Lightweight aggregate-based non-steam-cured high-performance pipe culvert and preparation method thereof

Patent metadata

Field	Value
Publication number	US-12410099-B1
Application number	US-202519202064-A
Country	US
Kind code	B1
Filing date	May 8, 2025
Priority date	Mar 10, 2025
Publication date	Sep 9, 2025
Grant date	Sep 9, 2025

Abstract

A lightweight aggregate-based non-steam-cured high-performance pipe culvert and a preparation method thereof. The lightweight aggregate-based non-steam-cured high-performance pipe culvert is prepared from a raw material including the following components by mass per unit volume: 300-450 kg/m 3 of a low-carbon sulfur-aluminum-ferric cementitious material; 800-920 kg/m 3 of a solid waste-based lightweight aggregate; 300-550 kg/m 3 of a solid waste-based artificial sand; 0-100 kg/m 3 of a mineral admixture; 0-50 kg/m 3 of an auxiliary material; and 110-160 kg/m 3 of water; and the lightweight aggregate-based non-steam-cured high-performance pipe culvert further includes a water reducer and a retarder. The lightweight aggregate-based non-steam-cured high-performance pipe culvert of the present invention can be demolded within 4 hours during forming, with short demolding time and no need for steam curing, resulting in a low production cost and high production efficiency. The obtained product has high strength, good impermeability and durability, and can utilize solid waste in a high proportion.

First claim

The invention claimed is:

1. A lightweight aggregate-based non-steam-cured pipe culvert, wherein the lightweight aggregate-based non-steam-cured pipe culvert is prepared from a raw material comprising the following components by mass per unit volume:
300-450 kg/m 3 of a sulfur-aluminum-ferric cementitious material;
800-920 kg/m 3 of a solid waste-based lightweight aggregate;
300-550 kg/m 3 of a solid waste-based artificial sand;
0-100 kg/m 3 of a mineral admixture;
0-50 kg/m 3 of an auxiliary material; and
110-160 kg/m 3 of water; and
the raw material further comprises a water reducer and a retarder, the water reducer being added in an amount of 1.5-5 wt % of the sulfur-aluminum-ferric cementitious material, and the retarder being added in an amount of 0.1-0.5 wt % of the sulfur-aluminum-ferric cementitious material;
the solid waste-based lightweight aggregate comprises the following components in percentage by mass: 10-20% of the sulfur-aluminum-ferric cementitious material, 0-90% of phosphogypsum or desulfurized gypsum, and 0-90% of fly ash or gold tailings, and the solid waste-based lightweight aggregate has a particle size of 5-20 mm;
the solid waste-based artificial sand comprises the following components in percentage by mass: 10-20% of the sulfur-aluminum-ferric cementitious material, 0-90% of phosphogypsum or desulfurized gypsum, and 0-90% of fly ash or gold tailings, and the solid waste-based artificial sand has a particle size of 0.15-4.75 mm.

2. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein in the sulfur-aluminum-ferric cementitious material, CaO≥37%, —Al 2 O 3 —≥20%, —Fe 2 O 3 ≥6%, and SO 3 ≥8%.

3. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein the solid waste-based lightweight aggregate has a bulk density of less than 1200 kg/m 3 , an apparent density of 1600-1800 kg/m 3 , a cylinder compressive strength of greater than 6 MPa, and a softening coefficient of greater than 0.82.

4. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein in the solid waste-based lightweight aggregate, a mass per unit volume of the solid waste-based lightweight aggregate with a particle size of 5-10 mm is 240-280 kg/m 3 , and a mass per unit volume of the solid waste-based lightweight aggregate with a particle size of 10-20 mm is 560-640 kg/m 3 .

5. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein the solid waste-based artificial sand has a bulk density of less than 1200 kg/m 3 , a fineness modulus of 2.4-3.0, and a cylinder compressive strength of greater than 6 MPa.

6. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein the mineral admixture is selected from one or both of fly ash and slag powder; and the auxiliary material is selected from one or more of carbide slag, red mud or slaked lime, and the auxiliary material has a pH≥11.

7. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein the water reducer is a polycarboxylic acid-based water reducer with a water-reducing rate of over 25%.

8. The lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , wherein the retarder is selected from boric acid or citric acid.

