Cementitious composition incorporating high levels of glass aggregate for producing solid surfaces

• US 7,771,529 B1
• Filed: 08/31/2005
• Issued: 08/10/2010
• Est. Priority Date: 08/31/2004
• Status: Active Grant

• Current Assignee: Georgia Architectural Stone Incorporated, Georgia Stone Quarries, Inc., Polycor, Inc., Polycor Stone Corp. (Polycor, Inc.)
• Original Assignee: Polycor Vetrazzo, Inc.
• Inventors: McPherson, Donald Martin
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US11/218,343
• Time in Patent Office: 1,805 Days
• Field of Search: 106/705, 106/716, 106/718, 106/737, 106/789, 106/DIG.1
• US Class Current: 106/716
• CPC Class Codes: C04B 14/043 Alkaline-earth metal silicates, e.g. wollastonite
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 20/0096 Fillers with bimodal grain size distribution
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 24/04 Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0046 characterised by their processing, e.g. sequence of mixing the ingredients when preparing the premixtures
• CPC Class Codes: C04B 40/0067 making use of vibrations
• CPC Class Codes: C04B 40/0259 Hardening promoted by a rise in pressure C04B40/024 takes precedence
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A cementitious composition for high density, low porosity sheet-form building materials having solid surfaces is comprised of cement, pozzolans, and a high percentage of fine and/or coarse glass aggregate, preferably present in an amount which by weight is at least 60% of the composition. The cement content is relatively low, preferably in the range of about 3% to 20% by weight, and the pozzolan to cement ratio is relatively high, preferably equal to or greater than unity, but which can suitably be in the range from 0.25 to 4. The composition preferably uses recycled glass and preferably has a high recycle content. The sheet-form material made in accordance with the invention can be used to provide exposed solid surfaces, for example, surfaces for shower walls and floors, counter-tops, table-tops, and the like, where low hydraulic permeability and high compressive and tensile strength are desired.

Claims

1. A cementitious composition for a sheet-form material having an exposed solid surface comprising cement, pozzolan, and aggregate glass, wherein said pozzolan is present at about 5% to about 20% by weight, said cement is present at about 3% to about 20% by weight, the pozzolan to cement ratio is from about 1 to about 4, and the aggregate glass is at least about 70% by weight of the composition, and wherein the size of the aggregate glass is about equal to or greater than 12 mesh glass aggregate.

2. The composition of claim 1 wherein said cement is present at about 5% to about 10% by weight.

3. The composition of claim 1 wherein the pozzolan is comprised of at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro-silica and finely ground glass powders.

4. The composition of claim 1 wherein the pozzolan is comprised of metakaolin, wollastonite, micro-silica, and finely ground glass powders.

5. The composition of claim 3 wherein the pozzolan is comprised of at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro silica and finely ground glass powder, and at least one pozzolan selected from the group consisting of fly ash, silica fume, and ground granulated blast furnace slag.

6. The composition of claim 1 wherein the pozzolan is comprised of at least three pozzolans selected from the group consisting of fly ash, silica fume, ground granulated blast furnace slag, metakaolin, wollastonite, micro-silica, and finely ground glass powders.

7. The composition of claim 1 wherein the pozzolan is comprised of finely ground glass powder selected from the group consisting of 100 mesh, 120 mesh, and 300 mesh glass powder.

8. The composition of claim 1 wherein the pozzolan is comprised of a mixture of 100 mesh, 120 mesh, and 300 mesh finely ground glass powder.

9. The composition of claim 1 wherein the aggregate glass is comprised of fine and coarse aggregate glass.

10. The composition of claim 9 wherein at least one of the fine and coarse aggregate glass is provided in the form of recycled glass.

11. The composition of claim 1 wherein said aggregate glass is provided in the form of recycled glass.

12. The composition of claim 1 wherein the pozzolan includes glass pozzolans, and wherein the glass pozzolans and the aggregate glass component combined are present at about 70% to about 90% by weight.

