GB2375347A - Stabilisation of clay materials; forming aggregate - Google Patents

Stabilisation of clay materials; forming aggregate Download PDF

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Publication number
GB2375347A
GB2375347A GB0111245A GB0111245A GB2375347A GB 2375347 A GB2375347 A GB 2375347A GB 0111245 A GB0111245 A GB 0111245A GB 0111245 A GB0111245 A GB 0111245A GB 2375347 A GB2375347 A GB 2375347A
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GB
United Kingdom
Prior art keywords
additive
clay material
portland cement
clay
aggregate
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.)
Granted
Application number
GB0111245A
Other versions
GB2375347B (en
GB0111245D0 (en
Inventor
Howard Lloyd Robinson
Nizar Ghazireh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tarmac Ltd
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Tarmac Ltd
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Filing date
Publication date
Application filed by Tarmac Ltd filed Critical Tarmac Ltd
Priority to GB0111245A priority Critical patent/GB2375347B/en
Publication of GB0111245D0 publication Critical patent/GB0111245D0/en
Publication of GB2375347A publication Critical patent/GB2375347A/en
Application granted granted Critical
Publication of GB2375347B publication Critical patent/GB2375347B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02Agglomerated materials, e.g. artificial aggregates
    • C04B18/021Agglomerated materials, e.g. artificial aggregates agglomerated by a mineral binder, e.g. cement
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Abstract

A method of treating a clay material to form a material usable as an aggregate comprises bringing the clay material to a condition receptive to the introduction and mixing of at least one binding additive; adding said additive and mixing it with the clay material; creating a paste of the clay material and additive(s); compacting the mixture and curing it. Additives include granulated blast furnace slag, basic oxygen steel slag, and Ordinary Portland Cement. Pulverised fuel ash and a blend of calcium oxide and gypsum may also be included. The treatment of the clay material prior to addition of the binding additive may comprise a) forming an aqueous slurry of the material and deflocculating the slurry of b) drying the clay material by heating it, or by addition of a dehydrating agent e.g. quicklime, hydrated lime or other lime based material. The paste may be roll pressed, pelletised or sheeted.

