WO2008128287A1 - Composition liante - Google Patents

Composition liante Download PDF

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Publication number
WO2008128287A1
WO2008128287A1 PCT/AU2008/000548 AU2008000548W WO2008128287A1 WO 2008128287 A1 WO2008128287 A1 WO 2008128287A1 AU 2008000548 W AU2008000548 W AU 2008000548W WO 2008128287 A1 WO2008128287 A1 WO 2008128287A1
Authority
WO
WIPO (PCT)
Prior art keywords
hydroxide
binding composition
composition according
weight
concrete
Prior art date
Application number
PCT/AU2008/000548
Other languages
English (en)
Inventor
Jean Desfosses
Original Assignee
Descrete Ip Pty Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from AU2007902102A external-priority patent/AU2007902102A0/en
Application filed by Descrete Ip Pty Limited filed Critical Descrete Ip Pty Limited
Publication of WO2008128287A1 publication Critical patent/WO2008128287A1/fr

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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
    • 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
    • C04B28/24—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 metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • 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
    • C04B28/006—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 mineral polymers, e.g. geopolymers of the Davidovits type
    • 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
    • C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
    • C04B2111/1037—Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention relates to binding compositions and to compositions and methods for making concrete.
  • a cement is a binder which is capable of uniting fragments or masses of solid matter to a compact whole .
  • cements are produced from compounds of lime and clay. Such cements are typically sold as dry compositions. In use, the cement is mixed with water, and then cured. During curing, the cement sets and hardens.
  • cements are used for various purposes including for the formation of mortar, grout, render and concrete.
  • a common use of cement is for the formation of concrete.
  • Concrete comprises aggregates bound together by cement. Concrete is typically made by mixing cement, aggregate and water, which then solidifies to create a stone-like material. Concrete is used to form products such as pavements, footings, structural elements and blocks for building purposes.
  • Portland cement The most commonly used cement for forming concrete for building and structural purposes is Portland cement.
  • a major disadvantage of Portland cement is the significant adverse environmental effects associated with the production of Portland cement.
  • One of these adverse environmental effects is the large quantities of carbon dioxide produced during the production of Portland cement, including from the calcining of limestone during the production process as well as from the fuel used during the production process.
  • Concretes made from Portland cement typically have a density of 2200 kg/m 3 to 2500 kg/m 3 . While the construction industry has adapted to the use of high density concrete, there are many applications where the completed structure as well as the building process would benefit from a lower density concrete.
  • Lightweight concretes are typically considered to be those concretes which have a density below 2100 kg/m 3 .
  • Various processes have been proposed for producing lightweight concretes. Some methods used to make lightweight concrete are : a) no- fines concrete in which only coarse aggregates are used in the production of the concrete; b) the use of lightweight aggregate such as pumice, scoria or foamed or water cooled slag; and c) the production of an aerated cement paste, either using chemical processes to aerate the cement or by foaming the cement paste.
  • Structural lightweight concrete typically has densities in the range of 1300 kg/m 3 to 2000 kg/m 3 .
  • a disadvantage of many conventional structural lightweight concretes is their moderate to low strength.
  • Prior art lightweight concrete having a density greater than 800 kg/m 3 typically has moderate strength, while only low strengths are typically achieved with concrete having a density below 800 kg/m 3 .
  • the present invention provides a binding composition
  • a binding composition comprising: a) pozzolanic material; and b) an aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide .
  • the present invention provides a method for forming a binding composition
  • a method for forming a binding composition comprising mixing: a) pozzolanic material; and b) an aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide.
  • the method further comprising adding additional water.
  • the binding composition comprises 70 to 95% by weight pozzolanic material .
  • the pozzolanic material is selected from fly ash, amorphas silica, metakalin and slag.
  • the pozzolanic material comprises a mixture of slag and fly ash. In some embodiments where the pozzolanic material comprises a mixture of slag and fly ash, at least a portion of the slag is milled to between about 2 and about 75 ⁇ m.
