Non-hydraulically reactive blended particulate compositions for use in making low carbon blended cement or low carbon concrete include a pozzolanic component having a first D90 and a mineral filler component having a second D90 greater than the first D90 dry blended without intergrinding, wherein the composition is free of hydraulic cement. The pozzolanic component can have a D90 less about 45 μm and the mineral filler can have a D90 greater than about 45 μm. The pozzolanic material can be fly ash, bottom ash, steel slag, silica fume, metakaolin, volcanic ash, natural pozzolan, calcined shale, calcined clay, and/or ground glass. The mineral filler component can be aggregate fines, quarry fines, limestone powder, granite fines, stone dust, rock dust, marble dust, mine tailings, pulverized bottom ash, pulverized metallurgical slag, ground recycled concrete, pulverized shale from shale oil extraction, or pulverized sand from tar sand extraction.
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
Cementitious compositions that contain a hydraulic cement with at least one calcium aluminate compound and a sulfate bearing material, at least one SCM that provides aluminates, and a source of supplemental sulfate that reacts with aluminates to control setting. The hydraulic cement can be OPC. The SCM can be GGBFS, fly ash, natural pozzolans, ground bottom ash, ground pumice, volcanic ash, calcined shale, metakaolin, trass, steel slag, calcined clay, and/or ground glass. The source of supplemental sulfate can be calcium sulfate hemihydrate, calcium sulfate dihydrate, gypsum, or alkali metal sulfate. The cementitious compositions may further include a mineral filler, one or more aggregates, and one or more performance enhancing admixtures. The cementitious compositions can be a dry blend, a fresh mix containing water, or a hardened composition. Supplemental sulfate can address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticizers, and SCMs containing aluminates.
C04B 28/14 - 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 calcium sulfate cements
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
3.
PERFORMANCE-ENHANCING PARTICULATE PREMIX COMPRISED OF MINERAL FINES TREATED WITH ONE OR MORE ADDITIVES
Performance-enhancing particulate premixes contain mineral fines treated with one or more performance-enhancing additives. Also disclosed are methods of manufacturing performance-enhancing particulate premixes and cementitious compositions that incorporate such performance-enhancing particulate premixes, a hydraulic cement binder, and optionally one or more supplementary cementitious materials (SCMs). The cementitious compositions can be dry cementitious compositions, fresh cementitious compositions (e.g., mixed with water to form a shapable mix), and hardened cementitious compositions (e.g., that contained hydrated cement). The performance-enhancing particulate premix can be formulated and manufactured to offset an increase in water demand and increase flow when used to replace a portion of Portland cement in concrete. For example, mineral fines are treated to yield performance-enhancing particulate premixes comprising one or more types of mineral fines and one or more types of water reducers.
A method of manufacturing an activated pozzolan composition includes: (i) grinding a natural pozzolan, alone or with another mineral component that is not cement clinker, to form a finely ground pozzolan component having a first d90 in a range of about 10 μm to about 45 μm and a first d10 less than about 5 μm; and (ii) blending, without intergrinding, the finely ground pozzolan component with a coarse particulate mineral component comprised of coarse mineral particles not interground with the fine interground particulate component, the coarse particulate component having a second d90 greater than the first d90 and a second d10 greater than the first d10. The natural pozzolan can be one or more of natural pozzolanic deposits, volcanic ash, metakaolin, shale dust, calcined clay, trass, and pumice.
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
Cement-SCM blends employ particle packing principles to increase particle packing density and reduce interstitial spacing between the cement and SCM particles. Particle packing reduces the amount of water required to obtain a cement paste having a desired flow, lowers the water-cementitious material ratio (w/cm), and increases early and long-term strengths. This may be accomplished by providing a hydraulic cement fraction having a narrow PSD and at least one SCM fraction having a mean particle size that differs from the mean particle size of the narrow PSD cement by a multiple of 3.0 or more to yield a cement-SCM blend having a particle packing density of at least 57.0%.
