CA2018889A1 - Very early setting ultra high early strength cement - Google Patents
Very early setting ultra high early strength cementInfo
- Publication number
- CA2018889A1 CA2018889A1 CA002018889A CA2018889A CA2018889A1 CA 2018889 A1 CA2018889 A1 CA 2018889A1 CA 002018889 A CA002018889 A CA 002018889A CA 2018889 A CA2018889 A CA 2018889A CA 2018889 A1 CA2018889 A1 CA 2018889A1
- Authority
- CA
- Canada
- Prior art keywords
- approximately
- weight
- ultra high
- high strength
- cement
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/32—Aluminous cements
- C04B7/323—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/06—Aluminous cements
- C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
Abstract
ABSTRACT OF THE DISCLOSURE
Methods for forming very early setting, ultra high strength cements and the cements so produced are claimed. The methods comprise forming a mixture of raw materials containing SiO2, Al2O3, CaO, Fe2O3, and SO3, respectively designated S, A, C, F, and ? and that the overall molar ratio of A/F exceeds approximately 0.64 and the overall molar ratio of ?/A + F is between approximately 0.35 and 0.25. This mixture is heated to an elevated temperature between 1,000° C and 1,200° C
for a sufficient period of time to produce a clinker amount of C4A3? is then determined and a final mixture is formed utilizing the high C4A3? clinker, C containing hydraulic or portland type cement and soluble C?
anhydride to produce a final cement mixture having a C4A3? content of approximately 10% to 30% by weight, a soluble C? anhydride content of approximately 5% to 20%
by weight, and the remainder being hydraulic or portland type cement. The cements so produced exhibit very early, ultra high strength ranging from 3,000 psi to 5,000 psi in one hour, 6,000 psi in one day, and 11,000 psi in 28 days.
Methods for forming very early setting, ultra high strength cements and the cements so produced are claimed. The methods comprise forming a mixture of raw materials containing SiO2, Al2O3, CaO, Fe2O3, and SO3, respectively designated S, A, C, F, and ? and that the overall molar ratio of A/F exceeds approximately 0.64 and the overall molar ratio of ?/A + F is between approximately 0.35 and 0.25. This mixture is heated to an elevated temperature between 1,000° C and 1,200° C
for a sufficient period of time to produce a clinker amount of C4A3? is then determined and a final mixture is formed utilizing the high C4A3? clinker, C containing hydraulic or portland type cement and soluble C?
anhydride to produce a final cement mixture having a C4A3? content of approximately 10% to 30% by weight, a soluble C? anhydride content of approximately 5% to 20%
by weight, and the remainder being hydraulic or portland type cement. The cements so produced exhibit very early, ultra high strength ranging from 3,000 psi to 5,000 psi in one hour, 6,000 psi in one day, and 11,000 psi in 28 days.
Description
POIl~;, SMITH, L~NDE, ~OSE TEL: Jun 5 ,~ 14 :51 tJ~ 019 P ,04/1 ., v 2()~L8889 ~, . 7~-120 VERY EARLY SE'I"l`ING UT.~I~RA~ G~ F!Ah~L.Y ~ N~ II C~t~E~T
Field of~the Inven.~lo!j The present inventior~ relates in a broad as~ect to fas~ setting hi~h ~ctlell~tll ~eme1~ con~pos.itlons and Iho~hod.~. for their Ic~r.ln;~tion. More p.~ t.~ r~I.y, t~lo pr~sent inv~ntlon is directe~ tv very ~.~rly setting, ultr.~ high stren~th c~ment composi~ions an~l metllods for thei~ form.~ion whi~h b~ eflcially utilize thc forma~ion ~f ettring~e to ~i~nifi~antly enhance the compressive stren~3th and e.~rly ~i.ng properties o~ the ~m~t.
.~ck~rou~d oP tl~e.Invent.ioD
H~drau~ic ~mcnt:~, or ~em~nts whi~}l har~en by re~ting with water, are most ~ypi~lly illustrated by portland type cement~. Por~la~d c~ment conc.rete h~s been )cnown fo~ al~o~t one huncl~e~ ye~r~ and is among one o~ the mo~ ~ommonly us~ stx~lctural m~terials.
Portland ~ements are cla~siflecl into at least ~ive major ~ypes ac~ording to ~hemi~al compbsitio~ and differing prope~ resul~in-J theref~om. ~c.ll~ral purpos¢
portland cem-~n~ typi~lly contain approximatel~ ~0-G~
~lcium oxide, ~0-2~ sili.ca, 4~ luminuni and about 2-5~ ferric oxic3~-. Raw materi~l s~uxces for th~.se ~;.nnr~l c~mpon~nt~ in~lude.lim~tone, clay, s~lale, sands~olle, bauxi~e and iron ~re. Mixt~res ~f these ~aw m~terial~
are proces~ed throu-3h a ~iln ired he~t treatmel)t tbur~ln~ t approximat~ly 1400-1600~ ~ ~2500-2~00~ F~
to produce A ~.inter-~3 or "clink~re~1~ mat~r;n.l., wl.l.~
th-~n pulverize.d wi~h 4-5~ gypsum to pJ.O~Ilce tl~c flnal ceme~t procluct~
~ or c-~nveni~ o~ furtllt~.r ~e~.c~r.i~-ti.oll, tll~.
~ollowih~ ~tan~ard te ~ inc3u~try abb.r- vl~tioll~ ~ill he utilized to t~e~orlbc th~ CompositiOn O~ g-lt.~h ~ired 3 5 mate~ ia 1~:
POMS, SI~ITH, L~IDE, ROSE TEL: Jun 5,gO 14:51 t~l~.01~ ~,fJ5/1 .. . ........................ .
~ 8~389 ~
H - represent~ water (H20) C - represen~s Calcium oxide (~0) A - represents Alum~"u~ oxide (A1203) F - represents Ferric Oxi~e (~e203) M - ~epresents ~agnesium oxide ~gO) S ~ ~epresents Silicon oxide (Sio2) K - repres¢nt~ Pot~ssium Oxide (K~O) N - repreSent.s 50di~m oxide (N~20) S - represen~g Sulphur Trioxide (S03) , General purpose po~tland ~ype cement (usu~lly designated ASTM I) t~pic~lly contain~ ~pproximately 50%
~3$, 2~% C~S, 12~ C3A, 8~ ~4A~ CS . Thus~ ~h~ ~ot~l a~oun~ ~f calclu~ ~ilica~e~ i~ approximately 7~, ~ith the pre~omin~n~ sili~ate being C3S. Af~er hydratioh~
such general purpose portland cement~ generally exhibit compress~va streng~h~ on the order of 1800 p~i after three day~ of curiny and 2800 psi a~ter s~ven days of curi~g, as de~ermi.ned ~y the ~tandard A~T~ procedure ~109 ~
20In many forms o~ concrete construct~on th~ 3 ra~e of ~trength development for ~neral purposa por~l~nd type cement ~ignif~can~l~ adds to the CQStS 0~ construation because the cRst hydr~ted concrete must remain supported by ~orm~ during a period of time su~cient to allow lt 25to develop adequate ~tr~ngth to permit xemoval ~ the form~ ~n~ to allow a~ditional construotlon.
Past e~fo~ts at ove~co~nin~ this sl~w rate of ~t~ength det~elopmen~ ln gen~r~l purpo6~ portland cement h~ve r~sulted in ~he procluction o~ hi~) earl~ ~trength 30po~land cements such as ~TM III whi~ll differs from o~her ~elnen~: b~r h~vlng higher ~mount~ o~ C3A and~or C3S. Th~ minim~m A~TM specific~tion fo~ ~pe III
portland cemant compre~siv~ strength i~ 1~00 psl ~t one day and 2800 p5i at three da~s. However, such cements 3S~ypiç~lly exhibit compr~se~iv~ ~tren~hs Ol~ the or~er of .
' ' POMS, SI~ITH, L~I~IDE, ~OSE TEL: Jun 5 ,~O 14 :51 ~l~ ,Ol~ P ,06/1 ~ ` ``J ~0~889 ~_ ~u00-2~00 psi ~t olle ~ay an(.3 may ~evolo~- c:o~ r e!;S i ve' strengtl~s on the order o~ 5000 psl at s~ven d~lys.
Nonetheles~, there remalns a great heed to develop cements h~vin~ m~l~h hi~her ea~ly strell~th~ r ex~mple, in the procluctlon o~ pre-~ast, pre~str~ssed, aon~rete product~, a Gompressiv~ str~ngth Oh the ord~.r of 3000-4qoo psi at one ~ay is oft~ll requlred.
Addi~ionally, in the ~onstruction ~nd repair of hiyhways, m~ny d~ys and even weeks of curing t~me are 10 require~ before the hi~hways m~y l~e utili2ed. ~Ior~over, in the construction o~ collcrete bu~lding~ and bridges where the cem~.nt matrix is c~st into ~onn~, it is nece~Ls~ry to allow days oP ~u~ ng timQ to allow the cem~nt to develop suffic.ient strength fo~ remov~l of the 15 Porms.
other hydr~uli-. CC~ 3 thAt m.~y or may not be hl.gll e~rly strengtl- ar~ tlle ~o-called "c~lcium alumino ~ul~ate't cements ba~ad upon 3C~0.3A1203.C~504, abhreviated ~s either C3A3~ or, preferahly, C~A35.
20 Typica~ ïy, the prim~ry characterlstic o~ C4A35 cement:s i~ their expansivenes3~ Concrete made ~rom portland cement together with sat~d, gravel, or oth~r mineral agyregate ~ypi~al~y under~oas shri.nkag~ upon drying.
~hls shrinkage is und~.qira~le in tha~, amotlt3 other reasons, it gives rise t~ crack~ whlGh ult~mately w~aken the ~et concreta~ ~dition o ad~iti~s S~GIl a~ C4A3S
coun~eract~ this ~hrink~g~ asld ~ay o~ m~y not produc~
c~ments ha~ing early high strength.
~r ~xa~pl~, type K portland c~ent a~ di~closed ln United 5tates Paten~ No. 3,155,~2~ tXl~in~ u~es the expan~iv~ prope.rty upor- hyd~atl.~n of ~3S in th¢
p~esehca of ~ree ~ ~nd C,~ t~ p~oduce expAn~.i.ve ~amel~t compone~lt~ ha~ing ~trengths ~n the rallye of st~ndard portland cement. Slm~ ly, U.s. P~t~sl~ No. 3,860,~33 ~ost et al . ) d~ a h~ ar:ly ~tr~ t~ m~llt con~ining C4A3S, cs ~ 2n~1 ~2~, wslieh exhibits PO~IS, SMITH, LflNDE, ~OSE TEL: Jun 5 ,30 14 :51 ~ Jl~ P,f~7/1 . , .
conlpres~ive strenyths o~ at le~st 2~00-4000 psi wlt.~lin 24 hour~ followi~ hydr~tlon.
In ~pite oE the~e ~dV.~ S in t]lC. procluctinn of e~rly settillg hiyh strengt}~ cemellt, ~ noted abov~, th~
development o~ portlancl typo cements havihq even ~reater co~nl:~re~ive stren~th~ l hic311cr r~tes or ~rel~c~t~
devqlopmen~ th~n those pre~ently ~vailable would be of great economic benefit ~o t}le ~on~truc~ion industry.
Ac~ordingly, i~ is a parti~lar object of the pr~sent 1~ invention to prov$de methods for tho produ~tio~ of very ea~ly setti.n~, ultrahigh strength ~ement oompo~itlons whiah, following hydration, will prod~lce compressiv~
s~ren~ths on ~he order o~ 3000-5000 psi within one hour, on th~ order o~ 7000 psi within on~ day.
Ik i~ ~ ~urther obje~ of the present invention to providc method~ for the productlon of ~ery early set~ing, ultra high ~treny~h cemen~ ~omposi~ons whic}
will producR compressivc ~tren~ths in ex~e.ss oP ~, 000 psi withln ~wcr,~y-e~ht ~ays followin~ ~lydr~tion.
It i~ an adflition~l objcct of ~he pre~en~ inv~n~ioh to provifle me~hod~ for t~le p~oduction ~ very early setting, ultra hi~h ~trength ce~ent com~o~ ns which ~re burned at low ~e~pera~ure~.
It i~ yet an addi~i.on~l object ~f th~ presen~
in~ention to provid~.methods for ~he prodllction of very early ~e~ting, ultra hi~h streng~ll aement ~ompositions which bene~ici~l.ly utilize the ~ormA~ion 0~ e~rin~ite cryst~ls ~o strellgtllen t}le hydra~e~ c~em~n~.
It is a f~r~i~er acldit~on~1 object oC t~l~. present inVC21t~cn to provide mçt~od~ for pr:Qdu~ cJ very carly ~etting, ultra hi~h ~relly~h ce~ellt ~ompositionR whi~h are p~rticul<~rly wel.l ~i.ted ~or u~ itl GOld temperAturQs clue ~o ~heir hlyh he~ts o.~ hy~1ratlon d~ring their ~in~l s~t.
It is a further ~dltion~l ohj~t of th~ p~scnt invention t~ provide me~l~ofl~ ~or prod~l~ing ~ry early ~" _ POMS, SMITH, LRII~E, ~SE TEL: Jun 5 ,~O 14 :51 f~l~ 015 P .
~ ~,.,..
2018 518~ -74-l~o setting, ultra high stren~3th cement co~posltions which achieve v~ry early ultra high strenyth throug~ ~he ~V~tl~et~U.~ u~il.i.7.~.Lon of Gom~ined llydr~t~d ~t~rl~glte (C6AS3~2H.) and calc.ium Alumltl~t~. hydrate (C~lOH).
S~mm.l~y of the ~nve1ltl0l~
Thes~ and other o~j~c~ ~re a~hieved by the me~lods ~nd ceme.nt compositi~ts of the present invcntion wh~ch utilize low temperatur~ burllit~g of speci~i~ mixtures of raw m~teri~ls to pro~uc~, in the klln, spccial clin~e~s havinc~ high coll~entrAt.i.olls of C4A3$ whic~ ~r~ ~ixec~ wlth hydraulic or portland type cemcnt and ~ in accordance wi~h a un~qu~ ~ix.i.nc~ formul~. When hyd~ated, the ~esultinc3 cement compoxit~ion~ prod~lce extrem~J.y hi~
1~ strength characte~istios in ~n unusu~liy short pe~iod o~
time ~nd ultimat~ly cl.lr~ ~o previously un~chievable compressive str~n~ths th~ou~h the conl~in~ act;on of thc aqueous pha~e~ o~ C~A~3 and CA.
Th~ ~.ir~t step o~ t.ll~. me~od for prod~ iJ)~ ve~-y early settlny ult~ hi~ strength c~tn~ compos~tions o~
the pr~sent invention involves the formation o~ a mixture o~ limestone, gypsum ~nd bauxit~, kaolonite or other high alumin~ clay to provicle the raw materi~l~
S,~,C,F, and S. Thi~ mixture prefer~ly ha~ ~n overall molar r~tio o~ A/F greater than or ~qual ~o approximately 0.64 ~nd s/~+F b~twe~.n approx~m~tely 0.35 ~nd 0.25.
