U.S. patent application number 10/090362 was filed with the patent office on 2002-11-21 for additive for dewaterable slurry and method of manufacturing and improving slurry containing same.
Invention is credited to Naji, Basil, O'Chee, Milton.
Application Number | 20020170466 10/090362 |
Document ID | / |
Family ID | 27507501 |
Filed Date | 2002-11-21 |
United States Patent
Application |
20020170466 |
Kind Code |
A1 |
Naji, Basil ; et
al. |
November 21, 2002 |
Additive for dewaterable slurry and method of manufacturing and
improving slurry containing same
Abstract
A method of reducing the water requirements of a cementitious
slurry and of improving the properties of a cementitious slurry by
adding a mineral additive comprising fly ash having a predominant
particle size of up to about 10 microns, and/or aluminous material
having a predominant particle size of up to about 150 microns. The
additive acts as a water reduction agent and can replace either
wholly or partially a conventional plasticiser.
Inventors: |
Naji, Basil; (Toongabbie,
AU) ; O'Chee, Milton; (Deniscone, AU) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
620 NEWPORT CENTER DRIVE
SIXTEENTH FLOOR
NEWPORT BEACH
CA
92660
US
|
Family ID: |
27507501 |
Appl. No.: |
10/090362 |
Filed: |
March 4, 2002 |
Current U.S.
Class: |
106/705 |
Current CPC
Class: |
C04B 2111/00612
20130101; Y10T 428/25 20150115; Y10T 428/249968 20150401; E04F
13/02 20130101; Y10T 442/10 20150401; B28B 7/46 20130101; E04C 2/06
20130101; B28B 1/522 20130101; Y10S 106/01 20130101; Y02W 30/91
20150501; E04F 15/12 20130101; Y10T 428/31667 20150401; C04B
2111/00482 20130101; Y10T 428/249932 20150401; Y10T 428/265
20150115; Y10T 428/249986 20150401; Y10T 428/31504 20150401; C04B
28/02 20130101; C04B 18/08 20130101; Y10T 428/249972 20150401; C04B
28/02 20130101; C04B 18/08 20130101; C04B 18/08 20130101; C04B
18/08 20130101; C04B 20/008 20130101 |
Class at
Publication: |
106/705 |
International
Class: |
C04B 014/00; C04B
018/06 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 2, 2001 |
AU |
PR3474 |
Mar 2, 2001 |
AU |
PR3475 |
Mar 2, 2001 |
AU |
PR3476 |
Mar 2, 2001 |
AU |
PR3477 |
Mar 2, 2001 |
AU |
PR3478 |
Claims
What is claimed is:
1. A method of reducing the water requirements of a cementitious
slurry comprising: adding to a formulation used to form the slurry
an effective amount of a mineral component selected from the group
consisting of: (i) fly ash having a predominant particle size of up
to about 10 microns; (ii) aluminous material having a predominant
particle size of up to about 150 microns; and (iii) both the fly
ash of (i) and the aluminous material of (ii).
2. A method according to claim 1, wherein the mineral component is
added to a dry formulation.
3. A method according to claim 1, wherein the mineral component is
added to the formulation after the formulation is formed into the
slurry.
4. A method according to claim 1, wherein the fly ash comprises
about 25-60% silica, about 10-30% Al.sub.2O.sub.3, about 5-25%
Fe.sub.2O.sub.3 up to about 20% CaO and up to about 5% MgO.
5. A method according to claim 1, wherein the fly ash comprises
about 30-100 wt % based on weight of cement in the slurry.
6. A method according to claim 1, wherein the aluminous material is
selected from the group consisting of hydrated alumina, partially
hydrated alumina and unhydrated alumina.
7. A method according to claim 1, wherein the aluminous material
comprises about 5 to 30 wt % based on weight of cement in the
slurry.
8. A method according to claim 1, wherein the ratio of hydrated
alumina to fly ash is between about 1:1 and 1:10.
9. A method according to claim 1, wherein the cementitious slurry
comprises a hydraulic binder that is between about 10 and 50 wt %
of total dry ingredients.
