NZ749524B2 - Lightweight concrete formulations - Google Patents
Lightweight concrete formulations Download PDFInfo
- Publication number
- NZ749524B2 NZ749524B2 NZ749524A NZ74952417A NZ749524B2 NZ 749524 B2 NZ749524 B2 NZ 749524B2 NZ 749524 A NZ749524 A NZ 749524A NZ 74952417 A NZ74952417 A NZ 74952417A NZ 749524 B2 NZ749524 B2 NZ 749524B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- formulation
- total weight
- grout
- concrete
- glass particles
- Prior art date
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 162
- 239000004567 concrete Substances 0.000 title claims abstract description 73
- 238000009472 formulation Methods 0.000 claims abstract description 109
- 239000011521 glass Substances 0.000 claims abstract description 92
- 239000011440 grout Substances 0.000 claims abstract description 78
- 239000002245 particle Substances 0.000 claims abstract description 67
- 239000011398 Portland cement Substances 0.000 claims abstract description 25
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 22
- 239000004576 sand Substances 0.000 claims description 26
- 239000004568 cement Substances 0.000 claims description 8
- 239000012615 aggregate Substances 0.000 abstract description 2
- 239000011378 shotcrete Substances 0.000 description 23
- 239000004570 mortar (masonry) Substances 0.000 description 5
- 238000007906 compression Methods 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000011324 bead Substances 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000003513 alkali Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000006011 modification reaction Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 239000006227 byproduct Substances 0.000 description 1
- 230000001413 cellular Effects 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 239000002734 clay mineral Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052622 kaolinite Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
Classifications
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/06—Quartz; Sand
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/10—Clay
- C04B14/106—Kaolin
-
- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/22—Glass ; Devitrified glass
- C04B14/24—Glass ; Devitrified glass porous, e.g. foamed glass
-
- 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
- C04B18/00—Use 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
- C04B18/02—Agglomerated materials, e.g. artificial aggregates
- C04B18/027—Lightweight materials
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/60—Agents for protection against chemical, physical or biological attack
- C04B2103/603—Agents for controlling alkali-aggregate reactions
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00146—Sprayable or pumpable mixtures
- C04B2111/00155—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/2023—Resistance against alkali-aggregate reaction
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/70—Grouts, e.g. injection mixtures for cables for prestressed concrete
-
- 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
- C04B28/04—Portland cements
Abstract
lightweight concrete formulation containing Portland cement, aggregate, glass particles, water and metakaolin. At least 80% of the glass particles have a grain size of less than 2 mm. The glass particles contribute between 3% and 20% of the total weight of the concrete formulation. The metakaolin contributes between 4% and 12% of the total weight of the concrete formulation. The glass particles are preferably expanded glass particles. Also provided is a lightweight grout formulation containing Portland cement, glass particles, water and metakaolin. At least 80% of the glass particles have a grain size of less than 2 mm. The glass particles contribute between 3% and 15% of the total weight of the grout formulation. The metakaolin contributes between 7% and 15% of the total weight of the grout formulation. contributes between 4% and 12% of the total weight of the concrete formulation. The glass particles are preferably expanded glass particles. Also provided is a lightweight grout formulation containing Portland cement, glass particles, water and metakaolin. At least 80% of the glass particles have a grain size of less than 2 mm. The glass particles contribute between 3% and 15% of the total weight of the grout formulation. The metakaolin contributes between 7% and 15% of the total weight of the grout formulation.
Description
EIGHT CONCRETE FORMULATIONS
FIELD OF THE INVENTION
The present invention relates generally to concrete formulations, and more
particularly to lightweight concrete formulations containing glass.
OUND OF THE INVENTION
People have tried for several decades to use glass as a component of
concrete. However, no such formulations have found significant commercial
success even though many ations of components in various proportions
have been made and tested. One issue is that the Alkali Silica Reaction (ASR)
causes concrete containing glass to deteriorate over time unless le
measures are taken to reduce the effect of ASR. While many such measures
have been proposed, formulations that are ASR—resistant while still ing
high compressive strength have not been disclosed or commercially exploited.
