Very fast setting cementitious composition

• US 6,869,474 B2
• Filed: 04/16/2003
• Issued: 03/22/2005
• Est. Priority Date: 08/29/2002
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Dubey, Ashish, Perez-Pena, Marianela
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US10/414,686
• Publication Number:
  US 20040040474A1
• Time in Patent Office: 706 Days
• Field of Search: 106/727, 106/819, 106/724, 106/823
• US Class Current: 106/727
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/122 Hydroxy amines
• 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 40/0082 making use of a rise in temperature, e.g. caused by an exothermic reaction
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Extremely fast setting of cementitious compositions for producing cement-based products such as cement boards is made possible by adding an alkanolamine to a hydraulic cement such as portland cement, and forming a slurry with water under conditions that provide an initial slurry temperature of at least 90° F. Use of alkanolamine under conditions disclosed herein allows an extremely rapid setting of the cementitious composition. Additional reactive materials may be included such as high alumina cement, calcium sulfate and a pozzolanic material such as fly ash. The extremely fast rapid set permits rapid production of cementitious products.

Claims

1. A method of providing a fast setting slurry comprising mixing an accelerating amount of an alkanolamine with hydraulic cement and water under conditions which provide an initial slurry temperature of at least 90°

F. or 32.2°

C. said slurry rapidly reaching peak temperature and achieving rapid setting compared to slurries having a lower initial temperature.

2. A method of claim 1 wherein said slurry has an initial temperature of at least 95°

F. or 35°

C.

3. A method of claim 1 wherein said slurry has an initial temperature of at least 100°

F. or 37.8°

C.

4. A method of claim 1 wherein said slurry has an initial temperature of at least 105°

F. or 40.6°

C.

5. A method of claim 1 wherein said slurry has an initial temperature of at least 110°

F. or 43.3°

C.

6. A method of claim 1 wherein said slurry has an initial temperature of about 110°

-120°

F. or 43.3-48.9°

C.

7. A method of claim 1 wherein said slurry has an initial temperature of at least 125°

F. or 51.6°

C.

8. A method of claim 1 wherein said slurry has an initial temperature of about 130°

F. or 54.4°

C.

9. A method of claim 1 wherein said slurry has an initial temperature of 90 to 130°

F. or 32.2°

-54.4°

C.

10. A method of claim 1 wherein said alkanolamine is selected from the group consisting of triethanolamine, diethanolamine, monoethanolamine and mixtures thereof.

11. A method of claim 1 wherein said alkanolamine is triethanol amine and said accelerating amount of triethanolamine is about 0.03 to 4.0 wt % based on the weight of hydraulic cement.

12. A method of claim 1 wherein said hydraulic cement is portland cement.

13. A method of claim 12 wherein said slurry further comprises a mineral additive.

14. A method of claim 13 wherein said mineral additive is fly ash.

15. A method of claim 14 wherein said fly ash is Class C fly ash.

16. A method of claim 13 wherein said mineral additive is ground granulated blast furnace slag.

17. A method of claim 13 wherein said slurry further comprises high alumina cement and calcium sulfate.

18. A method of claim 13 wherein said slurry further comprises an aggregate.

19. A method of claim 17 wherein said slurry further comprises an aggregate.

20. A method of claim 1 wherein said slurry further comprises a set retarder.

21. A method of claim 20 wherein said set retarder is sodium citrate.

22. A method of claim 17 wherein said portland cement is about 40 to 80 wt %, said high alumina cement is greater than zero up to 20 wt %, said alcium sulfate is greater than zero up to 7 wt %, said fly ash is greater than zero up to 55 wt %, based on the sum of said portland cement, high alumina cement, calcium sulfate and fly ash.

23. A method of claim 14 wherein said portland cement is about 40 to 80 wt % and said fly ash is 20 to 60 wt % based on the sum of said portland cement and fly ash.

24. A method of claim 22 wherein said alkanolamine is triethanolamine and in an amount of about 0.05 to 2.0 wt % based on the sum of said portland cement, high alumina cement, calcium sulfate, and fly ash.

25. A method of claim 23 wherein said alkanolamine is triethanolamine and in an amount of about 0.05 to 1.0 wt % based on the sum of portland cement and fly ash.

26. A method of claim 1 wherein said, initial slurry temperature is achieved by heating one or more of the components of said slurry.

27. A method of claim 1 wherein said slurry further comprises an inorganic set accelerator.

28. A method of claim 27 wherein said set accelerator is sodium carbonate.

29. A method of claim 1 wherein said slurry further comprises a superplasticizer.

30. A composition for preparing a cement board comprising:

(a) portland cement;

(b) mineral additive;

(c) aggregate;

(d) as an accelerator for components (a) and (b) an alkanolamine;

(e) sufficient water to prepare a slurry;

said slurry being at a temperature of at least 90°

F. or 32.2°

C. when components (a)-(e) are mixed to form said composition, said slurry rapidly reaching peak temperature and achieving rapid setting compared to slurries having a lower initial temperature.

31. A composition of claim 30 wherein said alkanolamine is selected from the group consisting of triethanolamine, diethanolamine, monoethanolamine and mixtures thereof.

32. A composition of claim 31 wherein said alkanolamine is triethanolamine and said accelerating amount of triethanolamine is about 0.03 to 4.0 wt % based on the weight of portland cement.

33. A composition of claim 30 wherein said mineral additive is fly ash.

34. A composition of claim 30 wherein said mineral additive is ground granulated blast furnace slag.

35. A composition of claim 33 wherein said composition further comprises high alumina cement and calcium sulfate.

36. A composition of claim 30 wherein said composition further comprises a set retarder.

37. A composition of claim 36 wherein set retarder is sodium citrate.

38. A composition of claim 35 wherein said portland cement is about 40 to 80 wt %, said high alumina cement is greater than zero up to 20 wt %, aid calcium sulfate is greater than zero up to 7 wt %, said fly ash is greater than zero up to 55 wt %, based on the sum of said portland cement, high alumina cement, calcium sulfate and fly ash.

39. A composition of claim 33 wherein said portland cement is about 40 to 80 wt % and said fly ash is 20 to 60 wt % based on the sum of said portland cement and fly ash.

40. A composition of claim 30 wherein said composition includes an inorganic set accelerator.

41. A composition of claim 40 wherein said inorganic set accelerator is sodium carbonate.

42. A composition of claim 30 wherein said composition further comprises a superplasticizer.