Use of alumina clay with cement fly ash mixtures

• US 5,693,137 A
• Filed: 11/29/1995
• Issued: 12/02/1997
• Est. Priority Date: 10/19/1993
• Status: Expired due to Fees

• Current Assignee: Headwaters Resources Incorporated (Seven Group Holdings Limited)
• Original Assignee: JTM Industries, Inc.
• Inventors: Styron, Robert W.
• Primary Examiner(s): MARCHESCHI, MICHAEL A
• Application Number:
  US08/563,952
• Time in Patent Office: 734 Days
• Field of Search: 106/705, 106/706, 106/709, 106/692, 106/819, 106/DIG. 1, 106/710, 106/695, 106/718, 106/811, 264/DIG. 49
• US Class Current: 106/706
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 18/021 agglomerated by a mineral binder, e.g. cement
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 20/1066 Oxides, Hydroxides
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2201/50 for the mechanical strength
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/021 Ash cements, e.g. fly ash cements fly ash as filler C04B18/08; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration alkali-activated combustion residues as such C04B7/243; mixtures of the lime-pozzuolane type C04B28/18; Kiln dust cements
• CPC Class Codes: C04B 7/32 Aluminous cements
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/01 Fly ash
• CPC Class Codes: Y10S 264/49 Processes of using fly ash

Abstract

A cementitious mixture includes hydraulic cement, fly ash, and an effective amount of unfired nature finely divided material, such as a clay, containing at least about 35% alumina, to accelerate the early strength of a mix. A method of accelerating early strength in a cementitious mix comprises the adding of alumina in the form of an unfired raw material, such as clay, in an effective amount in such mix.

Claims

1. A mix for making fly ash pellets, comprising about 10% portland cement, about 5% of a finely divided alumina containing material selected from the group consisting of calcium aluminate and alumina clays, class "F" fly ash as necessary to make up 100%, and sufficient water for hydration and pelletization, in which said alumina containing material contains at least 35% aluminum oxide.

2. Mix as recited in claim 1 wherein said alumina clay comprises alumina combined with silica.

3. Mix as recited in claim 1 wherein said alumina clay is mullite.

4. Mix as recited in claim 1 wherein said alumina clay is gibbsite.

5. A mix for making fly ash pellets, comprising about 10% portland cement, about 5% of a finely divided alumina containing material selected from the group consisting of calcium aluminate and alumina clays, class "F" fly ash as necessary to make up 100%, and sufficient water for hydration and pelletization, in which said alumina containing material contains at least 35% aluminum oxide and said alumina clay comprises unfired bauxite.

6. An essentially fly ash pellet having the ability to be dropped from a height of about 30 feet to a concrete surface in a green state without disintegrating upon contact with said surface made by the steps of:

forming a cementitious mixture comprising

     1) about 85 wt % and greater Class F fly ash having a SiO₂ coating surrounding an aluminate containing core, and

     2) a lime containing hydraulic cement component;

reacting said lime and said SiO₂ coating with a finely divided alumina containing material selected from the group consisting of calcium aluminate and alumina clays, said alumina containing material being present in an amount of at least about 5% of the combined dry weight of said mixture, adding sufficient water to hydrate said mixture, and forming said pellets from said hydrated mixture.

7. Pellet as recited in claim 6 wherein said alumina clay comprises alumina combined with silica.

8. Pellet as recited in claim 6 wherein said alumina clay is mullite.

9. Pellet as recited in claim 6 wherein said alumina clay is gibbsite.

10. An essentially fly ash pellet having the ability to be dropped from a height of about 30 feet to a concrete surface in a green state without disintegrating upon contact with said surface made by the steps of:

forming a cementitious mixture comprising

     1) about 85 wt % and greater Class F fly ash having a SIO₂ coating surrounding an aluminate containing core, and

     2) a lime containing hydraulic cement component;

reacting said lime and said SiO₂ coating with a finely divided alumina containing material selected from the group consisting of calcium aluminate and alumina clays, said alumina clay comprising unfired bauxite, said alumina containing material being present in an amount of at least about 5% of the combined dry weight of said mixture;

adding sufficient water to hydrate said mixture; and

forming said pellets from said hydrated mixture.

11. A mix for making fly ash pellets comprising portland cement, a finely divided alumina containing material and at least about 40% class F fly ash, said alumina containing material comprising alumina moieties combined with silica moieties, said mix further including sufficient water for hydration and pelletization, said alumina containing material comprising at least about 35% aluminum oxide.