C04B 7/26 - Cements from oil shales, residues or waste other than slag from raw materials containing flue dust
C04B 7/38 - Preparing or treating the raw materials individually or as batches
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
A non-conforming (or barely conforming) fly ash is converted into conforming (or better conforming) fly ash by: (1) obtaining an initial fly ash with at least one non-conforming (or barely conforming) characteristic selected from excess carbon content, low strength activity index, or low SAF as defined by ASTM C-618 and having a D10, D50 and D90; (2) classifying the initial fly ash using one or more air classifiers to produce at least two separate fly ash streams, including fine fly ash and coarse fly ash; (3) collecting the fine fly ash and the coarse fly ash, the fine fly ash having a D90 less than the D90 of the initial fly ash; (4) combining the fine fly ash with an aluminosilicate source to form a modified fly ash having a conforming carbon content, a conforming reactivity index, and a conforming SAF as defined by ASTM C-618.
C04B 22/14 - Acids or salts thereof containing sulfur in the anion, e.g. sulfides
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
Methods and systems for efficiently manufacturing particulate blending materials for use in making particle size optimized cements, SCMs, blended cements and cement-SCM blends. An initial hydraulic cement or SCM having an initial particle size distribution (PSD), an initial d10, and an initial d90 is processed using one or more air classifiers, and optionally one or more mills, to yield a plurality of hydraulic cement or SCM fractions having desired particle size distributions (PSDs). The hydraulic cement fractions can be blended with SCMs to form binary and ternary cement-SCM blends. The SCM fractions can also be used to make binary and ternary blends. A surplus fine cement fraction can be used to raise the fineness and/or reactivity of a less fine and/or less reactive hydraulic cement. A surplus fine SCM can be used as a silica fume substitute.
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
B02C 23/08 - Separating or sorting of material, associated with crushing or disintegrating
C04B 28/10 - Lime cements or magnesium oxide cements
C04B 28/18 - 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 mixtures of the silica-lime type
8.
Use of mineral fines to reduce clinker content of cementitious compositions
Cement compositions, namely, cement blends, being cement, and cementitious mixes, being cement mixes, that contain hydraulic cement, in particular Portland cement, and one or more supplementary materials, in particular man-made pozzolans, fly ash, metallurgical slag, ground glass, silica fume, calcined clay, shale dust, natural pozzolans, volcanic ash, pumice, trass, tuff, diatomaceous earth, metakaolin, and mineral fillers, in particular ground mineral powders, rock dust, stone dust, quarry fines, mine tailings, precipitated calcium carbonate, concrete mixer washout fines, and ground recycled concrete, the foregoing for use in concrete and concrete materials, in particular ready-mixed concrete, concrete premixes, mortar, concrete slabs, concrete walls, concrete pillars, precast concrete, sprayed concrete, grout, and stucco
10.
Cement-SCM compositions and methods and systems for their manufacture
Method of efficiently manufacturing cement-SCM compositions having improved strength compared to cement-SCM compositions made using conventional methods. The cement-SCM compositions may contain: (A) a fine interground particulate component with (1) a hydraulic cement fraction and (2) a supplementary cementitious material (SCM) fraction; (B) a coarse particulate component comprised of coarse SCM particles not interground with the fine interground particulate component; and optionally (C) an auxiliary particulate component not interground with the fine interground particulate component or the coarse particulate component. A method of manufacturing a cement-SCM composition may be performed by: (A) intergrinding hydraulic cement (e.g., cement clinker) with one or more SCMs to form a fine interground particulate component; (B) blending, without intergrinding, the fine interground particulate component with a coarse particulate component comprised of coarse SCM particles; and optionally (C) further combining, without intergrinding, an auxiliary particulate component with the fine interground particulate component and the coarse particulate component.
C04B 7/26 - Cements from oil shales, residues or waste other than slag from raw materials containing flue dust
C04B 7/28 - Cements from oil shales, residues or waste other than slag from combustion residues
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
A non-conforming fly ash is converted into conforming fly ash by: (1) obtaining an initial fly ash with at least one non-conforming characteristic selected from excess carbon or low reactivity index as defined by ASTM C-618 and having a D10, D50 and D90; (2) classifying the initial fly ash using one or more air classifiers to produce at least two separate fly ash streams, including fine fly ash and coarse fly ash; and (3) collecting the fine fly ash and the coarse fly ash, (4) the fine fly ash having a D90 approximately equal to or less than the D50 of the initial fly ash and a conforming carbon content and a conforming reactivity index as defined by ASTM C-618.