Description

<Desc/Clms Page number 1>
Title: Stabilisation of Clay Materials Description of Invention This invention relates to the stabilisation of cohesive and in particular clay-type materials in order to form a material usable as an aggregate.
When we refer herein to clay materials, we mean to include a broad range of materials, from the type of material characteristically produced by excavation in trenching activities ("utility arising"), to low grade products and waste generated by quarrying operations, known as"overburden clays"or "scalping".
The invention enables the formation from such clay materials of relatively low strength aggregates, suitable for use in a wide range of applications ranging from a non-subsiding backfill for trenches, as capping or sub-base material, to the manufacture of concrete blocks.
According to the present invention, we provide a method of treating a clay material to provide a material usable as an aggregate, comprising: bringing the clay material to a condition receptive to the introduction and mixing of at least one binding additive; adding said at least one additive and mixing it with the clay material; creating a paste of the clay material and mixed additive (s); compacting the mixture and allowing curing thereof.
The additive (s) may include granulated blast furnace slag, basic oxygen steel slag fines, and Portland Cement. Preferably all the above mentioned additives are included, in quantities described hereafter together with other additives as described.
The step of bringing the clay material to a condition in which it is receptive to the introduction of additives and for thorough mixing to be
<Desc/Clms Page number 2>
achieved may be carried out, in accordance with the invention, in either a"wet" process or a"dry"process. The former process includes the addition of water to the clay material thereby converting it into a slurry, prior to the addition of additives to deflocculate, stabilise, then dehydrate the material.
The"dry"method, also described in greater detail hereafter, includes the pre-blending of the clay material with lime, a lime-rich, or a highly alkaline, material in order to dehydrate and pelletise the clay, then crushing and screening the resultant material to produce a material of a suitable particle size prior to introduction of the additives at a controlled moisture content.
Whichever method is used, the mixed material may then be allowed to cure (harden) by storing it for, e. g. up to ninety days, in stockpiles, prior to final crushing and screening to produce a material usable as an aggregate.
As an alternative to stockpiling for curing, followed by crushing and screening, the paste of the clay and additives when used in the wet method may be agglomerated by roll pressing or ring die pelletisation, to produce a rounded aggregate material which can then be left to cure, preferably sheeted.
Now to describe the"wet"process above referred to in greater detail, the initial step is to mix the clay material into a smooth sluny or paste with the addition of water. The amount of water required to be added will be determined by the type of clay material involved and the conditions, i. e. its mineralogical, physical and chemical properties. By way of example, the amount of water required to be added could range from 15% (for a very wet clay material) to 45% (for a dry clay material). A deflocculant preferably the substance provided by Ciba Chemicals and known as"N40 Deflocculant" is added to the water prior to mixing, at typically 0. ] % of the weight of the clay material. Continuous mixing is then carried out until a smooth paste or slurry is obtained.
<Desc/Clms Page number 3>
When the clay material is well mixed and behaving in a fluid manner, additive materials can then be introduced in the following order (the percentages quoted are relative to the weight of the initial clay material): 1. Granulated blast furnace slag (5/0mm) in the range 10%-15% preferably 15%.
2. Basic oxygen steel slag, fines (3/0 mm) in the range 5-10%.
3. Portland Cement (42.5N, 52.5N, or 62.5N) in the range 3%-10%, preferably 8%.
Additions of granulated blast furnace slag and basic oxygen slag can be made either dry or with the material as usually supplied, i. e. with a moisture content. Addition of Portland Cement should be made based on the moisture content of the clay material after the addition of the granulated blast furnace slag and basic oxygen slag. If the mixture is still behaving in a fluid manner, with a moisture content of around 35% or greater, further Portland Cement may be added to dehydrate the material. This will also result in the production of a stronger final aggregate.
However, if the behaviour of the material is more like that of a sticky solid mass, additions of a thick paste of Portland Cement and water may be made to avoid excessive dehydration of the material into a form which would be difficult to blend into a smooth and consistent product.
The times required for mixing in the above-described process will vary in accordance with the type of mixer which is being used. A mixer utilising rotating blades is considered to be the preferred type to be used. The method depends on a certain degree of visual assessment during initial work. After mixing Portland Cement into the material, no longer than thirty minutes should be spent achieving a final mixture, while all other mixing times can be established in the course of mixing, depending on assessment of the behaviour of the material and the consistency of the mix which is being produced.
<Desc/Clms Page number 4>
Now to describe the above-refen'ed-to"dry"process in greater detail, the clay forming the starting material for this process is required to be, in essence, dry. To enable the clay material to be mixed efficiently it should be crushed to a particle size of less than 5mm, and it can be dried either physically by water evaporation in a heating apparatus or chemically by use of a dehydrating agent such as quick lime, hydrated lime, or any lime based material. Once dehydrated to a low moisture content, the clay material should then be crushed, using a ball or hammer mill, vertical impact crusher, or other suitable crusher.
The required additives can then be added dry to the mix. They can either be pre-blended and added as a total percentage of the weight of the clay present, or individually as respective percentages of the total clay weight. Two groups of binder additives are proposed, the first group being as follows: 1. Granulated blast furnace slag 10%-20%, preferably 15%.
2. Basic oxygen slag 5%-10%, preferably 5%.
P 3. Portland Cement (42. 5N, 52. 5N, 62. 5N) 5%-10%, preferably 8%. oi 4."Magnafloc" (a flocculating chemical supplied by Ciba Speciality Chemicals) 0. 1% preferably.
The second group of additives is as follows :- 1. Granulated blast furnace slag 10%-20%, preferably 10%.
2. Portland Cement (42.5N, 52.5N, 62.5N) 5%-10%, preferably 5%.
3. Pulverised fuel ash 10%-15%, preferably 10%.
4. CaO/Gypsum (a blend of 80% quick lime and 20% gypsum) (CaSO. 4. 2H20) 1%-2%, preferably 1.5%.
5. Magnafloc 0. 1% preferably.
Once the additives constituting either group as set forth above have been weighed into the prepared clay material, the dry blend must be mixed thoroughly to circulate the ingredients and produce a uniform mix. Thereafter water can be added, to produce a mixture ideally containing of the order of
<Desc/Clms Page number 5>
3%-5% water in excess of the optimum moisture content for the mixed material. This may be approximately 20%-25% total moisture content.
Mixing times will depend, as for the"wet"process first described above, on the type of mixer being used and the behaviour of the material which is being mixed. Blending the initial diy mix together can be achieved with a simple drum mixer, however the achievement of a good final product after water addition requires a more severe mixing action, preferably that provided by a"cement mixer"type of mixer, utilising rotating blades. When water is being added to the mixture of dry materials, absorption thereof takes more time so additions of water should be made gradually and around twenty minutes should be allowed for the moisture content of the material to reach equilibrium.
As above referred to, after the paste of the clay material mixed with the binding additives has been produced by either of the processes described above, agglomeration of the paste to produce usable aggregates may be achieved by methods such as roll pressing or ring die pelletisation. Either methods produce sound rounded aggregates, which when produced should be left to cure.
Preferably the aggregate is left sheeted during curing. The curing time is determined by the final strength of the aggregate required : longer curing times produce stronger aggregates. Climatic conditions during external storage will influence the rate of strength development, i. e. cold will delay the strength gain.
An alternative method of producing non-rounded aggregates from the clay paste, at reduced cost could comprise discharging the paste onto the ground and compacting it in layers using a steel-wheeled roller, after which it is sheeted and allowed to cure. Following the curing period, the material is dug out of the ground, crushed and screened to the required aggregate sizes. Fines generated by the crushing operation can be recycled back into the mixing process.
Aggregate obtained by the above methods may have its strength increased by coating with one or more of the following materials, namely quick
<Desc/Clms Page number 6>
lime (CaO), hydrated lime (CaOH2), pulverised fuel ash activated with cement, lime, lime based material, or Portland Cement. Efficient coating of the aggregate with such materials may be achieved by soaking the clay aggregates in water for twenty-four hours, then mixing with the any of the required coating materials. Thereafter the aggregates may be sheeted or bagged and left to cure for at least fourteen days.
In the present specification"comprise"means"includes or consists of and"comprising"means"including or consisting of.
The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims (31)

