Self-desiccating, dimensionally-stable hydraulic cement compositions with enhanced workability

Patent metadata

Field	Value
Publication number	US-2018162777-A1
Application number	US-201715825366-A
Country	US
Kind code	A1
Filing date	Nov 29, 2017
Priority date	Dec 12, 2016
Publication date	Jun 14, 2018
Grant date	—

Abstract

Cementitious binder compositions for cementitious products including a hydraulic cement-based reactive powder blend, an inorganic flow control agent, and a metal-based dimensional movement stabilizing agent including at least one member of the group of lithium salt and lithium base, and methods for making the cementitious binder compositions.

First claim

1 . A cementitious composition comprising a reaction product of a mixture of:
a hydraulic cement-based reactive powder comprising:
an aluminate cement selected from at least one member of the group consisting of calcium aluminate cement and calcium sulfoaluminate cement in an amount of 25-80 parts by weight per 100 parts by weight of the hydraulic cement-based reactive powder,
Portland cement in an amount of 2.5-45 parts by weight per 100 parts by weight of the hydraulic cement-based reactive powder, and
a calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, anhydrous calcium sulfate and mixtures thereof, the calcium sulfate in an amount of 15-45 parts by weight per 100 parts by weight of the hydraulic cement-based reactive powder;
an inorganic flow control agent in a weight ratio of inorganic flow control agent to hydraulic cement-based reactive powder of 0.25:1 to 3.0:1, wherein the inorganic flow control comprises at least one member selected from the group consisting of fly ash and calcium carbonate and wherein average particle size of the calcium carbonate ranges from about 10 to 150 microns; a metal-based dimensional movement stabilizing agent in an amount equal to 0 to 5.0 weight percent of the hydraulic cement-based reactive powder, wherein the metal-based dimensional movement stabilizing agent comprises a lithium compound selected from at least one member of the group of lithium salt and lithium base, wherein the lithium salt is at least one member of the group of lithium carbonate, lithium sulfate, lithium nitrate, lithium nitrite, and lithium silicate, wherein the base is lithium hydroxide; a filler in a weight ratio of filler to hydraulic cement-based reactive powder of 0:1 to 5.0:1; and water in a weight ratio of water to hydraulic cement-based reactive powder of 0.5:1 to 1.4:1.

2 . The composition of claim 1 ,
wherein the hydraulic cement-based reactive powder comprises: 30-75 parts by weight aluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder; 5-35 parts by weight Portland cement per 100 parts by weight of the hydraulic cement-based reactive powder; 20-40 parts by weight calcium sulfate per 100 parts by weight of the hydraulic cement-based reactive powder; wherein the weight ratio of inorganic flow control agent to hydraulic cement-based reactive powder equals 0.5:1 to 2.0:1; the amount of the metal-based dimensional movement stabilizing agent equals 1.0 to 4.0 weight percent of the hydraulic cement-based reactive powder; the weight ratio of filler to hydraulic cement-based reactive powder equals 0.5:1 to 3.5:1; and the weight ratio of water to hydraulic cement-based reactive powder is 0.6:1 to 1.3:1.

3 . The composition of claim 1 ,
wherein the hydraulic cement-based reactive powder comprises: 30-70 parts by weight aluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder; 7.5-25 parts by weight Portland cement per 100 parts by weight of the hydraulic cement-based reactive powder; 25 to 35 parts by weight calcium sulfate per 100 parts by weight of the hydraulic cement-based reactive powder; wherein the weight ratio of the inorganic flow control agent to hydraulic cement-based reactive powder equals 0.75:1 to 1.5:1; the amount of the metal-based dimensional movement stabilizing agent equals 1.5 to 3.5 weight percent of the hydraulic cement-based reactive powder; the weight ratio of filler to hydraulic cement-based reactive powder equals 1.0:1 to 2.5:1; and the weight ratio of water to hydraulic cement-based reactive powder is 0.7:1 to 1.2:1.

4 . The composition of claim 1 , wherein the hydraulic cement-based reactive powder comprises: 25-75 parts by weight calcium sulfoaluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder; and 2.5-45 parts by weight calcium aluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder.