Mineral fines are used to reduce clinker content in concrete, mortar and other cementitious compositions, typically in combination with one or more pozzolanically active SCMs. Mineral fines can replace and/or augment a portion of hydraulic cement binder and/or fine aggregate. Mineral fines can advantageously replace a portion of cement binder and fine aggregate, acting as an intermediate that fills a particle size void between the largest cement particles and smallest fine aggregate particles. Supplemental lime can advantageously maintain or enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can advantageously address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticizers, and SCMs containing aluminates. Such systematic approach to beneficially using mineral fines, SCMs, lime, and sulfate addresses many issues and permits high clinker reduction with similar or increased strength.
C04B 28/16 - 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 calcium sulfate cements containing anhydrite
C04B 28/14 - 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 calcium sulfate cements
C04B 40/02 - Selection of the hardening environment
C04B 18/16 - Waste materialsRefuse from building or ceramic industry
C04B 111/00 - Function, property or use of the mortars, concrete or artificial stone
An activated pozzolan composition includes a fine interground particulate blend of an initially unactivated natural pozzolan and a supplementary cementitious material (SCM) different than the initially unactivated natural pozzolan. The initially unactivated natural pozzolan may include volcanic ash or other natural pozzolanic deposit having a moisture content of at least 3%, and the activated pozzolan composition can have a moisture content less than 0.5% The initially unactivated natural pozzolan may have a particle size less than 1 mm before intergrinding with the SCM. The SCM used to activate the initially unactivated natural pozzolan can be initially coarse or granular with a size greater than 1-3 µm and may include granulated blast furnace slag, steel slag, other metallurgical slag, pumice, limestone, fine aggregate, shale, tuff, trass, geologic material, waste glass, glass shards, basalt, sinters, ceramics, recycled bricks, recycled concrete, refractory materials, other waste industrial products, sand, or natural mineral.
C04B 18/14 - Waste materialsRefuse from metallurgical processes
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
An activated pozzolan composition includes a fine interground particulate blend of an initially unactivated natural pozzolan and a supplementary cementitious material (SCM) different than the initially unactivated natural pozzolan. The initially unactivated natural pozzolan may include volcanic ash or other natural pozzolanic deposit having a moisture content of at least 3%, and the activated pozzolan composition can have a moisture content less than 0.5% The initially unactivated natural pozzolan may have a particle size less than 1 mm before intergrinding with the SCM. The SCM used to activate the initially unactivated natural pozzolan can be initially coarse or granular with a size greater than 1-3 μm and may include granulated blast furnace slag, steel slag, other metallurgical slag, pumice, limestone, fine aggregate, shale, tuff, trass, geologic material, waste glass, glass shards, basalt, sinters, ceramics, recycled bricks, recycled concrete, refractory materials, other waste industrial products, sand, or natural mineral.
C04B 28/00 - 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
C04B 32/00 - Artificial stone not provided for in other groups of this subclass
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 18/06 - Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
15.
Cement-SCM compositions and methods and systems for their manufacture
Cement-SCM compositions have improved strength compared to cement-SCM compositions made using conventional blended cements and methods. The cement-SCM compositions may contain: (A) a fine interground particulate component with (1) a hydraulic cement fraction and (2) a supplementary cementitious material (SCM) fraction; (B) a coarse particulate component comprised of coarse SCM particles not interground with the fine interground particulate component; and optionally (C) an auxiliary particulate component not interground with the fine interground particulate component or the coarse particulate component. A method of manufacturing a cement-SCM composition may be performed by: (A) intergrinding hydraulic cement (e.g., cement clinker) with one or more SCMs to form a fine interground particulate component; (B) blending, without intergrinding, the fine interground particulate component with a coarse particulate component comprised of coarse SCM particles; and optionally (C) further combining, without intergrinding, an auxiliary particulate component with the fine interground particulate component and the coarse particulate component.
