Masonry, mortar, and stucco cement compositions

• US 7,101,430 B1
• Filed: 09/21/2000
• Issued: 09/05/2006
• Est. Priority Date: 09/24/1999
• Status: Expired due to Fees

• Current Assignee: Oldcastle Architectural Incorporated (CRH PLC)
• Original Assignee: Headwaters Resources Incorporated (Seven Group Holdings Limited)
• Inventors: Nordmeyer, David H., Pike, Clinton W.
• Primary Examiner(s): Wood, Elizabeth D.
• Application Number:
  US10/088,291
• Time in Patent Office: 2,175 Days
• Field of Search: 106/705, 106/713
• US Class Current: 106/705
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/0039 according to ASTM
• CPC Class Codes: C04B 2111/00646 Masonry mortars
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

This invention pertains to a process of making ASTM quality masonry cement, mortar cement, and stucco cement (also called plastic cement) and to the products themselves which are useful in making ASTM quality mortar for masonry construction or ASTM quality stucco for plastering construction. These cements are classified as hydraulic cements and are made using selected pozzolan(s), such as natural pozzolan and fly ashes, Portland Cement, hydrated lime, and an air-entraining agent. Other additives, such as fibers, may be added to further modify its properties. The pozzolans act as functional ingredients in the mix rather than as a filler. As a result, concentrations of greater than 25 wt. % and more pozzolan can be produced.

Claims

1. Cementitious mortar or stucco composition comprising (a) Portland cement, (b) hydrated lime and (c) pozzolanic material selected from the group consisting of Class “

F”

fly ash, Class “

C”

fly ash and Class “

N”

pozzolan, and mixtures thereof, said (a) (b) and (c) adding up to 100 wt %, said Portland cement (a) being present in an amount of about 5-45 wt %, said hydrated lime (b) being present in an amount of about 10-30 wt % and said pozzolanic material (c) being present in an amount of greater than about 45 wt %.

2. Composition as recited in claim 1, said composition meeting or exceeding the standards of ASTM C-91 Type “

N”

masonry cement.

3. Composition as recited in claim 1, said composition meeting or exceeding the standards of ASTM 1329 Type N mortar cement.

4. Composition as recited in claim 1, said composition meeting or exceeding the standards set forth in ASTM C-1328 Type S stucco cement.

5. Composition as recited in claim 1 comprising about 50 wt % Class “

F”

fly ash, about 12 w % hydrated lime, and about 38 wt % Portland cement, said composition being useful as a Type “

S”

masonry cement.

6. Composition as recited in claim 1 comprising about 63 wt % of Class “

F”

fly ash, about 12 wt % hydrated lime, and about 25 wt % Portland cement, said composition being useful as a Type “

N”

masonry cement.

7. Composition as recited in claim 1 comprising about 46 wt % Class “

F”

fly ash, about 43 wt % Portland cement and about 11 wt % hydrated lime, said composition being useful as a stucco type “

S”

cement.

8. Cementitious composition as recited in claim 1 comprising about 50 wt % Class “

F”

fly ash, about 33 wt % Portland cement, and about 17 wt % hydrated lime, said composition being useful as a type “

N”

masonry mix.

9. Cementitious composition as recited in claim 1 comprising about 50 wt % Class “

F”

fly ash, about 22 wt % Portland cement, about 14 wt % Class “

C”

fly ash and about 14 wt % hydrated lime, said composition being useful as a Type N masonry cement.

10. Cementitious composition as recited in claim 1 comprising about 58 wt % Class “

F”

fly ash, about 30 wt % Portland cement and about 12 wt % hydrated lime, said composition being useful as a Type S masonry cement.

11. Cementitious composition as recited in claim 1, comprising about 43 wt % Class “

F”

fly ash, about 28 wt % Portland cement, about 12 wt % Class “

C”

fly ash, and about 17 wt % hydrated lime, said composition being useful as a Type S masonry.

12. Cementitious composition as recited in claim 1 comprising about 45 wt % Class “

F”

fly ash, about 37 wt % Portland cement and about 17 wt % hydrated lime, said composition being useful as a Type “

N”

mortar cement.

13. Cementitious composition as recited in claim 1 comprising about 48 wt % Class “

F”

fly ash, about 44 wt % Portland cement, and about 11 wt % hydrated lime, said composition being useful as a Type “

S”

stucco.

14. Cementitious composition as recited in claim 1 comprising about 60 wt % Class “

N”

pozzolan, about 10 wt % Portland cement, and about 30 wt % hydrated lime, said composition being useful as a Type N masonry cement.

15. Cementitious composition as recited in claim 1 comprising about 15-30% by weight Class “

C”

fly ash, about 30-60 wt % Class “

F”

fly ash, about 15-45% Portland cement and about 10-20% hydrated lime.