  • the binding composition comprises 5 to 15% by weight of the one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide.
  • the binding composition further comprises carbon, for example, carbon black.
  • the binding composition further comprises liquid silicate.
  • the liquid silicate may be any liquid silicate.
  • a liquid silicate is an aqueous solution of an alkali silicate.
  • the liquid silicate is an aqueous solution of sodium silicate, or an aqueous solution of potassium silicate, or a mixture thereof.
  • the binding composition comprises less than 3% by weight silicate (that is, the percentage by weight of silicate in the total composition is less than 3%) . In some embodiments, the binding composition comprises less than 0.2% by weight silicate.
  • the binding composition comprises 0.5 to 5% by weight calcium carbonate.
  • the binding composition is substantially free of Portland cement .
  • the binding composition of the present invention is cured by allowing the binding composition to stand at ambient temperatures, e.g. 15 to 30 °C, for a sufficient period of time for the binding composition to set and harden. In some embodiments, the binding composition is cured at above ambient temperatures. In some embodiments, the binding composition is exposed to an atmosphere containing elevated levels of CO 2 or an atmosphere containing steam during the curing of the binding composition.
  • the present invention provides a composition for making concrete, comprising: a) pozzolanic material; b) an aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide; and c) aggregate.
  • composition of the third aspect of the present invention comprises a binding composition of the first - S -
  • composition for making concrete comprising pozzolanic material, an aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide, and aggregate (i.e. the composition of the third aspect of the present invention) is referred to below as the "concrete composition of the present invention” .
  • the present invention provides a method for making concrete, comprising mixing: a) pozzolanic material; b) an aqueous solution of one or more of hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide; and c) aggregate, to form a composition according to the third aspect of the present invention, shaping the composition, and curing the composition to make concrete.
  • the present invention provides a product formed using the binding composition of the first aspect of the present invention or the composition of the third aspect of the present invention.
  • the present invention provides concrete made by the method of the fourth aspect of the present invention.
  • the present invention provides a kit for forming a binding composition, the kit comprising in separate containers : a) pozzolanic material; and b) an aqueous solution of one or more of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide.
  • the kit further comprises one or more agents selected from liquid silicates, carbon, calcium
  • kits further comprises written instructions to mix the pozzolanic material and the aqueous solution of one or more of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide, to form a binding composition.
  • the present invention provides a kit for forming a binding composition, the kit comprising in separate containers : a) pozzolanic material; and b) sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide, or a mixture of two or more of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide.
  • the kit further comprises one or more agents selected from liquid silicates, carbon, calcium carbonate, water reducing agents, polysaccaride, agents capable of reacting with excess hydroxide, and water retention agents.
  • the kit further comprises written instructions to add water to the sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide, or the mixture of two or more of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide, and to mix the resultant aqueous solution with the pozzolanic material to form a binding composition.
  • the binding composition of the present invention comprises : a) pozzolanic material; and b) an aqueous solution of one or more hydroxides selected from the group consisting of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide.
  • the pozzolanic material may be any pozzolanic material .
  • Pozzolanic materials are natural or artificial materials in finely divided form which react, in the presence of water, with calcium hydroxide to set and harden. Pozzolanic materials are sometimes used with Portland cement in the preparation of concrete to increase the long term strength and improve other physical properties of the concrete. Pozzolanic materials are primarily silicate materials which react with calcium hydroxide to form calcium silicates.
  • the pozzolanic material may be a natural material, such as pozzolanic ash, or an artificially produced material .
  • pozzolanic materials include fly ash from coal fired power plants, amorphous silica, metakaolin and slag, such as ground granulated blast furnace slag.
  • Pozzolanic materials include silica fume from silicon and ferrosilicon production and rice husk ash.
  • the binding composition of the present invention a mixture of pozzolanic materials is typically used.
  • the binding composition comprises a mixture of slag and fly ash.