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 28/00 - 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
C04B 32/00 - Artificial stone not provided for in other groups of this subclass
An activated pozzolan composition includes a fine interground particulate blend of an initially unactivated natural pozzolan and a supplementary cementitious material (SCM) different than the initially unactivated natural pozzolan. The initially unactivated natural pozzolan may include volcanic ash or other natural pozzolanic deposit having a moisture content of at least 3%, and the activated pozzolan composition can have a moisture content less than 0.5% The initially unactivated natural pozzolan may have a particle size less than 1 mm before intergrinding with the SCM. The SCM used to activate the initially unactivated natural pozzolan can be initially coarse or granular with a size greater than 1-3 μm and may include granulated blast furnace slag, steel slag, other metallurgical slag, pumice, limestone, fine aggregate, shale, tuff, trass, geologic material, waste glass, glass shards, basalt, sinters, ceramics, recycled bricks, recycled concrete, refractory materials, other waste industrial products, sand, or natural mineral.
Quarry fines and/or limestone powder are used to reduce clinker content in concrete, mortar and other cementitious compositions, typically in combination with one or more pozzolanically active SCMs. Quarry fines and/or limestone powder can replace and/or augment a portion of hydraulic cement binder and/or fine aggregate. Quarry fines and/or limestone powder can advantageously replace a portion of cement binder and fine aggregate, acting as an intermediate that fills a particle size void between the largest cement particles and smallest fine aggregate particles. Supplemental lime can advantageously maintain or enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can advantageously address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticers, and SCMs containing aluminates. Such systematic approach to beneficially using quarry fines, limestone powder, SCMs, lime, and sulfate addresses many issues and permits high clinker reduction with similar or increased strength.
C04B 28/10 - Lime cements or magnesium oxide cements
C04B 28/16 - 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 calcium sulfate cements containing anhydrite
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
Quarry fines and/or limestone powder are used to reduce clinker content in concrete, mortar and other cementitious compositions, typically in combination with one or more pozzolanically active SCMs. Quarry fines and/or limestone powder can replace and/or augment a portion of hydraulic cement binder and/or fine aggregate. Quarry fines and/or limestone powder can advantageously replace a portion of cement binder and fine aggregate, acting as an intermediate that fills a particle size void between the largest cement particles and smallest fine aggregate particles. Supplemental lime can advantageously maintain or enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can advantageously address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticers, and SCMs containing aluminates. Such systematic approach to beneficially using quarry fines, limestone powder, SCMs, lime, and sulfate addresses many issues and permits high clinker reduction with similar or increased strength.
C04B 40/00 - Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
2/kg, D90 between about 11-50 μm, and total combined iron oxide, manganese oxide, and chromium oxide <1.0% by weight (ii) light color pozzolan such as white silica fume, and (iii) at least one light color particulate material, such as ground granulated blast furnace slag (GGBFS) having a fineness greater than that of the white Portland cement, a D90 less than that of the white Portland cement, and total combined iron oxide, manganese oxide, and chromium oxide content <3.0% by weight and/or coarse limestone powder having a D90 greater than that of the white cement. The cementitious composition may include one or more of aggregates, fibers, or admixture. The cementitious composition can be a dry blend, fresh cementitious mixture, or hardened cementitious composition. The cementitious composition can be precast concrete, stucco, GFRC, UHPC or SCC.
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
20.
PARTICLE SIZE OPTIMIZED WHITE CEMENTITIOUS COMPOSITIONS
A cementitious composition includes (i) white Portland cement having a Blaine fineness between about 350 m2/kg and about 550 m2/kg, a D90 between about 11 µm and about 50 µm, and a total combined iron oxide, manganese oxide, and chromium oxide content of less than 1.0% by weight and (ii) a light color ground granulated blast furnace slag (GGBFS) having a Blaine fineness greater than the Blaine fineness of the white Portland cement, a D90 less than the D90 of the white Portland cement, and a total combined iron oxide, manganese oxide, and chromium oxide content of less than 2.0% by weight. The cementitious composition may optionally include at least one of additional SCM, aggregate, fibers, or admixture. The cementitious composition can be a dry blend, a fresh cementitious mixture, or hardened cementitious composition. The cementitious composition can be precast concrete, stucco, GFRC, UHPC or SCC.
B28C 7/00 - Controlling the operation of apparatus for producing mixtures of clay or cement with other substancesSupplying or proportioning the ingredients for mixing clay or cement with other substancesDischarging the mixture
B28C 7/02 - Controlling the operation of the mixing
B28C 7/04 - Supplying or proportioning the ingredients
21.