SUMMARY OF THE INVENTION
The invention provides a lightweight concrete formulation containing
Portland cement, aggregate, glass particles, water and metakaolin. At least 80%
of the glass particles preferably have a grain size of less than 2 mm. The glass
particles contribute between 3% and 20% of the total weight of the concrete
formulation. The metakaolin contributes between 4% and 12% of the total weight
of the concrete formulation. The glass les are preferably ed glass
particles.
Preferably at least 80% of the glass particles have a grain size of 1 mm or
less. More preferably, at least 80% of the glass particles have a grain size of 0.5
mm Or less. At least 80% of the glass particles may have a grain size of 0.25 mm
or greater.
The glass particles contribute n 6% and 15% of the total weight of
the concrete formulation. The glass particles may contribute at least 12% of the
total weight of the te formulation.
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The metakaolin may contribute between 6% and 12% of the total weight of
the concrete formulation, or preferably between 8% and 10% of the total weight
of the concrete ation.
The glass particles may contribute between 12% and 15% of the total
weight of the te formulation.
The Portland cement may contribute between 30% and 38% of the total
weight of the concrete formulation, where the aggregate contributes between
16% and 24% of the total weight of the te formulation, and the olin
contributes between 6% and 12% of the total weight of the concrete formulation.
The Portland cement may contribute between 32% and 36% of the total
weight of the concrete formulation, where the aggregate contributes n
19% and 23% of the total weight of the concrete ation, and the metakaolin
contributes between 8% and 10% of the total weight of the concrete formulation.
The concrete formulation may also include sand. The Portland cement
may contribute between 20% and 35% of the total weight of the te
formulation where the aggregate contributes between 16% and 24% of the total
weight of the concrete formulation, the sand contributes n 22% and 32%
of the total weight of the concrete formulation, the glass particles contribute
between 3% and 9% of the total weight of the concrete formulation, and the
metakaolin contributes between 5% and 11% of the total weight of the concrete
ation. The Portland cement may contribute between 21% and 25% of the
total weight of the concrete formulation where the aggregate contributes between
18% and 22% of the total weight of the concrete formulation, the sand
contributes between 25% and 29% of the total weight of the concrete formulation,
the glass particles contribute between 5% and 7% of the total weight of the
te formulation, and the metakaolin contributes between 6% and 8% of the
total weight of the concrete formulation.
The metakaolin is preferably Metapor®.
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The invention also provides a lightweight grout formulation containing
Portland cement, glass particles, water and metakaolin. At least 80% of the glass
les preferably have a grain size of less than 2 mm. The glass particles
bute between 3% and 15% of the total weight of the grout formulation. The
metakaolin contributes between 6% and 15% of the total weight of the grout
formulation. The glass particles are preferably expanded glass particles.
Preferably at least 80% of the glass particles have a grain size of 1 mm or less.
More preferably, at least 80% of the glass particles have a grain size of 0.5 mm
or less. At least 80% of the glass particles may have a grain size of 0.25 mm or
greater.
The glass particles may contribute between 6% and 15% of the total
weight of the grout formulation. The glass particles may contribute n 8%
and 13% of the total weight of the grout formulation.
The metakaolin may contribute between 8% and 13% of the total weight of
the grout formulation.
The glass particles may contribute between 8.5% and 10.5% of the total
weight of the grout formulation.
The Portland cement may contribute between 44% and 52% of the total
weight of the grout ation, and the metakaolin may contribute between 8%
and 13% of the total weight of the grout formulation.
The Portland cement may bute between 45.5% and 49.5% of the
total weight of the89rout formulation, and the metakaolin may bute between
9.5% and 11.5% of the tota1 weight of the grout formulation.
The grout formulation may also include sand. The Portland cement may
contribute between 32% and 37% of the total weight of the grout formulation, the
sand may contribute between 20% and 28% of the total weight of the grout
formulation, the glass particles may contribute between 3% and 9% of the total
weight of the grout formulation, and the olin may contribute between 8%
and 14% of the total weight of the grout formulation. The Portland cement may
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contribute between 33.5% and 35.5% of the total weight of the grout formulation,
the sand may contribute between 22% and 24% of the total weight of the grout
formulation, the glass particles may contribute between 5% and 7% of the total
weight of the grout formulation, and the olin may contribute between 9%
and 11% of the total weight of the grout formulation.