  1. CLAIMS 1. A method of treating a clay material to form a material usable as an aggregate, comprising : bringing the clay material to a condition receptive to the introduction and mixing of at least one binding additive; adding said at least one additive and mixing it with the clay material; creating a paste of the clay material and mixed additive (s); compacting the mixture and allowing curing thereof.
  2. 2. A method according to Claim I wherein said additive comprises granulated blast furnace slag, basic oxygen steel slag, and Portland Cement.
  3. 3. A method according to Claim 2 wherein said additive comprises 25%-30% by weight of the clay material.
  4. 4. A method according to Claim 1 wherein said additive comprises 0 granulated blast furnace slag, Portland Cement, pulverised fuel ash, and a blend zn of calcium oxide and gypsum.
  5. 5. A method according to Claim 4 wherein said additive comprises 25%-30% by weight of the clay material.
  6. 6. A method according to Claim 2 or Claim 3 wherein said additive comprises granulated blast furnace slag 10%-15%, basic oxygen steel slag 5%- 10% and Portland Cement 3%-10%.
    <Desc/Clms Page number 8>
  7. 7. A method according to Claim 6 wherein said additive comprises granulated blast furnace slag 10%-20%, basic oxygen steel slag 5%-10%, Portland Cement 3%-10%.
  8. 8. A method according to Claim 4 wherein said additive comprises granulated blast furnace slag 10%-20%, Portland Cement 5%-10%, pulverised fuel ash 10%-15%, and calcium oxide and gypsum (comprising 80% calcium oxide and 20% gypsum) 1%-2%.
  9. 9. A method according to Claim 8 wherein said additive comprises granulated blast furnace slag 10%, Portland Cement 5%, pulverised fuel ash 10%, and calcium oxide and gypsum 1.5%.
  10. 10. A method according to Claim 2 or any claim appendant thereto wherein said clay material is brought to a condition suitable for the introduction of additives by forming it into a slurry with water.
  11. 11. A method according to Claim 10 further comprising the addition of a deflocculant additive to the slurry.
  12. 12. A method according to Claim 11 wherein said deflocculant additive ZD comprises"N40 deflocculant".
  13. 13. A method according to any one of Claims 10 to 12 wherein said additive is introduced in the order firstly the granulated blast furnace slag, secondly the basic oxygen steel slag, and thirdly Portland Cement.
  14. 14. A method according to Claim 13 wherein the Portland Cement is added ZD dry or mixed with water, according to the water content of the mixture.
    <Desc/Clms Page number 9>
  15. 15. A method according to any one of Claims 2,3, 6,7, or Claim 4 or any claim appendant thereto, wherein said bringing of the clay material to a condition receptive to the introduction of said additive (s) comprises dehydration of the clay material.
  16. 16. A method according to Claim 15 wherein said dehydration is effected by evaporation of moisture or by use of a dehydrating agent.
  17. 17. A method according to Claim 15 or Claim 16 further comprising crushing the clay material to reduce its particle size.
  18. 18. A method according to Claim 17 wherein the clay material is crushed to a particle size of less than 5mm.
  19. 19. A method according to any one of Claims 15 to 18 wherein said additive is added dry to the mix and thoroughly mixed therewith.
  20. 20. A method according to Claim 19 further comprising the addition of a flocculating additive.
  21. 21. A method according to Claim 19 further comprising the addition of a defloculating additive.
  22. 22. A method according to Claim 19,20 or 21 comprising subsequent addition of water to the mixed clay material and additive, and subsequent mixing to produce said paste.
    <Desc/Clms Page number 10>
  23. 23. A method according to any one of the preceding claims wherein said paste is processed by roll pressing or ring die pelletisation to produce aggregate material for curing.
  24. 24. A method according to any one of Claims 1 to 22 wherein said paste is discharged and compacted by rolling after which it is allowed to cure.
  25. 25. A method according to Claim 23 or Claim 24 wherein the compacted paste is sheeted during curing.
  26. 26. A method according to Claim 24 or Claim 25 wherein, following curing, the aggregate material is dug from the ground, crushed and screened to the required aggregate particle size.
  27. 27. A method according to any one of Claims 23 to 26 further comprising coating the aggregate material with one or more further materials to increase the strength of the aggregate.
  28. 28. A method according to Claim 27 wherein said coating material C > comprises one or more of: quick lime, hydrated lime, pulverised fuel ash activated with cement, a lime based material, Portland Cement.
  29. 29. A method according to Claim 27 or Claim 28 wherein said coating is effected by soaking the aggregate material in water, mixing with the required
    coating material (s), and storage for curing.
    ZD 29. A method of treating a clay material, substantially as hereinbefore described.
    <Desc/Clms Page number 11>
  30. 30. An aggregate material, made by a method according to any one of the preceding claims.
  31. 31. Any novel feature or novel combination of features described herein and/or in the accompanying drawings.
GB0111245A 2001-05-09 2001-05-09 Stabilisation of clay materials Expired - Fee Related GB2375347B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0111245A GB2375347B (en) 2001-05-09 2001-05-09 Stabilisation of clay materials

