Complex admixture and method of cement based materials production

• US 6,645,289 B2
• Filed: 05/16/2000
• Issued: 11/11/2003
• Est. Priority Date: 05/26/1997
• Status: Expired due to Fees

• Current Assignee: SCIL Technology Company Limited
• Original Assignee: SCIL Technology Company Limited
• Inventors: Soboleva, Svetlana, Sobolev, Konstantin
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US09/424,564
• Publication Number:
  US 20030188669A1
• Time in Patent Office: 1,274 Days
• Field of Search: 106/705, 106/713, 106/714, 106/715, 106/718, 106/719, 106/724, 106/726, 106/735, 106/737, 106/820, 106/823, 106/DIG.1, 106/DIG.2
• US Class Current: 106/705
• CPC Class Codes: C04B 11/00 Calcium sulfate cements
• CPC Class Codes: C04B 14/04 Silica-rich materials; Silicates
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/101 Burned rice husks or other burned vegetable material
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/52 Grinding aids; Additives added during grinding
• CPC Class Codes: C04B 22/04 Metals, e.g. aluminium used as blowing agent
• CPC Class Codes: C04B 22/068 Peroxides, e.g. hydrogen peroxide
• CPC Class Codes: C04B 22/08 Acids or salts thereof C04B22/0013 takes precedence
• CPC Class Codes: C04B 22/147 Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 24/003 Phosphorus-containing compounds
• CPC Class Codes: C04B 24/04 Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 24/08 : Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
• CPC Class Codes: C04B 24/14 : Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 24/226 : Sulfonated naphtalene-formaldehyde condensation products
• CPC Class Codes: C04B 24/26 : obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 24/2641 : Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/34 : Natural resins, e.g. rosin C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 24/42 : Organo-silicon compounds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 38/02 : by adding chemical blowing agents
• CPC Class Codes: C04B 38/10 : by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 40/0039 : Premixtures of ingredients
• CPC Class Codes: C04B 40/0608 : Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
• CPC Class Codes: C04B 7/32 : Aluminous cements
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The present invention relates to admixtures production and to a method of application of the admixtures in cement and concrete technology. The method allows production of high-strength and high durable cement based systems, as well as cement systems with specially designed properties of cheap high-volume mineral admixture cements.

Claims

1. A process for the preparation of a cement composition, said process comprising:

(a) combining a silicon dioxide containing sorbent with a water reducer or high range water reducer solution to form a mixture;

(b) processing the mixture formed in step (a) to a dry or partially dry particulate or granular admixture; and

(c) combining said admixture with a portland cement component, in a ratio of cement component to admixture of about 100;

1 to 2;

1, to form a cement composition.

2. The process of claim 1 wherein step (c) comprises combining said admixture with said cement component by mixing or grinding.

3. The process of claim 1, wherein said portland cement component is selected from the group consisting of:

(i) portland cement clinker containing one or more combinations of calcium silicates and/or calcium aluminates and one or more types of calcium sulfate; and

(ii) portland cement.

4. The process according to claim 2, wherein said cement composition includes mineral components.

5. The process according to claim 4, wherein said mineral components are selected from the group consisting of pozzolans, volcanic glasses, diatomaceous earth, perlite, tuff, pumice, natural sand, quartz, marble, limestone, burnt gaize, burnt clay, burnt shale, rice hull ash, bentonite activated kaolin, granulated blast furnace slag, fly ash, silica fume, catalytic and alum waste, broken glass, broken ceramic, and calcium sulfate.

6. The process according to claim 4, wherein a mass ratio of said mineral components to said admixture is from about 100:

1 to about 1;

1.

7. The process according to claim 4, wherein step (c) comprises separately grinding said portland cement component and said mineral components and subsequently intergrinding or mixing with said admixture.

8. The process according to claim 7, wherein said intermixing or grinding step is carried out in apparatus selected from the group consisting of conventional mixers, high speed mixers, vibrating mixers or mills, air jet mixers or mills, ball mills, and tube ball mills.