  • the slag and fly ash may, for example, be present in a ratio by weight of slag to fly ash of from about 1.6:1 to 4:1. In some embodiments, the slag and fly ash are in a weight ratio of about 3+10%: 1.
  • the pozzolanic material is, or includes, slag
  • at least some of the slag is milled.
  • the slag may be milled to a particle size of between about 2 and about 75 ⁇ m. In some embodiments, the slag is milled to between 2 and 20 ⁇ m.
  • the milled slag may, for example, constitute 5 to 20% by weight of the total amount of slag in the binding composition.
  • the inventor has found that the inclusion of milled slag in the binding composition can influence the rate of high early strength and final strength of concrete formed using the binding composition. Accordingly, by adjusting the proportion of milled slag in the binding composition it is possible to influence the early and final strength of concrete formed using the binding composition.
  • the pozzolanic material constitutes 70 to 95% by weight of the binding composition. In some embodiments, the pozzolanic material constitutes 70 to 90% by weight of the binding composition.
  • the binding composition of the present invention comprises :
  • an aqueous solution comprising two or more of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide .
  • the binding composition comprises an aqueous solution of sodium hydroxide or potassium hydroxide, or a mixture thereof.
  • the binding composition comprises an aqueous solution of one or more of sodium hydroxide, potassium hydroxide or ammonium hydroxide.
  • the binding composition comprises an aqueous solution of one or more of sodium hydroxide, potassium hydroxide or magnesium hydroxide.
  • the binding composition comprises an aqueous solution of one or more of ammonium hydroxide, magnesium hydroxide or aluminium hydroxide.
  • the aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide is sometimes referred to below as "the hydroxide solution” .
  • the hydroxide solution may be prepared by adding water to sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide or a mixture of two or more of sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide or aluminium hydroxide .
  • the hydroxide solution may, for example, be included in the binding composition in an amount of from 5 to 25% by volume of the binding composition. Additional water may subsequently be added to the binding composition to form a workable paste or slurry.
  • the hydroxide solution has a pH less than 10, a greater volume of the hydroxide solution is typically included in the binding composition to provide an equivalent total amount of hydroxide ions in the binding composition.
  • the binding composition comprises 5 to 15% by weight of the one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide. In some embodiments, the binding composition comprises 10.1 to 15% by weight of the one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide.
  • the binding composition further comprises liquid silicate.
  • the liquid silicate may be any liquid silicate.
  • a liquid silicate is an aqueous solution of an alkali silicate.
  • the liquid silicate is an aqueous solution of sodium silicate, or an aqueous solution of potassium silicate, or a mixture thereof.
  • the liquid silicate has a silicate concentration of about 34 to 38% by weight.
  • the liquid silicate is included in the binding composition in an amount such that the binding composition comprises less than 3% by weight silicate (that is, the percentage by weight of silicate in the total composition is less than 3%) . In some embodiments, the binding composition comprises less than 0.2% by weight silicate. In some embodiments, the binding composition comprises less than 0.1% by weight silicate. In some embodiments, the binding composition comprises 0.01 to 0.1, 0.01 to 0.2, 0.01 to 2.5, 0.1 to 2.0, 0.1 to 1.5, 0.1 to 1.0 or 0.2 to 1.0% by weight silicate.
  • the inventor has found that the inclusion of a liquid silicate in the binding composition can influence the rate at which the binding composition sets and hardens. Accordingly, by adjusting the proportion of the liquid silicate in the binding composition it is possible to control the setting time of the binding composition.
  • the binding composition comprises : a) 70 to 95% by weight pozzolanic material; b) 5 to 15% by weight of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide, in the form of an aqueous solution of the one or more hydroxides; and c) 0.01 to 3% by weight silicate in the form of a liquid silicate.
  • Hydroxide solutions are corrosive.
  • hydroxide solutions are easier to handle when they contain calcium lignosulphonate, polysaccharide or metakalin, or a mixture of two or more of calcium lignosulphonate, polysaccharide and metakalin.
