 torr to about 1000 torr.

28. A method for preparing a hydraulically bonded composite article as defined in claim 26, wherein the gaseous water has a vapor pressure in a range from about 1 torr to about 50 torr.

29. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution is atomized liquid water.

30. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the hydrating step includes immersing the mechanically self-supporting structure within the aqueous solution.

31. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution has a pH in a range from about 7 to about 14.

32. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution has a pH in a range from about 9 to about 13.5.

33. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution has a pH in a range from about 10 to about 12.5.

34. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes calcium as a component.

35. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes carbon as a component.

36. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes sulfur as a component.

37. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes sodium as a component.

38. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes potassium as a component.

39. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes a sugar as a component.

40. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes a water reducer as a component.

41. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aqueous solution includes a superplasticizer as a component.

42. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is hydrated in an environment having a relative humidity in a range from about 25% to about 100%.

43. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is hydrated in a controlled gaseous environment including carbon dioxide.

44. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is hydrated in a controlled gaseous environment including carbon monoxide.

45. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is hydrated in a partial vacuum environment.

46. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition is hydrated in an environment having a temperature in a range from about -10°

C. to about 200°

C.

47. A method for preparing a hydraulically bonded composite article as defined in claim 26, wherein the powdered hydraulic cement composition is hydrated with gaseous water having a temperature in a range from about -10°

C. to about 200°

C.

48. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.01 to about 0.4.

49. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.025 to about 0.3.

50. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.05 to about 0.2.

51. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.1 to about 0.2.

52. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles have a predetermined polynary size distribution.

53. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles comprise a plurality of differently sized aggregates having particle sizes in a range from about 0.01 μ

m to about 3 cm.

54. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles comprise a plurality of differently sized aggregates having particle sizes in a range from about 1 μ

m to about 1 cm.

55. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles comprise a plurality of differently sized aggregates having particle sizes in a range from about 50 μ

m to about 100 μ

m.

56. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the air within the powdered hydraulic cement composition is substantially removed by positioning the powdered hydraulic cement composition in a vacuum environment.

57. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the air within the powdered hydraulic cement composition is substantially removed by positioning the powdered hydraulic cement composition by means of porous dies.

58. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the powdered hydraulic cement composition comprises a plurality of hydraulic cement particles having a predetermined polynary size distribution.

59. A method for preparing a hydraulically bonded composite article as defined in claim 58, wherein the predetermined polynary size distribution of the hydraulic cement particles is selected to increase particle packing efficiency of the hydraulic cement composition.

60. A method for preparing a hydraulically bonded composite article as defined in claim 52, wherein the hydraulic cement composition has a particle packing efficiency and wherein the predetermined polynary size distribution of the aggregate particles is selected to increase the particle packing efficiency of the hydraulic cement composition.

61. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include a plurality of fibers.

62. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include a plurality of graphite fibers.

63. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include a plurality of glass fibers.

64. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include a plurality of alumina fibers.

65. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include a plurality of silica fibers.

66. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include a plurality of polymeric fibers.

67. A method for preparing a hydraulically bonded composite article as defined in claim 12, wherein the aggregate particles include an electrically conducting aggregate.

68. A method for preparing a hydraulically bonded composite article as defined in claim 67, wherein the electrically conducting aggregate is capable of conducting electricity through the hydraulically bonded composite article.

69. A method for preparing a hydraulically bonded composite article as defined in claim 67, wherein the electrically conducting aggregate includes a plurality of metallic fibers mixed within the powdered hydraulic cement composition.

70. A method for preparing a hydraulically bonded composite article as defined in claim 12, further comprising the steps of:

drying the hydraulically bonded composite article after the hydrating step; and

reexposing the hydraulically bonded composite article to water.

71. A method for preparing a hydraulically bonded composite article as defined in claim 12, further comprising the step of exposing the hydraulically bonded composite article to carbon dioxide in a desiccating environment.

72. A method for preparing a hydraulically bonded composite article as defined in claim 12, further comprising the step of exposing the hydraulically bonded composite article to carbon monoxide in a desiccating environment.

73. A method for preparing a hydraulically bonded article shaped in a predetermined configuration, the method comprising the steps of:

(a) applying pressure to a powdered hydraulic cement composition within a mold such that air within the powdered hydraulic cement composition is substantially removed and the powdered hydraulic cement composition is positioned into a mechanically integral self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the hydraulically bonded article;

(b) removing the mechanically integral self-supporting structure from the mold; and

(c) hydrating the mechanically integral self-supporting structure with an aqueous solution having at least one component that modifies the hydration of the powdered hydraulic cement composition, thereby forming the hydraulically bonded article, the hydrating step being performed without substantial mechanical mixing of the powdered hydraulic cement composition and the aqueous solution.

74. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition has an initial density and is deliberately positioned by increasing the initial density of the powdered hydraulic cement composition.

75. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition has a given particle size distribution and a maximum achievable particle packing density and wherein the powdered hydraulic cement composition is deliberately positioned under pressure to a density in a range from about 75% to about 100% of the maximum achievable density for the given particle size distribution of the powdered hydraulic cement composition.

76. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition has a predetermined polynary size distribution.

77. A method for preparing a hydraulically bonded article as defined in claim 73, wherein individual cement particles of the powdered hydraulic cement composition are rounded to improve packing efficiency.

78. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition is deliberately positioned under pressure into the mechanically integral self-supporting structure of the predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded article by compressing the powdered hydraulic cement composition into the mold.

79. A method for preparing a hydraulically bonded article as defined in claim 78, wherein the powdered hydraulic cement composition is compressed into the mold under a load in a range from about 1,000 psi to about 200,000 psi.

