Cement formulation

• US 6,030,447 A
• Filed: 07/25/1997
• Issued: 02/29/2000
• Est. Priority Date: 08/25/1995
• Status: Expired due to Term

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Research Pty., Limited (James Hardie Industries Plc)
• Inventors: Duselis, Steven Alfred, Gleeson, James Albert, Naji, Basil Taha, Sloane, Brian Patrick, Klimesch, Danielle Simone, Stitt, David Malcolm
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US08/910,466
• Time in Patent Office: 949 Days
• Field of Search: 501/141, 501/144, 106/699, 106/718, 106/721, 106/737, 106/803
• US Class Current: 106/718
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 20/023 Chemical treatment
• CPC Class Codes: C04B 2111/00293 Materials impermeable to liquids
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• CPC Class Codes: C04B 40/024 Steam hardening, e.g. in an autoclave
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: Y02P 40/60 Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

This invention relates to a formulation for preparing a dry formulation for preparing an autoclave cured cementitious product comprising:

a cementitious material;

a siliceous material; and

a dehydroxylated clay mineral.

Claims

1. An autoclaved product having about 25-75% reduction in water permeability consisting essentially of:

Portland cement;

a crystalline siliceous material; and

a dehydroxylated clay mineral which is different from said crystalline siliceous material.

2. A formulation according to claim 1 wherein the siliceous material is present in an amount of from 10 to 80 wt. % based on the total weight of the dry formulation.

3. A formulation according to claim 1 wherein the siliceous material is ground sand or fine quartz.

4. A formulation according to claim 1 wherein the siliceous material has an average particle size of 1 to 50 microns.

5. A formulation according to claim 1 wherein the cementitious material is present in an amount of from 10 to 80 wt. % based on the total weight of the dry formulation.

6. A formulation according to claim 1 wherein the cementitious material is selected from the group consisting of cement, lime, lime containing material, and mixtures thereof.

7. A formulation according to claim 1 wherein the cementitious material has an average particle size of from 1 to 50 microns.

8. A formulation according to claim 1 wherein the dehydroxylated clay mineral is dehydroxylated kaolin;

dehydroxylated bentonite, dehydroxylated montmorrilonite, dehydroxylated muscovite or dehydroxylated phlogopite.

9. A formulation according to claim 8 wherein the dehydroxylated clay mineral is dehydroxylated kaolin.

10. A formulation according to claim 1 wherein the dehydroxylated clay mineral is present in an amount from 0.25 to 30 wt. % based on the total weight of the dry formulation.

11. A formulation according to claim 1 wherein the dehydroxylated clay mineral has an average particle size of 1 to 50 microns.

12. A formulation according to claim 1 further comprising a fibrous material.

13. A formulation according to claim 12 wherein the fibrous material is selected from cellulose, asbestos, mineral wool, steel fibre, synthetic polymers, glass, ceramic or carbon.

14. A formulation according to claim 13 wherein the fibrous material is cellulose having a degree of freeness of between 0 and 800 CSF.

15. A formulation according to claim 12 where the fibrous material is present in an amount up to 25 wt. % based on the total weight of the dry formulation.

16. A formulation according to claim 1 further consisting essentially of at least one other additive selected from the group consisting of mineral oxides, mineral hydroxides, mineral clays, fire retardants, thickeners, silica fume, amorphous silica, colorants, water sealing agents, water reducing agents, setting rate modifiers, plasticizers, dispersants, foaming agents, flocculating agents, and water-proofing agents.

17. A cementitious product comprising the autoclave cured reaction product of a composition consisting essentially of dehydroxylated clay mineral, Portland cement and a crystalline siliceous material which is different from said dehydroxylated clay mineral.

18. A cementitious product comprising the autoclave reaction product of a composition consisting essentially of fibrous material, a dehydroxylated clay mineral, Portland cement, and a crystalline siliceous material which is different from said dehydroxylated clay mineral.