~ n contrast to ~he kno~ll, prior art, method~ o ~çment prQdll~tion whic~ fire th~i.r r~w mAte.ri.~l mi.xtur~, at t~mperat~lres above 1.~.~0' ~, t~l~. mixtur.e ~rodl~e~
accordallc~ with the m~t}lod o~ ~he pr~erlt l~vellt~on i,~.
he.a~ed to An elevatc~l tem~:~er~.ure betwecn 1000 c and 1200~ C for a sufficient period o~ time ~o ~orm a ~linker having a hiqh CollCentr~tion of C4A3S- Xt should be em~ha,~ize.d th~t he<~tir-g the mixture of t~le pre~eht inven~ion to a temper~ture gr~ater than ~200" C will --S--POMS, S~VlITH, LRNDE, ROSE TEL: Jun 5 ,~O 14 :~1 ~lo r~l~ P .~g/l . , .
`~ 20~8~8~ ~
~eco~tpose the de~sired ~4~3.S. ~hu~, the method of th~
pr~sent lnven~ion p~od~lces the C4A3S phase in t~le kiln by ~urllin~3 the clinker ~t recluced temperAture.
On~e th~ clinker h~9 b~en formed, the average 5 ~tount of C4~35 is deterntin~d ancl ~ final mixture is forme~l ~y combininr~ c ~llnkcr with hydr~lllc or po~tland type cement al~d solu~le C5 anhydri~le in accordance wit}l the dc~igll ~ormula C4A3S + 2C + 2c~.S
~AS3 c~q ~ 2CA a~ ~o that ~he flnal mixtu~e ihrlucles a C4A3S contetlt of approximately l0-30~ by weight, 5-25~
by welght soluble CS atlhyd~ide, with tll~ remaining ~5-85~ by wei~ht ~einy hyl~raul ic or por~land cemetlt.
B¢~ause o~ t~le nc~rJ:oW tem~er~ture r~nr~e het~eell 1000 C and 1200~ C at w~lçll ~4~3S is stRble lll t~ie kiln, the method of t~e presen~ invcntion requi~es state of ~he art ki.ln tempcratUre corltrol. ~eCAU~e ~ont~mpor~ry cemcnt kllns do not h~ve temper~ure con~rol at ~he burning 20ne it~el~, the temperature control is pr~Eer~ly c~rr1ed out utl.l:1~in~3 t~e bene~lt ~0 of x-ray diffr~c~on techniyu~.s to perio~ J.y hn~lyz~
~he clinker for the p~o~-ler CO~t~tl~ of C4~3,5, Tllose skill~d in the ~rt will appre~atn t~ t ot~e~ for~lls o~
alinker analy~ls may be utiliz~d, though x-ray diffr~ctibtl i5 pre~er~ed.
2S The c~mcnt ~ompositions produced in accor~ance with the method and mixing formula of the prese~ inventicn, ~ollowing hydrRtion, pro~u~ ultr~ high ~t~eng~l~ early ~etting ~ements h~ving c~pr~sive strength~ on the ord~r o~ 3000 psi ~ithir~ one ~our, ~0~0 p~i within ~enty four hours and lO,OOo psi within t~en~y eight d~ys. ~hus, the cement ~ompositions 80 produ~ed are part.icul~ly w~ll .suit~d ~or u~.e ln corlcret~
constructlon where ~h~ reductiori irt set~ing ti~e will h~e ~igni~icant economic Adv~tage. ~oreover, the 3S previously unat~inahle CompresSiYe stren~ths exhi~ited P~I~S, SMITH, L~DE, ~OSE TEL: :lun 5,90 14:51 l~lo,~ .lf~i J 20~8~38g ~' 7~-120 by the cement c ompositions of the presen~ invention p~ovide slgnifican~ C~llsttuotio~ adv~ntag~-s sufh ~s ret.1uctlons in str~le~ r~ .e an~l weic~l~t. Wit~loUt.
corre~ponding reduatiol~ ln streh~th. Additionally, ~he 5 hi~h h~ats of hydration of the compositions of th~
pr~sent inves~ on preve~lt tht~ hyd~stt~cl ce~ntorlts f~om Preezinc3 in cold temper~tures, enablirlg corls~ruction t~
aontinue at temperAtUreS below 01 C.
P~urtller objects and advantage~ o~ t~le cement ~ompositions procluc~d isl acçord~nce with th~ teachis~gs of ~ht~ prese~-t in~e.l-t i.~n, a:~ wt~ e.tter ~nderstnnding tht~reof, will be aforded ~o tslose skilled in the ar~ ~rom a consicleration o~ t~le following d~tailecl ex~lanat~on ~e preferrecl exemE)lary em40di~nent~
thereo~.
e~t.~ ~escrlption ~of F:xeml?la~y_Fmbocl ;ment A~ noted a~ov~, cement o~omposi.~it3rls lnGo--por~tis C"7~3~ have been Xno~n il) ~.ho ~rt ~or almoF;l: 50 y~-~rs-~V Whes~ hyd~a~cd in the presehce of CS an~ C, C4A3S ~e~ct6 to produce expansive crystalfi of qttri~ite (C6AS3 aq) acco~ding to the ~ormul~:
C4A3S ~ 6(~ S + 31H2C~ ~ 3C6AS3 ~ 311~20 These ~xpans ~ve Grystals have been used in the past to ~5 offs~t the nor~nal~y oc~u~ring ~h~inkage in gener~l purpose por~la}ld type cemcnts. However, whan C4A35 is hydr~tecl uncont:rollably wi~h ~I?s~m in por~l~t~d cen~cnt, it prc:du~e~ ~n expansive react1 on that. i5 d~st~uctive ~-o the concrete.
~hou~ A n~lmber Or .)riot, ~rt p~tents. h~ve di.~close~-~
a ~arie~y ~ methods ~o~ cont~olling ~uch exp~nsive reaction~ i~ hydr~ted portlAnd ~em~nt, n~nc has becn ~ble ~o produce the very early setting, ultra high strength cement of ~he pre~ent lnvention. C~A3~g has be~n utillzed as A OOI~ti~Uent in mod~ie~ cement co~posi~ions, inclUding so~e high eArly ~trength '~ Z0~8~
~ompositions, yet nor-e of thes~ contpositions s~ccess~ully dif~erentiate bet~een the gypsum ph~ses present in the r~action. R~th~.r, ~uch compo~itions u~ilize the stoichiometric produr~tioll of ~xp~nslve e~tringi.te crys~flls in A~ord-~t~ce wit.~l the above-note(l fo~mula.
Moreover, in spite of the lorl~ history of ceme~t produ~tlon and use ino~t:~L-pora~-itl~ C4~3S, thc prlor art i~.
devoid oE pro~esse WlliC21 QEfectively produce C4A3$ in the cement kiln during the burning process. Typi~ally, the well establish~d procedures for produ~in~ portland type ~ement and ~ariations the.reo~ utili~e a rotary kiln heat treatnten~ ln exc~ss o~ l,Z00 C to slntcr or ~linkerize the raw ~naterictls. These hi~32~ t~nlper~tU~es 15 are utllized }:ecau~e tl~e d~sirable sllicates, C3S and czs, st~rt to form ~t t~nlEleratllre.s arc)urld l, 300 c arlci a~e stable flhove temper~ t:ures oE 1, 500 c . In colltra~t to thes~ ~ilica~s, c:alcium alutnino sulfa~e, C4A3.S , i~
not t~errnocly~tf3mi~cllly fit ~ble e~ teltlt1er~tt-1rc~ ov,e ~o 1, ZOO~ C and ~tct~3ally decomposes at SUC21 el~vated tempcratures~ Rath~r, C4A3S begirls to ~orlll a~
temper~ure~ o approxima~cly 1,000 ~ al~d b~comes s~able at approximately l,l~o~ c. 'l~hus, be~a~ e o~ t~is ~if~er~nce in t~mperAture s~a~lli.~y, con~mer~ially ~5 producing cement clinke~s GOIlt~inillg bo~ll C3~ ~nd ~2S A~
well as ~4~3S has be~n difPicu1t, i~ no~ lmpos~lble with existing cembnt pro~uc~ion tecllnology and kiln controlling a~t.
Accordin~ly, in co~ltr~t to t~le pri~r ~t cemen~
produ~inq methodologie~, the m~tho~s and co~posi~ions of the pre~e~t ,invell~ion utillz~ s~)~cial mix1n~ ~or~ul~ ~o design ra~ ma~eri~l ~ixe~ which in thc ~men~ kiln itself prod~lce unique clinkers h~vin~ high con~entr~tlons of C4A3S~ Further, regardle~s of the 35 ability of the special olinker~: so p~odt~ced to bec:ome hyd~ulic c:emell'c upon grihdin~ ar)d hydr~tion, when mixed -B -PCIMSI ~llITH, LRillJE, ROSE TEL: Jun 5,~0 14 J1 ~Sk l~l~ P,l~/l . , .
~.~ 201~
with por~lt~nd cemenk c~nd ~olubl.~ c;31ci-lm sul~ate ahhydride accordin~ to the te~ch.ing~ of tlle pre~cnt in~ent;oll, the.se ut~itlue cli.nk~rs procl~lcc very ctlrly s~.ttin~, ultr~ hl~h skren~th cements lla~ir~g GOmp~essive str~ngths ~anging f~oln 3,000 p~i i.n o~ hour, following hydr~ion to ~,O~)o psi. ill twellty-~nl]r IlOllt'S. allCl t.~.) 10,000 psi in twenty~igilt d~ys.
Before proceeding furth~.r, for purpo~es of expl~natio~ ~nd wi~ho~t wishin~ to be bo~ d to this ~h¢ory, it ha~ ~een detQrmihe~l t~l~t thc metho~l of th~
present in~ention pronlu~.s ~niq~l~ ce~l~nt con~positio whic~l, followi~g hydr~ti.on, ihcorpVr~te cry~t~l~ 0 ettrillgite and c~1cium nlum; oat~3 hy(:lr~t.e . It i.~
be.lieve~l th.lt tl~e nc~cll~ .li kc~ cryst~L~ Or nl.:tr. in~; to. .li)rl ct~lcium ~lumin~e hydr~te f~lnc~lon to str~n~3tl~n tl,~
hydralllic conçr~te~ so produ~ed by formirl~ tl~tworks o~
r~info~cillg micro Pibers. ~his internAl tl~rcn-dirnension~l rein~orcin~ fi~)~r matrix, in con~unckioll w.i~h the CA aq ph fie which oc~u~ in h~gl~ Alu~ina cem~.nt, co~bi.nes ~o pro~ ce thQ previously unattc~inable very ~arly, ultrc~ h.igh ~trencJth ~ha.r~cteri5tiC~ of tlle cement ~ompositions of the presont ~nven~ion. Prior ar~
cement ~omposi~ions h.~e been unable to combine ~ttringite or C6AS3 ~ a~ ~nd CA ~ and ~3S ~ ~q phas~s in a ~in~le c~m~nt ~QC~se ~ the exce~sive kiln tesnp~ratut:os ~til.i~,c~. Tho~e sk7.1l~d in the art will appreciate ~ha~ t~le forogoiny proposed mechanism ~or. the p~op~rti~s oP the cement compositions of t~e present invention ~3 the.orçtic!~1 oslly 3nd ~oes not limit khe ~cope or conten~ of t~e instc7nt in~entiotl.
A~ noted above bri~ly, ~he firs~ ~tep in the met~od o~ ~he presetl~ inv~tltion i~ tv produce ~ ~.p~ci.~l cemen~ clinker con~Lniny hig~l ~7moun~ o~ C4A3$ in the kiln. The r~w materj.~l~ for this clinker A_e tho~e ~ommonly kho~n and u3ed for the production of ordlnary portland cemont clinkers, n~mel~: hi~h all7minc~ clay or POI~S, SI~IITH~ LRN~E, ~OSE TEL: Jurl 5,gr~ 14:51 ~ ,rJ1~ P,13~1~
`~ 20~1 38~9 ~ ~
~4-~0 hauxite or k~olonite, limeston~ and gypsuJ~ r~ se skilled in the ~rt will app~eciat~ that ~hese raw materi~ls ~re ~ources ~f S, A, ~, F ~nd S, which ~r~, respectively SiO2, A1~03, CaO, Fe203, ~nd So3. These ~aw m~terials are c~lnblned in ac~ordance ~ith the ~eachil)ys of thc present il~v~lltion such t21at tll~ mixture ~ormed h~ an overall ~ol~r ra~io o~ A/F gre~ter th~n or equ~l ~o approxim.~tely O.fi~ and ~ mol~r r~tio of s/~
ketwc~n approxi~tely 0.3S and o~
10 , This raw material de~ign hAs been determined based upon ~he following cri~ria. First, it is known that small amo~nts of impu~iti~.s will naturally occur in the r~w materials ukili~ed to ~orm th~ r~w ~aterial. mix.
The impurities nor~nally enGouhter~d incl~lcle s~di~lm oxi~e 15(N~201, pot~ssium oxide (K20), magnesi~im oxide (M~O) ~nd the lik~. t~owev~r, becau~ of thc Uni~l.lC com~osition of the r~w m.aterials mix of tl~. pres~s~. invc~n~.ion, ~hes~
~mpurities d~ not h~ve ~ ificant a~vcrse efEects upon th¢ form~tion of c4A~S in tl~e kiln~
~OAdditionally, in accor~ance wi~h thc teachitl~s o~
the present invention, C i6 go~ng to react with ~lumina an~ sulfates ~o form C4~3S. ~ny lron pr~s-~nt in t}le raw ~aterial~ will mo~ ly sllbstitu~ L~r ~h¢ alumina in the C4A3~ ph~s~, b~t wilI not form C4AF or C2F a.~.; lotlg 2S a~ the r~tio o~ A/F is gr~ater than 0.64. Any silica present i~ the r~w m~terl~l~ will re~ct wit~ the rem~ining C to form c~s ~t the cllnkeri2.~tion te~p~rature utiliz~ ow~ver, this fo~m.n~ion i~
second~ry ~o the ~ormatioll C4A3.5~ Moteo~er~ C~,A3.g wil].
be in equi~ib~ m with ~e s.ili~ate ph~ses as loncJ as the r.~io of s/~ ~ ~ is b~tweet~ approximately 0.2; an~
0. 35 . If this r.~tio i~ l e~.~ thatl apprc)xillla~y 0.~
~he geh~lltlite phase or C~S will be dominatlt.
Conversely, i~ the r.3tio exceed~ approxi~nately 0.35, CS
35 will b~ the ~omlhc~1lt p~ 3~ atlC~ C3~ w.i~ olmed it~
~quilibriutn with it.
--~.0--7 4 ~ 1 2 0 Sim$1arly, imp~lriti.~.s such as sodium oxide (N) and pot~sslum oxide ~K~ will reAct with the sulfa~e prcsent in ~he rnw mlx c:om~o3ltio~ nd the remai.n;.n~ sul ~te will r~act ~o form C~4~3S witl~ut siyni l~i.c~21t adv~rse 5 e~fe.~;t on ~he v~ry early set~i2lg, ultr~ hi~h s'crength ~h~rac~eristio~ of the ~ .m-.~llt compo:~lt.iol-~ procltlcecl.