9. A dry mix composition comprising a cement composition made according to the process of claim 2 and dry aggregates.

10. A dry mix composition according to claim 9, wherein a mass ratio of said dry aggregates to said cement composition is from about 10:

1 to about 1;

2.

11. A process for producing the dry mix composition according to claim 9, comprising mixing said cement composition and said dry aggregates in conventional mixers, high speed mixers, vibrating mixers, or air jet mixers.

12. A concrete or mortar incorporating a cement composition produced according to the process of claim 2.

13. A concrete or mortar incorporating a dry mix composition produced according to the process of claim 11.

14. A concrete or mortar incorporating the dry mix composition according to claim 10.

15. The concrete or mortar of claim 12 further including additional fillers or aggregates selected from the group consisting of materials having chemicals, thermal or abrasion resistance, thermal expansion or electric conductivity properties, fibrous materials, and materials that increase the density of the concrete or mortar.

16. The concrete or mortar of claim 13, further including additional fillers or aggregates selected from the group consisting of materials having chemical, thermal or abrasion resistance, thermal expansion or electric conductivity properties, fibrous materials, and materials that increase the density of the concrete or mortar.

17. The concrete or mortar of claim 14, further including additional filler or aggregates selected from the group consisting of materials having chemical, thermal or abrasion resistance, thermal expansion or electric conductivity properties, fibrous materials, and materials that increase the density of the concrete or mortar.

18. A cement composition prepared according to the process of claim 2, wherein said portland cement component is selected from the group consisting of:

(i) portland cement clinker comprising one or more combinations of calcium silicates and/or calcium aluminates and one or more types of calcium sulfate; and

(ii) portland cement.

19. The cement composition according to claim 18, further comprising mineral components.

20. The cement composition according to claim 19, wherein said mineral components are selected from the group consisting of pozzolans, volcanic glasses, diatomaceous earth, perlite, tuff, pumice, natural sand, quartz, marble, limestone, burnt gaize, burnt clay, burnt shale, rice hull ash, bentonite, activated kaolin, granulated blast furnace slag, fly ash, silica fume, catalytic and alum wastes, broken glass, broken ceramic, and calcium sulfate.

21. The cement composition according to claim 19, wherein a mass ratio of said mineral components to said admixture is from about 100:

1 to about 1;

1.

22. The process of claim 2, wherein said sorbent is a fine alkali reactive non-crystalline silicon dioxide containing material, and wherein said water reducer or high range water reducer is selected from the group consisting of sulphonated melamine, naphthalene formaldehyde, polyacrylate containing admixtures, and mixtures thereof.

23. The process of claim 22, wherein a mass ratio of said sorbent to water reducer or high range water reducer is from about 5:

1 to 100;

1.

24. The process of claim 22, wherein said silicon dioxide containing materials are selected from the group consisting of fly ash, rice hull ash, zeolite, silica fume, bentonite, activated kaolin, montmorillonite and diatomaceous earth.

25. The process of claim 2, wherein said sorbent includes a water accumulating component selected from the group consisting of porous lightweight sand, volcanic pumice, tuff, expanded clay, expanded perlite, expanded slag, and expanded glass.

26. The process according to claim 25, wherein a mass ratio of said sorbent to said water accumulating component is from about 10:

1 to about 1;

1.

27. The process according to claim 2, wherein said sorbent includes non-organic or organic salts or hydroxides of metals as an electrolytic agent.

28. The process according to claim 27, wherein said electrolytic agent is selected from the group consisting of metal alkali and alkali earth aluminates, hydroxides and/or carbonates, sodium nitrite, Al, Na, K or Ca sulphate, calcium chloride, and calcium formate.

29. The process according to claim 28, wherein a mass ratio of said sorbent to said electrolytic agent is from about 10:

1 to about 1000;

1.