9. A method for preparing the lightweight aggregate-based non-steam-cured pipe culvert according to claim 1 , comprising:
pre-wetting a solid waste-based lightweight aggregate and a solid waste-based artificial sand by adding water separately to obtain a saturated surface dry solid waste-based lightweight aggregate and a saturated surface dry solid waste-based artificial sand; and
mixing a sulfur-aluminum-ferric cementitious material, a mineral admixture and an auxiliary material uniformly by stirring, then adding the saturated surface dry solid waste-based lightweight aggregate and the saturated surface dry solid waste-based artificial sand, water, a retarder and a water reducer, stirring, then pouring into a pipe culvert forming mold system for pipe culvert forming, allowing to stand naturally, demolding within 4 hours, spraying with water, and then covering with a plastic film and curing for 1-3 days.

10. A method for preparing the lightweight aggregate-based non-steam-cured pipe culvert according to claim 2 , comprising:
pre-wetting a solid waste-based lightweight aggregate and a solid waste-based artificial sand by adding water separately to obtain a saturated surface dry solid waste-based lightweight aggregate and a saturated surface dry solid waste-based artificial sand;
mixing a sulfur-aluminum-ferric cementitious material, a mineral admixture and an auxiliary material uniformly by stirring, then adding the saturated surface dry solid waste-based lightweight aggregate and the saturated surface dry solid waste-based artificial sand, water, a retarder and a water reducer, stirring, then pouring into a pipe culvert forming mold system for pipe culvert forming, allowing to stand naturally, demolding within 4 hours, spraying with water, and then covering with a plastic film and curing for 1-3 days.

11. A method for preparing the lightweight aggregate-based non-steam-cured pipe culvert according to claim 3 , comprising:
pre-wetting a solid waste-based lightweight aggregate and a solid waste-based artificial sand by adding water separately to obtain a saturated surface dry solid waste-based lightweight aggregate and a saturated surface dry solid waste-based artificial sand;
mixing a sulfur-aluminum-ferric cementitious material, a mineral admixture and an auxiliary material uniformly by stirring, then adding the saturated surface dry solid waste-based lightweight aggregate and the saturated surface dry solid waste-based artificial sand, water, a retarder and a water reducer, stirring, then pouring into a pipe culvert forming mold system for pipe culvert forming, allowing to stand naturally, demolding within 4 hours, spraying with water, and then covering with a plastic film and curing for 1-3 days.

12. A method for preparing the lightweight aggregate-based non-steam-cured pipe culvert according to claim 4 , comprising:
pre-wetting a solid waste-based lightweight aggregate and a solid waste-based artificial sand by adding water separately to obtain a saturated surface dry solid waste-based lightweight aggregate and a saturated surface dry solid waste-based artificial sand; and
mixing a sulfur-aluminum-ferric cementitious material, a mineral admixture and an auxiliary material uniformly by stirring, then adding the saturated surface dry solid waste-based lightweight aggregate and the saturated surface dry solid waste-based artificial sand, water, a retarder and a water reducer, stirring, then pouring into a pipe culvert forming mold system for pipe culvert forming, allowing to stand naturally, demolding within 4 hours, spraying with water, and then covering with a plastic film and curing for 1-3 days.

13. A method for preparing the lightweight aggregate-based non-steam-cured pipe culvert according to claim 5 , comprising:
pre-wetting a solid waste-based lightweight aggregate and a solid waste-based artificial sand by adding water separately to obtain a saturated surface dry solid waste-based lightweight aggregate and a saturated surface dry solid waste-based artificial sand;
mixing a sulfur-aluminum-ferric cementitious material, a mineral admixture and an auxiliary material uniformly by stirring, then adding the saturated surface dry solid waste-based lightweight aggregate and the saturated surface dry solid waste-based artificial sand, water, a retarder and a water reduce

Assignees

• Univ Shandong
• Kunming Shunhong New Mat Co Ltd

Inventors

• Hu Zhijuan
• Wang Zesheng
• Wang Wenlong
• Li Jingwei
• Wang Xujiang
• Yang Shizhao
• Li Yujie
• Zhang Xiangkun

Classifications

• C04B18/021

  agglomerated by a mineral binder, e.g. cement · CPC title

• C04B18/027

  Lightweight materials · CPC title

• C04B2111/00655

  Profiles · CPC title

• C04B2111/00215

  Mortar or concrete mixtures defined by their oxide composition · CPC title

• C04B28/065 Primary

  Calcium aluminosulfate cements, e.g. cements hydrating into ettringite · CPC title