  • the hydroxide solution contains calcium lignosulphonate, polysaccharide, or metakalin, or a mixture of two or more of calcium lignosulphonate, polysaccharide and metakalin.
  • the binding composition of the present invention may be used to bind aggregate together to form concrete.
  • the binding composition further comprises calcium carbonate.
  • the calcium carbonate is typically included in the binding composition in an amount of about 0.5 to 5% by weight of the binding composition, for example 0.5 to 4%, 1 to 4%, 0.5 to 3% or 0.5 to 2% by weight of the binding composition.
  • the binding composition is free, or substantially free, of calcium carbonate.
  • the binding composition comprises less than 5% by weight, less than 0.5% by weight or less than 0.1% by weight, calcium carbonate.
  • the binding composition may, in some embodiments, further include an agent which is capable of reacting with any excess hydroxide to reduce the efflorescence of hydroxide salts from any concrete products formed using the binding composition.
  • agents include refined clays such as calcined kaolin, for example metakalin.
  • the binding composition typically includes a water reducing agent .
  • Suitable water reducing agents include plasticisers and superplasticisers .
  • the water reducing agent may be a sulphonated melamine condensate, naphthalene formaldehyde condensate, or modified polycarboxylic ether polymer.
  • Suitable water reducing agents include lignosulphonates (e.g. calcium lignosulphonate) , polycarboxolate plasticisers and modified naphthalene sulphonates.
  • the water reducing agent may be added to the binding composition as a separate component or may be included in the pozzolanic material, liquid silicate or hydroxide solution mixed to form the binding composition.
  • the binding composition sets more quickly and forms a stronger material if some carbon is included in the binding composition or is present on the surface of the product to be bound by the binding composition, for example, on aggregate which is to be used in making concrete.
  • the binding composition comprises carbon.
  • the carbon is in the form of carbon black, soot or graphite.
  • the binding composition is free or substantially free of Portland cement.
  • the binding composition further includes a water retention agent such as a methyl cellulose.
  • the water retention agent acts to retain water in the binding composition, minimising water "bleeding" from the binding composition.
  • the binding composition consists essentially of : a) pozzolanic material; b) an aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide; and c) optionally one or more agents selected from liquid silicates, carbon, calcium carbonate, water reducing agents, polysaccaride, agents capable of reacting with excess hydroxide, and water retention agents .
  • the binding composition of the present invention can be prepared by mixing together the components of the binding composition.
  • the components may be mixed in any order.
  • the binding composition is prepared shortly before use.
  • the binding composition of the present invention is suitable for binding aggregate together to make concrete.
  • lightweight aggregates the inventor has found that the binding composition of the present invention can be used to form lightweight concrete products that have strength suitable for many building applications. Accordingly, the present invention allows for the formation of concrete building materials, such as masonry blocks, having strength similar to conventional concrete building materials, but which are relatively lightweight.
  • the concrete is prepared by mixing pozzolanic material, an aqueous solution of one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide, and aggregate to form the concrete composition of the present invention, shaping the concrete composition and curing the concrete composition.
  • the concrete composition of the present invention comprises a mixture of a binding composition of the first aspect of the present invention and aggregate.
  • the concrete composition of the present invention may be prepared by mixing a binding composition of the first aspect of the present invention with the aggregate.
  • the various constituents of a binding composition of the first aspect of the present invention and the aggregate may be mixed in any order to form a mixture of a binding composition of the first aspect of the present invention and aggregate.
  • the concrete composition of the present invention comprises : a) a binding composition comprising:
  • the binding composition comprises 70 to 95% by weight pozzolanic material.
  • the pozzolanic material is selected from fly ash, amorphous silica, metakalin and slag. In some embodiments, the pozzolanic material comprises a mixture of slag and fly ash.
  • the binding composition comprises 5 to 15% by weight of the one or more hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide.
