Pre-blend settable composition containing calcium chloride

• US 6,746,531 B1
• Filed: 12/23/2002
• Issued: 06/08/2004
• Est. Priority Date: 12/23/2002
• Status: Expired due to Fees

• Current Assignee: White Research & Development, Inc.
• Original Assignee: Ronald Lee Barbour
• Inventors: Barbour, Ronald Lee
• Primary Examiner(s): Green, Anthony J.
• Application Number:
  US10/325,751
• Time in Patent Office: 533 Days
• Field of Search: 106/705, 106/707, 106/709, 106/DIG.1, 106/734
• US Class Current: 106/709
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/081 from brown coal or lignite
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 22/124 Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 28/04 Portland 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

Abstract

The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and calcium chloride (CaCl₂) as a substantial replacement for Portland cement conventionally used in such compositions. The calcium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Claims

1. A pre-blend settable composition comprising at least about 50 percent cement, Class-C fly ash, Class-F fly ash, and calcium chloride, wherein all percentages are based on the total weight of the composition.

2. The composition of claim 1, wherein the cement is Portland cement.

3. The composition of claim 1, wherein the Class-C fly ash is present in an amount of about 10 percent to about 20 percent.

4. The composition of claim 1, wherein the Class-F fly ash is present in an amount of about 10 percent to about 20 percent.

5. The composition of claim 1, wherein the calcium chloride is present in an amount of about 1 percent to about 5 percent.

6. The composition of claim 1, wherein the cement is present in an amount of at least about 50 percent, the Class-C fly ash is present in an amount of about 10 percent to about 20 percent, the Class-F fly ash is present in an amount of about 10 percent to about 20 percent, and the calcium chloride is present in an amount of about 1 percent to about 5 percent.

7. The composition of claim 1, further comprising slag.

8. The composition of claim 7, wherein the slag is present in an amount of about 10 percent to about 20 percent.

9. A method of making concrete comprising steps of

i) providing the pre-blend composition of claim 1;

ii) mixing said pre-blend composition with water, sand, and gravel to form a mixture;

iii) forming the mixture into a shape; and

iv) allowing the mixture to harden to form concrete.

10. The method of claim 9, wherein the cement is Portland cement.

11. The method of claim 9, wherein the Class-C fly ash is present in an amount of about 10 percent to about 20 percent.

12. The method of claim 9, wherein the Class-F fly ash is present in an amount of about 10 percent to about 20 percent.

13. The method of claim 9, wherein the calcium chloride is present in an amount of about 1 percent to about 5 percent.

14. The method of claim 9, wherein the cement is present in an amount of at least about 50 percent, the Class-C fly ash is present in an amount of about 10 percent to about 20 percent, the Class-F fly ash is present in an amount of about 10 percent to about 20 percent, and the calcium chloride is present in an amount of about 1 percent to about 5 percent.

15. The method of claim 9, wherein the mixture further comprising slag.

16. The method of claim 15, wherein the slag is present in an amount of about 10 percent to about 20 percent.