USE OF QUARRY FINES AND/OR LIMESTONE POWDER TO REDUCE CLINKER CONTENT OF CEMENTITIOUS COMPOSITIONS
Quarry fines and/or limestone powder are used to reduce clinker content in concrete, mortar and other cementitious compositions, typically in combination with one or more pozzolanically active SCMs. Quarry fines and/or limestone powder can replace and/or augment a portion of hydraulic cement binder and/or fine aggregate. Quarry fines and/or limestone powder can advantageously replace a portion of cement binder and fine aggregate, acting as an intermediate that fills a particle size void between the largest cement particles and smallest fine aggregate particles. Supplemental lime can advantageously maintain or enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can advantageously address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticers, and SCMs containing aluminates. Such systematic approach to beneficially using quarry fines, limestone powder, SCMs, lime, and sulfate addresses many issues and permits high clinker reduction with similar or increased strength.
C04B 16/08 - Macromolecular compounds porous, e.g. expanded polystyrene beads
C04B 28/02 - 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
C08J 3/21 - Compounding polymers with additives, e.g. colouring in the presence of a liquid phase the polymer being premixed with a liquid phase
22.
Use of quarry fines and/or limestone powder to reduce clinker content of cementitious compositions
Quarry fines and/or limestone powder are used to reduce clinker content in concrete, mortar and other cementitious compositions, typically in combination with one or more pozzolanically active SCMs. Quarry fines and/or limestone powder can replace and/or augment a portion of hydraulic cement binder and/or fine aggregate. Quarry fines and/or limestone powder can advantageously replace a portion of cement binder and fine aggregate, acting as an intermediate that fills a particle size void between the largest cement particles and smallest fine aggregate particles. Supplemental lime can advantageously maintain or enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can advantageously address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticers, and SCMs containing aluminates. Such systematic approach to beneficially using quarry fines, limestone powder, SCMs, lime, and sulfate addresses many issues and permits high clinker reduction with similar or increased strength.
2/kg, a D90 between about 11 μm and about 50 μm, and a total combined iron oxide, manganese oxide, and chromium oxide content of less than 1.0% by weight and (ii) a light color ground granulated blast furnace slag (GGBFS) having a Blaine fineness greater than the Blaine fineness of the white Portland cement, a D90 less than the D90 of the white Portland cement, and a total combined iron oxide, manganese oxide, and chromium oxide content of less than 2.0% by weight. The cementitious composition may optionally include at least one of additional SCM, aggregate, fibers, or admixture. The cementitious composition can be a dry blend, a fresh cementitious mixture, or hardened cementitious composition. The cementitious composition can be precast concrete, stucco, GFRC, UHPC or SCC.
Methods for producing a blended pozzolan having one or more characteristics, such as one or more chemical and/or physical characteristic, in an established amount or range from two or more different pozzolans. Two or more pozzolans having different chemical and/or physical characteristics can be blended together and a chemical analyzer used to determine a chemical and/or physical characteristic of the blended pozzolan. Upon determining that the chemical and/or physical characteristic of the blended pozzolan is outside the established amount or range, modifying a blending ratio of the two or more pozzolans to restore the chemical and/or physical characteristic to the established amount or range.
3S content and narrow PSD provide desired reactivity and set time when combined with the one or more SCMs. The clinker fraction may be combined with one or more ultrafine SCM fractions and/or one or more coarser SCM fractions to achieve a desired wide particle size distribution. By engineering the chemistry and the particle size of the clinker fraction and the SCM fraction to work together, the engineered cements can have superior packing density, water demand, reactivity, set time, sulfate resistance, and strength development as compared to conventional OPC-SCM blends.
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
26.
Modification of pozzolanic chemistry through blending
The present disclosure relates to methods for controlling the chemical composition of a first pozzolan by blending it with a different pozzolan having a different chemical composition. The method includes intimately mixing the two pozzolans and using a chemical analyzer to determine a chemical characteristic of the pozzolan fraction being produced. The output from the chemical analyzer is then used to control the blending of the first and second outputs to maintain the chemical characteristic within a desired range.