30. The process according to claim 2, wherein said sorbent includes hydrates, partially hydrated and dehydrated salts or compounds that combine with water as a water combining component of said sorbent.

31. The process according to claim 30, wherein said water combining component is selected from the group consisting of calcium sulfate, high alumina cement and Na sulphate.

32. The process according to claim 30, wherein a mass ratio of sorbent to water combining component is from about 1:

1 to about 100;

1.

33. The process according to claim 2, wherein said admixture includes a water-soluble polymer.

34. The process according to claim 33, wherein said water-soluble polymer is selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, polyacrylamide, cellulose ethers, methylcellulose, carboxymethyl celluose, and hydroxyethyl cellulose.

35. The process according to claim 34, wherein a mass ratio of said sorbent to said water soluble polymer is from about 3:

1 to about 100;

1.

36. The process according to claim 22, wherein said admixture includes a retarder of hydration, setting, and/or hardening of a cement composition.

37. The process according to claim 36, wherein said retarder is selected from the group consisting of lignosulphonates, sugars, hydroxycarbonic acids, and their salts, carboxylates, phosphonic or phosphoric acids, and their ethers and salts.

38. The process according to claim 37, wherein a mass ratio of sorbent to retarder is from about 50:

1 to about 1000;

1.

39. The process according to claim 2, wherein said admixture includes air detraining, hydrophobic, air entraining, foaming and/or gas creating components as structure formation components.

40. The process according to claim 39, wherein said air detraining component is three-butyl phosphate.

41. The process according to claim 39, wherein said hydrophobic component is selected from the group consisting of silicon-containing compounds containing silicones, silanes, silanols and/or siloxanes groups.

42. The process according to claim 39, wherein said air entraining or said foaming components are selected from the group consisting of neutralised hydroaromatic and fatty carboxylic acid, tall oil, vinsol resin and protein-containing mixtures.

43. The process according to claim 39, wherein said gas creating component is metal powder and/or hydrogen peroxide.

44. The process according to claim 39, wherein a mass ratio of said sorbent to said structure formation components is from about 10:

1 to about 10000;

1.

45. The process according to claim 2, wherein said admixture includes grinding aid components.

46. The process according to claim 45, wherein said grinding aid components are selected from the group consisting of triethanol amine, amine acetate salts, EDTA, acetic acid, hydrocarbons, silanes, methyl chlorine and fluorine silane.

47. The process according to claim 45, wherein a mass ratio of said sorbent to said grinding aid components is from about 10:

1 to about 10000;

1.

48. The process according to claim 2, wherein step (a) comprises combining said sorbent and said water reducer or high range water reducer in mixing apparatus selected from the group consisting of conventional mixers, high speed spindle or planetary mixers, vibrating mixers or mills, and air jet mixers or mills.

49. The process according to claim 2, further comprising at least one of granulating, drying, pressing, extrusion, crushing, and calendering of said admixture.

50. A cement composition prepared according to the process of claim 2 and comprising a dry or partially dry granular admixture of a silicon dioxide containing sorbent and a water reducer or high range water reducer, and said admixture combined with a portland cement component.

51. The composition of claim 50, wherein said sorbent is a fine alkali reactive non-crystalline silicon dioxide containing material, and said water reducer or high range water reducer is selected from the group consisting of sulphonated melamine, naphthalene formaldehyde, polyacrylate containing admixtures, and mixtures thereof.

52. The composition of claim 51, wherein a mass ratio of said sorbent to water reducer or high range water reducer is from about 5:

1 to about 100;

1.

53. The composition according to claim 51, wherein said silicon dioxide containing material is selected from the group consisting of fly ash, rice hull ash, zeolite, silica fume, bentonite, activated kaolin, montmorillonite and diatomaceous earth.

54. The composition according to claim 50, wherein said sorbent includes porous lightweight sand, volcanic pumice, tuff, expanded clay, expanded perlite, expanded slag, and/or expanded glass as a water accumulating component.