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0111245A GB2375347B (en) 2001-05-09 2001-05-09 Stabilisation of clay materials

Publications (3)

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GB0111245D0 GB0111245D0 (en) 2001-06-27
GB2375347A true GB2375347A (en) 2002-11-13
GB2375347B GB2375347B (en) 2005-05-11

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004106250A1 (en) * 2003-06-02 2004-12-09 Anton Francois De Jager A composition for the preparation of a vitrified product
CN103864326A (en) * 2014-01-27 2014-06-18 济南大学 Steel slag aggregate and preparation method thereof
GB2513417A (en) * 2013-04-26 2014-10-29 Univ Coventry Composition

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4490178A (en) * 1980-04-17 1984-12-25 Aarding Weerstandlas B.V. Granulated material
GB2218412A (en) * 1988-05-13 1989-11-15 Philip Leonard Owens Lightweight aggregates
GB2273095A (en) * 1992-12-04 1994-06-08 Gareth Anthony Owens Lightweight aggregates made with pulverised-fuel ash
GB2292940A (en) * 1994-09-10 1996-03-13 Gareth Anthony Owens Lightweight aggregate

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4490178A (en) * 1980-04-17 1984-12-25 Aarding Weerstandlas B.V. Granulated material
GB2218412A (en) * 1988-05-13 1989-11-15 Philip Leonard Owens Lightweight aggregates
GB2273095A (en) * 1992-12-04 1994-06-08 Gareth Anthony Owens Lightweight aggregates made with pulverised-fuel ash
GB2292940A (en) * 1994-09-10 1996-03-13 Gareth Anthony Owens Lightweight aggregate

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004106250A1 (en) * 2003-06-02 2004-12-09 Anton Francois De Jager A composition for the preparation of a vitrified product
GB2513417A (en) * 2013-04-26 2014-10-29 Univ Coventry Composition
GB2513417B (en) * 2013-04-26 2015-04-29 Univ Coventry A cementitious mix formed from industrial waste materials
US10227257B2 (en) 2013-04-26 2019-03-12 Coventry University Cement binder
CN103864326A (en) * 2014-01-27 2014-06-18 济南大学 Steel slag aggregate and preparation method thereof
CN103864326B (en) * 2014-01-27 2015-12-02 济南大学 A kind of slag aggregate processing method

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Publication number Publication date
GB2375347B (en) 2005-05-11
GB0111245D0 (en) 2001-06-27

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Effective date: 20110509