In the grout formulations the metakaolin is preferably Metapor®.
ED DESCRIPTION OF THE INVENTION
The invention provides formulations, or mixes, of shotcrete and grout that
provide excellent compressive strength and ASR resistance.
A preferred mix design for a conventional form of concrete for use as
ete is shown below. The amounts shown are designed to produce a cubic
metre of shotcrete.
Component Weight %
Portland 19.4%
cement
Aggregate
Sand
Water
Total
In preferred lightweight shotcrete mixes, some or all of the sand may be
replaced with glass. For example, in one mix, half of the sand (631.5 kg) in the
above standard mix may be replaced by 158 kg of glass. The preferred form of
glass is expanded glass particles having grain sizes less than 4 mm (ASTM
C135 mesh no. 5 or less), preferably less than 2 mm (ASTM C135 mesh no. 10
or less) or 1 mm (ASTM C135 mesh no. 18 or less) and most preferably less
than 0.5 mm (ASTM C135 mesh no. 35 or less) or less than 0.3 mm (ASTM
C135 mesh no. 50 or less). Such glass les may be made from recycled
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glass that is finely ground, mixed and formed to granules, which are sintered and
expanded in a rotary kiln. This process creates lightweight s with a fine
closed cellular pore structure. A preferred product is Poraver® expanded glass
beads with grain sizes from 0.04 mm to 4 mm. The preferred Poraver t
has a grain size of 025—05 mm, mesh no. 60-35 and a fineness modulus of
about 1.92. Alternatively, a Poraver product having a grain size or 3 mm,
mesh no. 140-50 and a fineness modulus of about 0.66 may be used. These
products have 10% or less ze particles and l5% or less undersize particles.
Generally herein when referring to a maximum le grain size, it is meant that
at least 80% of the particles do not have a larger grain size and preferably at
least 90% of the particles do not have a larger grain size. Most ably 100%
of the particles do not have a larger grain size.
The use of such fine expanded glass particles reduces ASR so that ASR-
related damage is less likely to occur.
In preferred mixes, a strengthening/hardening and stabilizing agent is also
added. The preferred agent is metakaolin, a dehydroxylated form of the clay
mineral kaolinite. Metakaolin further reduces the deterioration of concrete by
ASR. Metakaolin is a pozzolan. Testing has shown that the use of olin
provides better s than other pozzolans that have been tried. Metakaolin is
added to contribute about 4% to 15% of the weight of a mix, or more preferably
4% to 12%, 6% to 10% or 8% to 12%. A preferred form of metakaolin is
Metapor®, which is metakaolin with small amounts of fine expanded glass
produced by Poraver as a byproduct of the production of expanded glass beads.
As such, Metapor is relatively inexpensive.
Two preferred shotcrete mixes are shown below.
Component ‘ Shotcrete Mix 1 ‘ Shotcrete Mix 2
Weight Weight °/o Weight Weight %
(k9) (k9)
Portland cement 10.5 35.1% 8.75 27.0%
Aggregate 5.6 18.7% 5.5 16.9%
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Sand 0 0 8.0 24.7%
‘ Glass 4.0 13.4% 2.0 6.2%
Water 7.4 24.7% 6.0 18.5%
_l_____
r 2.4 8.0% 6.8%
Total 29.9 100% 32.45 100%
A mix similar to Shotcrete Mix 1 was tested for compressive strength
starting on May 5, 2016 according to the standard CSA A23.2-3C and -9C. Six
cylinders were formed with an e density of 1561 kg/m3 with a standard
deviation of 6.7 kg/m3. The ete temperature was 18°C and the air
temperature was 15 °C. The initial 24 hour curing temperature was between 20°C
and 25°C. The compressive strength was measured as 21.6 MPa (2 days), 23.2
MPa (5 days), and 23.3 MPa (7 days).
