Very fast setting cementitious composition with high early-age compressive strength

• US 7,670,427 B2
• Filed: 06/06/2007
• Issued: 03/02/2010
• Est. Priority Date: 06/06/2007
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Perez-Pena, Marianela, Peng, Yanfei, Veeramasuneni, Srinivas
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US11/758,947
• Publication Number:
  US 20080302276A1
• Time in Patent Office: 1,000 Days
• Field of Search: 106/727, 106/819, 106/823
• US Class Current: 106/727
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/122 Hydroxy amines
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 28/065 Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
• CPC Class Codes: C04B 40/0082 making use of a rise in temperature, e.g. caused by an exothermic reaction
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A method of making a rapid setting composition for cement boards is disclosed. Compositions including portland cement, fly ash, gypsum, alkanolamine and phosphate are disclosed. A synergistic interaction between the alkanolamine and phosphate increases the effectiveness of accelerating reactions thus allowing for quick setting and increased early-age compressive strength compositions.

Claims

1. A method of providing a fast setting cementitious mixture comprising:

mixing

water,

a cementitious reactive powder comprising hydraulic cement, and

a set accelerating amount of alkanolamine and polyphosphate,

under conditions which provide a mixture temperature of at least about 90°

F.

2. The method of claim 1, wherein the mixture has a temperature of about 90-135°

F.

3. The method of claim 1, wherein the mixture has a temperature of at least about 100°

F.

4. The method of claim 1, wherein the mixture has a temperature of at least about 105°

F.

5. The method of claim 1, wherein the polyphosphate is selected from at least one member of the group consisting of sodium trimetaphosphate, potassium tripolyphosphate, sodium tripolyphosphate, tetrasodium pyrophosphate and tetrapotassium pyrophosphate.

6. The method of claim 1, wherein the polyphosphate is provided in an amount of about 0.15 to 1.5 wt. % phosphate based on the weight of the cementitious reactive powder.

7. The method of claim 1, wherein the polyphosphate is provided in an amount of about 0.3 to 1.0 wt. % based on the weight of the cementitious reactive powder.

8. The method of claim 1, wherein the polyphosphate is provided in an amount of about 0.4 to 0.75 wt. % based on the weight of the cementitious reactive powder.

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

10. The method of claim 1, wherein the alkanolamine is provided in an amount of about 0.025 to 1 wt. % based on the weight of the cementitious reactive powder.

11. The method of claim 1, wherein the alkanolamine is provided in an amount of about 0.05 to 0.25 wt. % based on the weight of the cementitious reactive powder.

12. The method of claim 1, wherein the polyphosphate comprises sodium trimetaphosphate and is provided in an amount of about 0.4 to 0.75 wt. % based on the weight of cementitious reactive powder,

wherein the alkanolamine comprises triethanolamine and is provided in an amount of about 0.05 to 0.1 wt. % based on the weight of the cementitious reactive powder.

13. The method of claim 1, wherein the cementitious reactive powder comprises the hydraulic cement and optionally at least one member of the group consisting of a mineral additive, calcium aluminate cement, and calcium sulfate.

14. The method of claim 1, wherein the hydraulic cement comprises portland cement.

15. The method of claim 1, wherein the cementitious reactive powder further comprises a mineral additive.

16. The method of claim 1, wherein the cementitious reactive powder further comprises fly ash.

17. The method of claim 1, wherein the cementitious reactive powder further comprises calcium sulfate.

18. The method of claim 1, wherein the cementitious reactive powder comprises about 40 to 80 wt % portland cement, 0 to 20 wt % calcium aluminate cement, 0 to 7 wt % calcium sulfate, 0 to 55 wt % fly ash, based on the sum of the portland cement, calcium aluminate cement, calcium sulfate and fly ash.

19. The method of claim 1, wherein the cementitious reactive powder comprises about 40 to 80 wt. % portland cement and 20 to 60 wt. % fly ash based on the sum of the portland cement and fly ash.

20. The method of claim 1, wherein the mixture further comprises an aggregate.

21. The method of claim 1, further comprising admixing at least one member of the group consisting of set retarder, air-entraining agent, secondary inorganic set accelerator, and superplasticizer to the mixture.

22. The method of claim 1, wherein the mixture further comprises a set retarder.

23. The method of claim 1, wherein the mixture further comprises an air-entraining agent.

24. The method of claim 1, wherein the mixture further comprises a secondary inorganic set accelerator.

25. The method of claim 1, wherein the mixture further comprises a superplasticizer.

26. The method of claim 1, wherein the mixture temperature is achieved 0 to 5 minutes after forming the mixture by heating one or more of the components of the mixture.

27. The method of claim 1, comprising providing sufficient water to form the mixture as a slurry.

28. A composition for preparing a cement board comprising a mixture of:

a cementitious reactive powder comprising;

(a)hydraulic cement; and

(b)optional mineral additive;

an alkanolamine and polyphosphate as accelerators for components (a) and (b); and

water,

formed by a method comprising mixing the mixture at a temperature of at least 90°

F.

29. The composition of claim 28, wherein the polyphosphate is at least one member selected from the group consisting of sodium trimetaphosphate, potassium tripolyphosphate, sodium tripolyphosphate, tetrasodium pyrophosphate and tetrapotassium pyrophosphate and mixtures thereof.

30. The composition of claim 28, wherein the mixture comprises about 0.15 to 1.5 wt. % phosphate based on the weight of the cementitious reactive powder.

31. The composition of claim 28, wherein the mixture comprises about 0.3 to 1.0 wt. % phosphate based on the weight of cementitious reactive powder.

32. The composition of claim 28, wherein the mixture comprises about 0.4 to 0.75 wt. % phosphate based on the weight of cementitious reactive powder.

33. The composition of claim 28, wherein the alkanolamine is selected from the group consisting of triethanolamine, diethanolamine, monoethanolamine and mixtures thereof.

34. The composition of claim 28, wherein the mixture comprises about 0.025 to 1 wt. % alkanolamine based on the weight of the cementitious reactive powder.

35. The composition of claim 28, wherein the mixture comprises about 0.05 to 0.25 wt. % alkanolamine based on the weight of the cementitious reactive powder.

36. The composition of claim 28, wherein the mixture comprises:

about 0.4 to 0.75 wt % phosphate based on the weight of cementitious reactive powder, wherein the phosphate comprises sodium trimetaphosphate, and

about 0.05 to 0.1 wt % alkanolamine based on the weight of the cementitious reactive powder, wherein the alkanolamine comprises triethanolamine.

37. The composition of claim 28, wherein the cementitious reactive powder comprises the hydraulic cement and optionally at least one member of the group consisting of a mineral additive, calcium aluminate cement, and calcium sulfate.

38. The composition of claim 28, wherein the hydraulic cement comprises portland cement.

39. The composition of claim 28, wherein the mixture further comprises a mineral additive.

40. The composition of claim 28, wherein the mixture further comprises fly ash.

41. The composition of claim 28, further comprising at least one member selected from the group consisting of aggregate, set retarder, foaming agent, air-entraining agent, secondary inorganic set accelerator, superplasticizer and mixtures thereof.

42. The composition of claim 28, comprising sufficient water to form a slurry.