55. The composition according to claim 54, wherein a mass ratio of said sorbent to said water accumulating component is from about 10:

1 to about 1;

1.

56. The composition according to claim 50, wherein said sorbent includes non-organic or organic salts or hydroxides of metals as an electrolytic agent.

57. The composition according to claim 56, wherein said electrolytic agent is selected from the group consisting of metal alkali and alkali earth aluminates, hydroxides and/or carbonates, sodium nitrite, Al, Na, K or Ca sulphate, calcium chloride, and calcium formate.

58. The composition according to claim 57, wherein a mass ratio of said sorbent to said electrolytic agent is from about 10:

1 to about 1000;

1.

59. The composition according to claim 50, wherein said sorbent includes hydrated, partially hydrated and dehydrated salts or combinations thereof that combine with water as a water combining component of said sorbent.

60. The composition according to claim 59, wherein said water combining component is selected from the group consisting of calcium sulfate, high alumina cement and Na sulphate.

61. The composition according to claim 59, wherein a mass ratio of sorbent to water combining component is from about 1:

1 to about 100;

1.

62. The composition according to claim 50, wherein said admixture further comprises a water-soluble polymer.

63. The composition according to claim 62, wherein said water-soluble polymer is selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, polyacrylamide, cellulose ethers, methylcellulose, carboxymethyl cellulose, and hydroxyethyl cellulose.

64. The composition according to claim 62, wherein a mass ratio of said sorbent to said water soluble polymer is from about 3:

1 to about 100;

1.

65. The composition according to claim 50, wherein said admixture further comprises a retarder of hydration, setting, and/or hardening of a cement composition.

66. The composition according to claim 65, wherein said retarder is selected from the group consisting of lignosulphonates, sugars, hydroxycarbonic acids and their salts, carboxylates, phosphonic or phosphoric acids, and their ethers and salts.

67. The composition according to claim 65, wherein a mass ratio of sorbent to retarder is from about 50:

1 to about 1000;

1.

68. The composition according to claim 50, wherein said admixture further comprises air detraining, hydrophobic, air entraining, foaming and/or gas creating components as structure formation components.

69. The composition according to claim 68, wherein said air detraining component is three-butyl phosphate.

70. The composition according to claim 68, wherein said hydrophobic component is selected from the group consisting of silicon-containing compounds containing silicones, silanes, silanols and/or siloxanes groups.

71. The composition according to claim 68, wherein said air entraining or said foaming components are selected from the group consisting of neutralized hydroaromatic and fatty carboxylic acid, tall oil, vinsol resin and protein-containing mixtures.

72. The composition according to claim 68, wherein said gas creating component is metal powder and/or hydrogen peroxide.

73. The composition according to claim 68, wherein a mass ratio of said sorbent to said structure formation components is from about 10:

1 to about 10000;

1.

74. The composition according to claim 50, further comprising grinding aid components.

75. The composition according to claim 71, wherein said grinding aid components are selected from the group consisting of triethanol amine, amine acetate salts, EDTA, acetic acid, hydrocarbons, silanes, methyl chlorine and fluorine silane.

76. The composition according to claim 74, wherein a mass ratio of said sorbent to said grinding aid components is from about 10:

1 to about 10000;

1.

77. The process of claim 38 wherein said portland cement comprises at least one of moderate heat of hardening cements, high early strength cements, low heat cements, sulfate resisting cements, white portland cements, blended hydraulic cements, portland blast furnace slag cements, portland-pozzolan cements, expanding cements, high alumina cements and oil-well cements.

78. The cement composition of claim 18 wherein said portland cement comprises at least one of moderate heat of hardening cements, high early strength cements, low heat cements, sulfate resisting cements, white portland cements, blended hydraulic cements, portland blast furnace slag cements, portland-pozzolan cements, expanding cements, high alumina cements and oil-well cements.