Masonry block having a biased-rubber face

Patent metadata

Field	Value
Publication number	US-10435889-B2
Application number	US-201816194541-A
Country	US
Kind code	B2
Filing date	Nov 19, 2018
Priority date	Feb 13, 2018
Publication date	Oct 8, 2019
Grant date	Oct 8, 2019

Abstract

A cementitious composite and cured masonry block made from the cementitious composite. The cementitious composite contains a cement, a non-rubber aggregate, a crumb rubber and at least one of cement kiln dust and limestone powder. The crumb rubber aggregate is extracted from scrap tires after being processed and then mixed in specified percentages with the aggregate, the cement and water, then cured in forms to make the masonry blocks. In the present disclosure sand, which is used in conventional masonry blocks, is at least partially replaced with crumb rubber to produce a sand-free or sand-reduced masonry block that contains crumb rubber. The crumb rubber masonry blocks satisfy the ASTM non-load bearing requirements. The use of crumb rubber decreases the unit weight and increases thermal resistance of the masonry blocks. The use of cement kiln dust or limestone as a partial replacement of cement will lead to decrease in the cost. The use of industrial waste materials, such as crumb rubber, limestone powder and cement kiln dust, will lead to economic and environmental benefits.

First claim

The invention claimed is:

1. A masonry block having a biased-rubber face, comprising:
5-10 wt % cement;
75-80 wt % of an aggregate, which is not crumb rubber;
5-8 wt % water;
5-10 wt % crumb rubber relative to the total weight of the masonry block;
wherein the crumb rubber is in the form of coarse particles having a particle size of 1.5-5 mm, fine particles having a particle size of 50-250 μm, or a mixture of the coarse particles and the fine particles; and
at least one of cement kiln dust and limestone powder, wherein the limestone powder has an average particle size of from 1 to 50 μm,
wherein the aggregate is at least one selected from the group consisting of a crushed recycled concrete material and crushed limestone having an average particle size of greater than 1 millimeter,
wherein the masonry block has a rectangular form with a front face, a back face, a first end face and a second end face forming a face perimeter, and
wherein the crumb rubber concentration is higher concentration at the front face at a face depth of 10 mm of the masonry block in comparison to the other faces of the masonry block.

2. The masonry block of claim 1 , wherein the crumb rubber is in the form of coarse particles having a particle size of 1.5-5 mm.

3. The masonry block of claim 1 , wherein the crumb rubber is in the form of fine particles having a particle size of 50-250 μm.

4. The masonry block of claim 3 , wherein the fine particles have a particle size of 100-148 μm.

5. The masonry block of claim 1 , wherein the mixture of the coarse particles and fine particles is present.

6. The masonry block of claim 5 , wherein a ratio of the coarse particles to the fine particles ranges from 2:1 to 1:2.

7. The masonry block of claim 6 , wherein the ratio of the coarse particles to the fine particles is about 1:1.

8. The masonry block of claim 1 , which has a unit weight of 1000-1250 kg/m 3 .

9. The masonry block of claim 1 , wherein the masonry block has a water absorption of 6.0-9.0% as determined by ASTM C 642.

10. The masonry block of claim 1 , wherein no aggregate, filler, or additive which comprises a group 13 element is present in the masonry block.

11. The masonry block of claim 10 , wherein the group 13 element is boron.

12. The masonry block of claim 1 , wherein the crumb rubber is carboxylic acid surface modified crumb rubber obtained by treating crumb rubber with hydrogen peroxide.

13. The masonry block of claim 1 , which has a wt % of crumb rubber ranging from 12 to 18%, relative to the total weight of the masonry block.

14. The masonry block of claim 1 , which consists of the cement, the aggregate, the water, the crumb rubber, the limestone powder and the cement kiln dust.

Assignees

• Univ King Fahd Pet & Minerals
• King Fahd Univ Of Petroleum And Mineral

Inventors

• Al-Aqeeli Nasser M
• Assehdi Homoud M
• Maslehuddin Mohammad

Classifications

• C04B28/02

  containing hydraulic cements other than calcium sulfates · CPC title

• C04B18/22 Primary

  Rubber {, e.g. ground waste tires} · CPC title

• E04B2/14

  Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element · CPC title

• C04B2111/10

  Compositions or ingredients thereof characterised by the absence or the very low content of a specific material · CPC title

• C04B12/04

  Alkali metal or ammonium silicate cements {; Alkyl silicate cements; Silica sol cements; Soluble silicate cements (alkali metal silicates per se, their preparation C01B33/32; ammonium silicates per se, their preparation C01C1/00)} · CPC title