Shotcrete Mix 2 was tested for compressive th starting on May 5,
2016 according to the standard CSA A23.2-3C and —9C. Six cylinders were
formed with an average density of 1913 kg/m3 with a standard deviation of 7.0
kg/m3. The shotcrete temperature was 165°C and the air temperature was 15°C.
The initial 24 hour curing temperature was n 20°C and 25°C. The
compressive strength was measured as 24.8 MPa (2 days), 26.3 MPa (5 days),
and 28.4 MPa (7 days).
Experimentation and testing has shown that Shotcrete Mix 1 and
Shotcrete Mix 2 produce concrete with high compressive strength relative to
other concrete formulations containing glass, and it is believed that the
formulation using ASR-resistant expanded glass in ation with metakaolin,
preferably in the form of Metapor®, in the tions disclosed herein will
reduce or prevent ASR-related damage. Several other mixes using different
amounts of glass particles and Metapor and other components were made and
tested. In several cases where 50% of the sand was replaced by glass, as in
Shotcrete Mix 2, such other mixes produced concrete with compression
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strengths below 20 MPa. When using no sand, as in Shotcrete Mix 1, some such
other mixes produced concrete with compression ths below 10 MPa.
Two additional preferred shotcrete mixes are shown below.
ent Shotcrete Mix 3 Shotcrete Mix 4
Weight Weight Weight
W680 33.6% 464W
cement
Aggregate 420 20.8% 420 20.3%
Sand
Glass 270 13.4%
Water 461 22.8% 326.5 15.8%
Metapor 190 9.4% 170 8.2%
Total 2021 2068
J __J
Weights and weight percentages of glass as used herein are for dry glass.
The glass does in fact absorb some of the water. For example, in shotcrete mix
3, about 100 kg of the water is typically absorbed by the glass. in general, in all
mixes discussed herein, the amount of water required will vary based on various
factors, such as the nment (e.g. the relative humidity) and the water
content of the sand in mixes employing sand.
Shotcrete Mix 3 was tested for compressive strength starting on
December 14, 2016 by exp Services Inc. of Brampton, Ontario, Canada. The
shotcrete temperature was 16°C and the air ature was -2°C with a relative
humidity of 8.5%. 101.5 mm diameter cylinders were tested. The following results
were measured.
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Duration Mass F
(days) (kg/m3) (MPa)
ti:::_ 1662 “TTTZT7T
1 1656‘ 233
3 1644‘ 278
3 1662 278
7 1644 375
____l
7 28A
7 370
28 1650 325
‘28 1662‘ 301
Shotcrete Mix 4 was tested for compressive strength starting on February
16, 2017 by exp Services Inc. of Brampton, Ontario, Canada. The shotcrete
temperature was 21 .5°C and the air temperature was 20°C with a relative
humidity of 8.0%. 101.5 mm diameter ers were tested. The ing results
were measured.
Duration Mass Strength
(daYS)
In general, a water/cement ratio of 0.35 to 0.45 is preferred. The
water/cement ratio is calculated as the amount of water, excluding the water
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absorbed by the glass, divided by the sum of the amount of Portland and
metapor. So for Shotcrete Mix 3, for example, the water cement ratio is 0.41.
A preferred mix design for a conventional form of grout is shown below.
The amounts shown are designed to produce a cubic metre of grout.
Component Weight Weight °/o
(k9)
Portland
In preferred lightweight grout mixes, some or all of the sand may be
replaced with glass. For example, in one mix, half of the sand (586 kg) in the
above rd mix may be replaced by 146.5 kg of glass. The preferred form of
glass is ed glass particles having grain sizes as described above with
respect to shotcrete.
in preferred mixes, metakaolin, a strengthening/hardening and izing
agent as discussed above, is also added. Metakaolin is added to contribute
about 7% to 15% of the weight of a mix, or more preferably 9% to 13%, or most
preferably about 10% to 12%.
Two examples of preferred grout mixes are shown below.
