Recycled concrete aggregates and heavy oil fuel ash for green controlled low strength material

Patent metadata

Field	Value
Publication number	US-12252440-B2
Application number	US-202217862198-A
Country	US
Kind code	B2
Filing date	Jul 11, 2022
Priority date	Mar 11, 2019
Publication date	Mar 18, 2025
Grant date	Mar 18, 2025

Abstract

A controlled low strength material has constituents that include a cement, an aggregate, and a water. The aggregate includes concrete demolition waste. The controlled low strength material has a compressive strength that does not exceed 8.3 MPa, measured at 28 days. The controlled low strength material can alternately include a heavy oil fuel ash and the controlled low strength material can have a compressive strength that does not exceed 2.10 MPa, measured at 28 days.

First claim

What is claimed is:

1. A controlled low strength material, constituents of the controlled low strength material including:
a cement, the cement in an amount of 2 wt % to 5 wt % of the constituents of the controlled low strength material;
a heavy oil fuel ash in an amount of 10 wt % to 50 wt % of the sum of the cement and the heavy oil fuel ash;
an aggregate, where the aggregate includes concrete demolition waste, the aggregate in an amount of 20 wt % to 95 wt % of the constituents of the controlled low strength material; and
a water, the water in an amount of 10 wt % to 20 wt % of the constituents of the controlled low strength material; where

the controlled low strength material has a compressive strength that does not exceed 8.3 MPa, measured at 28 days.

2. The controlled low strength material of claim 1 , where the controlled low strength material has a compressive strength that does not exceed 2.10 MPa, measured at 28 days.

3. The controlled low strength material of claim 1 , where the heavy oil fuel ash includes carbon in an amount of 90 wt % to 95 wt % based on a weight of heavy oil fuel ash.

4. The controlled low strength material of claim 1 , where at least 80% of the heavy oil fuel ash has a particle size smaller than 45 micrometers.

5. The controlled low strength material of claim 1 , where an amount of aggregate with a particle size greater than 9.5 mm is 10% or less of the amount of aggregate.

6. The controlled low strength material of claim 1 , where the aggregate includes a fine aggregate formed of a concrete demolition waste that has a particle size less than 4.75 mm, and a coarse aggregate.

7. The controlled low strength material of claim 1 , where the aggregate includes a fine aggregate formed of a concrete demolition waste that has a particle size less than 4.75 mm, and a coarse aggregate formed of a concrete demolition waste that has a particle size larger than 5 mm.

8. The controlled low strength material of claim 7 , where the coarse aggregate has a particle size up to 19 mm.

9. A method for forming a controlled low strength material, the method including:
mixing together constituents that include:
a cement, the cement in an amount of 2 wt % to 5 wt % of the constituents of the controlled low strength material;
a heavy oil fuel ash in an amount of 10 wt % to 50 wt % of the sum of the cement and the heavy oil fuel ash;
an aggregate, where the aggregate includes concrete demolition waste, the aggregate in an amount of 20 wt % to 95 wt % of the constituents of the controlled low strength material; and
a water, the water in an amount of 10 wt % to 20 wt % of the constituents of the controlled low strength material; where

after mixing, the controlled low strength material has a compressive strength that does not exceed 8.3 MPa, measured at 28 days.

10. The method of claim 9 , such that after mixing, the controlled low strength material has a compressive strength that does not exceed 2.10 MPa, measured at 28 days.

11. The method of claim 9 , where the heavy oil fuel ash includes carbon in an amount of 90 wt % to 95 wt % based on a weight of heavy oil fuel ash.

12. The method of claim 9 , where at least 80% of the heavy oil fuel ash has a particle size smaller than 45 micrometers.

13. The method of claim 9 , where an amount of aggregate with a particle size greater than 9.5 mm is 10% or less of the amount of aggregate.

14. The method of claim 9 , where the aggregate includes a fine aggregate formed of a concrete demolition waste that has a particle size less than 4.75 mm, and a coarse aggregate.

15. The method of claim 9 , where the aggregate includes a fine aggregate, and a coarse aggregate formed of a concrete demolition waste that has a particle size larger than 5 mm.

16. The method of claim 15 , where the coarse aggregate has a particle size up to 19 mm.

17. The method of claim 9 , where the heavy oil fuel ash is part of a heavy oil fuel ash slurry that includes the heavy oil fuel ash and a slurry water, the method further including adding the heavy oil fuel ash slurry directly to the cement and the aggregate to produce the controlled low strength material.

18. The method of claim 17 , where the slurry water and the mixing water together are in an amount of 10 wt % to 20 wt % of the constituents of the controlled low strength material.

Assignees

• Saudi Arabian Oil Co
• Univ King Fahd Pet & Minerals

Inventors

• Al-Helal Zakariya Saleh
• Rahman Muhammad Kalimur
• Acero Carlos Ernesto
• Ibrahim Mohammed
• Alhems Luai M

Classifications

• C04B18/06

  Combustion residues, e.g. purification products of smoke, fumes or exhaust gases · CPC title

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• C04B18/167 Primary

  Recycled materials, i.e. waste materials reused in the production of the same materials · CPC title

• C04B28/04 Primary

  Portland cements · CPC title