G01N 31/00 - Investigating or analysing non-biological materials by the use of the chemical methods specified in the subgroupsApparatus specially adapted for such methods
G06F 19/00 - Digital computing or data processing equipment or methods, specially adapted for specific applications (specially adapted for specific functions G06F 17/00;data processing systems or methods specially adapted for administrative, commercial, financial, managerial, supervisory or forecasting purposes G06Q;healthcare informatics G16H)
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 18/06 - Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
Cement-SCM blends employ particle packing principles to increase particle packing density and reduce interstitial spacing between the cement and SCM particles. Particle packing reduces the amount of water required to obtain a cement paste having a desired flow, lowers the water-cementitious material ratio (w/cm), and increases early and long-term strengths. This may be accomplished by providing a hydraulic cement fraction having a narrow PSD and at least one SCM fraction having a mean particle size that differs from the mean particle size of the narrow PSD cement by a multiple of 3.0 or more to yield a cement-SCM blend having a particle packing density of at least 57.0%.
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 18/06 - Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
C04B 28/02 - 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
C04B 111/00 - Function, property or use of the mortars, concrete or artificial stone
Cement-SCM blends employ particle packing principles to increase particle packing density and reduce interstitial spacing between the cement and SCM particles. Particle packing reduces the amount of water required to obtain a cement paste having a desired flow, lowers the water-cementitious material ratio (w/cm), and increases early and long-term strengths. This may be accomplished by providing a hydraulic cement fraction having a narrow PSD and at least one SCM fraction having a mean particle size that differs from the mean particle size of the narrow PSD cement by a multiple of 3.0 or more to yield a cement-SCM blend having a particle packing density of at least 57.0%.
C04B 7/38 - Preparing or treating the raw materials individually or as batches
C04B 20/00 - Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups and characterised by shape or grain distributionTreatment of materials according to more than one of the groups specially adapted to enhance their filling properties in mortars, concrete or artificial stoneExpanding or defibrillating materials
4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 18/06 - Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
C04B 24/00 - Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
C04B 9/12 - Mixtures thereof with other inorganic cementitious materials with hydraulic cements, e.g. Portland cements
C04B 28/00 - 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
Cement-SCM blends employ particle packing principles to increase particle packing density and reduce interstitial spacing between the cement and SCM particles. Particle packing reduces the amount of water required to obtain a cement paste having a desired flow, lowers the water-cementitious material ratio (w/cm), and increases early and long-term strengths. This may be accomplished by providing a hydraulic cement fraction having a narrow PSD and at least one SCM fraction having a mean particle size that differs from the mean particle size of the narrow PSD cement by a multiple of 3.0 or more to yield a cement-SCM blend having a particle packing density of at least 57.0%.
C04B 28/02 - 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
Engineered cements are described that include an engineered clinker fraction designed for use with one or more supplementary cementitious material ("SCM") fractions. The engineered clinker fraction has a narrow particle size distribution ("PSD") with a relatively high tricalcium silicate ("C3S") content as compared to traditional ordinary Portland cement ("OPC"). The high C3S content and narrow PSD provide desired reactivity and set time when combined with the one or more SCMs. The clinker fraction may be combined with one or more ultrafme SCM fractions and/or one or more coarser SCM fractions to achieve a desired wide particle size distribution. By engineering the chemistry and the particle size of the clinker fraction and the SCM fraction to work together, the engineered cements can have superior packing density, water demand, reactivity, set time, sulfate resistance, and strength development as compared to conventional OPC-SCM blends.
4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 24/00 - Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
C04B 18/06 - Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
C04B 9/12 - Mixtures thereof with other inorganic cementitious materials with hydraulic cements, e.g. Portland cements
C04B 28/00 - 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
C04B 28/14 - 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 calcium sulfate cements
34.
