Cementitious patch compositions and methods

Patent metadata

Field	Value
Publication number	US-2016340251-A1
Application number	US-201514714653-A
Country	US
Kind code	A1
Filing date	May 18, 2015
Priority date	May 18, 2015
Publication date	Nov 24, 2016
Grant date	—

Abstract

A cementitious hydrating patch composition is provided with improved strength and abrasion resistance. The patch comprises Portland cement in the amount from 2% to 10%, Calcium Sulfate Hemihydrate in the amount from 2% to 30%, Gypsum in the amount from 0% to 15%, Calcium Aluminate Cement in the amount from 15% to 40%, Calcium Carbonate in the amount from 0% to 40%, at least one filler in the amount from 1% to 30%; and at least one binder in the amount from 10% to 40%, wherein all amounts are based on dry weight of the composition. Methods of preparing and using the patch composition are provided as well.

First claim

What is claimed is:

1 . A hydrating patch composition, the composition comprising:
Portland cement in the amount from 2% to 10%, Calcium Sulfate Hemihydrate in the amount from 2% to 30%, Gypsum in the amount from 0% to 15%, Calcium Aluminate Cement in the amount from 15% to 40%, Calcium Carbonate in the amount from 0% to 40%, at least one filler in the amount from 1% to 30%; and at least one binder in the amount from 10% to 40%,
wherein all amounts are based on dry weight of the composition.

2 . The hydrating patch composition of claim 1 , wherein calcium sulfate hemihydrate is calcined synthetic gypsum spray-coated with diethylene-triamine-pentaacetic acid (DTPA).

3 . The hydrating patch composition of claim 1 , wherein the at least one filler is selected from the group consisting of hollow borosilicate glass beads, a combination of borosilicate glass beads and lime, perlite, siloxane-coated perlite, and a combination of hollow borosilicate glass beads and silica flour.

4 . The hydrating patch composition of claim 1 , wherein the composition is formulated as a deep patch formulation and where the filler is a combination of sand and siloxane-coated perlite.

5 . The hydrating patch composition of claim 3 , wherein the hollow borosilicate glass beads have a crush strength from 250 to 6,000 psi.

6 . The hydrating patch composition of claim 3 , wherein the hollow borosilicate glass beads have a crush strength from 250 to 6,000 psi and wherein the ratio between the hollow borosilicate glass beads and the silica flour is from 1:1 to 3:1.

7 . The hydrating patch composition of claim 1 , wherein the at least one filler is selected from the group consisting of hollow borosilicate glass beads and lime, and wherein the lime is used in the amount from 0.0625% to 10% of the dry weight of hollow borosilicate glass beads.

8 . The hydrating patch composition of claim 7 , wherein the lime is ivory lime.

9 . The hydrating patch composition of claim 1 , wherein the filler is selected from the group consisting of perlite, a combination of perlite with aluminum oxide, and a combination of perlite, aluminum oxide and fibers.

10 . The hydrating patch composition of claim 9 , wherein the fibers are selected from the group consisting of polypropylene stealth fibers, acrylic fibers and cellulosic fibers.

11 . The hydrating patch composition of claim 1 , wherein the filler is siloxane-coated perlite.

12 . The hydrating patch composition of claim 11 , wherein the siloxane-coated perlite is in the amount from 2% to 50%, based on the dry weight of the hydrating patch composition.

13 . The hydrating patch composition of claim 1 , wherein the hydrating patch composition further comprises a compound selected from the group consisting of: at least one abrasive agent, at least one rheological modifier, at least one set retarder and any composition thereof.

14 . The hydrating patch composition of claim 1 , wherein the hydrating patch composition comprises at least one compound selected from the group consisting of hydroxyethyl methyl cellulose, magnesium aluminum silicate, diutan gum and any combination thereof.

15 . The hydrating patch composition of claim 1 , wherein the hydrating patch composition comprises at least one abrasive agent in the amount from 0.05% to 60% and wherein the abrasive agent is selected from the group consisting of: aluminum oxide brown, aluminum oxide white, garnet dust, stardust, copper slag, silica flour and combinations thereof.

16 . The hydrating patch composition of claim 1 , wherein the binder is selected from the group consisting of polyacrylates, polyacetates and polyvinyl-acetates.

17 . The hydrating patch composition of claim 1 , wherein the hydrating patch composition comprises at least one rheological modifier in the amount form 0.05% to 10% by dry weight of the composition, and wherein the rheological modifier is selected from the group consisting of magnesium aluminum silicate, polycarboxylate, lime, clay and stabilizers.

18 . The hydrating patch composition of claim 1 , wherein the hydrating patch composition comprises hollow borosilicate glass beads and lime as a filler, and wherein the composition further comprises at least one compound selected from the group consisting of polycarboxylate ether, citric acid, cream of tartar or a combination thereof.

19 . A kit for making a hydrating patch formulation, the kit comprising a powder mixture of calcium aluminate cement, DTPA-coated calcined synthetic gypsum, gypsum, class C cement, calcium carbonate, and wherein the kit further comprises hollow borosilicate glass beads and lime, and wherein the hollow borosilicate glass beads and lime are stored separately from the powder mixture.

20 . A method for controlling viscosity of a hydrating patch formulation, the method comprising:
mixing together Portland cement in the amount from 2% to 10%, Calcium Sulfate Hemihydrate in the amount from 2% to 30%, Gypsum in the amount from 0% to 15%, Calcium Aluminate Cement in the amount from 15% to 40%, Calcium Carbonate in the amount from 0% to 40%, hollow borosilicate glass beads in the amount from 1% to 30%; and at least one binder in the amount from 10% to 40%, and controlling the viscosity of the mixture by adding to the mixture lime in the amount from 0.0625% to 10%.

Assignees

• United States Gypsum Co

Inventors

• Lettkeman Dennis Mark
• Wilson John Wesley
• Bedwell William Kelly
• Kaligian Raymond A

Classifications

• C04B28/06 Primary

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

• Y02W30/91

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

• C04B2111/00482

  Coating or impregnation materials · CPC title

• C04B28/14

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

• C04B2111/72

  Repairing or restoring existing buildings or building materials · CPC title