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Component Grout Mix 1 Grout Mix 2
Weight Weight % Weight %
“(9)
Portland cement _T 12.3 51.7% 35_50%
Sand 61—“—
Water 6.5 27.3% 55 23.80%
r 2.5 10.5% 25 10.80%
Total 23.8 100%
Grout Mix 1 was tested for compressive strength starting on May 5, 2016
according to the standard CSA A23.2-3C and -9C. Six cubes were formed with
an average density of 1595 kg/m3 with a standard deviation of 33.9 kg/m3. The
grout temperature was 22°C and the air temperature was 14°C. The initial 24
hour curing temperature was between 18°C and 20°C. The compressive
strengths measured were 25.0 MPa (2 days), 39.1 MPa (5 days), and 45.2 MPa
(7 days).
Grout Mix 2 was tested for compressive strength ng on May 5, 2016
according to the standard CSA A23.2-3C and —90. Six cubes were formed with
an average density of 1735 kg/m3 with a standard deviation of 40.9 kg/m3. The
grout temperature was 19°C and the air temperature was 14°C. The initial 24
hour curing ature was between 18°C and 20°C. The compressive
strengths measured were 28.2 MPa (2 days), 45.9 MPa (5 days), 48.8 MPa (7
days) and 49.2 MPa (7 days).
Experimentation and testing has shown that Grout Mix 1 and Grout Mix 2
produce concrete with high compressive strength relative to other concrete
formulations containing glass, and it is believed that the formulation using ASR-
resistant ed glass in combination with metakaolin, preferably in the form
of Metapor®, will reduce or prevent lated damage. Several other mixes
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using different amounts of glass particles and Metapor and other components
were made and tested. In several cases where 50% of the sand was ed by
glass, as in Grout Mix 2, such other mixes ed grout with compression
strengths below 30 MPa. When using no sand, as in Grout Mix 1, some such
other mixes produced concrete with compression strengths below 30 MPa, with
some even below 10 MPa.
Two additional examples of preferred grout mixes are shown below.
Component Grout Mix Grout Mix
3 4
Weight °/o Weight "/0
Portland cement
Sand
Grout Mix 3 was tested for compressive strength starting on March 15,
2017 by exp Services Inc. of Brampton, Ontario, Canada. The grout temperature
was 204°C and the air temperature was 209°C. 50 mm cubes were tested. The
following s were measured.
ation] jvs
None set by jvs
[Annotation] jvs
MigrationNone set by jvs
[Annotation] jvs
Unmarked set by jvs
Duration Grout Mix 3
(daVSl Strength
(MPa)
27.6
24.4
.6
46.2
7 50.8
7 50.0
Grout Mix 4 was tested for compressive strength ng on March 15,
2017 by exp es lnc. of Brampton, Ontario, Canada. The grout temperature
was 201°C and the air temperature was 21 .2°C. 50 mm cubes were tested. The
following results were measured.
Duration Grout Mix
(days) 4
Strength
(MPa)
2 20.6
2 23.3
2 22.3
7 43.0
7 43.9
7 44.8
Linear shrinkage tests were also performed by exp Services Inc. of
Brampton, Ontario, Canada. The mix had a slump of 180 mm, air content of 8.4%
and concrete temperature of 207°C. The test mix employed 13.6 kg of cement,
3.8 kg of metapor, 5.4 kg of glass, and 7.2 kg of water. Three prisms were tested
with the following results.
[Annotation] jvs
None set by jvs
[Annotation] jvs
MigrationNone set by jvs
[Annotation] jvs
Unmarked set by jvs
Prism 7day dry
shrinkage dry
shrinkage shrinkage shrinkage
0.010% 0.009% 0.022% 0.033%
B ] 0.010% 0.008% 0.022% ] 0.032%
c 0.010% 0.008% 0.021% [ 0.032%
Mean 0.010% 0.008% 0.022% 0.032%
As would be evident to skilled persons, the shrinkage results would have
been even better if the al had a maximum of a 100 mm slump. Anything
under 0.040% is ered to be acceptable.