5 . The composition of claim 2 , wherein the hydraulic cement-based reactive powder comprises: 30-70 parts by weight calcium sulfoaluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder; and 5-40 parts by weight calcium aluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder.

6 . The composition of claim 3 , wherein the hydraulic cement-based reactive powder comprises: 35-65 parts by weight calcium sulfoaluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder; and 10-35 parts by weight calcium aluminate cement per 100 parts by weight of the hydraulic cement-based reactive powder.

7 . The composition of claim 1 , further comprising:
an organic rheology modifier in an amount equal to 0.02 to 1 wt. % of the hydraulic cement-based reactive powder; an inorganic viscosity enhancing agent in an amount equal to 0 to 1 wt. % of the hydraulic cement-based reactive powder; a superplasticizer in an amount equal to 0.3 to 3.5 wt. % of the hydraulic cement-based reactive powder; a defoamer in an amount equal to 0 to 2.0 wt. % of the hydraulic cement-based reactive powder; a set retarding agent in an amount equal to 0 to 2.0 wt. % of the hydraulic cement-based reactive powder; a color pigment in an amount equal to 0 to 8.0 wt. % of the hydraulic cement-based reactive powder; an air entraining agent in an amount equal to 0 to 1.0 wt. % of the hydraulic cement-based reactive powder; an organic film forming polymer in an amount equal to 0 to 15.0 wt. % of the hydraulic cement-based reactive powder; and a pozzolan other than fly ash in a weight ratio of pozzolan to hydraulic cement-based reactive powder of 0 to 1.

8 . The composition of claim 2 , further comprising:
an organic rheology modifier in an amount equal to 0.04 to 0.75 wt. % of the hydraulic cement-based reactive powder; an inorganic viscosity enhancing agent in an amount equal to 0 to 0.75 wt. % of the hydraulic cement-based reactive powder; a superplasticizer in an amount equal to 0.40 to 2.50 wt. % of the hydraulic cement-based reactive powder; a defoamer in an amount equal to 0.25 to 1.50 wt. % of he hydraulic cement-based reactive powder; a set retarding agent in an amount equal to 0.10 to 1.50 wt. % of the hydraulic cement-based reactive powder; a color pigment in an amount equal to 0 to 6.00 wt. % of the hydraulic cement-based reactive powder; an air entraining agent in an amount equal to 0 to 0.50 wt. % of the hydraulic cement-based reactive powder; an organic film forming polymer in an amount equal to 0 to 10.00 wt. % of the hydraulic cement-based reactive powder; and a pozzolan other than fly ash in a weight ratio of pozzolan other than fly ash to hydraulic cement-based reactive powder of 0:1 to 1:1.

9 . The composition of claim 3 , further comprising:
an organic rheology modifier in an amount equal to 0.06 to 0.50 wt. % of the hydraulic cement-based reactive powder; an inorganic viscosity enhancing agent in an amount equal to 0 to 0.50 wt. % of the hydraulic cement-based reactive powder; a superplasticizer in an amount equal to 0.50 to 1.50 wt. % of the hydraulic cement-based reactive powder; a defoamer in an amount equal to 0.50 to 1.00 wt. % of the hydraulic cement-based reactive powder; a set retarding agent in an amount equal to 0.20 to 1.00 wt. % of the hydraulic cement-based reactive powder; a color pigment in an amount equal to 0 to 4.00 wt. % of the hydraulic cement-based reactive powder; an air entraining agent in an amount equal to 0 to 0.25 wt. % of the hydraulic cement-based reactive powder; an organic film forming polymer in an amount equal to 0 to 5.00 wt. % of the hydraulic cement-based reactive powde

Assignees

• United States Gypsum Co

Inventors

• White Paul
• Dubey Ashish

Classifications

• C04B2111/00612

  as one or more layers of a layered structure · CPC title

• C04B2111/34

  Non-shrinking or non-cracking materials · CPC title

• C04B2111/70

  Grouts, e.g. injection mixtures for cables for prestressed concrete · CPC title

• C04B28/04

  Portland cements · CPC title

• C04B2103/54

  Pigments; Dyes · CPC title