Heat resistant and fire retardant materials and methods for preparing same

• US 8,172,938 B2
• Filed: 06/30/2009
• Issued: 05/08/2012
• Est. Priority Date: 07/01/2008
• Status: Expired due to Fees

• Current Assignee: Specialty Concrete Design, Inc.
• Original Assignee: Specialty Concrete Design, Inc.
• Inventors: Alright, John, Taylor, David Wayne
• Primary Examiner(s): Green, Anthony J
• Application Number:
  US13/002,184
• Publication Number:
  US 20110155019A1
• Time in Patent Office: 1,043 Days
• Field of Search: 106/672, 106/675, 106/737, 106/816, 106/676, 106/677, 106/716, 106/733, 252/601, 428/920, 428/921
• US Class Current: 106/672
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/301 porous or hollow
• CPC Class Codes: C04B 14/305 Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• 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 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 2111/285 Intumescent materials
• CPC Class Codes: C04B 2111/29 Frost-thaw resistance
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 38/085 of micro- or nanosize
• 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: C08K 3/36 Silica
• CPC Class Codes: C08K 7/22 Expanded, porous or hollow particles
• CPC Class Codes: C09D 5/004 : Reflecting paints; Signal paints
• CPC Class Codes: C09D 5/028 : Pigments; Filters
• CPC Class Codes: C09D 5/18 : Fireproof paints including high temperature resistant paints
• CPC Class Codes: C09D 7/61 : inorganic
• CPC Class Codes: C09D 7/65 : macromolecular C09D7/41-C09D7/48 take precedence
• CPC Class Codes: C09D 7/69 : Particle size larger than 1000 nm
• CPC Class Codes: C09D 7/70 : characterised by shape, e.g. fibres, flakes or microspheres
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A silica cement blend having an insulating, fire retarding and high temperature characteristic capable of withstanding temperatures ranging from ambient to greater than 40000 F without degradation of the concrete structure. In addition to its high temperature capabilities the blend can be produced as ultra light weight to heavy weight concrete. The silica based mixture when added to cementitious materials such as Portland cement, Class C Fly Ash, silica fume and other cementitious materials. Presented also are methods for reducing fire damage by coating interior/exterior walls, ceiling, and roofs of a building with a water based latex coating containing a fire retardant material and low heat conductivity silicas. Methods for painting internal/external walls, ceilings, and roof are also presented. This coating retains thermal blocking properties comprised of processed, expanded and/or finely milled, pyrogenic silicas and micro spheres in combination of but not limited to, one, two or more component water based polymer/copolymer latex binders and a water born fluoropolymer emulsion. The combined properties of these elements create a coating similar to paint with a high level of thermatic resistance which slows the composition break-down from fire, extreme temperatures, and restricts the thermal conductivity which helps to preserve the integrity of the substructure or underlying materials. The properties of this coating reduce or slow the potential of catastrophic fire by retarding flashover and protecting the under structure; which in turn assist fire fighters and rescue personnel by helping to retard the potential of a catastrophic fire.

Claims

1. A cement blend for making concrete, the cement blend comprising:

60-90 wt. % Portland cement

0.1-6 wt. % fumed silica having an average particle size of from 1 to 150 microns;

1.9 wt % hollow microspheres; and

0.1-10 wt. % titanium dioxide.

2. The cement blend of claim 1, further comprising

0.1-7 wt. % perlite;

0.1-20 wt. % fused silica; and

0.1-40 wt. % fly ash.

3. The cement blend of claim 2, comprising

60-88 wt. % Portland cement;

0.1-3 wt. % fumed silica;

1-4.5 wt. % microspheres;

0.1-5 wt. % titanium dioxide;

0.1-3.6 wt. % perlite;

0.1-10 wt. % fused silica; and

0.1-30 wt. % fly ash.

4. The cement blend of claim 1, wherein the hollow microspheres have a mean particle size of 80 microns+/−

8 microns and a particle size of from 10 to 500 microns.

5. The cement blend of claim 2, wherein the fused silica has an average particle size of from 1 to 150 microns.

6. A method for forming the cement blend of claim 2, the method comprising, in sequence:

combining Portland cement and titanium dioxide to obtain a combination;

mixing the combination for two to twenty minutes;

adding fumed silica and Portland cement to the combination;

mixing the combination for two to twenty minutes;

adding perlite and Portland cement to the combination;

mixing the combination for two to twenty minutes;

adding fused silica and fly ash to the combination;

mixing the combination for two to twenty minutes;

adding microspheres;

mixing the combination for two to twenty minutes;

adding perlite and Portland cement to the combination; and

mixing the combination for two to twenty minutes;

whereby a cement blend is obtained.

7. A method for forming the cement blend of claim 2, the method comprising, in sequence:

combining Portland cement and titanium dioxide to obtain a combination;

mixing the combination for five to fifteen minutes;

adding fumed silica and Portland cement to the combination;

mixing the combination for five to fifteen minutes;

adding perlite and Portland cement to the combination;

mixing the combination for five to fifteen minutes;

adding fused silica and fly ash to the combination;

mixing the combination for five to fifteen minutes;

adding microspheres;

mixing the combination for five to fifteen minutes;

adding perlite and Portland cement to the combination; and

mixing the combination for five to fifteen minutes;

whereby a cement blend is obtained.

8. A method for forming a concrete, the method comprising, in sequence:

adding water to a blender;

adding a cement blend according to claim 1 to the blender to obtain a combination;

mixing the combination for two to twenty minutes;

adding aggregate to the blender;

mixing the combination for two to twenty minutes;

adding superplasticer to the blender;

mixing the combination for two to twenty minutes;

adding sand to the blender; and

mixing the combination for two to twenty minutes;

whereby a concrete is obtained.

9. A method for forming a concrete, the method comprising, in sequence:

adding water to a blender;

adding a cement blend according to claim 1 to the blender to obtain a combination;

mixing the combination for five to fifteen minutes;

adding an aggregate to the blender;

mixing the combination for five to fifteen minutes;

adding a superplasticer to the blender; and

mixing the combination for five to fifteen minutes;

adding sand to the blender; and

mixing the combination for five to fifteen minutes;

whereby a concrete is obtained.

10. A concrete comprising the cement blend according to claim 1 and an aggregate, wherein the cement blend comprises 45-25 wt. % of the concrete.

11. A cement blend for making concrete, the cement blend comprising:

60-90 wt. % Portland cement

0.1-6 wt. % fumed silica having an average particle size of from 1 to 150 microns;

1-9 wt % hollow microspheres, wherein all solid components of the cement blend have an average particle size of from 1 to 150 microns.