An accelerated mortar bar expansion test was performed on three mortar
bars (also referred to as prisms) using test method LS-620 or CSA A23.2—25A,
with 80°C NaOH curing. The accelerated mortar bar expansion test provides a
measure of the resistance of the material to damage due to the Alkali Silica
Reaction (ASR). The mortar bars were formed incorporating metapor and
Poraver ed glass beads with grain size of 025-05 mm, mesh no. 60—35
and a fineness modulus of about 1.92. The following average expansions were
measured: 0.009% (3 days), 0.012% (7 days), 0.020% (10 days) and 0.038% (14
days). This compares favorably with the maximum allowable limit of 0.150%. In
contrast, a mortar bar of reference al was also tested and an expansion of
0.429% was measured, which was tent with expectations for the reference
material.
In addition a cylinder was cut, prepared and tested according to ASTM
designation C1202 “Electrical Indication of Concrete’s Ability to Resist Chloride
Ion Penetration”. The results showed 1765 Coulombs of charged passed in a
test on day 8, and 694 Coulombs of charged passed in a test on day 28.
Anything under about 2500 Coulombs at day 28 is considered acceptable.
in this document, nces to “mix”, lation” and “composition”
mean the same thing, and refer to a ular mixture of component ingredients.
D 13
[Annotation] jvs
None set by jvs
[Annotation] jvs
MigrationNone set by jvs
[Annotation] jvs
Unmarked set by jvs
The abbreviation mm as used herein refers to millimetres (or in the US,
“millimeters”). The abbreviation m as used herein refers to metres (or in the US,
s”). The abbreviation kg as used herein refers to kilograms. The
abbreviation MPa as used herein refers to megapascals.
It should be understood that the above-described ments of the
present invention, particularly, any “preferred” embodiments, are only examples
of implementations, merely set forth for a clear understanding of the principles of
the invention. Many variations and modifications may be made to the above-
described embodiment(s) of the invention as will be evident to those skilled in the
art. That is, persons skilled in the art will appreciate and understand that such
modifications and ions are, or will be, possible to utilize and carry out the
teachings of the invention described herein.
Where, in this nt, a list of one or more items is prefaced by the
expression “such as" or “including”, is followed by the abbreviation “etc”, or is
prefaced or followed by the expression “for example”, or “e.g.”, this is done to
expressly convey and emphasize that the list is not exhaustive, irrespective of
the length of the list. The absence of such an expression, or another similar
expression, is in no way ed to imply that a list is tive. Unless
otherwise expressly stated or clearly implied, such lists shall be read to include
all comparable or equivalent variations of the listed item(s), and alternatives to
the item(s), in the list that a skilled person would understand would be le
for the purpose that the one or more items are listed.
The words “comprises” and “comprising”, when used in this specification
and the claims, are used to specify the presence of stated es, ts,
integers, steps or components, and do not preclude, nor imply the necessity for,
the presence or on of one or more other features, elements, integers, steps,
components or groups thereof.
The scope of the claims that follow is not limited by the ments set
forth in the description. The claims should be given the broadest purposive
construction consistent with the description and figures as a whole.
D 14
Claims (20)
1. A concrete formulation comprising Portland cement, aggregate, expanded glass particles, water and metakaolin, wherein at least 80% of the expanded glass particles have a grain size of less than 2 mm, the expanded glass particles contribute between 3% and 20% of the total weight of the concrete formulation, and the metakaolin contributes n 7% and 15% of the total weight of the concrete formulation, and wherein the compressive strength of the concrete formulation is at least 24 MPa after curing.
2. The concrete formulation of claim 1, wherein at least 80% of the expanded glass particles have a grain size of between 0.25 mm and 0.5 mm.
3. The concrete formulation of claim 1, wherein the expanded glass particles contribute between 6% and 15% of the total weight of the concrete formulation.
4. The concrete formulation of claim 1, wherein the expanded glass particles contribute at least 12% of the total weight of the concrete ation.
5. The te formulation of claim 1, n the metakaolin contributes between 8% and 12% of the total weight of the concrete ation.
6. The te formulation of claim 1, n the expanded glass particles contribute between 12% and 15% of the total weight of the concrete formulation.
7. The concrete formulation of claim 1, wherein the Portland cement contributes between 30% and 38% of the total weight of the concrete formulation, the aggregate contributes between 16% and 24% of the total weight of the concrete formulation, and the metakaolin butes between 7% and 12% of the total weight of the concrete formulation.