10. A method according to claim 1, wherein the slurry contains
conventional plasticiser.
11. A method according to claim 10 wherein the amount of
conventional plasticiser is between about 0.3 and 3 wt % based on
weight of the dry cement.
12. A method according to claim 1, wherein the cementitious slurry
contains about 5 to 30 wt % of fillers.
13. A method according to claim 1, wherein the mineral component is
fly ash having a predominant particle size of up to about 10
microns.
14. A method according to claim 1, wherein the mineral component is
aluminous material having a predominant particle size of up to
about 150 microns.
15. A method according to claim 1, wherein the mineral component
includes both the fly ash of (i) and the aluminous material of
(ii).
16. A method of manufacturing a cementitious slurry, comprising:
providing a hydraulic binder used to form the slurry; adding to the
hydraulic binder an effective amount of a mineral component
selected from the group consisting of: (i) fly ash having a
predominant particle size of up to about 10 microns; (ii) aluminous
material having a predominant particle size of up to about 150
microns; and (iii) both the fly ash of (i) and the aluminous
material of (ii).
17. A method according to claim 16, wherein the mineral component
is added to the hydraulic binder after forming a slurry with the
hydraulic binder.
18. A method according to claim 16, wherein the mineral component
is added to the hydraulic binder before forming a slurry with the
hydraulic binder.
19. A method according to claim 16, wherein the fly ash comprises
about 25-60% silica, about 10-30% Al.sub.2O.sub.3, about 5-25%
Fe.sub.2O.sub.3 up to about 20% CaO and up to about 5% MgO.
20. A method according to claim 16, wherein the fly ash comprises
about 30-100 weight percent based on weight of cement.
21. A method according to claim 16, wherein the aluminous material
is selected from the group consisting of hydrated alumina partially
hydrated alumina and unhydrated.
22. A method according to claim 16, wherein the alumina content of
the aluminous material is between about 5 and 30% based on weight
of cement.
23. A method according to claim 16, wherein the ratio of hydrated
alumina to fly ash is between about 1:1 and 1:10.
24. A method according to claim 16, wherein the hydraulic binder is
selected from the group consisting of common Portland cements, fast
setting or extra fast setting cement, sulphate resisting cements,
modified cements, alumina cements, high alumina cements, calcium
aluminate cements and cements which contain secondary components
such as fly ash, slag and the like.
25. A method according to claim 16, wherein the hydraulic binder is
between about 10 and 50 wt % of total dry ingredients.
26. A method according to claim 16, wherein the slurry contains
conventional plasticiser.
27. A method according to claim 26, wherein the amount of
conventional plasticiser between about 0.3 and 3 wt % based on
weight of the dry cement.
28. A method according to claim 16, wherein the hydraulic binder
contains about 5 to 30 wt % of fillers.
29. A method according to claim 16, wherein the addition of the
mineral components improves one or more of setting time,
workability, pumpability, bleeding during settling, resultant
compressive strength and shrinkage.
30. A method according to claim 16, wherein the mineral components
are added to replace either partially or wholly a conventional
plasticiser in the cementitious slurry.
31. A method according to claim 16, wherein the mineral component
is fly ash having a predominant particle size of up to about 10
microns.
32. A method according to claim 16, wherein the mineral component
is aluminous material having a predominant particle size of up to
about 150 microns.
33. A method according to claim 16, wherein the mineral component
includes both the fly ash of (i) and the aluminous material of
(ii).
Description
PRIORITY CLAIM
[0001] This application claims priority from the following
Australian provisional patent applications, the full contents of
which are hereby incorporated by cross-reference.
1 Application No Title Date Filed PR3474 A Composite Product 2 Mar.
2001 PR3475 Spattering Apparatus 2 Mar. 2001 PR3476 Additive for a
Dewaterable Slurry 2 Mar. 2001 PR3477 A Method and Apparatus for
Forming a 2 Mar. 2001 Laminated Sheet Material by Spattering PR3478
Coatings for Building Products 2 Mar. 2001
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to admixtures for slurries and
in particular cementitious slurry compositions, and methods of
manufacturing and improving the same.
