Lightweight cementitious compositions and building products and methods for making same

• US 8,298,332 B2
• Filed: 10/27/2011
• Issued: 10/30/2012
• Est. Priority Date: 07/05/2007
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Dubey, Ashish
• Primary Examiner(s): Marcantoni, Paul
• Application Number:
  US13/282,689
• Publication Number:
  US 20120040165A1
• Time in Patent Office: 369 Days
• Field of Search: 106/713, 264/333, 156/39
• US Class Current: 106/713
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/185 expanded
• 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 20/008 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 20/1051 Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 2111/40 Porous or lightweight materials
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 22/147 Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/122 Hydroxy amines
• CPC Class Codes: C04B 24/226 : Sulfonated naphtalene-formaldehyde condensation products
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 38/0074 : expressed as porosity percentage
• CPC Class Codes: C04B 38/10 : by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 40/0082 : making use of a rise in temperature, e.g. caused by an exothermic reaction
• CPC Class Codes: C04B 7/32 : Aluminous cements
• CPC Class Codes: E04C 2/049 : completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/02 : Perlite
• CPC Class Codes: Y10T 442/10 : Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Abstract

Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.

Claims

1. A cement board having a density of about 45 to 85 pounds per cubic foot (0.72 to 1.36 g/cc), and having a continuous phase resulting from the curing of an aqueous mixture comprising:

35-60 parts by weight Portland cement-based binder,

2-10 parts by weight expanded and coated perlite filler having a mean particle diameter of about 20 to 90 microns,

10-50 volume % entrained air, and

optional additives selected from one or more members of the group consisting of water reducing agents, set-accelerators, set-retarders; and

0-25 parts by weight secondary filler, wherein the secondary filler is at least one of blast furnace slag, volcanic tuff, expanded clay, shale aggregate, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads and pumice.

2. A method of forming a board of claim 1 from a lightweight cementitious slurry comprising:

forming the slurry as a mixture of;

35 to 60 wt. %, on a wet basis, cementitious reactive powder comprising Portland cement,

2 to 10 wt. %, on a wet basis, expanded and coated and water repellant perlite filler,

20 to 40 wt. % water,

0 to 25 wt. %, on a wet basis, secondary filler, wherein the secondary filler is at least one of blast furnace slag, volcanic tuff, expanded clay, shale aggregate, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads and pumice;

10 to 50 vol. %, on a wet basis, entrained air;

air-entraining agent and/or foaming agent and

optional additive from at least one of water reducing agents, set-accelerators, and set-retarders;

under conditions which provide an initial slurry temperature of at least about 40°

F. (4.4°

C.),

wherein the perlite filler has a mean particle diameter between 20 to 90 microns; and

forming and setting the slurry to produce the board.

3. The board of claim 1, wherein the perlite filler is coated with at least one of silane, siloxane, silicone and mixtures thereof.

4. The board of claim 1, wherein the board has top and bottom surfaces reinforced with reinforcing mesh, wherein the reinforcing mesh comprises inorganic material.

5. The board of claim 1, wherein the board has top and bottom surfaces reinforced with reinforcing mesh, wherein the reinforcing mesh comprises organic material.

6. The board of claim 1, wherein the reinforcing mesh comprises an alkali resistant fiberglass.

7. The board of claim 1, wherein the board has a thickness of about ¼

to 1 inches (6.3 to 25.4 mm).

8. The board of claim 1, wherein the board has nail pull strength of at least 90 lbs (40.8 kg) per ASTM D1037.

9. The board of claim 1, wherein the perlite filler has a mean particle diameter between 20 to 60 microns.

10. The board of claim 1, wherein the board has flexural strength of at least 400 psi (2.76 MPa) per ASTM C947.

11. The board of claim 1, wherein the perlite filler has a particle density less than 0.50 g/cc.

12. The board of claim 1, wherein the perlite filler has a particle density less than 0.30 g/cc.

13. The board of claim 1, wherein the board has shear strength to ceramic tile and cement mortar of at least 50 psi (0.34 MPa) per ANSI A118.10.

14. The board of claim 1,

wherein the mixture comprises 10 to 25 wt. % said secondary fillers;

and

wherein the mixture further comprises a mineral additive comprising at least one of pumice, diatomaceous earth, silica fume, tuff, trass, rice husk, metakaolin, ground granulated blast furnace slag, Class C fly ash, calcium carbonate, mica and talc; and

wherein a total of the perlite filler and secondary fillers is at least 20 wt. % of the mixture.

15. The board of claim 1, wherein the mixture comprises the set-accelerator, wherein the set-accelerator comprises an alkanolamine selected from the group consisting of triethanolamine, diethanolamine, monoethanolamine and mixtures thereof, wherein the amount of the alkanolamine is about 0.03 to 4 wt. % based on the weight of the cementitious reactive powder on a dry basis.

16. The board of claim 1, wherein the mixture further comprises at least one of high alumina cement and calcium sulfate.

17. A floor comprising cement boards of claim 1, with ability to pass a minimum of first three cycles of a test per ASTM C627 for structural durability.

18. The board of claim 1, wherein the mixture comprises the secondary filler, wherein the secondary filler is at least one of blast furnace slag, volcanic tuff, expanded clay, shale aggregate, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads and pumice.