Low density cementitious compositions using limestone

• US 8,858,704 B2
• Filed: 07/14/2011
• Issued: 10/14/2014
• Est. Priority Date: 07/15/2010
• Status: Active Grant

• Current Assignee: Holcim Technology, Ltd. (Holcim Limited)
• Original Assignee: Lafarge SA (Holcim Limited)
• Inventors: Woytowich, Wes, Carruthers, Bill, Lehoux, Paul, Daderko, Greg
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US13/182,848
• Publication Number:
  US 20120012315A1
• Time in Patent Office: 1,188 Days
• Field of Search: 106/713, 106/718, 106/737, 106/738
• US Class Current: 106/713
• CPC Class Codes: C04B 14/02 Granular materials , e.g. microballoons
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/26 Carbonates
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/14 Hardening accelerators
• CPC Class Codes: C04B 2111/00068 Mortar or concrete mixtures with an unusual water/cement ratio
• CPC Class Codes: C04B 2111/00146 Sprayable or pumpable mixtures
• CPC Class Codes: C04B 2111/40 Porous or lightweight materials
• CPC Class Codes: C04B 2111/74 Underwater applications
• CPC Class Codes: C04B 22/008 Cement and like inorganic materials added as expanding or shrinkage compensating ingredients in mortar or concrete compositions, the expansion being the result of a recrystallisation mixtures of cements C04B7/00, C04B28/00
• CPC Class Codes: C04B 22/124 Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 22/142 : Sulfates
• CPC Class Codes: C04B 2201/20 : for the density
• 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 28/06 : Aluminous cements monolithic refractories or refractory mortars C04B35/66
• 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 40/0028 : Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C09K 8/473 : Density reducing additives, e.g. for obtaining foamed cement compositions
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A manufactured cementitious binder includes a hydraulic binder in an amount in the range of from 40 to 75% by weight of the cementitious binder; metakaolin in an amount in the range of from 1 to 30% by weight of the cementitious binder; silica fume in an amount up to 15% by weight of the cementitious binder; limestone in an amount of from 5 to 30% by weight of the cementitious binder, and a cementitious accelerator in a controlled amount of at least 0.5% by weight of the cementitious binder, the cementitious binder providing a cementitious settable composition when added with water, wherein for a density lower than 13 pounds per gallon and of at least 11 pounds per gallon obtained without a lightweight additive, said cementitious settable composition exhibits a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

Claims

1. A manufactured cementitious binder comprising:

a hydraulic binder in an amount in the range of from 40 to 75% by weight of the cementitious binder;

metakaolin in an amount in the range of from 1 to 30% by weight of the cementitious binder;

silica fume in an amount up to 15% by weight of the cementitious binder;

limestone in an amount of from 5 to 30% by weight of the cementitious binder, and

a cementitious accelerator in a controlled amount of at least 0.5% by weight of the cementitious binder,

the cementitious binder providing a cementitious settable composition when added with water, wherein for a density lower than 13 pounds per gallon and of at least 11 pounds per gallon obtained without a lightweight additive, said cementitious settable composition exhibits a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

2. The binder of claim 1, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

3. The binder of claim 2, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

4. The binder of claim 1, wherein the cementitious accelerator is in an amount from 0.6% to 3% by weight of the cementitious binder.

5. The binder of claim 4, wherein the cementitious accelerator is in an amount from 0.8% to 2.5% by weight of the cementitious binder.

6. The binder of claim 1, comprising microspheres in an amount less than 15% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density lower than 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

7. The binder of claim 6, wherein the cementitious settable composition has a density of about 10 pounds per gallon.

8. The binder of claim 6, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

9. The binder of claim 1, comprising microspheres in an amount less than 35% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density of about 8 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

10. The binder of claim 1, wherein metakaolin is present in the cementitious binder in an amount in the range of from 8 to 25% by weight of the cementitious binder.

11. The binder of claim 1, wherein a content of calcium carbonate CaCO₃ in the limestone is at least 60% by weight of limestone.

12. The binder of claim 1, wherein limestone is in an amount of from 10 to 25% by weight of the cementitious binder.

13. A cementitious settable composition comprising:

water; and

a cementitious binder including

a hydraulic binder in an amount in the range of from 40 to 75% by weight of the cementitious binder;

metakaolin in an amount in the range of from 1 to 30% by weight of the cementitious binder;

silica fume in an amount-up to 15% by weight of the cementitious binder;

limestone in an amount of from 5 to 30% by weight of the cementitious binder, and

a cementitious accelerator in a controlled amount of at least 0.5% by weight of the cementitious binder,

wherein, without a lightweight additive, the cementitious settable composition has a density lower than 13 pounds per gallon and of at least 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

14. The composition of claim 13, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

15. The composition of claim 14, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

16. The composition of claim 15, wherein the cementitious binder comprises microspheres in an amount less than 15% by weight of the cementitious binder, wherein the cementitious settable composition has a density lower than 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

17. The composition of claim 16, wherein the settable composition has a density of about 10 pounds per gallon.

18. The composition of claim 17, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

19. The composition of claim 17, wherein metakaolin is present in the cementitious binder in an amount in the range of from 8 to 25% by weight of the cementitious binder.

20. The composition of claim 19, wherein metakaolin is present in the cementitious binder in an amount in the range of from 8 to 18% by weight of the cementitious binder.

21. The composition of claim 13, wherein limestone is in an amount of from about 10 to 25% by weight of the cementitious binder.

22. A method of cementing comprising:

providing a cementitious settable composition comprising;

water; and

a cementitious binder including

a hydraulic binder in an amount in the range of from 40 to 75% by weight of the cementitious binder;

metakaolin in an amount in the range of from 1 to 30% by weight of the cementitious binder;

silica fume in an amount up to 15% by weight of the cementitious binder;

limestone in an amount of from 5 to 30% by weight of the cementitious binder, and

a cementitious accelerator in a controlled amount of at least 0.5% by weight of the cementitious binder,

wherein, without a lightweight additive, the cementitious settable composition has a density lower than 13 pounds per gallon and of at least 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi; and

introducing the cementitious settable composition into an underground formation.

23. The method of claim 22, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 700 psi.

24. The method of claim 22, wherein the settable composition has a 24 hour compressive strength at 100 F, as hardened, of at least 800 psi.

25. The method of claim 22, wherein the cementitious binder comprises microspheres in an amount less than 15% by weight of the cementitious binder, wherein the cementitious binder provides a cementitious settable composition, when added with water, that has a density lower than about 11 pounds per gallon and a 24 hour compressive strength at 100 F, as hardened, of at least 500 psi.

26. The method of claim 22, wherein the underground formation is a well bore.