[0004] 2. Description of the Related Art
[0005] As is well known in the art, most cementitious compositions
are laid down or used in a slurry form. Increasing difficulty and
expense in obtaining high quality aggregate for use in such
cementitious material such as concrete has forced manufacturers to
resort to low grade materials such as crushed stone, marine sand
and even recycled crushed concrete obtained from demolitions or old
structures. This leads to problems with the concrete such as a
higher water demand, bleeding (where, as the slurry settles, water
migrates to the surface), lower workability and pumpability.
[0006] In the past, these problems have been overcome by the
addition of certain additives to the cementitious composition.
These plasticisers, sometimes known as water reducers, dispersion
agents or super plasticisers, act to increase the workability and
validity of the slurry for a given quantity of water. Examples
include lignosulphonates, naphthalene sulphonate-formaldehyde
condensates.
[0007] Typically, these water reducers are added at around 0.3% by
weight of cement and provide between 8 and 12% reduction in the
water cement ratio, depending upon the addition procedure.
Additions of up to 1% by cement provide up to 35% reduction in the
water to cement ratio. In high performance concrete application, eg
ultra high strength concrete, it is common to overdose in
plasticiser/water reducer, (or combinations thereof) to obtain
further water reduction of up to 50%. However, at such dosage
levels detrimental effects are produced, eg setting times increased
and compressive strength of a cementitious mixture reduced.
[0008] It is an object of the present invention to overcome or
ameliorate at least one of the disadvantages of the prior art, or
to provide a useful alternative.
SUMMARY OF THE INVENTION
[0009] In a broad aspect, the present invention provides an
additive for a cementitious slurry comprising of one or both of the
following mineral components:
[0010] i) fly ash having a predominant particle size of up to about
10 microns, and
[0011] ii) aluminous material having a predominant particle size of
up to about 150 microns.
[0012] The applicants have found that use of the small particle
size fraction fly ash or large particle size fraction aluminous
material acts as an efficient water reducer for cementitious
slurries. The applicants have found that addition of a suitable
quantity of such a mineral additive indeed provides a substantial
reduction in water required to maintain a predetermined viscosity
without any of the aforementioned detrimental effects arising from
conventional techniques. The aforementioned additive does not
significantly increase set times or cause excessive aeration, which
can be a major problem with some known admixtures. Further, it
inhibits bleeding and improves workability.
[0013] In a preferred embodiment, the aforementioned mineral
additive can be used in combination with a conventional water
reducer/plasticiser to enhance the water reduction capabilities of
such a conventional additive.
[0014] In a second aspect, the present invention provides a
cementitious slurry comprising an hydraulic binder, water, a
plasticiser and a mineral additive including one or both of the
following components:
[0015] i) fly ash having a predominant particle size of up to about
10 microns,
[0016] ii) aluminous material having a predominant particle size of
up to about 150 microns, and
[0017] the mineral additive being added in a quantity sufficient to
provide a water reduction effect.
[0018] In a third aspect, the present invention provides a method
of reducing the water requirements of a cementitious slurry
comprising adding an effective amount of one or both of the
following mineral components: i) fly ash having a predominant
particle size of up to about 10 microns, and ii) aluminous material
having a predominant particle size of up to about 150 microns.
[0019] In a fourth aspect, the present invention provides a method
of improving the properties of a cementitious slurry comprising
adding an effective amount of one or both of the following mineral
components: i) fly ash having a predominant particle size of up to
about 10 microns, and ii) aluminous material having a predominant
particle size of up to about 150 microns.
[0020] The reference to water reduction effect relates to the
ability of the mineral additive to effectively reduce the quantity
of water required to obtain a particular viscosity. As will be
clear to persons skilled in the art, for certain applications, a
slurry is designed to have a particular predetermined viscosity for
flowability, pumpability or application reasons. The mineral
additive described above provides excellent water reduction
properties for a slurry. As discussed, it can be used on its own to
provide water reduction to the slurry or in combination with a
conventional plasticiser/water reducer.