Any un~omhined S wi.l.l rea~t with C to for~n C.S a2~c~ the remainin~ C will re~ct to form c2S with ~ilica, ~ho~e ~killed in t.h~. art will ~lso ~I~prec:Late that 10 1;he design oE 'ch~ raw mat~rii~l mix of the present inventio2~ can be pcrf~rm~.d u~;ing tra~liti~ l. c`2le~
ani~lysis te~hniques oL the raw mat~rials utilized. ~or ex~mple, ~ssuml~ an exe~nplary r~w ~erlal mix is ~ormcd from hi~h alum.l.na ~l~y, l.lmesto~e al~d gy~sum 15 cont~initlg S, ~, C, F, M, K, i~ and L. IØ The followl2 g ratio~ ~n h~ util i.~ed in accor~larlce with t~l~ t~ac~in~s o~ ~he pre~ent in~entio~ to de~lgn t~le ~w materlal mix.
(:1) l'he ;~mou~ f ~ulf.~l:e in K;~SO,I -O. ~I2 K~O
( Z ) llhe amourlt: Or ~ at~ in N~
OA 6~; Na2O
(3) The a~nou~lt o~ C41~3$ ~ 9S A.120 1. 63 Fe~03 + 1. ~4 Mn2~
(4) The amount of sulfF~te in C4~S =
0.26 A12C)3 + 0-11 (Fe;23 + ~Sn23) (S) The amount o~ c~lclum in C4A3S =~
0.73 A12O3 1 0.47 (Fe203 -t Mnz03) (6~ The amourlt o~ CS = 1.7 CS - (0.~5 Na20 ~ 0. 47,5 K~0 + O . 2~ A1203 + 0.17 31) ~Fe203 t ~ 3~ ) ]
( 7 ) The amount o~ C in C5 = 0 . 41 CS
(8) Th~. amount o~ C ln C,15 = 1. 87 S
~9) The tot~l reqlllred amoun~ o~ C -~, 5~ A1203 + O . 35 (F~203 + ~n~;)3) 1.87 S + 0.7 x - 0.45 Na2C~ - 0.30 K2~
. , , ~ Z0~38139 ~
74-1~0 (10) The total re(~l;.rcl:t alno~ t of S -0. 65 1~a20 + 0 . 42~ K~0 ~ O A ;26 A1203 0 .17 ( P'~203 ~ M~03 ) As noted abov6:~, the temper~ture rang~ wllcr~ C41~3$
5 is stable varies between approx~mately 1, 000 C and l,aoo~ C. Accor~.it-gly, t)l~ previously produce-l ~;xt~1r~
of r~w ~aterials is he~te-~ to an elevated temper~ture between these relatlvely narrow li~it~ for a suffi~Lent : period of t~me ~o form the ~esired clln}cer having ~ h~gh çoncentr~tion ~f C4A3S. This ~ime period wi11 v~ry : ~ependiny upon the ¢o~po~ition of the mixture ~nd the kiln geometry will r~nye from fraction~ of on~ hour to sever~l hours or more. Th~ high concentrAtion of C~4~3S
will r~nge hetween approxim;ltely 15% ~n~ 75% by wei~ht.
It should be noted t}lAt tlle prescnt ~tAte of the ~ciln temper~ture control ~rt doRs not involve tradition~lly un(3c!r~t:ood t~nperature cont~ol~ ~t tll~
burnin~ zone. 'rypic~lly, t~ control of t~ clin~c~r t~mper~t~lre. in t~le ~ci.l.n ;~ ~; carr.ied QUt by we~ ch~]nlc~l 20 an~lysis for free C ~r~ lime). Fcr example; the design fo~mulas for tr~itional portlAn~ cemeJIt r~w materials per~it the pre~en~e of pred~t~rmillcd amoul~ts o~ free C in the ~linlcer. If wet chemiGal ana1ysis of ~he ~1 lnk~r d~'ct~rmineE~ t.h~t ~he amo~nt o~ free ~ is l~;s 25 than the d~ssign amo~n~, th~ c1inker i~ over~urninq and ~he kiln temperature ne.~!d~ to be reduced. C~o~ ersely, if the an~lyzcd amoul-t of ~re~ C i~ h.igher ~h~n the deeign amount, the ~llnker ~9 ~eln~ u~derbur.ne~
ki1n telnper~t.ure n~ t ~-~ rai~.~t3.
~lowever, su-ch w~t cll~mi~1 m~t:l~o(l~, m~y nn~ }~e pra~tica11y app1i-~b1~:! tn til~ pro~ tion 0~ ; nkex ~i ht~v~n-~ hi~3l~ w~:igl~ po.rc~c~l~t..~ C4.1~3~ n~t~ tt~llql~t by ~l)e pr~5t~nt inventio~-. Wet chemic~a1 ~tlaly~i~ may be dec~eivint3 in ~ g context h-~cau~3-a thF~ all~minu~, cl~y, ~5 bauxite and the ~ce, oon~ln S. l'hi3 slli~:~ wlll re~t . ~ ~
~ ~0:~889 ~_, with calcium and the w~t ch~mical methods may n~t indicate whioh phase i5 currently pres,cllt in the cl.inke~.
~cc~ordinyly, a pr~.rc~ met~od for controll.lng t~
el4va~ed temperatures of tlle heat treatmetlt ~f the ~r~ .nt itlV~l~t ion u~ 3 p~rioclic x-ray ~ f~a~tion ~nalysis of samples taketl fro~ tl~e hcat~d mixture ~a~her than wet chemis~ry. ~s ~itl~ the wet chemical methods o~
analysis, t~le previou~ly described formul~s o~ tlle 10 ~resen~ invention allow tlle determlnation o~ a dcsig~
amoullt o E C4~3.S . By ~-ro~-aring a pre~aJ.i~ra~e(.l x-ray diffraction curve ~sed ~pOIl la~or~tory ~eference ~tandards for ~u~ntit~t i~e~y anAlyzing tlle ~mount of C47~35 p~esent in know~ ercnc~ ampl~3s, .it bCCOmCF3 pos~ble to periodicnlly remove sampl~s frolll the he~tecl mixture and to quatltit~.ively ~naly~,e tllelll for the proper design ~ontent of C,~A3S tllrou~ll x-ray di~rac~tion analysls. ~hen, a5 with t.radi~iot~ et chem;.~ry metho or kiln contrv1, t}~e tempernture o~ tlle }le.~ted 20 mixture c~n be adjus'ced e:i~her up or dow~1 to p:r~c~u{~e tl~e hi~h concen~r~tion of C4~3S ~ de~igl1ed ~n th~ raw material mix.
It should be emphasi2~d t~1at t~e el~vat~d ~emp~ature ranges ~eces~ary to produc;:e the ~4A3~
~5 containing cl inker o~ t}le p~esent inv~tion are relatively narrow when~ ~o~npared to tratlit.iona1 ~emen~
clinkeriza'cion temper;itllre3~ Acc:or~linc3ly~ cælreful temperat~re c::ontro1 throuc~h x-r~y dif~ractioll ana1ys3.
or som~ other Ine~hod o~ fi.ne tempcrature c~rltrol, ,~houl~
30 ~e pr.~cticecl to procl~1c~ st~bl~ C4A3~ phh~ itl t~e cl inker .
Those sk11led ~n the art will ~lso ~ppreci~te that.
an exen~71ary x-ray ~i~fra~tio11 pr~calibra~scl cu~ve ca be preparec~ by co11du~t.it~g a n~1~n~er of labor~tory trial 3S de~ n burn~, of the de.sired raw ma ~rial mix. The trials shoulcl inclutle underbu~n}n~, overburnlng and I~UI''15 7 ~ 11 H ~ LHl'~llt, ~IJSt I t.L: Jun ~ J 1~ :Ul IJo ~rJ ~ ,U4/1 Z~3889 ~
7~ 12 bur~lny ~t the cor~ec~ tc~npera~ure~ Th~ a~no~ t o~ CqA3S
in eac~l trial bur2l can then b~ quallti.t~t;.ve.ly nnalyzed tlo.~o~2gll x-ray di~frat~ cl co~llp~:c(l to ~S~l~ll st.~ 3ilrtl c~rve~ for qu~n~.it~tively calcula~irl~ t}~e co~lte~t~.~ of C3S and C2S, ~3A and C4A3S.
~ urillg prod~ of the act.~a.l colnlllerc.i~l. cl;nke.2-in accordanc:~ wi~h ~he present invcr-tion, ~ s(a~ lc oE
the heat ~re~ted r~w mntcri.~l will preferahly ~ t~ken fro~ the ~iln approxima~ely each one~hal~ ~our o~ hollr ~o ~e analyzed ~uan~it~t.ively by x-ray dif~r~ction. 'I`o ~a~ ate thls atlalysis ~n x-ray di~fr~ctinn m~tchine ~an be ¢omputerized ~o be calibrated to th~. prebur2~ing trials.
once t}le ~,lin~er has ~ecn properly clinkcrizc~ th~
next step in the prod~cti.on of the cement com~ositiotl~
o the pr~sent inventio~l involvcs ~ete~m~ni.ng the ~vera~e amount o~ C4~3S present in thc clih~er, Typic~lly, the clinker 50 pro~uced wlll not h~e cem~n~itiou~ value~ it5el. ~ upon grind~ng~ ~cco~]it~gly, the next step of ~he pr~nt inv~ntion i~volves ~ormi a final mix~ure o~ the clinker with C con~ainin~
portland typ~ cemeh~ and sol~ble CS ~nhydride such that the compoei~ion of the ~in~l mix~ure includes a C4A3S
con~en~ of ~pproxl~t~ly lO~ - 30% by welght ~nd a ~oluble ~$ anhydri~e coll~erlt of approximAtely 5~ - 25~.
Mixin~ the speciAl ~linker of ~h~ instan~ i~vention with hydrAulic or portl~nd type c¢me.nt is a preE~rred te~hnique be~ause it incorporate~ ~3S illtO the ~etnetlt by p~ovidin~ ~rec lime an~ C3S to ~he mixture.
In contr~st ~o ~le p~ior ~rt metllo(t~ ~f cement production utilizirl~ th~ known stoic~liometrlc r~action of C41~3S to pJ 0~3~ .x~)~t~ yst~l c., t.l~ }locl o~
the present inventior- forms t~ firla1 mix~ure of the high c4A3$ contAinin~ clink~er accorditlg to t~l~ follow~ng aqucou~ mix~nq formul~s:
r ~ I r~ nl~ J JL I CL ~ ll ,J ~ ~J',J l J ' ',Jl I'll~ . ~J~J r . ~
'' ~0~ 389~ ' 74-1~0 I C4A~S + 2~ = ~4~S aq + 2CA aq II C4A3S a~ ~ 2~' = C6AS3 aq by adding I ~ II th~ f~11Owin~ aqueous mixing ~ormula is produced.
~4A3S ~ 2C ~ 2cS - c6~s3 ~ a~ ~ 2~A ~q Tho~ sklll~d in the ~rt wil t ~~E~r¢c-i~te t21.~t t11e CA ~q ph~se ln the cement produc~d in ~c~ordance with the teachi.ng~s of the present ihVellt~oll is ~ pr~ ncip1e ph~e present in hig~ a1umina cèmen~ and, it is ~elieved, ~h~t ~h~ earl.y str~ng~h in suc~ cemellts is due to khe presenoe of this ph~se. However, unli.ke the prior ar~ cement composi~ions, following hy~ration the Gemeht co~pos~tions O~ the prescllt ~nvention produGe a conc~ete including th~ ~A ~q ph~se, the C~S ~q ph~se a~ well as the ~3S ~ ~q ~nd C~AS aq ettringite phase without the adverse e~e~t o~ the C1~7 ~ ~q p~a,~e~
whi~h su~fers ~ry~ta1 ~ransformation after ~evera1 years following hydration.
Tho~e skil1ed ~n t)~e ~t wll l al~o ap~r~c1~te t~t the de~igtl mlx o the Cemellt ~o~pos1tiolls of t~le presetlt invention ~an be mod.i.i.ed to produGe a wide ~ari~.ty o~
desir~hl~ ~cry early ~et~ g, ~ltra hig~ re~gth charact~ri~tics. At~ditior~ally, ~ario1.1f ad~itives ~n be incorporated itltO the c~mcl1t ~o provide ~ld;.tiot~al ~sirahl~ propert~es. Simi~.arly, ~he ~ettint~ tln1~ o~
the ~emen~ sompositiO11~ of th~ p~efient invetlt~on c~n be con~rolled ~hrough t1~e ~djust.ment o~ t.l~e mix.1.nt3 prop~ion~ of th~ thre.e maitl raw material ao1npo~en~s, For ~x~mpl~, in colA or ~.cvcre we~ther condi~iot1s ~he 6etting ~im~ may intrease ~om fi~te~t1 ~.itl~t&~ to ~pproximately two hours. ThUf~ a sui~able accelerator, such a~ al-lmlnum ~ulea~e or iron s~ te may be incorporated into the c~men~ to i~c~e~6e tl1~ r~te o~
cure of th~ Cem~ . In at.~t.1ition to th~f~ let,~tor~
~r~vlo~ note~l, nny ~ r.Lt~ ~cc~ t~nl.o~ U! ~ r _~5_ I~U~ l I H, LHI'Ill~, KU~ L: Jun ~ ~ylJ l~ Ul ISJ0 V~IJ ~ IJ~
.
~ Z0~38~9 ~
- 7 ~ 0 portlan~ cement ¢ztn also bc used with the cemet t compo~itions o~ the pre.sent illvelltions. Adcli.tio~ .lly, a citric aci~3 re~.~rder mc~y be ~(~tlc~l ~o the cemct1t t ompo~itions of the present inVCnt:iOIl to increa~e the 5 initi~1 s~t up time to !~Omet}tirlg on the orde.r of two hours. ilo~ever, it shollld b~ ~ppr~ci.c~t~cl t~ tt: c~lll initi,~tl set time of fiftee.ll minu~os followin~ hydrat.ion is ~n ide~1 ~ime for m~ X; n~ the. cemC~I~t Wi~ a super plasticiz~r to reduo~e the~ mixin~ wc~er or concrete 10 S;lU~ltp.
It sh~lld al~n b~. apE. r ec.Latec3 th~t. t~le new c~t~ellt compo:.itiorls pro~:t~loed il~ ~cc~o~ d~ e witll tlle t.e.~ of the presQtlt invention c~e WAtor impe~menh].e, sulfclte ~e~stant, an~ non-.sll~.~in}cin~3 compositin~ls. Mor~ove~, 1~ the cement compositioll~ are also se~ ~ater re~istc~l~t.
