High early strength pozzolan cement blends
First Claim
1. A pozzolan cement composition comprising:
- a hydraulic cement fraction comprised of a distribution of differently sized hydraulic cement particles at least partially comprised of tricalcium silicate and/or dicalcium silicate that provide excess calcium hydroxide, when mixed with water, that is available for reaction with a pozzolan, the hydraulic cement fraction having a Blaine fineness greater than about 500 m2/kg; and
a pozzolan fraction comprised of a distribution of differently sized pozzolan particles that react with calcium hydroxide in the presence of water, including calcium hydroxide provided by the hydraulic cement particles when mixed with water, in order to form solid hydration products having cementitious properties, the pozzolan fraction having a Blaine fineness that is less than the Blaine fineness of the hydraulic cement fraction,wherein a majority of the combined hydraulic cement and pozzolan particles above 20 μ
m are pozzolan particles and a majority of the combined hydraulic cement and pozzolan particles below 20 μ
m are hydraulic cement particles.
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Abstract
A high early strength pozzolan cement includes larger sized pozzolan particles blended with smaller sized hydraulic cement particles containing tricalcium silicate and/or dicalcium silicate (e.g., Portland cement). Excess calcium release from the hydraulic cement when mixed with water forms calcium hydroxide available for reaction with the pozzolan. The fineness of the hydraulic cement particles is substantially greater than the fineness of the pozzolan particles (e.g., about 1.25 to about 50 times greater). Reducing or eliminating coarse hydraulic cement particles that cannot fully hydrate but include unreacted cores reduces or eliminates wasted cement normally found in concrete. Replacing some or all of the coarse cement particles with pozzolan particles provides a pozzolan cement composition having significantly lower water demand compared to the hydraulic cement by itself.
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Citations
49 Claims
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1. A pozzolan cement composition comprising:
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a hydraulic cement fraction comprised of a distribution of differently sized hydraulic cement particles at least partially comprised of tricalcium silicate and/or dicalcium silicate that provide excess calcium hydroxide, when mixed with water, that is available for reaction with a pozzolan, the hydraulic cement fraction having a Blaine fineness greater than about 500 m2/kg; and a pozzolan fraction comprised of a distribution of differently sized pozzolan particles that react with calcium hydroxide in the presence of water, including calcium hydroxide provided by the hydraulic cement particles when mixed with water, in order to form solid hydration products having cementitious properties, the pozzolan fraction having a Blaine fineness that is less than the Blaine fineness of the hydraulic cement fraction, wherein a majority of the combined hydraulic cement and pozzolan particles above 20 μ
m are pozzolan particles and a majority of the combined hydraulic cement and pozzolan particles below 20 μ
m are hydraulic cement particles. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A pozzolan cement composition comprising:
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a Portland cement fraction comprised of a distribution of differently sized Portland cement particles having a chemistry and a Blaine fineness so that the Portland cement fraction either qualifies as a Type III Portland cement under ASTM C-150 or is finer than a Type III Portland cement under ASTM C-150; and a pozzolan fraction comprised of a distribution of differently sized pozzolan particles blended but not interground with the Portland cement particles and that react with calcium hydroxide in the presence of water, including calcium hydroxide provided by the hydraulic cement particles when mixed with water, in order to form solid hydration products having cementitious properties, the pozzolan fraction having a Blaine fineness, wherein the Blaine fineness of the Portland cement fraction is about 1.25 times to about 50 times greater than the Blaine fineness of the pozzolan fraction, wherein a majority of the combined hydraulic cement and pozzolan particles above 20 μ
m are pozzolan particles and a majority of the combined hydraulic cement and pozzolan particles below 20 μ
m are hydraulic cement particles. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38, 39, 40)
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41. A method of manufacturing a pozzolan cement composition, comprising:
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obtaining a hydraulic cement fraction comprised of a distribution of differently sized hydraulic cement particles at least partially comprised of tricalcium silicate and/or dicalcium silicate that provide excess calcium hydroxide, when mixed with water, that is available for reaction with a pozzolan, the hydraulic cement fraction having a Blaine fineness greater than about 500 m2/kg and/or having a chemistry and a Blaine fineness so that it qualifies as a Type III Portland cement under ASTM C-150; obtaining a pozzolan fraction that is initially separate from the hydraulic cement fraction and comprised of a distribution of differently sized pozzolan particles that react with calcium hydroxide in the presence of water in order to form solid hydration products having cementitious properties, the pozzolan fraction having a Blaine fineness that is less than the Blaine fineness of the hydraulic cement fraction, the Blaine fineness of the Portland cement fraction being about 1.25 times to about 50 times greater than the Blaine fineness of the pozzolan fraction, a majority of the combined hydraulic cement and pozzolan particles above 20 μ
m being pozzolan particles and a majority of the combined hydraulic cement and pozzolan particles below 20 μ
m being hydraulic cement particles; andcombining the hydraulic cement fraction and the pozzolan fraction without intergrinding to yield the pozzolan cement composition. - View Dependent Claims (42, 43, 44, 45, 46, 47, 48, 49)
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Specification