[0021] When used in combination with an amount of conventional
plasticiser/water reducer, it has been found that the
aforementioned mineral additive enhances the water reduction
properties of the slurry as will be discussed below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The preferred embodiments of the present invention relate to
the use of a mineral additive to manufacture and improve the
properties of a cementitious slurry. More preferably, one or both
of the following mineral components are added to the slurry: i) fly
ash having a predominant particle size of up to about 10 microns,
and ii) aluminous material having a predominant particle size of up
to about 150 microns.
[0023] The fly ash in the mineral additive refers to fly ash with a
predominant particle size of up to about 10 microns. As will be
clear to persons skilled in the art, fly ash is a solid powder
having a chemical composition similar to or the same as the
composition of material that is produced during the combustion of
powdered coal. The composition typically comprises about 25 to 60%
silica, about 10 to 30% Al.sub.2O.sub.3, about 5 to 25%
Fe.sub.2O.sub.3, up to about 20% CaO and up to about 5% MgO.
[0024] Fly ash particles are typically spherical and range in
diameter from about 1 to 100 microns. It is the smaller size
fraction of fly ash particles with a predominant size below about
10 microns that has surprising water reduction properties.
[0025] The fly ash preferably makes up about 30-100% based on
weight of cement. Preferably, the fly ash is between about 40 and
90% and most preferably about 50 to 70% based on weight of
cement.
[0026] Larger size fly ash particles have been known in the past to
provide a water reduction effect. Smaller size particles, however,
have always been considered unsuitable for water reduction for a
few reasons. Firstly, it is expected in the art that the smaller
the particle size, the more reactive the particle. Fly ash is a
reactive pozzalan and accordingly, smaller size fraction fly ash
was considered inappropriately reactive to act as a water
reducer.
[0027] In addition, due to the high specific surface area of the
smaller size fraction fly ash, it was expected that this material
would in fact increase water demand. The applicants have
surprisingly found that the opposite is in fact the case. The
smaller size fraction fly ash boosts the water reducing properties
of conventional water reduction agents by a substantial extent.
[0028] The aluminous material in the mineral additive preferably
has a predominant particle size less than about 150 microns. The
reference to "aluminous material" should not be taken literally but
refers to alumina type materials including hydrated, partially
hydrated and unhydrated alumina. Preferably, the alumina content of
aluminous material based on the weight of cement is between about 5
and 30%, preferably about 10 to 25% and most preferably about 15 to
20%.
[0029] If a blend of hydrated alumina and fly ash is used in the
mineral additive, the ratio of hydrated alumina:fly ash is
preferably between about 1:1 to 1:10.
[0030] The term "hydraulic or cementitious binder" as used herein,
means all inorganic materials which comprise compounds of calcium,
aluminum, silicon, oxygen, and/or sulfur which exhibit "hydraulic
activity" that is, which set solid and harden in the presence of
water. Cements of this type include common Portland cements, fast
setting or extra fast setting, sulphate resisting cements, modified
cements, alumina cements, high alumina cements, calcium aluminate
cements and cements which contain secondary components such as fly
ash, slag and the like. The amount of cement present in the
composition of the preferred embodiments of the present invention
has a lower limit of about 10 weight percent based on the total dry
ingredients, preferably about 15 weight percent, more preferably
about 20 weight percent, the upper limit of the amount of the
cement is about 50 weight percent, preferably about 40 weight
percent, more preferably about 30 weight percent.
[0031] The cementitious composition may optionally but preferably
include at least one filler material, e.g. graded and ungraded
aggregate such as washed river gravel, crushed igneous rock or
limestone, lightweight aggregate, crushed hard-burnt clay bricks or
air-cooled blast furnace slag, sand, calcium carbonate, silica
flour, vermiculite, perlite, gypsum, etc.
[0032] The amount of filler present in the cementitious composition
preferably has a lower limit of about 5 weight percent based on the
total dry ingredients, preferably about 10 weight percent, more
preferably about 15 weight percent; the upper limit being about 30
weight percent, preferably about 25 weight percent, more preferably
about 20 weight percent.