Fnr increased resistallce to ~r~C~.Z~ ~nd t~law, l~t.~wcver, addition o~ super-plas~.icize~ is re~omme~-ded. A ~urt}ler understanding of the exe~ ry ~ement com~o~:it..Lorl~ of the pres~nt inve~inn will l~e a~orc~ed ~c tllo3~ ski] 1 ~fl 20 in the art from ~hç fol lowing non~ ni~lng example~:
EXAMl~
~ n accordance with the method o~ the pre~nt inven~ion a, mixture or limestonq, gypsum, and hi.gh ~5 a~umina cl~y was prodl~ced ~o form a ~aw mix~ure for a hig~ C4A3S çl inker . Ths~ componentfi of the mixt~e wer~
combine~l ln the ~c>rm oP dry powders . Tha c:hem ~ cal ~nalysl~ o~ the raw m~terials was as follow~:
~laY_Ji.me~:tone Gypsum sio2 32, oog62 . 00~6 ~. 00 Al?,03 55 . 009~ o . 70~ 0 . 50 CaO 1. S0%55 . 00% 3~ 0 Ot)~
35 Fe O3 1. 00%0 . 50% . ~. 20g~
Mg~ 0 . 25~6 0 . 60~6 0. 6096 K20 2 . 60~ 0 . ~59~ 0. 05 SO3 3 . ~0~ 0 . 10% 4 3 . 00 L.O.I. 4.00~641.00% 21.00 PO~IS, SI~ITH, LRI~ E, ~OSE TEL: Jun 5 ,90 15 :Ol ~ O~O P 07~1 ~ Z0~3889 `~
7~ o U~ilizing the ~ixi.n~ formulas o tl~e pr~eht inven~ion it wa5 deter~in~.d t}~t a ~linker con~ainirlg an avera~e of ~proxima~ly 3~ C4~3S cou~d be proc]llce~1 from these raw mate.r~c~ls by mixi~ 55~ ~y W~ t of ~he limestone. witll 20~ by wei.yl~. of the gyp~ m an~ ~5% by Wei~CJI~t Or ~}~e clay. Tl1i~; raw mclterial lnlxtut~c wa~ ~ir~d ~t a temperature between 1,000 C a~d l,200 C to produce hi~h ~4~3S clinker. Th~ ~linker so produced did not have any ccm~ntit~o-~s valuo~.
, Again usin~ th~ mixi~l~J formulas o~ tlle pre~.ent invention this ~l.{.nker was f~lrtheI- mix~d wit~l soluble C
S anhydride a~d portlan~i ~ement in the oll~wil~g proportions: 70% hic3h C4A3S ~linkcr, 20% ~rtl~nd ce.ment ~ype III, an~ lO~ sol~ CS a~ y~r-lde. l`i~e resu.ltan~ ~ement ~.ixture contained approxim~tely ~'c~
C4A3S, approximately 3% fre~ C, appr-ximfltely lO't CS
anhydric3~ an~ approxlmately ~5% sil.1.~a~ (C3S and C2S).
~ n acJ~reyate w~ orm~d ~rotn ~h i ~ c:enlellt havitlg a 1 ~o 1 ratio of cem~t-t tc~ ~nd. Wat~r wa~s tl\c~l a-.l(l~d to 20 t}~ aggr~c~Ate in ~he propor~ion of 1 part wator to 3 parts cem~:nt. The com~rcssiv~ strength o~ this mol~
composition w~s d~termi ned usin~ the modi~ied c10~-c~lb~.
~re~g~h teæt whi~h p~od~lc~d the ~llowin~ ~es~1ta:
~qe ~ompressiv.e.Strengtt one hour ~, 000 psi one d~y 7, oon psi séven days ~, 0~0 psi twen~y-eight ~y~ ~11, 000 psi EX7~ r..F: I I
AF~ wi~ Ex~mple I~ a~ initifll mix~ure of raw materials this time comprisl.ng bauxite inst~ad of ~ay, limestol1c ~n~ gyp~um w~s E~ro~1uce~1 to fbL-m a r~w m.n~
mixt-l~e for U~e in prscl~cltly a hi~h ~4~35 ~lin~er. Tho chemical an~lysis of ~he raw materi~ls was as follows:
POMS,SMITH, LRIlDE, ~OSE TEL: Jun 5,gO 15:01 flo 0~0 P,O~/1 ., Z~1388~ - -B~uxlte l,im qtol~e G~psum sio23 . 00% 2 . 00% l. 00%
Al2O355. 00% 0 . 70~ 0. 50%
CaO2.OO~;i 55.oO~ 34.n~
Fe;~032'7 . 00% ~. 50% 0. 20~
M~O0 . 0 0 ~ 0 . G 0 % 0 . ~ 0 %
K2Oll. 00~ 0.15% 0. 05~
50~ 0. 00~ 0 . lO~ 43 . 00%
L. O . I . 0 . 00~6 4 l . 00~ 21. 0096 l~ Tio23 . 00~ 0. 00% 0. ~0%
Utili7.1ny tlle mi~ g formul.;l~ of the preseJ~t inv~ntion it w~s ~et~rmllled th~t after ~irin~ ~ cl~t~ker could be proc~uoed cont~i.tl Lng ~2~ C4l~3S by çoln~.~inlng 40%
by weight b~uxi~e with 40% by ~eig~l~ lim~to~le anc~ 20%
weight gypsum. Ag~in, utili.z.ing t~le mixin~ ~ormulas of the prescnt invention, the f~red clit~ker WA~: ~ombiJ~
Wi~h portland type III cemellt atlcl soluhle CS al~hyclride in the proportior~fi of 35~ hic3ll C47\3.S c~ 1c~r, lO~
~oluble ca anhydri~e, ahd 55% portl~nd type III cement ~o produce a ~inal cem~l~t ~ompos.i.ti~.~n CO~ a.i.l~ y ;~n~
C A ~
Whell hydrflted~ t.h~ llt C0111~0:3.it.iO11 0~ F,x~mpl~
11`, exhihi~e~l a h~ he~ hyclration rc~nc.~ .3 75n C~ at ~e ~inal set. This hi~h h~At c~ hydratiotl made the ceme.nt composition of E:xflrnp~e II p~rti,~ulRrly tYell suit~l fo~ ~E)pli~atiolls irl ~:old wea~er ~nd sub-zero temperatu~es.
~0 l'ho~e skilled in th~ art will apprecint~e t~-at t}~e ~ange o~ C~,A ~S that may b6 produ~ed in accordAnce ~itl the tea~hing~ of the present ln~rentic)r~ th~ initial fired c:linker can vary widely. However, ~ C4h3g contsn~
o~ leE~ than ~pprax.imatcly lS~, thou~h c:ol~templ~t~<l a-cl being within thc $cope 0~ the pr~s~r t tnv~ntion, mo~t likely would not be economically fea~ible. ~onversely, clepending upon the chenl.lcal composition of t~e raw m~ ri~ls invol~fed in produc.~.ng ~he original mixture ~or the clinXer, a C4A3S ~ontent a~ high as approximately P0~1S, SI~IITH, L~NDE, F~OSE TEL: Jun 5,30 15:01 Il~.O~rJ P,c1~4 . , .
~ 389 '~
7 ~ 2 ~) 75~6 is col~t~mplated as. belnq Withill t}~e. pracl~ic~]. F.Cnpe of the presen~ inventioll.
Similarly, mixirlg r~ti.~. for tlle firecl c.lirlker, portl~n~ c:ement an~.~ solui:,le CS an~lyclr i.~e c-ll) al~;o vary 5 widely clf3pen~ing upon tll~ desired perC~lt.lrJe o~ c,~7~3.5 in - the f ina1 cement C~ pO~ io~. Howevl3r, i~ .is antiaip~ed that the mo~t econom~ cal cement compo~itio produced in accord~nce with thc presollt lnvetl~ion will contain a weight pel-cellta~e of C4?~3S r~llgi--~ from 10 ~pproxim~ely 10~ to 30~. Accordingly, th~ associated content o~ sol~ble ~ a1lhyc3ride will most econom~ c~lîy vary ~rom ~pproximately 5% to ~S%. The remalnder of tlle composition can be fqrm~d o~ any type of hydrAulia cement, However, it is pre~e~-recl that the ~em~nt hav~ a 15 high con~ent o~ the Ç3S phase . Thus, the rema inder of th~ cement ~ompo~;iti.on will pref~rahly conlprise portl2.nd typ~ cemcn~ arying f rom approxim~tely ~ 5~6 to 8~ y wei~ht, depending upon thc flesire~l stren~th anâ other prc:perties o~ the fin~l. hydraulio cement pro-.tllct~
lh the foregoihcJ ~e~crip~ion c~f ~he presen~
invention, preEerred ex~3mplary em40dimellts of the inventlon h~ve becn disclosed~ It is to be understood th~t by those skilled in the art that othe:~ equiv~lent cement composition~ ~e con~emplat~ed as }~eill~ within the ~S scope of t~le presellt invention. Accordingly, tl~o present in~en'cion i6 not limited to ~he particu~ar exempl~y cemeht compo~itivns w}li~h havo bee:
i~lUst~t~d ~nd descrih~cl in d~tail hQr~ih.
I)OCS 741~0PAT. 011~
Field of~the Inven.~lo!j The present inventior~ relates in a broad as~ect to fas~ setting hi~h ~ctlell~tll ~eme1~ con~pos.itlons and Iho~hod.~. for their Ic~r.ln;~tion. More p.~ t.~ r~I.y, t~lo pr~sent inv~ntlon is directe~ tv very ~.~rly setting, ultr.~ high stren~th c~ment composi~ions an~l metllods for thei~ form.~ion whi~h b~ eflcially utilize thc forma~ion ~f ettring~e to ~i~nifi~antly enhance the compressive stren~3th and e.~rly ~i.ng properties o~ the ~m~t.
.~ck~rou~d oP tl~e.Invent.ioD
H~drau~ic ~mcnt:~, or ~em~nts whi~}l har~en by re~ting with water, are most ~ypi~lly illustrated by portland type cement~. Por~la~d c~ment conc.rete h~s been )cnown fo~ al~o~t one huncl~e~ ye~r~ and is among one o~ the mo~ ~ommonly us~ stx~lctural m~terials.
Portland ~ements are cla~siflecl into at least ~ive major ~ypes ac~ording to ~hemi~al compbsitio~ and differing prope~ resul~in-J theref~om. ~c.ll~ral purpos¢
portland cem-~n~ typi~lly contain approximatel~ ~0-G~
~lcium oxide, ~0-2~ sili.ca, 4~ luminuni and about 2-5~ ferric oxic3~-. Raw materi~l s~uxces for th~.se ~;.nnr~l c~mpon~nt~ in~lude.lim~tone, clay, s~lale, sands~olle, bauxi~e and iron ~re. Mixt~res ~f these ~aw m~terial~
are proces~ed throu-3h a ~iln ired he~t treatmel)t tbur~ln~ t approximat~ly 1400-1600~ ~ ~2500-2~00~ F~
to produce A ~.inter-~3 or "clink~re~1~ mat~r;n.l., wl.l.~
th-~n pulverize.d wi~h 4-5~ gypsum to pJ.O~Ilce tl~c flnal ceme~t procluct~
~ or c-~nveni~ o~ furtllt~.r ~e~.c~r.i~-ti.oll, tll~.
~ollowih~ ~tan~ard te ~ inc3u~try abb.r- vl~tioll~ ~ill he utilized to t~e~orlbc th~ CompositiOn O~ g-lt.~h ~ired 3 5 mate~ ia 1~:
POMS, SI~ITH, L~IDE, ROSE TEL: Jun 5,gO 14:51 t~l~.01~ ~,fJ5/1 .. . ........................ .
~ 8~389 ~
H - represent~ water (H20) C - represen~s Calcium oxide (~0) A - represents Alum~"u~ oxide (A1203) F - represents Ferric Oxi~e (~e203) M - ~epresents ~agnesium oxide ~gO) S ~ ~epresents Silicon oxide (Sio2) K - repres¢nt~ Pot~ssium Oxide (K~O) N - repreSent.s 50di~m oxide (N~20) S - represen~g Sulphur Trioxide (S03) , General purpose po~tland ~ype cement (usu~lly designated ASTM I) t~pic~lly contain~ ~pproximately 50%
~3$, 2~% C~S, 12~ C3A, 8~ ~4A~ CS . Thus~ ~h~ ~ot~l a~oun~ ~f calclu~ ~ilica~e~ i~ approximately 7~, ~ith the pre~omin~n~ sili~ate being C3S. Af~er hydratioh~
such general purpose portland cement~ generally exhibit compress~va streng~h~ on the order of 1800 p~i after three day~ of curiny and 2800 psi a~ter s~ven days of curi~g, as de~ermi.ned ~y the ~tandard A~T~ procedure ~109 ~
20In many forms o~ concrete construct~on th~ 3 ra~e of ~trength development for ~neral purposa por~l~nd type cement ~ignif~can~l~ adds to the CQStS 0~ construation because the cRst hydr~ted concrete must remain supported by ~orm~ during a period of time su~cient to allow lt 25to develop adequate ~tr~ngth to permit xemoval ~ the form~ ~n~ to allow a~ditional construotlon.
Past e~fo~ts at ove~co~nin~ this sl~w rate of ~t~ength det~elopmen~ ln gen~r~l purpo6~ portland cement h~ve r~sulted in ~he procluction o~ hi~) earl~ ~trength 30po~land cements such as ~TM III whi~ll differs from o~her ~elnen~: b~r h~vlng higher ~mount~ o~ C3A and~or C3S. Th~ minim~m A~TM specific~tion fo~ ~pe III
portland cemant compre~siv~ strength i~ 1~00 psl ~t one day and 2800 p5i at three da~s. However, such cements 3S~ypiç~lly exhibit compr~se~iv~ ~tren~hs Ol~ the or~er of .
' ' POMS, SI~ITH, L~I~IDE, ~OSE TEL: Jun 5 ,~O 14 :51 ~l~ ,Ol~ P ,06/1 ~ ` ``J ~0~889 ~_ ~u00-2~00 psi ~t olle ~ay an(.3 may ~evolo~- c:o~ r e!;S i ve' strengtl~s on the order o~ 5000 psl at s~ven d~lys.
Nonetheles~, there remalns a great heed to develop cements h~vin~ m~l~h hi~her ea~ly strell~th~ r ex~mple, in the procluctlon o~ pre-~ast, pre~str~ssed, aon~rete product~, a Gompressiv~ str~ngth Oh the ord~.r of 3000-4qoo psi at one ~ay is oft~ll requlred.
Addi~ionally, in the ~onstruction ~nd repair of hiyhways, m~ny d~ys and even weeks of curing t~me are 10 require~ before the hi~hways m~y l~e utili2ed. ~Ior~over, in the construction o~ collcrete bu~lding~ and bridges where the cem~.nt matrix is c~st into ~onn~, it is nece~Ls~ry to allow days oP ~u~ ng timQ to allow the cem~nt to develop suffic.ient strength fo~ remov~l of the 15 Porms.
other hydr~uli-. CC~ 3 thAt m.~y or may not be hl.gll e~rly strengtl- ar~ tlle ~o-called "c~lcium alumino ~ul~ate't cements ba~ad upon 3C~0.3A1203.C~504, abhreviated ~s either C3A3~ or, preferahly, C~A35.
