Method of producing a cementitious sheet-form material having a high level of glass aggregate and a solid surface

• US 8,236,230 B2
• Filed: 07/23/2010
• Issued: 08/07/2012
• 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:
  US12/842,031
• Publication Number:
  US 20110037200A1
• Time in Patent Office: 746 Days
• Field of Search: 264/333, 106/716, 106/718, 106/737
• US Class Current: 264/333
• 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 method of producing a sheet-form material having an exposed solid surface comprises pre-mixing cement with at least one pozzolan to provide a cement/pozzolan mixture with a high pozzolan to cement ratio, adding to the cement/pozzolan mixture an aqueous solution comprised of water and a high range water reducer to produce a cement/pozzolan dough-like substance, adding and mixing a sufficient quantity of glass aggregate to said cement/pozzolan dough-like substance to produce a moldable composition, wherein, after adding and mixing in the glass aggregate, the pozzolan is present in the composition at about 5% to about 20% by weight, the cement is present in the composition at about 3% to about 20% by weight, and the aggregate glass is by weight a relatively high percentage of the composition. The moldable composition is placed into a mold and vibrated, and is allowed to cure.

Claims

1. A method of producing a sheet-form material having an exposed solid surface comprising

mixing cement with at least one pozzolan to provide a cement/pozzolan mixture with the pozzolan to cement ratio between about 1 and about 4,

adding to said cement/pozzolan mixture an aqueous solution comprised of water and a high range water reducer to produce a cement/pozzolan mixture,

adding and mixing a sufficient quantity of 12 mesh or larger glass aggregate to said cement/pozzolan mixture to produce a moldable composition, wherein, after adding and mixing in the glass aggregate, the pozzolan is present in the composition at about 5% to about 20% by weight, the cement is present in the composition at about 3% to about 20% by weight, and the aggregate glass is at least about 70% by weight of the composition,

placing said moldable composition into a mold,

vibrating the mold,

allowing the moldable composition to cure in the mold.

2. The method of claim 1 wherein, after adding and mixing in the glass aggregate, the cement is present in the moldable composition at about 5% to about 10% by weight.

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

4. The method of claim 1 wherein the pozzolan of the cement/pozzolan mixture is comprised of a mixture of metakaolin, wollastonite, micro-silica, and finely ground glass powder.

5. The method 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 powder, and at least one pozzolan selected from the group consisting of fly ash, silica fume, and ground granulated blast furnace slag.

6. The method 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 powder.

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

8. The method 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 method of claim 1 wherein the aggregate glass comprises fine and coarse aggregate glass.

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

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

12. The method of claim 1 wherein all the aggregate glass is provided in the form of recycled glass.

13. The method of claim 1 wherein the pozzolans of the cement/pozzolan mixture include glass pozzolans, and wherein the glass pozzolans and the aggregate glass combined are present at about 70% to about 90% by weight.

14. The method of claim 13 wherein the glass pozzolans and aggregate glass are provided in the form of recycled material.

15. The method of claim 1 further comprising adding a silica containing filler to the cement/pozzolan mixture, wherein the ratio of silica containing filler to cement is present at about 1.0 to about 4.

16. The method of claim 1 further comprising adding a liquid acrylic in an amount equal to or less than about 2% by dry weight to the cement/pozzolan mixture.

17. The method of claim 1 wherein the cement of the cement/pozzolan mixture is comprised of ordinary Portland cement selected the group consisting of Type I ordinary Portland cement and Type III ordinary Portland cement.

18. The method of claim 1 wherein the pozzolan of the cement/pozzolan mixture is comprised of at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro-silica, and finely ground glass powder, and wherein, after adding and mixing in the glass aggregate, said at least one pozzolan is 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 powder—

5% to 20% by weight.

19. The method of claim 1 wherein the pozzolan of the cement/pozzolan mixture is comprised of at least one pozzolan selected from the group consisting of metakaolin, wollastonite, micro-silica and finely ground glass powder, and wherein, after adding and mixing in the glass aggregate, said at least one pozzolan is 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 powder—

5% to 20% by weight.

20. The method of claim 1 wherein the pozzolan of said cement/pozzolan mixture is comprised of metakaolin, wollastonite, micro-silica, and finely ground glass powder, and wherein, after adding and mixing in the glass aggregate, said pozzolans are 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 powder—

5% to 20% by weight.

21. The method of claim 1 wherein the pozzolan of said cement/pozzolan mixture is comprised of metakaolin, wollastonite, micro-silica, and finely ground glass powder, and wherein, after adding and mixing in the glass aggregate, said pozzolans are 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 powder—

5% to 20% by weight.

22. The method of claim 1 wherein, after adding and mixing in the glass aggregate, the pozzolan is present at about 5% to about 10% by weight.

23. The method of claim 1 wherein, after adding and mixing in the glass aggregate, the glass aggregate is at least about 75% to about 90% by weight of the composition.

24. A method of producing a sheet-form material having an exposed solid surface comprising

mixing cement with pozzolans to provide a cement/pozzolan mixture with the pozzolan to cement ratio between about 1 and about 4, said pozzolans comprising metakaolin, wollastonite, micro-silica, and finely ground glass powder,

adding to said cement/pozzolan mixture an aqueous solution comprised of water and a high range water reducer to produce a cement/pozzolan mixture,

adding and mixing a sufficient quantity of about 12 mesh or larger glass aggregate to said cement/pozzolan mixture to produce a moldable composition, wherein, after adding and mixing in the glass aggregate, the aggregate glass is present at about 75% to about 90% by weight, and the cement of said moldable composition is between about 3% to about 20% by weight, and the pozzolans are present in the following ranges:

metakolin—

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 powder—

5% to 20% by weight,

placing said moldable composition into a mold,

vibrating the mold,

allowing the moldable composition to cure in the mold.