[0033] The cementitious composition may optionally contain other
additives including: cement plasticising agents such as melamine
sulphonate-formaldehyde condensates, naphthalene
sulphonate-formaldehyde condensates, naphthalene sulphonates,
calcium lignosulphonates, sodium lignosulphonates, saccharose,
sodium gluconate, sulphonic acids, carbohydrates, amino carboxylic
acids, polyhydroxy carboxylic acids, sulphonated melamine, and the
like.
[0034] The amount of conventional plasticiser used in the dry
cement composition will vary, depending on the fluidising ability
of the particular cement plasticiser selected. Generally, the
amount of cement plasticiser is preferably in the range of about
0.3 to about 3 wt %, and more preferably about 0.5 to about 2 wt %,
based on the weight of the dry cement composition.
[0035] Preferred plasticisers include Melment. F-10, a
melamine-formaldehyde-sodium bisulphite polymer dispersant,
marketed by SKW-Trostberg in the form of a fine white powder.
Another suitable plasticiser is Neosyn, a condensed sodium salt of
sulphonated naphthalene formaldehyde, available from Hodgson
Chemicals.
[0036] Thickener may also be used in the cementitious composition
including one or more of the polysaccharide rheology modifiers
which can be further subdivided into cellulose based materials and
derivatives thereof, starch based materials and derivatives
thereof, and other polysaccharides.
[0037] Suitable cellulose based rheology-modifying agents include,
for example, methylhydroxyethylcellulose,
hydroxymethylethylcellulose, carboxymethylcellulose,
methylcellulose, ethylcellulose, hydroxyethylcellulose,
hydroxyethylpropylcellulose, etc. The entire range of suitable
rheology modifiers will not be listed here, nevertheless, many
other cellulose materials have the same or similar properties as
these and are equivalent.
[0038] Suitable starch based materials include, for example,
amylopectin, amylose, sea-gel, starch acetates, starch hydroxyethyl
ethers, ionic starches, long-chain alkylstarches, dextrins, amine
starches, phosphate starches, and dialdehyde starches.
[0039] Other natural polysaccharide based rheology-modifying agents
include, for example, alginic acid, phycocolloids, agar, gum
arabic, guar gum, welan gum, locust bean gum, gum karaya, and gum
tragacanth.
[0040] The thickener addition rate in the cementitious composition
may range between 0.0001 and 0.5% based on the weight of the dry
cement composition.
[0041] Latex addition of at least one latex selected from the group
consisting of: an acrylic latex, a styrene latex , and a butadiene
latex is also preferred. This component improves adherence,
elasticity, stability and impermeability of the cementitious
compositions containing it, and also favours formation of flexible
films.
[0042] The latex may be used in solid amounts of about 0.5 to about
20 wt %, based on the weight of the dry cement composition.
Preferably, it is present in an amount of about 1 to about 15 wt %,
and more preferably about 10 wt %, based on the weight of the dry
cement composition.
[0043] The cementitious composition may optionally incorporate as a
substitute to the latex emulsion a proportion of a powdered vinyl
polymer or other equivalent polymeric material, to enhance the
adhesion; resilience and flexural strength; and abrasion resistance
of the composition.
[0044] The powdered vinyl polymer is preferably polyvinyl acetate
or a copolymer of vinyl acetate with another monomer, such as
ethylene. A preferred vinyl acetate resin is VINNAPAS LL5044
thermoplastic resin powder, containing a vinyl acetate-ethylene
copolymer, available from WACKER.
[0045] The powdered vinyl polymer may be used in amounts of about
0.5 to about 20 wt %, based on the weight of the dry cement
composition. Preferably, it is present in an amount of about 1 to
about 15 wt %, and more preferably about 10 wt %, based on the
weight of the dry cement composition.
[0046] The cementitious composition may optionally contain about
0-40 wt % of other fillers/additives such as mineral oxides,
hydroxides and clays, metal oxides and hydroxides, fire retardants
such as magnesite, thickeners, silica fume or amorphous silica,
colorants, pigments, water sealing agents, water reducing agents,
setting rate modifiers, hardeners, filtering aids, plasticisers,
dispersants, foaming agents or flocculating agents, water-proofing
agents, density modifiers or other processing aids
EXAMPLES
[0047] So that the present invention may be more clearly understood
it will now be described by way of example only with reference to
the following embodiments.