20 Typica~ ïy, the prim~ry characterlstic o~ C4A35 cement:s i~ their expansivenes3~ Concrete made ~rom portland cement together with sat~d, gravel, or oth~r mineral agyregate ~ypi~al~y under~oas shri.nkag~ upon drying.
~hls shrinkage is und~.qira~le in tha~, amotlt3 other reasons, it gives rise t~ crack~ whlGh ult~mately w~aken the ~et concreta~ ~dition o ad~iti~s S~GIl a~ C4A3S
coun~eract~ this ~hrink~g~ asld ~ay o~ m~y not produc~
c~ments ha~ing early high strength.
~r ~xa~pl~, type K portland c~ent a~ di~closed ln United 5tates Paten~ No. 3,155,~2~ tXl~in~ u~es the expan~iv~ prope.rty upor- hyd~atl.~n of ~3S in th¢
p~esehca of ~ree ~ ~nd C,~ t~ p~oduce expAn~.i.ve ~amel~t compone~lt~ ha~ing ~trengths ~n the rallye of st~ndard portland cement. Slm~ ly, U.s. P~t~sl~ No. 3,860,~33 ~ost et al . ) d~ a h~ ar:ly ~tr~ t~ m~llt con~ining C4A3S, cs ~ 2n~1 ~2~, wslieh exhibits PO~IS, SMITH, LflNDE, ~OSE TEL: Jun 5 ,30 14 :51 ~ Jl~ P,f~7/1 . , .
conlpres~ive strenyths o~ at le~st 2~00-4000 psi wlt.~lin 24 hour~ followi~ hydr~tlon.
In ~pite oE the~e ~dV.~ S in t]lC. procluctinn of e~rly settillg hiyh strengt}~ cemellt, ~ noted abov~, th~
development o~ portlancl typo cements havihq even ~reater co~nl:~re~ive stren~th~ l hic311cr r~tes or ~rel~c~t~
devqlopmen~ th~n those pre~ently ~vailable would be of great economic benefit ~o t}le ~on~truc~ion industry.
Ac~ordingly, i~ is a parti~lar object of the pr~sent 1~ invention to prov$de methods for tho produ~tio~ of very ea~ly setti.n~, ultrahigh strength ~ement oompo~itlons whiah, following hydration, will prod~lce compressiv~
s~ren~ths on ~he order o~ 3000-5000 psi within one hour, on th~ order o~ 7000 psi within on~ day.
Ik i~ ~ ~urther obje~ of the present invention to providc method~ for the productlon of ~ery early set~ing, ultra high ~treny~h cemen~ ~omposi~ons whic}
will producR compressivc ~tren~ths in ex~e.ss oP ~, 000 psi withln ~wcr,~y-e~ht ~ays followin~ ~lydr~tion.
It i~ an adflition~l objcct of ~he pre~en~ inv~n~ioh to provifle me~hod~ for t~le p~oduction ~ very early setting, ultra hi~h ~trength ce~ent com~o~ ns which ~re burned at low ~e~pera~ure~.
It i~ yet an addi~i.on~l object ~f th~ presen~
in~ention to provid~.methods for ~he prodllction of very early ~e~ting, ultra hi~h streng~ll aement ~ompositions which bene~ici~l.ly utilize the ~ormA~ion 0~ e~rin~ite cryst~ls ~o strellgtllen t}le hydra~e~ c~em~n~.
It is a f~r~i~er acldit~on~1 object oC t~l~. present inVC21t~cn to provide mçt~od~ for pr:Qdu~ cJ very carly ~etting, ultra hi~h ~relly~h ce~ellt ~ompositionR whi~h are p~rticul<~rly wel.l ~i.ted ~or u~ itl GOld temperAturQs clue ~o ~heir hlyh he~ts o.~ hy~1ratlon d~ring their ~in~l s~t.
It is a further ~dltion~l ohj~t of th~ p~scnt invention t~ provide me~l~ofl~ ~or prod~l~ing ~ry early ~" _ POMS, SMITH, LRII~E, ~SE TEL: Jun 5 ,~O 14 :51 f~l~ 015 P .
~ ~,.,..
2018 518~ -74-l~o setting, ultra high stren~3th cement co~posltions which achieve v~ry early ultra high strenyth throug~ ~he ~V~tl~et~U.~ u~il.i.7.~.Lon of Gom~ined llydr~t~d ~t~rl~glte (C6AS3~2H.) and calc.ium Alumltl~t~. hydrate (C~lOH).
S~mm.l~y of the ~nve1ltl0l~
Thes~ and other o~j~c~ ~re a~hieved by the me~lods ~nd ceme.nt compositi~ts of the present invcntion wh~ch utilize low temperatur~ burllit~g of speci~i~ mixtures of raw m~teri~ls to pro~uc~, in the klln, spccial clin~e~s havinc~ high coll~entrAt.i.olls of C4A3$ whic~ ~r~ ~ixec~ wlth hydraulic or portland type cemcnt and ~ in accordance wi~h a un~qu~ ~ix.i.nc~ formul~. When hyd~ated, the ~esultinc3 cement compoxit~ion~ prod~lce extrem~J.y hi~
1~ strength characte~istios in ~n unusu~liy short pe~iod o~
time ~nd ultimat~ly cl.lr~ ~o previously un~chievable compressive str~n~ths th~ou~h the conl~in~ act;on of thc aqueous pha~e~ o~ C~A~3 and CA.
Th~ ~.ir~t step o~ t.ll~. me~od for prod~ iJ)~ ve~-y early settlny ult~ hi~ strength c~tn~ compos~tions o~
the pr~sent invention involves the formation o~ a mixture o~ limestone, gypsum ~nd bauxit~, kaolonite or other high alumin~ clay to provicle the raw materi~l~
S,~,C,F, and S. Thi~ mixture prefer~ly ha~ ~n overall molar r~tio o~ A/F greater than or ~qual ~o approximately 0.64 ~nd s/~+F b~twe~.n approx~m~tely 0.35 ~nd 0.25.
~ n contrast to ~he kno~ll, prior art, method~ o ~çment prQdll~tion whic~ fire th~i.r r~w mAte.ri.~l mi.xtur~, at t~mperat~lres above 1.~.~0' ~, t~l~. mixtur.e ~rodl~e~
accordallc~ with the m~t}lod o~ ~he pr~erlt l~vellt~on i,~.
he.a~ed to An elevatc~l tem~:~er~.ure betwecn 1000 c and 1200~ C for a sufficient period o~ time ~o ~orm a ~linker having a hiqh CollCentr~tion of C4A3S- Xt should be em~ha,~ize.d th~t he<~tir-g the mixture of t~le pre~eht inven~ion to a temper~ture gr~ater than ~200" C will --S--POMS, S~VlITH, LRNDE, ROSE TEL: Jun 5 ,~O 14 :~1 ~lo r~l~ P .~g/l . , .
`~ 20~8~8~ ~
~eco~tpose the de~sired ~4~3.S. ~hu~, the method of th~
pr~sent lnven~ion p~od~lces the C4A3S phase in t~le kiln by ~urllin~3 the clinker ~t recluced temperAture.
On~e th~ clinker h~9 b~en formed, the average 5 ~tount of C4~35 is deterntin~d ancl ~ final mixture is forme~l ~y combininr~ c ~llnkcr with hydr~lllc or po~tland type cement al~d solu~le C5 anhydri~le in accordance wit}l the dc~igll ~ormula C4A3S + 2C + 2c~.S
~AS3 c~q ~ 2CA a~ ~o that ~he flnal mixtu~e ihrlucles a C4A3S contetlt of approximately l0-30~ by weight, 5-25~
by welght soluble CS atlhyd~ide, with tll~ remaining ~5-85~ by wei~ht ~einy hyl~raul ic or por~land cemetlt.
B¢~ause o~ t~le nc~rJ:oW tem~er~ture r~nr~e het~eell 1000 C and 1200~ C at w~lçll ~4~3S is stRble lll t~ie kiln, the method of t~e presen~ invcntion requi~es state of ~he art ki.ln tempcratUre corltrol. ~eCAU~e ~ont~mpor~ry cemcnt kllns do not h~ve temper~ure con~rol at ~he burning 20ne it~el~, the temperature control is pr~Eer~ly c~rr1ed out utl.l:1~in~3 t~e bene~lt ~0 of x-ray diffr~c~on techniyu~.s to perio~ J.y hn~lyz~
~he clinker for the p~o~-ler CO~t~tl~ of C4~3,5, Tllose skill~d in the ~rt will appre~atn t~ t ot~e~ for~lls o~
alinker analy~ls may be utiliz~d, though x-ray diffr~ctibtl i5 pre~er~ed.
2S The c~mcnt ~ompositions produced in accor~ance with the method and mixing formula of the prese~ inventicn, ~ollowing hydrRtion, pro~u~ ultr~ high ~t~eng~l~ early ~etting ~ements h~ving c~pr~sive strength~ on the ord~r o~ 3000 psi ~ithir~ one ~our, ~0~0 p~i within ~enty four hours and lO,OOo psi within t~en~y eight d~ys. ~hus, the cement ~ompositions 80 produ~ed are part.icul~ly w~ll .suit~d ~or u~.e ln corlcret~
constructlon where ~h~ reductiori irt set~ing ti~e will h~e ~igni~icant economic Adv~tage. ~oreover, the 3S previously unat~inahle CompresSiYe stren~ths exhi~ited P~I~S, SMITH, L~DE, ~OSE TEL: :lun 5,90 14:51 l~lo,~ .lf~i J 20~8~38g ~' 7~-120 by the cement c ompositions of the presen~ invention p~ovide slgnifican~ C~llsttuotio~ adv~ntag~-s sufh ~s ret.1uctlons in str~le~ r~ .e an~l weic~l~t. Wit~loUt.
corre~ponding reduatiol~ ln streh~th. Additionally, ~he 5 hi~h h~ats of hydration of the compositions of th~
pr~sent inves~ on preve~lt tht~ hyd~stt~cl ce~ntorlts f~om Preezinc3 in cold temper~tures, enablirlg corls~ruction t~
aontinue at temperAtUreS below 01 C.
P~urtller objects and advantage~ o~ t~le cement ~ompositions procluc~d isl acçord~nce with th~ teachis~gs of ~ht~ prese~-t in~e.l-t i.~n, a:~ wt~ e.tter ~nderstnnding tht~reof, will be aforded ~o tslose skilled in the ar~ ~rom a consicleration o~ t~le following d~tailecl ex~lanat~on ~e preferrecl exemE)lary em40di~nent~
thereo~.
e~t.~ ~escrlption ~of F:xeml?la~y_Fmbocl ;ment A~ noted a~ov~, cement o~omposi.~it3rls lnGo--por~tis C"7~3~ have been Xno~n il) ~.ho ~rt ~or almoF;l: 50 y~-~rs-~V Whes~ hyd~a~cd in the presehce of CS an~ C, C4A3S ~e~ct6 to produce expansive crystalfi of qttri~ite (C6AS3 aq) acco~ding to the ~ormul~:
C4A3S ~ 6(~ S + 31H2C~ ~ 3C6AS3 ~ 311~20 These ~xpans ~ve Grystals have been used in the past to ~5 offs~t the nor~nal~y oc~u~ring ~h~inkage in gener~l purpose por~la}ld type cemcnts. However, whan C4A35 is hydr~tecl uncont:rollably wi~h ~I?s~m in por~l~t~d cen~cnt, it prc:du~e~ ~n expansive react1 on that. i5 d~st~uctive ~-o the concrete.
~hou~ A n~lmber Or .)riot, ~rt p~tents. h~ve di.~close~-~
a ~arie~y ~ methods ~o~ cont~olling ~uch exp~nsive reaction~ i~ hydr~ted portlAnd ~em~nt, n~nc has becn ~ble ~o produce the very early setting, ultra high strength cement of ~he pre~ent lnvention. C~A3~g has be~n utillzed as A OOI~ti~Uent in mod~ie~ cement co~posi~ions, inclUding so~e high eArly ~trength '~ Z0~8~
~ompositions, yet nor-e of thes~ contpositions s~ccess~ully dif~erentiate bet~een the gypsum ph~ses present in the r~action. R~th~.r, ~uch compo~itions u~ilize the stoichiometric produr~tioll of ~xp~nslve e~tringi.te crys~flls in A~ord-~t~ce wit.~l the above-note(l fo~mula.
Moreover, in spite of the lorl~ history of ceme~t produ~tlon and use ino~t:~L-pora~-itl~ C4~3S, thc prlor art i~.
devoid oE pro~esse WlliC21 QEfectively produce C4A3$ in the cement kiln during the burning process. Typi~ally, the well establish~d procedures for produ~in~ portland type ~ement and ~ariations the.reo~ utili~e a rotary kiln heat treatnten~ ln exc~ss o~ l,Z00 C to slntcr or ~linkerize the raw ~naterictls. These hi~32~ t~nlper~tU~es 15 are utllized }:ecau~e tl~e d~sirable sllicates, C3S and czs, st~rt to form ~t t~nlEleratllre.s arc)urld l, 300 c arlci a~e stable flhove temper~ t:ures oE 1, 500 c . In colltra~t to thes~ ~ilica~s, c:alcium alutnino sulfa~e, C4A3.S , i~
not t~errnocly~tf3mi~cllly fit ~ble e~ teltlt1er~tt-1rc~ ov,e ~o 1, ZOO~ C and ~tct~3ally decomposes at SUC21 el~vated tempcratures~ Rath~r, C4A3S begirls to ~orlll a~
temper~ure~ o approxima~cly 1,000 ~ al~d b~comes s~able at approximately l,l~o~ c. 'l~hus, be~a~ e o~ t~is ~if~er~nce in t~mperAture s~a~lli.~y, con~mer~ially ~5 producing cement clinke~s GOIlt~inillg bo~ll C3~ ~nd ~2S A~
well as ~4~3S has be~n difPicu1t, i~ no~ lmpos~lble with existing cembnt pro~uc~ion tecllnology and kiln controlling a~t.
Accordin~ly, in co~ltr~t to t~le pri~r ~t cemen~
produ~inq methodologie~, the m~tho~s and co~posi~ions of the pre~e~t ,invell~ion utillz~ s~)~cial mix1n~ ~or~ul~ ~o design ra~ ma~eri~l ~ixe~ which in thc ~men~ kiln itself prod~lce unique clinkers h~vin~ high con~entr~tlons of C4A3S~ Further, regardle~s of the 35 ability of the special olinker~: so p~odt~ced to bec:ome hyd~ulic c:emell'c upon grihdin~ ar)d hydr~tion, when mixed -B -PCIMSI ~llITH, LRillJE, ROSE TEL: Jun 5,~0 14 J1 ~Sk l~l~ P,l~/l . , .
~.~ 201~
with por~lt~nd cemenk c~nd ~olubl.~ c;31ci-lm sul~ate ahhydride accordin~ to the te~ch.ing~ of tlle pre~cnt in~ent;oll, the.se ut~itlue cli.nk~rs procl~lcc very ctlrly s~.ttin~, ultr~ hl~h skren~th cements lla~ir~g GOmp~essive str~ngths ~anging f~oln 3,000 p~i i.n o~ hour, following hydr~ion to ~,O~)o psi. ill twellty-~nl]r IlOllt'S. allCl t.~.) 10,000 psi in twenty~igilt d~ys.