80. A method for preparing a hydraulically bonded article as defined in claim 78, wherein the powdered hydraulic cement composition is compressed into the mold using an isostatic press.

81. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition is deliberately positioned under pressure into the mechanically integral self-supporting structure of the predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded article by the process of dry pressing the powdered hydraulic cement composition between die faces.

82. A method for preparing a hydraulically bonded article as defined in claim 81, wherein the powdered hydraulic cement composition is deliberately positioned under pressure by the process of dry pressing between die faces under a load in a range from about 10,000 psi to about 200,000 psi.

83. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition is deliberately positioned into the predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded article by the process of vibrational compaction of the powdered hydraulic cement composition into the mold.

84. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition includes a mixture of chemically different hydraulic cements.

85. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition includes a portland cement.

86. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition includes a calcium aluminate cement.

87. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition includes dicalcium silicate.

88. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition includes tricalcium silicate.

89. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition includes a phosphate cement.

90. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution comprises lime water.

91. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution has a pH in a range from about 7 to about 14.

92. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution has a pH in a range from about 9 to about 13.5.

93. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution has a pH in a range from about 10 to about 12.5.

94. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes calcium as a component.

95. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes hydroxide ions as a component.

96. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes carbon as a component.

97. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes sulfur as a component.

98. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes sodium as a component.

99. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes potassium as a component.

100. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes a sugar as a component.

101. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes a water reducer as a component.

102. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the aqueous solution includes a superplasticizer as a component.

103. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the powdered hydraulic cement composition is hydrated in an environment having a temperature in a range from about -10°

C. to about 200°

C.

104. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.01 to about 0.4.

105. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.025 to about 0.3.

106. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.05 to about 0.2.

107. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the hydrated powdered hydraulic cement composition has a ratio of water to cement in a range from about 0.1 to about 0.2.

108. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the step of mixing at least one aggregate within the powdered hydraulic cement composition.

109. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the step of mixing a plurality of differently sized aggregate particles having a predetermined polynary size distribution within the powdered hydraulic cement composition.

110. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the air within the powdered hydraulic cement composition is removed by positioning the powdered hydraulic cement composition in a vacuum environment.

111. A method for preparing a hydraulically bonded article as defined in claim 73, wherein the air within the powdered hydraulic cement composition is substantially removed by positioning the powdered hydraulic cement composition by means of porous dies.

112. A method for preparing a hydraulically bonded article as defined in claim 109, wherein the aggregate particles have a particle packing efficiency and wherein the plurality of differently sized aggregate particles are selected to increase the particle packing efficiency of the aggregate particles.

113. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the step of mixing an electrically conducting aggregate with the powdered hydraulic cement composition.

114. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the step of mixing a plurality of fibers with the powdered hydraulic cement composition.

115. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising a powdered aggregate mixed with the powdered hydraulic cement composition.

116. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the steps of:

drying the hydraulically bonded article after the hydrating step; and

reexposing the hydraulically bonded article with water.

117. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the step of exposing the powdered hydraulic cement composition to carbon dioxide in a desiccating environment.

118. A method for preparing a hydraulically bonded article as defined in claim 73, further comprising the step of exposing the powdered hydraulic cement composition to carbon monoxide in a desiccating environment.

119. A method for preparing a hydraulically bonded article shaped in a predetermined configuration, the method comprising the steps of:

(a) applying pressure to a powdered hydraulic cement composition having a predetermined polynary size distribution within a mold such that air within the powdered hydraulic cement composition is substantially removed and the powdered hydraulic cement composition is positioned into a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the hydraulically bonded article;

(b) removing the mechanically self-supporting structure from the mold; and

(c) hydrating the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the powdered hydraulic cement composition and water, thereby forming the hydraulically bonded article.

120. A method for preparing a hydraulically bonded article as defined in claim 119, wherein the powdered hydraulic cement composition is deliberately positioned under pressure into the mechanically self-supporting structure of a predetermined configuration corresponding substantially to the desired configuration of the hydraulically bonded article by compressing the powdered hydraulic cement composition into the mold.

121. A method for preparing a hydraulically bonded article as defined in claim 119, wherein the powdered hydraulic cement composition is hydrated by contacting the powdered hydraulic cement composition with the aqueous solution.

122. A method for preparing a hydraulically bonded article as defined in claim 119, wherein the powdered hydraulic cement composition is hydrated in a controlled gaseous environment including carbon dioxide.

123. A method for preparing a hydraulically bonded article as defined in claim 119, wherein an aggregate is dispersed within with the powdered hydraulic cement composition prior to hydrating the hydraulic cement composition.

124. A method for preparing a hydraulically bonded article from a hydraulic cement composition shaped in a predetermined configuration, the method comprising the steps of:

(a) applying pressure to and controlling the density of a powdered hydraulic cement composition within a vessel such that air within the powdered hydraulic cement composition is substantially removed, thereby forming the hydraulic cement composition into a mechanically self-supporting structure having a predetermined configuration corresponding substantially to a desired configuration of the hydraulically bonded article;

(b) removing the mechanically self-supporting structure from the vessel;

(c) exposing the powdered hydraulic cement composition to water so as to hydrate the cement composition without substantial mechanical mixing of the cement composition and the water; and

(d) allowing the hydrating cement composition to cure into the hydraulically bonded article.

125. A method for preparing a hydraulically bonded article as defined in claim 124, wherein the hydrated cement composition is cured without significant change in the configuration of the hydraulic cement composition.