Narrow PSD hydraulic cement, cement-SCM blends, and methods for making same
4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
C04B 14/00 - Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stoneTreatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
C04B 24/00 - Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
C04B 18/06 - Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
C04B 9/12 - Mixtures thereof with other inorganic cementitious materials with hydraulic cements, e.g. Portland cements
C04B 28/00 - 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
C04B 28/14 - 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 calcium sulfate cements
A high early strength blended cement composition includes larger sized fly ash and/or natural pozzolan particles blended with smaller sized hydraulic cement particles containing tricalcium silicate and/or dicalcium silicate (e.g., Portland cement and/or ground granulated blast furnace slag). Excess calcium released from the hydraulic cement particles when mixed with water forms calcium hydroxide available for reaction with the fly ash and/or natural pozzolan. The fineness of the hydraulic cement particles is substantially greater than the fineness of the fly ash and/or natural pozzolan particles (e.g., about 1.25 to about 50 times greater). Reducing or eliminating coarse hydraulic cement particles that cannot fully hydrate but include unreacted cores reduces or eliminates wasted cement normally found in concrete. Replacing some or all of the coarse cement particles with coarse pozzolan particles provides a blended cement composition having significantly lower water demand compared to the hydraulic cement fraction by itself.
Hydraulic cements, such as Portland cements and other cements that include substantial quantities of tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and/or tetracalcalcium alumino-ferrite (C4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
C04B 28/00 - 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
Modified pozzolans and methods for making modified pozzolans that have desired chemical characteristics. The desired chemical characteristics are achieved by introducing one or more supplementary materials into the production plant that produces the pozzolans (e.g., usually as a waste material such as fly ash or slag). The supplementary material is incorporated into the pozzolan during its formation in the production plant and becomes an integral chemical constituent of the pozzolan. By forming the pozzolan with the desired characteristics in the production plant, the pozzolan can have optimal performance when blended with Portland cement for use in concrete.
A high early strength pozzolan cement includes larger sized pozzolan particles blended with smaller sized hydraulic cement particles containing tricalcium silicate and/or dicalcium silicate (e.g., Portland cement). Excess calcium release from the hydraulic cement when mixed with water forms calcium hydroxide available for reaction with the pozzolan. The fineness of the hydraulic cement particles is substantially greater than the fineness of the pozzolan particles (e.g., about 1.25 to about 50 times greater). Reducing or eliminating coarse hydraulic cement particles that cannot fully hydrate but include unreacted cores reduces or eliminates wasted cement normally found in concrete. Replacing some or all of the coarse cement particles with pozzolan particles provides a pozzolan cement composition having significantly lower water demand compared to the hydraulic cement by itself.
A high early strength pozzolan cement includes larger sized pozzolan particles and smaller sized hydraulic cement particles which contain tricalcium silicate (e.g., Portland cement). Particles larger than 10 μm are predominantly (50%, 65%, 75%, 85% or 95%) pozzolan particles, and particles smaller than 10 μm are predominantly (50%, 65%, 75%, 85% or 95%) hydraulic cement particles. Excess calcium from the hydraulic cement forms calcium hydroxide available for reaction with the pozzolan particles, optionally in combination with supplemental lime. At least 30%, 40%, 45%, 55%, 65% or 75% of the pozzolan cement (combined pozzolan and hydraulic cement particles) consists of pozzolan, and less than 70%, 60%, 55%, 45%, 35% or 25% consists of hydraulic cement.
A high early strength pozzolan cement includes larger sized pozzolan particles and smaller sized hydraulic cement particles which contain tricalcium silicate (e.g., Portland cement). Particles larger than 10 μm are predominantly (50%, 65%, 75%, 85% or 95%) pozzolan particles, and particles smaller than 10 μm are predominantly (50%, 65%, 75%, 85% or 95%) hydraulic cement particles. Excess calcium from the hydraulic cement forms calcium hydroxide available for reaction with the pozzolan particles, optionally in combination with supplemental lime. At least 30%, 40%, 45%, 55%, 65% or 75% of the pozzolan cement (combined pozzolan and hydraulic cement particles) consists of pozzolan, and less than 70%, 60%, 55%, 45%, 35% or 25% consists of hydraulic cement.
C04B 28/24 - 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 alkyl ammonium or alkali metal silicatesCompositions 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 silica sols
Hydraulic cement compositions, namely, blended cements and other cement mixes that contain Portland cement and one or more pozzolans, such as a man-made pozzolan such as fly ash, slag, fumed silica or metakaolin, or a natural pozzolan such as volcanic ash, trass or diatomaceous earth, the foregoing for use in ready mix concrete