Before proceeding furth~.r, for purpo~es of expl~natio~ ~nd wi~ho~t wishin~ to be bo~ d to this ~h¢ory, it ha~ ~een detQrmihe~l t~l~t thc metho~l of th~
present in~ention pronlu~.s ~niq~l~ ce~l~nt con~positio whic~l, followi~g hydr~ti.on, ihcorpVr~te cry~t~l~ 0 ettrillgite and c~1cium nlum; oat~3 hy(:lr~t.e . It i.~
be.lieve~l th.lt tl~e nc~cll~ .li kc~ cryst~L~ Or nl.:tr. in~; to. .li)rl ct~lcium ~lumin~e hydr~te f~lnc~lon to str~n~3tl~n tl,~
hydralllic conçr~te~ so produ~ed by formirl~ tl~tworks o~
r~info~cillg micro Pibers. ~his internAl tl~rcn-dirnension~l rein~orcin~ fi~)~r matrix, in con~unckioll w.i~h the CA aq ph fie which oc~u~ in h~gl~ Alu~ina cem~.nt, co~bi.nes ~o pro~ ce thQ previously unattc~inable very ~arly, ultrc~ h.igh ~trencJth ~ha.r~cteri5tiC~ of tlle cement ~ompositions of the presont ~nven~ion. Prior ar~
cement ~omposi~ions h.~e been unable to combine ~ttringite or C6AS3 ~ a~ ~nd CA ~ and ~3S ~ ~q phas~s in a ~in~le c~m~nt ~QC~se ~ the exce~sive kiln tesnp~ratut:os ~til.i~,c~. Tho~e sk7.1l~d in the art will appreciate ~ha~ t~le forogoiny proposed mechanism ~or. the p~op~rti~s oP the cement compositions of t~e present invention ~3 the.orçtic!~1 oslly 3nd ~oes not limit khe ~cope or conten~ of t~e instc7nt in~entiotl.
A~ noted above bri~ly, ~he firs~ ~tep in the met~od o~ ~he presetl~ inv~tltion i~ tv produce ~ ~.p~ci.~l cemen~ clinker con~Lniny hig~l ~7moun~ o~ C4A3$ in the kiln. The r~w materj.~l~ for this clinker A_e tho~e ~ommonly kho~n and u3ed for the production of ordlnary portland cemont clinkers, n~mel~: hi~h all7minc~ clay or POI~S, SI~IITH~ LRN~E, ~OSE TEL: Jurl 5,gr~ 14:51 ~ ,rJ1~ P,13~1~
`~ 20~1 38~9 ~ ~
~4-~0 hauxite or k~olonite, limeston~ and gypsuJ~ r~ se skilled in the ~rt will app~eciat~ that ~hese raw materi~ls ~re ~ources ~f S, A, ~, F ~nd S, which ~r~, respectively SiO2, A1~03, CaO, Fe203, ~nd So3. These ~aw m~terials are c~lnblned in ac~ordance ~ith the ~eachil)ys of thc present il~v~lltion such t21at tll~ mixture ~ormed h~ an overall ~ol~r ra~io o~ A/F gre~ter th~n or equ~l ~o approxim.~tely O.fi~ and ~ mol~r r~tio of s/~
ketwc~n approxi~tely 0.3S and o~
10 , This raw material de~ign hAs been determined based upon ~he following cri~ria. First, it is known that small amo~nts of impu~iti~.s will naturally occur in the r~w materials ukili~ed to ~orm th~ r~w ~aterial. mix.
The impurities nor~nally enGouhter~d incl~lcle s~di~lm oxi~e 15(N~201, pot~ssium oxide (K20), magnesi~im oxide (M~O) ~nd the lik~. t~owev~r, becau~ of thc Uni~l.lC com~osition of the r~w m.aterials mix of tl~. pres~s~. invc~n~.ion, ~hes~
~mpurities d~ not h~ve ~ ificant a~vcrse efEects upon th¢ form~tion of c4A~S in tl~e kiln~
~OAdditionally, in accor~ance wi~h thc teachitl~s o~
the present invention, C i6 go~ng to react with ~lumina an~ sulfates ~o form C4~3S. ~ny lron pr~s-~nt in t}le raw ~aterial~ will mo~ ly sllbstitu~ L~r ~h¢ alumina in the C4A3~ ph~s~, b~t wilI not form C4AF or C2F a.~.; lotlg 2S a~ the r~tio o~ A/F is gr~ater than 0.64. Any silica present i~ the r~w m~terl~l~ will re~ct wit~ the rem~ining C to form c~s ~t the cllnkeri2.~tion te~p~rature utiliz~ ow~ver, this fo~m.n~ion i~
second~ry ~o the ~ormatioll C4A3.5~ Moteo~er~ C~,A3.g wil].
be in equi~ib~ m with ~e s.ili~ate ph~ses as loncJ as the r.~io of s/~ ~ ~ is b~tweet~ approximately 0.2; an~
0. 35 . If this r.~tio i~ l e~.~ thatl apprc)xillla~y 0.~
~he geh~lltlite phase or C~S will be dominatlt.
Conversely, i~ the r.3tio exceed~ approxi~nately 0.35, CS
35 will b~ the ~omlhc~1lt p~ 3~ atlC~ C3~ w.i~ olmed it~
~quilibriutn with it.
--~.0--7 4 ~ 1 2 0 Sim$1arly, imp~lriti.~.s such as sodium oxide (N) and pot~sslum oxide ~K~ will reAct with the sulfa~e prcsent in ~he rnw mlx c:om~o3ltio~ nd the remai.n;.n~ sul ~te will r~act ~o form C~4~3S witl~ut siyni l~i.c~21t adv~rse 5 e~fe.~;t on ~he v~ry early set~i2lg, ultr~ hi~h s'crength ~h~rac~eristio~ of the ~ .m-.~llt compo:~lt.iol-~ procltlcecl.
Any un~omhined S wi.l.l rea~t with C to for~n C.S a2~c~ the remainin~ C will re~ct to form c2S with ~ilica, ~ho~e ~killed in t.h~. art will ~lso ~I~prec:Late that 10 1;he design oE 'ch~ raw mat~rii~l mix of the present inventio2~ can be pcrf~rm~.d u~;ing tra~liti~ l. c`2le~
ani~lysis te~hniques oL the raw mat~rials utilized. ~or ex~mple, ~ssuml~ an exe~nplary r~w ~erlal mix is ~ormcd from hi~h alum.l.na ~l~y, l.lmesto~e al~d gy~sum 15 cont~initlg S, ~, C, F, M, K, i~ and L. IØ The followl2 g ratio~ ~n h~ util i.~ed in accor~larlce with t~l~ t~ac~in~s o~ ~he pre~ent in~entio~ to de~lgn t~le ~w materlal mix.
(:1) l'he ;~mou~ f ~ulf.~l:e in K;~SO,I -O. ~I2 K~O
( Z ) llhe amourlt: Or ~ at~ in N~
OA 6~; Na2O
(3) The a~nou~lt o~ C41~3$ ~ 9S A.120 1. 63 Fe~03 + 1. ~4 Mn2~
(4) The amount of sulfF~te in C4~S =
0.26 A12C)3 + 0-11 (Fe;23 + ~Sn23) (S) The amount o~ c~lclum in C4A3S =~
0.73 A12O3 1 0.47 (Fe203 -t Mnz03) (6~ The amourlt o~ CS = 1.7 CS - (0.~5 Na20 ~ 0. 47,5 K~0 + O . 2~ A1203 + 0.17 31) ~Fe203 t ~ 3~ ) ]
( 7 ) The amount o~ C in C5 = 0 . 41 CS
(8) Th~. amount o~ C ln C,15 = 1. 87 S
~9) The tot~l reqlllred amoun~ o~ C -~, 5~ A1203 + O . 35 (F~203 + ~n~;)3) 1.87 S + 0.7 x - 0.45 Na2C~ - 0.30 K2~
. , , ~ Z0~38139 ~
74-1~0 (10) The total re(~l;.rcl:t alno~ t of S -0. 65 1~a20 + 0 . 42~ K~0 ~ O A ;26 A1203 0 .17 ( P'~203 ~ M~03 ) As noted abov6:~, the temper~ture rang~ wllcr~ C41~3$
5 is stable varies between approx~mately 1, 000 C and l,aoo~ C. Accor~.it-gly, t)l~ previously produce-l ~;xt~1r~
of r~w ~aterials is he~te-~ to an elevated temper~ture between these relatlvely narrow li~it~ for a suffi~Lent : period of t~me ~o form the ~esired clln}cer having ~ h~gh çoncentr~tion ~f C4A3S. This ~ime period wi11 v~ry : ~ependiny upon the ¢o~po~ition of the mixture ~nd the kiln geometry will r~nye from fraction~ of on~ hour to sever~l hours or more. Th~ high concentrAtion of C~4~3S
will r~nge hetween approxim;ltely 15% ~n~ 75% by wei~ht.
It should be noted t}lAt tlle prescnt ~tAte of the ~ciln temper~ture control ~rt doRs not involve tradition~lly un(3c!r~t:ood t~nperature cont~ol~ ~t tll~
burnin~ zone. 'rypic~lly, t~ control of t~ clin~c~r t~mper~t~lre. in t~le ~ci.l.n ;~ ~; carr.ied QUt by we~ ch~]nlc~l 20 an~lysis for free C ~r~ lime). Fcr example; the design fo~mulas for tr~itional portlAn~ cemeJIt r~w materials per~it the pre~en~e of pred~t~rmillcd amoul~ts o~ free C in the ~linlcer. If wet chemiGal ana1ysis of ~he ~1 lnk~r d~'ct~rmineE~ t.h~t ~he amo~nt o~ free ~ is l~;s 25 than the d~ssign amo~n~, th~ c1inker i~ over~urninq and ~he kiln temperature ne.~!d~ to be reduced. C~o~ ersely, if the an~lyzcd amoul-t of ~re~ C i~ h.igher ~h~n the deeign amount, the ~llnker ~9 ~eln~ u~derbur.ne~
ki1n telnper~t.ure n~ t ~-~ rai~.~t3.
~lowever, su-ch w~t cll~mi~1 m~t:l~o(l~, m~y nn~ }~e pra~tica11y app1i-~b1~:! tn til~ pro~ tion 0~ ; nkex ~i ht~v~n-~ hi~3l~ w~:igl~ po.rc~c~l~t..~ C4.1~3~ n~t~ tt~llql~t by ~l)e pr~5t~nt inventio~-. Wet chemic~a1 ~tlaly~i~ may be dec~eivint3 in ~ g context h-~cau~3-a thF~ all~minu~, cl~y, ~5 bauxite and the ~ce, oon~ln S. l'hi3 slli~:~ wlll re~t . ~ ~
~ ~0:~889 ~_, with calcium and the w~t ch~mical methods may n~t indicate whioh phase i5 currently pres,cllt in the cl.inke~.
~cc~ordinyly, a pr~.rc~ met~od for controll.lng t~
el4va~ed temperatures of tlle heat treatmetlt ~f the ~r~ .nt itlV~l~t ion u~ 3 p~rioclic x-ray ~ f~a~tion ~nalysis of samples taketl fro~ tl~e hcat~d mixture ~a~her than wet chemis~ry. ~s ~itl~ the wet chemical methods o~
analysis, t~le previou~ly described formul~s o~ tlle 10 ~resen~ invention allow tlle determlnation o~ a dcsig~
amoullt o E C4~3.S . By ~-ro~-aring a pre~aJ.i~ra~e(.l x-ray diffraction curve ~sed ~pOIl la~or~tory ~eference ~tandards for ~u~ntit~t i~e~y anAlyzing tlle ~mount of C47~35 p~esent in know~ ercnc~ ampl~3s, .it bCCOmCF3 pos~ble to periodicnlly remove sampl~s frolll the he~tecl mixture and to quatltit~.ively ~naly~,e tllelll for the proper design ~ontent of C,~A3S tllrou~ll x-ray di~rac~tion analysls. ~hen, a5 with t.radi~iot~ et chem;.~ry metho or kiln contrv1, t}~e tempernture o~ tlle }le.~ted 20 mixture c~n be adjus'ced e:i~her up or dow~1 to p:r~c~u{~e tl~e hi~h concen~r~tion of C4~3S ~ de~igl1ed ~n th~ raw material mix.
It should be emphasi2~d t~1at t~e el~vat~d ~emp~ature ranges ~eces~ary to produc;:e the ~4A3~
~5 containing cl inker o~ t}le p~esent inv~tion are relatively narrow when~ ~o~npared to tratlit.iona1 ~emen~
clinkeriza'cion temper;itllre3~ Acc:or~linc3ly~ cælreful temperat~re c::ontro1 throuc~h x-r~y dif~ractioll ana1ys3.
or som~ other Ine~hod o~ fi.ne tempcrature c~rltrol, ,~houl~
30 ~e pr.~cticecl to procl~1c~ st~bl~ C4A3~ phh~ itl t~e cl inker .
Those sk11led ~n the art will ~lso ~ppreci~te that.
an exen~71ary x-ray ~i~fra~tio11 pr~calibra~scl cu~ve ca be preparec~ by co11du~t.it~g a n~1~n~er of labor~tory trial 3S de~ n burn~, of the de.sired raw ma ~rial mix. The trials shoulcl inclutle underbu~n}n~, overburnlng and I~UI''15 7 ~ 11 H ~ LHl'~llt, ~IJSt I t.L: Jun ~ J 1~ :Ul IJo ~rJ ~ ,U4/1 Z~3889 ~
7~ 12 bur~lny ~t the cor~ec~ tc~npera~ure~ Th~ a~no~ t o~ CqA3S
in eac~l trial bur2l can then b~ quallti.t~t;.ve.ly nnalyzed tlo.~o~2gll x-ray di~frat~ cl co~llp~:c(l to ~S~l~ll st.~ 3ilrtl c~rve~ for qu~n~.it~tively calcula~irl~ t}~e co~lte~t~.~ of C3S and C2S, ~3A and C4A3S.
~ urillg prod~ of the act.~a.l colnlllerc.i~l. cl;nke.2-in accordanc:~ wi~h ~he present invcr-tion, ~ s(a~ lc oE
the heat ~re~ted r~w mntcri.~l will preferahly ~ t~ken fro~ the ~iln approxima~ely each one~hal~ ~our o~ hollr ~o ~e analyzed ~uan~it~t.ively by x-ray dif~r~ction. 'I`o ~a~ ate thls atlalysis ~n x-ray di~fr~ctinn m~tchine ~an be ¢omputerized ~o be calibrated to th~. prebur2~ing trials.
once t}le ~,lin~er has ~ecn properly clinkcrizc~ th~
next step in the prod~cti.on of the cement com~ositiotl~
o the pr~sent inventio~l involvcs ~ete~m~ni.ng the ~vera~e amount o~ C4~3S present in thc clih~er, Typic~lly, the clinker 50 pro~uced wlll not h~e cem~n~itiou~ value~ it5el. ~ upon grind~ng~ ~cco~]it~gly, the next step of ~he pr~nt inv~ntion i~volves ~ormi a final mix~ure o~ the clinker with C con~ainin~
portland typ~ cemeh~ and sol~ble CS ~nhydride such that the compoei~ion of the ~in~l mix~ure includes a C4A3S
con~en~ of ~pproxl~t~ly lO~ - 30% by welght ~nd a ~oluble ~$ anhydri~e coll~erlt of approximAtely 5~ - 25~.