8. The concrete formulation of claim 1, wherein the Portland cement contributes between 32% and 36% of the total weight of the concrete formulation, the aggregate contributes between 19% and 23% of the total weight of the concrete formulation, and the metakaolin contributes between 8% and 10% of the total weight of the concrete formulation.
9. A te formulation comprising Portland cement, aggregate, expanded glass particles, sand, water and metakaolin, wherein at least 80% of the ed glass particles have a grain size of less than 2 mm, the expanded glass particles contribute between 3% and 20% of the total weight of the concrete ation, and the metakaolin contributes between 5% and 15% of the total weight of the concrete formulation, and wherein the compressive strength of the concrete formulation is at least 24 MPa after curing.
10. The concrete formulation of claim 9, wherein the nd cement contributes between 20% and 35% of the total weight of the concrete formulation, the aggregate contributes between 16% and 24% of the total weight of the concrete formulation, the sand butes between 22% and 32% of the total weight of the concrete formulation, the expanded glass particles contribute between 3% and 9% of the total weight of the concrete formulation, and the metakaolin contributes between 5% and 11% of the total weight of the te formulation.
11. The te formulation of claim 10, wherein the Portland cement butes between 21% and 25% of the total weight of the concrete ation, the aggregate contributes between 18% and 22% of the total weight of the concrete formulation, the sand contributes between 25% and 29% of the total weight of the concrete formulation, the expanded glass particles contribute between 5% and 7% of the total weight of the concrete formulation, and the metakaolin contributes between 6% and 8% of the total weight of the concrete formulation.
12. A grout formulation comprising Portland cement, expanded glass particles, water and metakaolin, wherein at least 80% of the expanded glass particles have a grain size of less than 2 mm, the expanded glass particles contribute n 3% and 15% of the total weight of the grout formulation, and the metakaolin contributes between 5% and 15% of the total weight of the grout ation, and wherein the compressive strength of the grout formulation is at least 24 MPa after curing.
13. The grout formulation of claim 12, wherein at least 80% of the expanded glass particles have a grain size of between 0.25 mm and 0.5 mm.
14. The grout formulation of claim 12, wherein the expanded glass particles bute between 8% and 13% of the total weight of the grout formulation.
15. The grout formulation of claim 12, wherein the metakaolin contributes between 8% and 11% of the total weight of the grout ation.
16. The grout formulation of claim 12, wherein the expanded glass particles contribute between 8.5% and 10.5% of the total weight of the grout formulation.
17. The grout formulation of claim 12, n the Portland cement contributes between 44% and 52% of the total weight of the grout formulation, and the metakaolin contributes n 8% and 13% of the total weight of the grout formulation.
18. The grout ation of claim 12, wherein the Portland cement contributes between 45.5% and 49.5% of the total weight of the grout formulation, and the metakaolin contributes between 9.5% and 11.5% of the total weight of the grout formulation.
19. The grout formulation of claim 12 further comprising sand, wherein the nd cement contributes between 32% and 37% of the total weight of the grout formulation, the sand contributes between 20% and 28% of the total weight of the grout formulation, the expanded glass particles contribute n 3% and 9% of the total weight of the grout formulation, and the metakaolin contributes between 8% and 14% of the total weight of the grout formulation.
20. The grout ation of claim 12, wherein the Portland cement contributes between 33.5% and 35.5% of the total weight of the grout formulation, the sand contributes between 22% and 24% of the total weight of the grout formulation, the expanded glass particles contribute between 5% and 7% of the total weight of the grout formulation, and the metakaolin contributes between 9% and 11% of the total weight of the grout formulation.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201662340801P | 2016-05-24 | 2016-05-24 | |
US62/340,801 | 2016-05-24 | ||
PCT/CA2017/000130 WO2017201607A1 (en) | 2016-05-24 | 2017-05-23 | Lightweight concrete formulations |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ749524A NZ749524A (en) | 2020-09-25 |
NZ749524B2 true NZ749524B2 (en) | 2021-01-06 |
Family
ID=
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