Example 1
[0048] Effect of Water Reducer and Small Size Fraction Fly Ash
Addition on % Water Reduction in a Cement: Fly Ash Mixture
[0049] Three mixes (total weight of solids=1000 gm each) were mixed
with water to achieve a mix viscosity of 4-3 seconds cup drainage
time. The details of the mixes are shown in Table 1 below.
2TABLE 1 Mix 1 Mix 2 Mix 3 Mix ingredients weight, gm weight, gm
weight, gm Cement 300 gm 300 gm 300 gm Fly ash (large size
fraction) 700 gm 700 gm 500 gm Fly ash (small size fraction) -- --
200 gm Water reducer -- 3 gm 3 gm (sulphonated naphthalene
formaldehyde) Styrene Acrylic Latex 60 ml 60 ml 60 ml Emulsion (56%
solids) Welan Gum (Kelcocrete) .sup. 0.1 gm .sup. 0.1 gm .sup. 0.1
gm Water 550 ml 350 ml 325 ml Water reduction in mix, % -- 36% 41%
Viscosity (drainage time in 3 seconds 3 seconds 4 seconds 50 ml
cup)
[0050] It can be seen that the addition of 1% water reducer by
weight in cement resulted in 36% reduction in mix water. This level
of water reduction is, according to literature, about the limit of
what can be achieved at such high water reducer dose. Using higher
doses would result in excessively delayed setting time and
reduction in the compressive strength in cementitious mixes. When
part of the large size fraction fly ash was substituted with
smaller size fraction (predominant particle size less that 10
microns) in mix 3, further water reduction was achieved, bringing
total water reduction to 41%. This result is quite surprising, as
the finer fly ash was expected to in fact increase the water demand
in the mix due to its high surface area.
[0051] Although the water reducing effect of fly ash in
cementitious mixes is well documented in literature, the plasticity
enhancing effect of the smaller size fraction in an already
plasticised cement:fly ash mixture is considered surprising given
the universal rule that finer material exhibit larger surface area,
leading to an increase in the water demand, needed as mechanical
water coating the finer particles.
[0052] Example 1 demonstrates a means of enhancing the water
reduction effect in plasticised mixes using a mineral additive with
a specified size range, namely the small size fraction fly ash,
without resorting to overdosing with water reducer. The result is a
more durable mix with higher strength and reduced shrinkage.
Example 2
[0053] Water Reduction in Plasticised Mixes Substituting Large Size
Fraction Fly Ash for Smaller Size Fraction Fly Ash
[0054] Two mixes (total weight of solids=1000 gm each) were mixed
with water to achieve a mix viscosity in the range of 6-10 Poise.
The details of the two mixes are shown in Table 2 below.
3TABLE 2 Mix 1 Mix 2 Mix ingredients weight, gm weight, gm Cement
300 gm 300 gm Fly ash (large size fraction) 400 gm 250 gm Fly ash
(small size fraction) -- 150 gm Cenospheres 300 gm 300 gm Melment
15 (SKW Chemicals) 3 gm 3 gm (sulphonated melamine formaldehyde) MC
1834 Acrylic Resin (Rohm & 10 ml 10 ml Haas) Water 400 ml 325
ml Water reduction -- 19% Viscosity (Rotothinner) .sup. 6.5 Poise
.sup. 8.8 Poise
[0055] It can be seen that Mix 1 which was comprised of cement, fly
ash and cenospheres (ceramic hollow spheres) required 400 ml of
water to achieve the required viscosity (in the presence of 1%
addition of Melment F15 water reducer). The % solids in this case
is 71.4%.
[0056] Mix 2, however, required only 325 ml of water to achieve a
similar flowability. Such water reduction (around 20%) was enabled
by substituting part of the larger fly ash particles with a smaller
size fraction (minus 10 microns in size, average size=4 microns).
The % solids in this case was increased to 75.5%.