Mixin~ the speciAl ~linker of ~h~ instan~ i~vention with hydrAulic or portl~nd type c¢me.nt is a preE~rred te~hnique be~ause it incorporate~ ~3S illtO the ~etnetlt by p~ovidin~ ~rec lime an~ C3S to ~he mixture.
In contr~st ~o ~le p~ior ~rt metllo(t~ ~f cement production utilizirl~ th~ known stoic~liometrlc r~action of C41~3S to pJ 0~3~ .x~)~t~ yst~l c., t.l~ }locl o~
the present inventior- forms t~ firla1 mix~ure of the high c4A3$ contAinin~ clink~er accorditlg to t~l~ follow~ng aqucou~ mix~nq formul~s:
r ~ I r~ nl~ J JL I CL ~ ll ,J ~ ~J',J l J ' ',Jl I'll~ . ~J~J r . ~
'' ~0~ 389~ ' 74-1~0 I C4A~S + 2~ = ~4~S aq + 2CA aq II C4A3S a~ ~ 2~' = C6AS3 aq by adding I ~ II th~ f~11Owin~ aqueous mixing ~ormula is produced.
~4A3S ~ 2C ~ 2cS - c6~s3 ~ a~ ~ 2~A ~q Tho~ sklll~d in the ~rt wil t ~~E~r¢c-i~te t21.~t t11e CA ~q ph~se ln the cement produc~d in ~c~ordance with the teachi.ng~s of the present ihVellt~oll is ~ pr~ ncip1e ph~e present in hig~ a1umina cèmen~ and, it is ~elieved, ~h~t ~h~ earl.y str~ng~h in suc~ cemellts is due to khe presenoe of this ph~se. However, unli.ke the prior ar~ cement composi~ions, following hy~ration the Gemeht co~pos~tions O~ the prescllt ~nvention produGe a conc~ete including th~ ~A ~q ph~se, the C~S ~q ph~se a~ well as the ~3S ~ ~q ~nd C~AS aq ettringite phase without the adverse e~e~t o~ the C1~7 ~ ~q p~a,~e~
whi~h su~fers ~ry~ta1 ~ransformation after ~evera1 years following hydration.
Tho~e skil1ed ~n t)~e ~t wll l al~o ap~r~c1~te t~t the de~igtl mlx o the Cemellt ~o~pos1tiolls of t~le presetlt invention ~an be mod.i.i.ed to produGe a wide ~ari~.ty o~
desir~hl~ ~cry early ~et~ g, ~ltra hig~ re~gth charact~ri~tics. At~ditior~ally, ~ario1.1f ad~itives ~n be incorporated itltO the c~mcl1t ~o provide ~ld;.tiot~al ~sirahl~ propert~es. Simi~.arly, ~he ~ettint~ tln1~ o~
the ~emen~ sompositiO11~ of th~ p~efient invetlt~on c~n be con~rolled ~hrough t1~e ~djust.ment o~ t.l~e mix.1.nt3 prop~ion~ of th~ thre.e maitl raw material ao1npo~en~s, For ~x~mpl~, in colA or ~.cvcre we~ther condi~iot1s ~he 6etting ~im~ may intrease ~om fi~te~t1 ~.itl~t&~ to ~pproximately two hours. ThUf~ a sui~able accelerator, such a~ al-lmlnum ~ulea~e or iron s~ te may be incorporated into the c~men~ to i~c~e~6e tl1~ r~te o~
cure of th~ Cem~ . In at.~t.1ition to th~f~ let,~tor~
~r~vlo~ note~l, nny ~ r.Lt~ ~cc~ t~nl.o~ U! ~ r _~5_ I~U~ l I H, LHI'Ill~, KU~ L: Jun ~ ~ylJ l~ Ul ISJ0 V~IJ ~ IJ~
.
~ Z0~38~9 ~
- 7 ~ 0 portlan~ cement ¢ztn also bc used with the cemet t compo~itions o~ the pre.sent illvelltions. Adcli.tio~ .lly, a citric aci~3 re~.~rder mc~y be ~(~tlc~l ~o the cemct1t t ompo~itions of the present inVCnt:iOIl to increa~e the 5 initi~1 s~t up time to !~Omet}tirlg on the orde.r of two hours. ilo~ever, it shollld b~ ~ppr~ci.c~t~cl t~ tt: c~lll initi,~tl set time of fiftee.ll minu~os followin~ hydrat.ion is ~n ide~1 ~ime for m~ X; n~ the. cemC~I~t Wi~ a super plasticiz~r to reduo~e the~ mixin~ wc~er or concrete 10 S;lU~ltp.
It sh~lld al~n b~. apE. r ec.Latec3 th~t. t~le new c~t~ellt compo:.itiorls pro~:t~loed il~ ~cc~o~ d~ e witll tlle t.e.~ of the presQtlt invention c~e WAtor impe~menh].e, sulfclte ~e~stant, an~ non-.sll~.~in}cin~3 compositin~ls. Mor~ove~, 1~ the cement compositioll~ are also se~ ~ater re~istc~l~t.
Fnr increased resistallce to ~r~C~.Z~ ~nd t~law, l~t.~wcver, addition o~ super-plas~.icize~ is re~omme~-ded. A ~urt}ler understanding of the exe~ ry ~ement com~o~:it..Lorl~ of the pres~nt inve~inn will l~e a~orc~ed ~c tllo3~ ski] 1 ~fl 20 in the art from ~hç fol lowing non~ ni~lng example~:
EXAMl~
~ n accordance with the method o~ the pre~nt inven~ion a, mixture or limestonq, gypsum, and hi.gh ~5 a~umina cl~y was prodl~ced ~o form a ~aw mix~ure for a hig~ C4A3S çl inker . Ths~ componentfi of the mixt~e wer~
combine~l ln the ~c>rm oP dry powders . Tha c:hem ~ cal ~nalysl~ o~ the raw m~terials was as follow~:
~laY_Ji.me~:tone Gypsum sio2 32, oog62 . 00~6 ~. 00 Al?,03 55 . 009~ o . 70~ 0 . 50 CaO 1. S0%55 . 00% 3~ 0 Ot)~
35 Fe O3 1. 00%0 . 50% . ~. 20g~
Mg~ 0 . 25~6 0 . 60~6 0. 6096 K20 2 . 60~ 0 . ~59~ 0. 05 SO3 3 . ~0~ 0 . 10% 4 3 . 00 L.O.I. 4.00~641.00% 21.00 PO~IS, SI~ITH, LRI~ E, ~OSE TEL: Jun 5 ,90 15 :Ol ~ O~O P 07~1 ~ Z0~3889 `~
7~ o U~ilizing the ~ixi.n~ formulas o tl~e pr~eht inven~ion it wa5 deter~in~.d t}~t a ~linker con~ainirlg an avera~e of ~proxima~ly 3~ C4~3S cou~d be proc]llce~1 from these raw mate.r~c~ls by mixi~ 55~ ~y W~ t of ~he limestone. witll 20~ by wei.yl~. of the gyp~ m an~ ~5% by Wei~CJI~t Or ~}~e clay. Tl1i~; raw mclterial lnlxtut~c wa~ ~ir~d ~t a temperature between 1,000 C a~d l,200 C to produce hi~h ~4~3S clinker. Th~ ~linker so produced did not have any ccm~ntit~o-~s valuo~.
, Again usin~ th~ mixi~l~J formulas o~ tlle pre~.ent invention this ~l.{.nker was f~lrtheI- mix~d wit~l soluble C
S anhydride a~d portlan~i ~ement in the oll~wil~g proportions: 70% hic3h C4A3S ~linkcr, 20% ~rtl~nd ce.ment ~ype III, an~ lO~ sol~ CS a~ y~r-lde. l`i~e resu.ltan~ ~ement ~.ixture contained approxim~tely ~'c~
C4A3S, approximately 3% fre~ C, appr-ximfltely lO't CS
anhydric3~ an~ approxlmately ~5% sil.1.~a~ (C3S and C2S).
~ n acJ~reyate w~ orm~d ~rotn ~h i ~ c:enlellt havitlg a 1 ~o 1 ratio of cem~t-t tc~ ~nd. Wat~r wa~s tl\c~l a-.l(l~d to 20 t}~ aggr~c~Ate in ~he propor~ion of 1 part wator to 3 parts cem~:nt. The com~rcssiv~ strength o~ this mol~
composition w~s d~termi ned usin~ the modi~ied c10~-c~lb~.
~re~g~h teæt whi~h p~od~lc~d the ~llowin~ ~es~1ta:
~qe ~ompressiv.e.Strengtt one hour ~, 000 psi one d~y 7, oon psi séven days ~, 0~0 psi twen~y-eight ~y~ ~11, 000 psi EX7~ r..F: I I
AF~ wi~ Ex~mple I~ a~ initifll mix~ure of raw materials this time comprisl.ng bauxite inst~ad of ~ay, limestol1c ~n~ gyp~um w~s E~ro~1uce~1 to fbL-m a r~w m.n~
mixt-l~e for U~e in prscl~cltly a hi~h ~4~35 ~lin~er. Tho chemical an~lysis of ~he raw materi~ls was as follows:
POMS,SMITH, LRIlDE, ~OSE TEL: Jun 5,gO 15:01 flo 0~0 P,O~/1 ., Z~1388~ - -B~uxlte l,im qtol~e G~psum sio23 . 00% 2 . 00% l. 00%
Al2O355. 00% 0 . 70~ 0. 50%
CaO2.OO~;i 55.oO~ 34.n~
Fe;~032'7 . 00% ~. 50% 0. 20~
M~O0 . 0 0 ~ 0 . G 0 % 0 . ~ 0 %
K2Oll. 00~ 0.15% 0. 05~
50~ 0. 00~ 0 . lO~ 43 . 00%
L. O . I . 0 . 00~6 4 l . 00~ 21. 0096 l~ Tio23 . 00~ 0. 00% 0. ~0%
Utili7.1ny tlle mi~ g formul.;l~ of the preseJ~t inv~ntion it w~s ~et~rmllled th~t after ~irin~ ~ cl~t~ker could be proc~uoed cont~i.tl Lng ~2~ C4l~3S by çoln~.~inlng 40%
by weight b~uxi~e with 40% by ~eig~l~ lim~to~le anc~ 20%
weight gypsum. Ag~in, utili.z.ing t~le mixin~ ~ormulas of the prescnt invention, the f~red clit~ker WA~: ~ombiJ~
Wi~h portland type III cemellt atlcl soluhle CS al~hyclride in the proportior~fi of 35~ hic3ll C47\3.S c~ 1c~r, lO~
~oluble ca anhydri~e, ahd 55% portl~nd type III cement ~o produce a ~inal cem~l~t ~ompos.i.ti~.~n CO~ a.i.l~ y ;~n~
C A ~
Whell hydrflted~ t.h~ llt C0111~0:3.it.iO11 0~ F,x~mpl~
11`, exhihi~e~l a h~ he~ hyclration rc~nc.~ .3 75n C~ at ~e ~inal set. This hi~h h~At c~ hydratiotl made the ceme.nt composition of E:xflrnp~e II p~rti,~ulRrly tYell suit~l fo~ ~E)pli~atiolls irl ~:old wea~er ~nd sub-zero temperatu~es.
~0 l'ho~e skilled in th~ art will apprecint~e t~-at t}~e ~ange o~ C~,A ~S that may b6 produ~ed in accordAnce ~itl the tea~hing~ of the present ln~rentic)r~ th~ initial fired c:linker can vary widely. However, ~ C4h3g contsn~
o~ leE~ than ~pprax.imatcly lS~, thou~h c:ol~templ~t~<l a-cl being within thc $cope 0~ the pr~s~r t tnv~ntion, mo~t likely would not be economically fea~ible. ~onversely, clepending upon the chenl.lcal composition of t~e raw m~ ri~ls invol~fed in produc.~.ng ~he original mixture ~or the clinXer, a C4A3S ~ontent a~ high as approximately P0~1S, SI~IITH, L~NDE, F~OSE TEL: Jun 5,30 15:01 Il~.O~rJ P,c1~4 . , .
~ 389 '~
7 ~ 2 ~) 75~6 is col~t~mplated as. belnq Withill t}~e. pracl~ic~]. F.Cnpe of the presen~ inventioll.
Similarly, mixirlg r~ti.~. for tlle firecl c.lirlker, portl~n~ c:ement an~.~ solui:,le CS an~lyclr i.~e c-ll) al~;o vary 5 widely clf3pen~ing upon tll~ desired perC~lt.lrJe o~ c,~7~3.5 in - the f ina1 cement C~ pO~ io~. Howevl3r, i~ .is antiaip~ed that the mo~t econom~ cal cement compo~itio produced in accord~nce with thc presollt lnvetl~ion will contain a weight pel-cellta~e of C4?~3S r~llgi--~ from 10 ~pproxim~ely 10~ to 30~. Accordingly, th~ associated content o~ sol~ble ~ a1lhyc3ride will most econom~ c~lîy vary ~rom ~pproximately 5% to ~S%. The remalnder of tlle composition can be fqrm~d o~ any type of hydrAulia cement, However, it is pre~e~-recl that the ~em~nt hav~ a 15 high con~ent o~ the Ç3S phase . Thus, the rema inder of th~ cement ~ompo~;iti.on will pref~rahly conlprise portl2.nd typ~ cemcn~ arying f rom approxim~tely ~ 5~6 to 8~ y wei~ht, depending upon thc flesire~l stren~th anâ other prc:perties o~ the fin~l. hydraulio cement pro-.tllct~
lh the foregoihcJ ~e~crip~ion c~f ~he presen~
invention, preEerred ex~3mplary em40dimellts of the inventlon h~ve becn disclosed~ It is to be understood th~t by those skilled in the art that othe:~ equiv~lent cement composition~ ~e con~emplat~ed as }~eill~ within the ~S scope of t~le presellt invention. Accordingly, tl~o present in~en'cion i6 not limited to ~he particu~ar exempl~y cemeht compo~itivns w}li~h havo bee:
i~lUst~t~d ~nd descrih~cl in d~tail hQr~ih.
