Construction composition

Patent metadata

Field	Value
Publication number	US-12415752-B2
Application number	US-202118023276-A
Country	US
Kind code	B2
Filing date	Aug 25, 2021
Priority date	Aug 26, 2020
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

A construction composition comprises a) a cementitious binder comprising one or more calcium silicate mineral phases and one or more calcium aluminate mineral phases; b) optionally, an extraneous aluminate source; c) a sulfate source; d) an ettringite formation controller comprising (i) glyoxylic acid, a glyoxylic acid salt and/or a glyoxylic acid derivative; and (ii) at least one of a borate source and a carbonate source; and e) a polyol in an amount of 0.2 to 2.5 wt.-%, relative to the amount of cementitious binder a). The composition contains 0.05 to 0.2 mol of total available aluminate, calculated as Al(OH) 4 − , from the calcium aluminate mineral phases plus the optional extraneous aluminate source, per 100 g of cementitious binder a); and the molar ratio of total available aluminate to sulfate is 0.4 to 2.0. The construction composition exhibits high early strength and sufficient open time.

First claim

The invention claimed is:

1. A construction composition comprising
a) a cementitious binder comprising one or more calcium silicate mineral phases and one or more calcium aluminate mineral phases;
b) optionally, an extraneous aluminate source;
c) a sulfate source;
d) an ettringite formation controller comprising (i) glyoxylic acid, a glyoxylic acid salt and/or a glyoxylic acid derivative; and (ii) at least one of a borate source and a carbonate source, wherein the carbonate source is selected from inorganic carbonates having an aqueous solubility of 0.1 g·L −1 or more at 25° C., organic carbonates, and mixtures thereof; and
e) a polyol in an amount of 0.2 to 2.5 wt.-%, relative to the amount of cementitious binder a);
wherein the composition contains 0.05 to 0.2 mol of total available aluminate, calculated as Al(OH) 4 − , from the calcium aluminate mineral phases plus the optional extraneous aluminate source, per 100 g of cementitious binder a); and the molar ratio of total available aluminate to sulfate is 0.4 to 2.0.

2. The composition according to claim 1 , wherein the calcium silicate mineral phases and calcium aluminate mineral phases constitute at least 90 wt.-% of the cementitious binder a), and the calcium silicate mineral phases constitute at least 60 wt.-% of the cementitious binder a).

3. The composition according to claim 1 , wherein the calcium aluminate mineral phases are selected from C3A, C4AF and C12A7.

4. The composition according to claim 1 , wherein the cementitious binder a) is Portland cement.

5. The composition according to claim 1 , wherein the composition additionally comprises
f) at least one of a latent hydraulic binder, a pozzolanic binder and a filler material.

6. The composition according to claim 1 , wherein the optional extraneous aluminate source b) is selected from non-calciferous aluminate sources and calciferous aluminate sources.

7. The composition according to claim 1 , wherein the sulfate source c) is a calcium sulfate source.

8. The composition according to claim 1 , wherein the amount of polyol e) is 0.2 to 1 wt.-%, relative to the amount of cementitious binder a), if the Blaine surface area of the cementitious binder a) is 1500 to 4000 cm 2 /g.

9. The composition according to claim 1 , wherein the polyol, in a calcium aluminate precipitation test in which a test solution, obtained by supplementing 400 mL of a 1 wt.-% aqueous solution of the polyol with 20 mL of a 1 mol/L NaOH aqueous solution and 50 mL of a 25 mmol/L NaAlO 2 aqueous solution, is titrated with a 0.5 mol/L CaCl 2 ) aqueous solution at 20° C., inhibits precipitation of calcium aluminate up to a calcium concentration of 75 ppm.

10. The composition according to claim 9 , wherein the polyol is selected from monosaccharides, oligosaccharides, water-soluble polysaccharides, compounds of general formula (P-I) or dimers or trimers of compounds of general formula (P-I):

wherein X is

wherein
R is —CH 2 OH, —NH 2 ,
n is an integer from 1 to 4,
m is an integer from 1 to 8.

11. The composition according to claim 1 , wherein the glyoxylic acid derivative is a glyoxylic acid polymer.

12. The composition according to claim 1 , wherein the inorganic carbonate is selected from sodium carbonate, sodium bicarbonate, potassium carbonate, lithium carbonate and magnesium carbonate; and the organic carbonate is selected from ethylene carbonate, propylene carbonate and glycerol carbonate.

13. The composition according to claim 1 , wherein the ettringite formation controller additionally comprises (iii) a polycarboxylic acid or a salt thereof whose milliequivalent number of carboxyl groups is 3.0 meq/g or higher, if all the carboxyl groups are in unneutralized form.

14. The composition according to claim 13 , wherein the polycarboxylic acid is selected from phosphonoalkyl carboxylic acids, amino carboxylic acids, and polymeric carboxylic acids.

15. The composition according to claim 1 , wherein the ettringite formation controller additionally comprises (iv) a α-hydroxy monocarboxylic acid or a salt thereof.

16. The composition according to claim 1 additionally comprising a dispersant selected from
comb polymers having a carbon-containing backbone to which are attached pendant cement-anchoring groups and polyether side chains,
non-ionic comb polymers having a carbon-containing backbone to which are attached pendant hydrolysable groups and polyether side chains, the hydrolysable groups upon hydrolysis releasing cement-anchoring groups,
colloidally disperse preparations of polyvalent metal cations, such as Al 3+ , Fe 3+ or Fe 2+ , and a polymeric dispersant which comprises anionic and/or anionogenic groups and polyether side chains, and the polyvalent metal cation is present in a superstoichiometric quantity, calculated as cation equivalents, based on the sum of the anionic and anionogenic groups of the polymeric dispersant,
sulfonated melamine-formaldehyde condensates,
lignosulfonates,
sulfonated ketone-formaldehyde condensates,
sulfonated naphthalene-formaldehyde condensates,
phosphonate containing dispersants,
phosphate containing dispersants, and
mixtures thereof.

17. The composition according to claim 1 , wherein the construction composition comprises less than 5 wt.-% of cementitious hydration products, relative to the total weight of the construction composition.

18. The construction composition according to claim 1 , in freshly mixed form, wherein the ratio of water to cementitious binder a) is in the range of 0.2 to 0.7.

19. The composition according to claim 1 , wherein the amount of polyol e) is 1 to 2.5 wt.-%, relative to the amount of cementitious binder a), if the Blaine surface area is more than 4000 cm 2 /g.

Assignees

• Construction Research & Technology Gmbh

Inventors

• Lorenz Klaus
• Seidl Wolfgang
• Mitkina Tatiana
• Himmelein Sabine
• Schwesig Peter
• Bandiera Massimo
• Sachsenhauser Bernhard
• Ramzi Farra
• Carnelli Davide
• Parks Johanna
• Weldert Kai Steffen
• Klein Matthias
• Ramroo Beni Jasveer

Classifications

• C04B2103/408

  Dispersants · CPC title

• C04B28/188

  the Ca-silicates being present in the starting mixture · CPC title

• C04B28/14 Primary

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

• C04B28/06

  Aluminous cements (monolithic refractories or refractory mortars C04B35/66) · CPC title

• C04B28/04

  Portland cements · CPC title