Example 3
[0057] Water Reduction in Plasticised Mixes--Comparison of Silica
to Fly Ash
[0058] Two mixes (total weight of solids=1000 gm) were mixed with
water to achieve a mix viscosity of 4-3 seconds cup drainage time.
The details of the two mixes are shown in Table 3 below.
4TABLE 3 Mix 1 Mix 2 Mix ingredients weight, gm weight, gm Cement
300 gm 300 gm Fly ash (large size fraction) 500 gm 500 gm Fly ash
(small size fraction) -- 200 gm Silica 200 gm -- Water reducer 3 gm
3 gm (sulphonated naphthalene formaldehyde) Styrene Acrylic Latex
Emulsion 60 ml 60 ml (56% solids) Welan Gum (Kelcocrete) .sup. 0.1
gm .sup. 0.1 gm Water 400 ml 325 ml Water reduction in plasticised
mix -- 19% Viscosity (drainage time in 50 ml 4 seconds 4 seconds
cup)
[0059] It can be seen that Mix 1 which was comprised of cement, fly
ash and silica required 400 ml of water to achieve the required
viscosity (in the presence of 1% water reducer addition). The %
solids in this case is 71.4%.
[0060] Mix 2, however, required only 325 ml of water to achieve a
similar flowability. Such water reduction (around 20%) was enabled
by substituting the silica with ultra fine fraction (minus 10
microns in size, average size=4 microns). The % solids in this case
was increased to 75.5%.
Example 4
[0061] Water Reduction in Plasticised Mixes Incorporating
Combination of Hydrated Alumina and Fly Ash
[0062] In Table 4, the water requirements for two mixes containing
1.0% addition (by weight of cement) of a water reducer, ie
sulphonated naphthalene formaldehyde, are compared.
5TABLE 4 Weight (Mix 1) Weight (Mix 2) without hydrated With
hydrated Mix ingredients alumina alumina Cement 10000 gm 10000 gm
Fly ash (large size fraction) 16000 gm 16000 gm Fly ash (small size
fraction) 8000 gm 8000 gm Calcium Carbonate (Omyacarb Grade 6000 gm
4000 gm 40) Hydrated Alumina -- 2000 gm Water reducer 100 gm 100 gm
(naphthalene formaldehyde sulphonate) Welan Gum (Kelcocrete) 3 gm 3
gm Styrene Acrylic Latex Emulsion 2000 ml 2000 ml (56% solids)
Water 16500 ml 12500 Water reduction in plasticised mix, % -- 25%
Viscosity (drainage time in 50 ml .sup. 3.5 seconds 3 seconds
cup)
[0063] It can be seen that the addition of 2000 gm of hydrated
alumina in mix 2 (in substitution of calcium carbonate), resulted
in a significant reduction in the water demand, ie from 16500 to
12500 ml, for the same viscosity level.
[0064] This level of water reduction (around 25% in an already
heavily plasticised mix) is quite unexpected. It is also contrary
to conventional water reduction trends presented in cement
chemistry literature which suggest that the amount of water
reduction ranges generally between 15% to 35%, and that (beyond a
particular dosage) further water reduction is not possible
(Concrete Admixtures Handbook by, Ramachandran, 2.sup.nd edition,
page 447).
[0065] From the examples outlined above it can be seen that using a
mineral additive comprising small size fraction fly ash and/or
aluminous materials provide water reduction in non-plasticised
cementitious mixes or additional/enhanced water reduction in
plasticised cementitious mixes containing a conventional water
reducing agent. Such significant increase in water reduction
between 20% and 40% will enable production of high performance
cementitious mixes (lower shrinkage, higher strength, more
durable), without the disadvantages of overdosing with conventional
organic water reducers, ie delayed setting time, strength
reduction, excessive aeration. etc.
[0066] It will be understood that the modifications or variations
can be made to the aforementioned embodiments without departing
from the spirit or scope of the present invention. In particular,
it will be appreciated that the formulations, coatings, additives,
methods and composite products of the present invention are
suitable or may be adapted for use in conjunction with the methods
and apparatus as described in the various priority documents.
* * * * *