I)OCS 741~0PAT. 011~
Claims (18)
1. A method for forming a very early setting, ultra high strength cement, said method comprising the steps of:
forming a mixture of limestone, gypsum, and one or more members from the group consisting of bauxite, kaolonite, or high alumina clay such that said mixture has an overall molar ratio of A/F greater than or equal to approximately 0.64 and an overall molar ration ?/A+F
between approximately 0.35 and approximately 0.25, where A, F and ? are, respectively, Al2O3, Fe2O3 and SO3;
heating said mixture to an elevated temperature on the order of approximately 1,000° C to approximately 1,200° C for a sufficient period of time to form a clinker having a high concentration of C4A3?;
determining the average amount of C4A3? present in said clinker; and forming a final mixture of said clinker, CaO
containing hydraulic cement and soluble CaSo4 anhydride such that the composition of said final mixture includes a C4A3? content of approximately 10% to 30% by weight and a soluble CaSO4 anhydride content of approximately 5% to 25% by weight.
forming a mixture of limestone, gypsum, and one or more members from the group consisting of bauxite, kaolonite, or high alumina clay such that said mixture has an overall molar ratio of A/F greater than or equal to approximately 0.64 and an overall molar ration ?/A+F
between approximately 0.35 and approximately 0.25, where A, F and ? are, respectively, Al2O3, Fe2O3 and SO3;
heating said mixture to an elevated temperature on the order of approximately 1,000° C to approximately 1,200° C for a sufficient period of time to form a clinker having a high concentration of C4A3?;
determining the average amount of C4A3? present in said clinker; and forming a final mixture of said clinker, CaO
containing hydraulic cement and soluble CaSo4 anhydride such that the composition of said final mixture includes a C4A3? content of approximately 10% to 30% by weight and a soluble CaSO4 anhydride content of approximately 5% to 25% by weight.
2. The method of claim 1 further comprising the additional step of:
controlling said elevated temperature through the periodic x-ray diffraction analysis of samples taken from said heated mixture.
controlling said elevated temperature through the periodic x-ray diffraction analysis of samples taken from said heated mixture.
3. The method of claim 2 wherein said controlling step comprises the additional steps of:
preparing a pre-calibrated c-ray diffraction curve based upon reference standards for quantitatively analyzing the content of C4A3? present in a sample;
periodically removing a sample from said heated mixture;
quantitatively analyzing the content of C4A3?
present in each of said samples through x-ray diffraction analysis; and adjusting the temperature of said heated mixture to produce said high concentration of C4A3?.
preparing a pre-calibrated c-ray diffraction curve based upon reference standards for quantitatively analyzing the content of C4A3? present in a sample;
periodically removing a sample from said heated mixture;
quantitatively analyzing the content of C4A3?
present in each of said samples through x-ray diffraction analysis; and adjusting the temperature of said heated mixture to produce said high concentration of C4A3?.
4. The method of claim 1 wherein said high concentration of C4A3? is between approximately 15% and approximately 75% by weight.
5. A very early setting, ultra high strength cement produced in accordance with the method of claim 1.
6. A very early setting, ultra high strength cement produced in accordance with the method of claim 1 wherein the content of C4A3? present in said final mixture is between approximately 15% to 25% by weight.
7. A very early setting, ultra high strength cement produced in accordance with the method of claim 1 wherein the content of C4A3? present in said final mixture is approximately 20 % by weight, and the content of soluble CaSO4 anhydride is approximately 10% by weight.
8. The very early setting, ultra high strength cement of claim 5 further comprising a super plasticizer additive.
9. The very early setting, ultra high strength cement of claim 5 further comprising a citric acid retarder.
10. The very early setting, ultra high strength cement of claim 5 further comprising an accelerator additive selected from the group consisting of aluminum sulfate, iron sulfate, or chloride accelerator.
11. A very early setting, ultra high strength cement comprising approximately 10% to 30% by weight C4A3?, approximately 5% to 25% by weight soluble CaSO4 anhydride and approximately 45% to 85% by weight hydraulic cement.
12. A very early setting, ultra high strength cement if claim 11 comprising approximately 15% to 25%
by weight C4A3?, approximately 10% to 20% by weight soluble CaSO4 anhydride and approximately 55% to 75% by weight hydraulic cement.
by weight C4A3?, approximately 10% to 20% by weight soluble CaSO4 anhydride and approximately 55% to 75% by weight hydraulic cement.
13. A very early setting, ultra high strength cement of claim 11 comprising approximately 20% by weight C4A3?, approximately 10% by weight soluble CaSO4 anhydride and approximately 70% by weight hydraulic cement.
14. A method for producing a very early setting, ultra high strength cement said method comprising the steps of:
mixing predetermined amounts of S, A, C, F, and ?
containing raw materials, where S, A, C, F, and ? are, respectively SiO2, Al2)3, CaO, Fe2O3, and SO3;
subjecting said raw materials to a heat treatment at temperatures between about 1,000° C to 1,200° C for a period of time sufficient to form a clinker containing approximately 15% to 75% by weight C4A3?;
determining the quantity of C4A3? present in said clinker; and mixing said clinker with C containing hydraulic cement and soluble C? anhydride according to the aqueous formula C4A3? + 2C + 2C? = C6A?3 ? aq + 2CA ? aq
mixing predetermined amounts of S, A, C, F, and ?
containing raw materials, where S, A, C, F, and ? are, respectively SiO2, Al2)3, CaO, Fe2O3, and SO3;
subjecting said raw materials to a heat treatment at temperatures between about 1,000° C to 1,200° C for a period of time sufficient to form a clinker containing approximately 15% to 75% by weight C4A3?;
determining the quantity of C4A3? present in said clinker; and mixing said clinker with C containing hydraulic cement and soluble C? anhydride according to the aqueous formula C4A3? + 2C + 2C? = C6A?3 ? aq + 2CA ? aq
15. The method of claim 14 further comprising the additional step of:
controlling the temperature of said heat treatment through x-ray diffraction analysis of said heat treated raw material.
controlling the temperature of said heat treatment through x-ray diffraction analysis of said heat treated raw material.
16. The method of claim 14 further comprising the additional step of:
controlling the temperature of said heat treatment through x-ray diffraction analysis of the content of C4A3? in said heated treated raw material.
controlling the temperature of said heat treatment through x-ray diffraction analysis of the content of C4A3? in said heated treated raw material.
17. A very early setting, ultra high strength cement produced in accordance with the method of claim 14.
18. A very early setting, ultra high strength cement produced in accordance with the method of claim 16.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US363,587 | 1989-06-08 | ||
| US07/363,587 US4957556A (en) | 1989-06-08 | 1989-06-08 | Very early setting ultra high early strength cement |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2018889A1 true CA2018889A1 (en) | 1990-12-15 |
Family
ID=23430812
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002018889A Abandoned CA2018889A1 (en) | 1989-06-08 | 1990-06-13 | Very early setting ultra high early strength cement |
Country Status (12)
| Country | Link |
|---|---|
| US (1) | US4957556A (en) |
| EP (1) | EP0476031B1 (en) |
| JP (1) | JP2985103B2 (en) |
| AT (1) | ATE131802T1 (en) |
| AU (1) | AU638722B2 (en) |
| BR (1) | BR9007424A (en) |
| CA (1) | CA2018889A1 (en) |
| DE (1) | DE69024353T2 (en) |
| DK (1) | DK0476031T3 (en) |
| ES (1) | ES2081992T3 (en) |
| NO (1) | NO304367B1 (en) |
| WO (1) | WO1990015033A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5741357A (en) * | 1994-01-21 | 1998-04-21 | Sheikh; Shamim A. | Hydrated high alumina cement |
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| US6406534B1 (en) * | 1999-04-16 | 2002-06-18 | Hassan Kunbargi | Rapid hardening, ultra-high early strength portland-type cement compositions, novel clinkers and methods for their manufacture which reduce harmful gaseous emissions |
| CA2316059A1 (en) | 1999-08-24 | 2001-02-24 | Virgilio C. Go Boncan | Methods and compositions for use in cementing in cold environments |
| CA2318703A1 (en) | 1999-09-16 | 2001-03-16 | Bj Services Company | Compositions and methods for cementing using elastic particles |
| FR2807424B1 (en) * | 2000-04-05 | 2002-12-13 | Energetic Ind Internat | HYDRAULIC BINDER RESULTING FROM THE MIXTURE OF A SULFATIC BINDER AND A BINDER CONTAINING THE MINERALOGIC COMPOUND C4A3S |
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| FR2831161B1 (en) | 2001-10-24 | 2004-09-10 | Francais Ciments | IRONLESS AND FREE LIMELESS SULFOALUMINOUS CLINKER, PREPARATION METHOD THEREOF AND USE IN WHITE BINDERS |
| FR2832402B1 (en) * | 2001-11-19 | 2004-12-10 | Carrieres Du Boulonnais | CEMENTITIOUS COMPOSITION, PROCESS FOR PRODUCING WITHDRAWAL CAPS AND LIFTING OF REDUCED EDGES AND OBTAINED CAPS |
| FR2839066B1 (en) * | 2002-04-24 | 2005-02-04 | Lafarge Aluminates | ETTRINGTIC BINDER FOR DENSE MORTAR, COMPRISING CALCIUM SULFATES AND A MINERAL COMPOUND OF CALCIUM ALUMINATES |
| FR2868772A1 (en) * | 2004-02-17 | 2005-10-14 | Vanna Ly | Calcium sulfate based composition incorporating sulfo-aluminous clinker for the preparation of a hydraulic binder for the subsequent preparation of concrete based construction materials |
| MXPA04007614A (en) | 2004-08-05 | 2006-02-09 | Cemex Trademarks Worldwide Ltd | Process to produce portland cement clinker and obtained clinker. |
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| FR2892116B1 (en) * | 2005-10-14 | 2008-05-23 | Inst Nat Sciences Appliq | PROCESS FOR THE PREPARATION OF A WATER RESISTANT CALCIUM SULFATE COMPOSITION |
| FR2892115B1 (en) * | 2005-10-17 | 2008-06-20 | Vicat Sa | HYDRAULIC BINDER WITH LOW CO2 EMISSION |
| US7927417B2 (en) * | 2008-02-04 | 2011-04-19 | Capitol Aggregates, Ltd. | Cementitious composition and apparatus and method for manufacturing the same |
| US8715409B2 (en) | 2010-05-07 | 2014-05-06 | Pkl Corporation | Fast setting low permeability cement and concrete |
| FR2961505B1 (en) * | 2010-06-18 | 2013-08-02 | Cemex Res Group Ag | CLINKER AND METHOD FOR PREPARING HYDRAULIC CEMENT WITH LOW CO2 EMISSION AND HIGH STRENGTH |
| US9284226B2 (en) * | 2010-12-08 | 2016-03-15 | Minova International Limited | Cementitious compositions |
| JP2015507184A (en) * | 2011-12-30 | 2015-03-05 | 江蘇博特新材料有限公司Ｊｉａｎｇｓｕ Ｂｏｔｅ Ｎｅｗ Ｍａｔｅｒｉａｌｓ Ｃｏ．，Ｌｔｄ | Cement-based material setting time test method |
| US20140060391A1 (en) | 2012-08-28 | 2014-03-06 | Pkl Corporation | Shrinkage-compensating concrete |
| US8944165B2 (en) * | 2013-01-11 | 2015-02-03 | Halliburton Energy Services, Inc. | Cement composition containing an additive of a pozzolan and a strength retrogression inhibitor |
| KR20210024001A (en) | 2018-06-15 | 2021-03-04 | 사로드 그린백 엘엘피 | Engineered concrete binder composition containing mechanical-chemically modified components and method for manufacturing the same |
| JP2023505199A (en) * | 2019-12-06 | 2023-02-08 | ザ ボード オブ トラスティーズ オブ ザ レランド スタンフォード ジュニア ユニバーシティー | Fregocement made from a novel earth-inspired clinker |
| CN114213042B (en) * | 2021-12-27 | 2023-02-17 | 南京科工煤炭科学技术研究有限公司 | Double-fast sulphoaluminate cement for fast setting and fast strengthening in severe cold environment and preparation method and use method thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3194673A (en) * | 1961-08-29 | 1965-07-13 | Licencia Talalmanyokat | Hydraulic cement and process for making same |
| US3155526A (en) * | 1961-10-18 | 1964-11-03 | Chem Prestressed Concrete | Calcium aluminosulfate and expansive cements containing same |
| US3860433A (en) * | 1972-05-30 | 1975-01-14 | Borje W A Ost | Very high early strength cement |
| US4036657A (en) * | 1975-07-23 | 1977-07-19 | Reagents Of The University Of California | High iron oxide hydraulic cement |
| US4249952A (en) * | 1980-03-03 | 1981-02-10 | Pennsylvania Engineering Corporation | Method for producing cement clinker from cement kiln waste dust |
| CN85108582B (en) * | 1984-10-30 | 1988-08-17 | 蓝圈工业有限公司 | Settable cementitious compositions |
| IN168901B (en) * | 1986-12-09 | 1991-07-06 | Raffaele Cioffi | |
| GB8818113D0 (en) * | 1988-07-29 | 1988-09-01 | Blue Circle Ind Plc | Reinforced cementitious compositions |
-
1989
- 1989-06-08 US US07/363,587 patent/US4957556A/en not_active Expired - Lifetime
-
1990
- 1990-06-05 WO PCT/US1990/003159 patent/WO1990015033A1/en active IP Right Grant
- 1990-06-05 BR BR909007424A patent/BR9007424A/en not_active IP Right Cessation
- 1990-06-05 DK DK90909543.2T patent/DK0476031T3/en active
- 1990-06-05 JP JP2509000A patent/JP2985103B2/en not_active Expired - Lifetime
- 1990-06-05 AT AT90909543T patent/ATE131802T1/en not_active IP Right Cessation
- 1990-06-05 EP EP90909543A patent/EP0476031B1/en not_active Expired - Lifetime
- 1990-06-05 AU AU58362/90A patent/AU638722B2/en not_active Ceased
- 1990-06-05 DE DE69024353T patent/DE69024353T2/en not_active Expired - Fee Related
- 1990-06-05 ES ES90909543T patent/ES2081992T3/en not_active Expired - Lifetime
- 1990-06-13 CA CA002018889A patent/CA2018889A1/en not_active Abandoned
-
1991
- 1991-12-06 NO NO914819A patent/NO304367B1/en not_active IP Right Cessation
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5741357A (en) * | 1994-01-21 | 1998-04-21 | Sheikh; Shamim A. | Hydrated high alumina cement |
Also Published As
| Publication number | Publication date |
|---|---|
| WO1990015033A1 (en) | 1990-12-13 |
| AU5836290A (en) | 1991-01-07 |
| ATE131802T1 (en) | 1996-01-15 |
| NO914819D0 (en) | 1991-12-06 |
| BR9007424A (en) | 1992-06-16 |
| AU638722B2 (en) | 1993-07-08 |
| DE69024353D1 (en) | 1996-02-01 |
| DE69024353T2 (en) | 1996-07-25 |
| DK0476031T3 (en) | 1996-05-06 |
| US4957556A (en) | 1990-09-18 |
| NO914819L (en) | 1991-12-06 |
| NO304367B1 (en) | 1998-12-07 |
| ES2081992T3 (en) | 1996-03-16 |
| EP0476031B1 (en) | 1995-12-20 |
| JPH04506201A (en) | 1992-10-29 |
| JP2985103B2 (en) | 1999-11-29 |
| EP0476031A1 (en) | 1992-03-25 |
| EP0476031A4 (en) | 1992-07-08 |
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| EEER | Examination request | ||
| FZDE | Discontinued |