13. The composition of claim 12 wherein the glass pozzolans and aggregate glass are provided from recycled material.

14. The composition of claim 1 further comprising an acrylic present in an amount equal to or less than about 2% by dry weight.

15. The composition of claim 1 wherein the cement comprises ordinary Portland cement (OPC) selected from the group consisting of Type I OPC and Type III OPC.

19. The composition of claim 1 wherein the pozzolan is comprised of at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro-silica and finely ground glass powders present in the following ranges:

metakaolin—

0.5% to 10% by weight

wollastonite—

0.5% to 10% by weight

micro-silica—

0.25% to 5% by weight

finely ground glass powders—

5% to 20% by weight.

20. The composition of claim 1 wherein the pozzolan is comprised of at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro-silica and finely ground glass powders present in the following ranges:

metakaolin—

1.5% to 2.5% by weight

wollastonite—

1.5% to 3.0% by weight

micro-silica—

0.25% to 5% by weight

finely ground glass powders—

5% to 20% by weight.

21. The composition of claim 1 wherein the pozzolan is comprised of metakaolin, wollastonite, micro-silica, and finely ground glass powders present in the following ranges:

metakaolin—

0.5% to 10% by weight

wollastonite—

0.5% to 10% by weight

micro-silica—

0.25% to 5% by weight

finely ground glass powders—

5% to 20% by weight.

22. The composition of claim 1 wherein the pozzolan is comprised of metakaolin, wollastonite, micro-silica, and finely ground glass powders present in the following ranges:

metakaolin—

1.5% to 2.5% by weight

wollastonite—

1.5% to 3.0% by weight

micro-silica—

0.25% to 5% by weight

finely ground glass powders—

5% to 20% by weight.

23. The composition of claim 1 wherein the pozzolan is present at about 5% to about 10% by weight.

24. The composition of claim 1 wherein the aggregate glass is at least about 75% to about 90% by weight of the composition.

25. The composition of claim 9 wherein the size of the fine aggregate glass is less than a No. 4 screen (4.75 mm) glass aggregate.

16. A cementitious composition for a sheet-form material having an exposed solid surface comprising

cement,

pozzolan comprising at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro-silica and finely ground glass powders, said finely ground glass powders being made from recycled glass, and

aggregate glass comprised of recycled fine and coarse aggregate glass, the size of the fine aggregate glass being about or less than 12 mesh glass aggregate,

the cement being present at about 5% to about 10% by weight, and the pozzolan to cement ratio being greater than unity, and wherein the aggregate glass and finely ground glass powders constitute at least about 70% by weight of the composition.

17. A cementitious composition for a sheet-form material having an exposed solid surface comprising

ordinary Portland cement (OPC) selected from the group consisting of Type I OPC and Type III OPC,

a pozzolan comprising finely ground glass powders selected from the group consisting of 100 mesh, 120 mesh, and 300 mesh glass powders, and at least other one pozzolan selected from the group consisting of metakaolin, wollastonite, and micro-silica, and

an aggregate glass comprised of fine and coarse aggregate glass,

the OPC being present at about 3% to about 20% by weight, and the pozzolan to cement ratio being between about 1 to about 4, and wherein the aggregate glass and finely ground glass powder combined are at least about 70% by weight of the composition.

18. The composition of claim 17 wherein the finely ground glass powder and the aggregate glass are provided from recycled glass materials.

26. A cementitious composition for a sheet-form material having an exposed solid surface comprising by weight about 3% to 20% cement, about 5% to 20% pozzolans, and about 75% to 90% aggregate glass, wherein the pozzolan to cement ratio is from about 1 to about 4, and wherein the size of the aggregate glass is about equal to or greater than 12 mesh glass aggregate, and wherein the pozzolans comprise of metakaolin, wollastonite, micro-silica, and finely ground glass powders present in the following ranges:

metakaolin—

1.5% to 2.5% by weight

wollastonite—

1.5% to 3.0% by weight

micro-silica—

0.25% to 5% by weight

finely ground glass powders—

5% to 20% by weight.