Process for the preparation of cement, mortars, concrete compositions containing a calcium carbonate-based filler treated with an ultrafine filler and a superplastifier, compositions and cement products obtained and their applications

Patent metadata

Field	Value
Publication number	US-9802861-B2
Application number	US-201314373491-A
Country	US
Kind code	B2
Filing date	Feb 27, 2013
Priority date	Feb 28, 2012
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

Process for the preparation of cement/mortar/concrete compositions or systems, (for simplicity hereafter “cement” compositions or systems or even “cements”), of a generally known type containing low or medium (standard) “filler(s)”, and/or optionally HP filler(s), as carbonate-based filler(s), namely coarse low or medium calcium carbonate(s), namely coarse marble(s); Product comprising, or consisting of, the pre-blend (A) of coarse, low or medium (or optionally HP) “calcium carbonate-based filler” pre-blended with at least an UF; Aqueous compositions (B) obtained by mixing the above pre-blend (A) of coarse filler(s) with UF(s) with an aqueous system such as mix water, aqueous mix fluid; Product (C) consisting of, or comprising, the pre-blend (A) or the compositions (B), treated or pretreated with at least one superplastifier or aqueous system containing superplastifier(s); Cement and Use of cement.

First claim

The invention claimed is:

1. A process for preparing a cement composition comprising introducing during the manufacture of a cement composition as a filler a blend of a coarse calcium carbonate—comprising filler and an ultrafine filler, wherein the blend is treated with at least one treating agent comprising at least one superplastifier before being introduced into the cement composition, wherein the coarse calcium-carbonate comprising filler has a d 50 >6 microns, and the ultrafine filler has a d 50 from 1 to 6 microns and a Blaine of greater than 1000 m 2 /kg, and wherein the cement composition so prepared comprises cement, said blend treated with said treating agent as a filler, optionally aggregates selected from the group consisting of sand and gravel, and optionally one or more additives.

2. The process according to claim 1 , wherein the coarse calcium carbonate—comprising filler is ground natural calcium carbonate, precipitated calcium carbonate, modified calcium carbonate, or any mixture thereof.

3. The process according to claim 1 , wherein the coarse calcium carbonate—comprising filler is a mixture of ground natural calcium carbonate and precipitated calcium carbonate at a ratio of 30/70 to 70/30% by dry weight.

4. The process according to claim 1 , wherein the coarse calcium carbonate—comprising filler is selected from the group consisting of (i) calcium carbonate having a d 50 of 7 to 9 microns and a Blaine of 462 to 690 m 2 /g, (ii) calcium carbonate having d 50 of 10.4 to 10.8, and (iii) calcium carbonate having a d 50 of 18 microns and a Blaine of about 365 m 2 /g.

5. The process according to claim 1 , wherein the ultrafine filler has a d 50 from 1 to 5 microns and a Blaine of greater than 1000 m 2 /kg and of less than 2000 m 2 /kg.

6. The process according to claim 1 , wherein the ultrafine filler has a d 50 from 1 to 3 microns and a Blaine of greater than 1000 m 2 /kg and of less than 2000 m 2 /kg.

7. The process according to claim 1 , wherein the ultrafine filler has a d 50 from 2 to 3 microns and a Blaine of greater than 1000 m 2 /kg and of less than 2000 m 2 /kg.

8. The process according to claim 1 , wherein the ultrafine filler has a d 50 of less than <5 microns and a Blaine of greater than 1000 m 2 /kg and of less than 2000 m 2 /kg.

9. The process according to claim 1 , wherein the ultrafine filler has a d 50 from 1 to 5 microns and a Blaine of greater than 1500 m 2 /kg.

10. The process according to claim 1 , wherein the ultrafine filler is selected from the group consisting of: (i) a silica fume having a d 50 of 1 to 2 microns, (ii) metakaolin having a d 50 of 3 to 5 microns, (iii) metakaolin having a d 50 of 3 to 6 microns, a chalk having a d 50 of 1 to 5 microns, (iv) a calcite having a d 50 of about 1 micron; (v) white limestone having a d 50 of about 2 microns, (vi) a marble having a d 50 of 1 to 6 microns, (vii) a marble having a d 50 of 1 to 5 microns, (viii) ultrafine calcium carbonate having a d 50 of 1-2 microns, (ix) ultrafine calcium carbonate from microcrystalline whiting having a d 50 of about 2.4 micron, (x) an ultrafine siliceous product having a d 50 of about 1.86 microns, (xi) modified calcium carbonate having a d 50 of about 2.29 microns, and (xii) precipitated calcium carbonate having a d 50 of about 1.52 microns.

11. The process according to claim 1 , wherein the ultrafine filler is selected from the group consisting of: (i) ultrafine calcium carbonate having a d 50 of about 2.4 microns, (ii) silica fume, (iii) metakaolin, and (iv) ultrafine calcium carbonate having a d 50 of 1 to 2 microns.

12. The process according to according to 1 , wherein superplastifier is a polycarboxylate, a polycarboxylate ether, or a product manufactured from sulfonated naphthalene condensate or sulfonated melamine formaldehyde.

13. The process according to claim 1 , wherein the superplastifier is a polycarboxylate ether.

14. The process according to claim 1 , wherein the superplastifier is present in an amount of from 0.3 to 3 kg for 100 kg of the cement composition, on a dry to dry basis.

15. The process according to claim 1 , wherein the superplastifier is present in an amount of from 0.3 to 2 kg for 100 kg of the cement composition, on a dry to dry basis.

16. The process according to claim 1 , wherein the superplastifier is present in an amount of from 0.8 to 1.23 kg for 100 kg of the cement composition, on a dry to dry basis.

17. The process according to claim 1 , wherein the superplastifier is present in an amount of from 0.05 to 0.1% per dry weight based on the dry weight of the coarse calcium carbonate—comprising filler.

18. The process according to claim 1 , wherein the at least one treating agent comprises a superplastifier only, or a superplastifier and a plasticizer.

19. The process according to claim 1 , wherein the at least one treating agent comprises a superplastifier and a plasticizer in a ratio of from 95/5 to 85/15 on a dry weight basis.

20. The process according to claim 1 , wherein the cement composition further comprises a fluidifier.

21. The process according to claim 20 , wherein the fluidifier is a modified polycarboxylate.

22. The process according to claim 20 , wherein the fluidifier is present in an amount from 3 to 4 g per dry weight of the total cement composition.

23. The process according to claim 1 , wherein the cement composition comprises one or more of a setting accelerator, a setting retarder and an air entrainment agent as additives.

24. The process according to claim 1 , wherein the coarse calcium carbonate—comprising filler is dry calcium carbonate, the at least one treating agent is a superplastifier, and the cement composition further comprises one or more additives, and optionally aggregates selected from the group consisting of sand and gravel.

25. The process according to claim 1 , wherein the coarse calcium carbonate—comprising filler is dry calcium carbonate, the at least one treating agent is a superplastifier, and the cement composition further comprises one or more additives, water and optionally aggregates selected from the group consisting of sand and gravel.

Assignees

• Omya Int Ag

Inventors

• Skovby Michael
• Gonnon Pascal

Classifications

• C04B24/023

  Ethers · CPC title

• C04B40/0039

  Premixtures of ingredients · CPC title

• C04B40/0028

  Aspects relating to the mixing step of the mortar preparation · CPC title

• C04B24/045

  Esters, e.g. lactones · CPC title

• C04B2103/32

  Superplasticisers · CPC title