High performance concretes and methods of making thereof

Patent metadata

Field	Value
Publication number	US-10882791-B2
Application number	US-201816146319-A
Country	US
Kind code	B2
Filing date	Sep 28, 2018
Priority date	Sep 28, 2018
Publication date	Jan 5, 2021
Grant date	Jan 5, 2021

Abstract

Concrete compositions containing cement, a fine aggregate such as sand, a coarse aggregate such as crushed limestone, an industrial waste material such as electric arc furnace dust, cement kiln dust, oil ash, or limestone powder. High performance concretes made therefrom and methods of producing such concretes are also specified. The addition of industrial waste materials and nano silica provides enhanced mechanical strength (e.g. compressive strength, flexural strength) and improved durability (e.g. resistance to penetration of chloride ions) to the high performance concretes.

First claim

The invention claimed is:

1. A concrete composition, comprising:
a hydraulic cement;
a fine aggregate comprising dune sand having a specific gravity of 2.2-2.8;
a coarse aggregate;
an industrial waste material; and
a nano silica;
wherein:
a weight ratio of the industrial waste material to the hydraulic cement ranges from 0.01:1 to 0.3:1; and
a weight ratio of the nano silica to the hydraulic cement ranges from 0.01:1 to 0.1:1.

2. The concrete composition of claim 1 , wherein the industrial waste material is at least one selected from the group consisting of electric arc furnace dust having a specific gravity of 1.5-2.5, cement kiln dust having a specific gravity of 2.5-3.5, oil ash having a specific gravity of 0.3-1.0, and limestone powder having a specific gravity of 2.0-3.2.

3. The concrete composition of claim 1 , wherein the industrial waste material is in the form of particles.

4. The concrete composition of claim 1 , which has a weight percentage of the industrial waste material ranging from 0.5-10% relative to a total weight of the concrete composition.

5. The concrete composition of claim 1 , wherein the nano silica has a bulk density of 1.0-2.0 g/cm 3 .

6. The concrete composition of claim 1 , wherein the nano silica has an average particle size of 1-80 nm.

7. The concrete composition of claim 1 , which has a weight percentage of the nano silica ranging from 0.5-5% relative to a total weight of the concrete composition.

8. The concrete composition of claim 1 , wherein the hydraulic cement comprises ASTM C150 Type I Portland cement.

9. The concrete composition of claim 1 , which has a weight percentage of the hydraulic cement ranging from 15-20% relative to a total weight of the concrete composition.

10. The concrete composition of claim 1 , wherein the fine aggregate has an average particle size in a range of 0.05-1 mm.

11. The concrete composition of claim 1 , wherein the coarse aggregate has an average particle size in a range of 2-15 mm.

12. The concrete composition of claim 1 , wherein the coarse aggregate comprises crushed limestone having a specific gravity of 2.2-3.0.

13. The concrete composition of claim 1 , further comprising a superplasticizer.

14. The concrete composition of claim 1 , which is devoid of nano calcium carbonate, steel fibers, or both.

15. A wet concrete slurry, comprising:
the concrete composition of claim 1 ; and
40-50 wt % water relative to a total weight of the wet concrete slurry.

16. A high performance concrete, comprising a cured form of the wet concrete slurry of claim 15 .

17. The high performance concrete of claim 16 , which has a compressive strength of 50-75 MPa as determined by ASTM C39.

18. The high performance concrete of claim 16 , which has a flexural strength of 3.4-6.0 MPa as determined by ASTM C78.

19. A method of producing the high performance concrete of claim 16 , the method comprising:
casting the wet concrete slurry in a mold to form a casted wet concrete; and
curing the casted wet concrete for 2-30 days thereby forming the high performance concrete.

Assignees

• Univ King Fahd Pet & Minerals

Inventors

• Alkhatib Anas
• Maslehuddin Mohammed
• Al-Dulaijan Salah Uthman
• Shameem Mohammed

Classifications

• C04B2201/05

  Materials having an early high strength, e.g. allowing fast demoulding or formless casting · CPC title

• C04B28/14 Primary

  containing calcium sulfate cements {(gypsum-paper plates E04C)} · CPC title

• C04B2111/10

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

• C04B14/28

  of calcium · CPC title

• C04B18/162

  Cement kiln dust; Lime kiln dust · CPC title