Environmentally friendly construction material compositions having improved early strength

Patent metadata

Field	Value
Publication number	US-2023110621-A1
Application number	US-202117911438-A
Country	US
Kind code	A1
Filing date	Mar 15, 2021
Priority date	Mar 20, 2020
Publication date	Apr 13, 2023
Grant date	—

Abstract

The present invention relates to construction material compositions comprising at most 55% by dry weight of Portland cement with a high early and late compressive strength. The other main components in the cement are SCMs, limestone, sulfate source and accelerator.

First claim

1 - 17 . (canceled)

18 . A construction material composition comprising
a) Portland cement clinker in an amount of from 15 to 55% by dry weight based on the total dry weight of the construction material composition; b) a supplementary cementitious material in an amount of from 20 to 75% by dry weight based on the total dry weight of the construction material composition; c) a calcium carbonate phase in an amount of from 5 to 40% by dry weight based on the total dry weight of the construction material composition; d) a sulfate source selected from the group consisting of gypsum, bassanite, anhydrite, and mixtures thereof in an amount of from more than 2.2 to 8 wt.-% of SO 3 based on the total dry weight of the construction material composition; and e) a hardening accelerator A comprising particles with calcium and silicon in a molar ratio Ca/Si of 0.1 to 2.2 in an amount of from 0.1 to 5% by weight related to the weight of the sum of CaO and SiO 2 of the hardening accelerator A based on the total dry weight of the construction material composition.

19 . The construction material composition according to claim 18 , wherein the supplementary cementitious material is selected from the group consisting of slag, fly ash, natural pozzolans, calcinated clay, silica fume, and mixtures thereof and/or wherein the calcium carbonate phase is selected from limestone, dolomite, calcite, aragonite, vaterite, and mixtures thereof.

20 . The construction material composition according to claim 18 , wherein the total SO 3 content and the total Al 2 O 3 content determined by elemental analysis are present in a weight ratio of from 1:10 to 5:1.

21 . The construction material composition according to claim 18 , wherein the Portland cement clinker and the supplementary cementitious material are present in a weight ratio of from 2:1 to 1:5.

22 . The construction material composition according to claim 18 , wherein the Portland cement clinker and the limestone are present in a weight ratio of from 4:1 to 1:2.

23 . The construction material composition according to claim 18 , wherein the hardening accelerator A further comprises a water soluble polymer in an amount of from 0.1% to 50% by weight related to the dry weight of the hardening accelerator A.

24 . The construction material composition according to claim 18 , wherein the hardening accelerator A comprises particles which are calcium-silicate-hydrate of the following empirical formula
a CaO, SiO 2 , b Al 2 O 3 , c H 2 O, d X, e W X is an alkali metal W is an alkaline earth metal 0.5≤a≤2.5 0≤b≤1 1≤c≤6 0≤d≤1 0≤e≤2.

25 . The construction material composition according to claim 18 , wherein the composition comprises
a) the Portland cement clinker in an amount of from 40 to 55% by dry weight based on the total dry weight of the construction material composition; b) the supplementary cementitious material in an amount of from 30 to 45% by dry weight based on the total dry weight of the construction material composition; c) the calcium carbonate phase in an amount of from 15 to 30% by dry weight based on the total dry weight of the construction material composition; d) the sulfate source in an amount of from 2.5 to 7 wt.-% of SO 3 based on the total dry weight of the construction material composition; and e) the hardening accelerator A in an amount of from 0.1 to 5% by weight related to the weight of the sum of CaO and SiO 2 of the hardening accelerator A based on the total dry weight of the construction material composition.

26 . The construction material composition according to claim 18 , wherein the composition comprises
a) the Portland cement clinker in an amount of from 30 to 40% by dry weight based on the total dry weight of the construction material composition; b) the supplementary cementitious material in an amount of from 30 to 45% by dry weight based on the total dry weight of the construction material composition; c) the calcium carbonate phase in an amount of from 20 to 30% by dry weight based on the total dry weight of the construction material composition; d) the sulfate source in an amount of from 2.5 to 7 wt.-% of SO 3 based on the total dry weight of the construction material composition; and e) the hardening accelerator A in an amount of from 0.5 to 5% by weight related to the weight of the sum of CaO and SiO 2 of the hardening accelerator A based on the total dry weight of the construction material composition.

27 . The construction material composition according to claim 18 , wherein the composition comprises
a) Portland cement clinker in an amount of from 20 to 30% by dry weight based on the total dry weight of the construction material composition; b) the supplementary cementitious material in an amount of from 30 to 50% by dry weight based on the total dry weight of the construction material composition; c) the calcium carbonate phase in an amount of from 20 to 40% by dry weight based on the total dry weight of the construction material composition; d) the sulfate source in an amount of from 2.5 to 7 wt.-% of SO 3 based on the total dry weight of the construction material composition; and e) the hardening accelerator A in an amount of from 1.0 to 5% by weight related to the weight of the sum of CaO and SiO 2 of the hardening accelerator A based on the total dry weight of the construction material composition.

28 . The construction material composition according to claim 18 , wherein the construction material composition comprises from more than 30 to 75% by dry weight of the supplementary cementitious material, based on the total dry weight of the construction material composition.

29 . The construction material composition according to claim 18 , wherein the construction material composition comprises
a) the Portland cement clinker in an amount of from 15 to 47% by dry weight based on the total dry weight of the construction material composition; b) the supplementary cementitious material in an amount of from more than 30 to 70% by dry weight based on the total dry weight of the construction material composition; c) the calcium carbonate phase in an amount of from 5 to 20% by dry weight based on the total dry weight of the construction material composition; d) the sulfate source in an amount of from 2.5 to 7 wt.-% of SO 3 based on the total dry weight of the construction material composition; and e) the hardening accelerator A in an amount of from 0.1 to 5% by weight related to the weight of the sum of CaO and SiO 2 of the hardening accelerator A based on the total dry weight of the construction material composition.

30 . The construction material composition according to claim 18 , additionally comprising at least one additive selected from the group consisting of inorganic carbonates, alkali metal sulfates, polymeric dispersants, hardening accelerators, hardening retarders, thickeners, and stabilizers or a mixture of two or more thereof and/or
additionally comprising at least one polymeric dispersant, in particular a polycarboxylate ether, phosphorylated polycondensation product or a sulfonic acid and/or sulfonate group containing dispersant and/or additionally comprising at least one polymeric dispersant, which is a sulfonic acid and/or sulfonate group containing dispersant selected from the group consisting of lignosulfonates, melamine formaldehyde sulfonate condensates, beta-naphthalene sulfonic acid condensates, sulfonated ketone-formaldehyde-condensates, and copolymers comprising sulfo group containing units and/or sulfonate group-containing units and carboxylic acid and/or carboxylate group-containin

Assignees

• Basf Se

Inventors

• Li Xuerun
• Hesse Christoph
• Mayr Bernhard
• Bizzozero Julien

Classifications

• C04B14/28

  of calcium · CPC title

• C04B28/04 Primary

  Portland cements · CPC title

• Y02P40/18

  Carbon capture and storage [CCS] · CPC title

• C04B28/145

  Calcium sulfate hemi-hydrate with a specific crystal form · CPC title

• Y02P40/10

  Production of cement, e.g. improving or optimising the production methods; Cement grinding · CPC title