  • the binding composition further comprises carbon, for example, carbon black.
  • the binding composition further comprises liquid silicate. In some embodiments, the binding composition comprises less than 3% by weight silicate. In some embodiments, the binding composition comprises less than 0.2% by weight silicate.
  • the binding composition comprises 0.5 to 5% by weight calcium carbonate.
  • the binding composition is substantially free of Portland cement.
  • the concrete composition of the present invention comprises: a) a binding composition consisting essentially of: (i) pozzolanic material;
  • hydroxides selected from sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium hydroxide and aluminium hydroxide
  • agents selected from liquid silicates, carbon, calcium carbonate, water reducing agents, polysaccaride, agents capable of reacting with excess hydroxide, and water retention agents and b) aggregate.
  • the concrete composition of the present invention is cured by allowing the concrete composition to stand at ambient temperatures for a sufficient period of time for the concrete composition to set and harden. In some embodiments, the concrete composition of the present invention is exposed to an atmosphere containing elevated CO 2 levels to accelerate curing. In some embodiments, the concrete composition of the present invention is heated to above ambient temperatures. In some embodiments, the concrete composition of the present invention is steam cured, that is, the concrete composition is exposed to an atmosphere containing steam.
  • the concrete composition of the present invention is compacted, for example using conventional concrete vibration processes, prior to curing .
  • the aggregate may be any aggregate.
  • the aggregate is typically an inorganic aggregate.
  • the aggregate may, for example, be sand, gravel, crushed stone, slag or recycled crushed concrete.
  • the aggregate is a lightweight aggregate.
  • the lightweight aggregate may be a naturally occurring material such as pumice or may be manufactured lightweight aggregate such as scoria, bottom ash expanded clay or foamed or water cooled slag.
  • the sizing of the aggregate can be used to improve the lightweight properties of the concrete.
  • a suitable aggregate sizing is a mix of about 0 to 30% by weight of 0 to 1 mm aggregate and 70 to 100% by weight of 1 to 4 mm aggregate.
  • the aggregate comprises a mix of about 20 to 30% by weight of 0 to 1 mm aggregate and 70 to 80% by weight of 1 to 4 mm aggregate, e.g. 26% by weight of 0 to 1 mm aggregate and 74% by weight of 1 to 4 mm aggregate .
  • the binding composition and the aggregate are in a weight ratio of dry weight of binding composition (i.e. excluding water from the weight of the binding composition) : fine aggregate (less than 1 mm) : coarse aggregate (1 mm to 4 mm) of 1:0.5:1.5 to 1:1.5:4.5
  • fine aggregate course aggregate
  • the weight ratio of dry weight of the binding composition to total weight of aggregate is typically about 1:2 to 1:9.
  • composition of the third aspect of the present invention is free or substantially free of Portland cement .
  • composition of the third aspect of the present invention may be used to form concrete for similar purposes to conventional concrete.
  • the concrete formed using the binding composition of the present invention has a density lower than 2000 kg/m 3 . In some embodiments, the density is less than about 1850 kg/m 3 . In some embodiments, the density is between about 800 to about 1850 kg/m 3 .
  • the inventor has found that using the binding composition of the present invention, it is possible to prepare lightweight concrete having strength similar to concrete prepared using Portland cement. For example, using bottom ash as the aggregate (with a bulk density of 1850 kg/m 3 ) mixed with a binding composition of the present invention in a ratio of 2.6:1 by weight (aggregate to dry weight of binding composition) , hollow concrete masonry units such as 2091/units having a density of 1550 kg/m 3 and a strength of 18MPa after 28 days can be prepared.
  • Hollow masonry units were prepared by mixing together the components A, B, C, D and E as described below. The resultant mixture was then shaped into blocks and the blocks cured. All the percentages referred to below in relation to the components A, B, C, D and E are percentages by volume.
  • the aggregate used was Bayswater bottom ash produced by the Bayswater power station.
  • the bulk density of the aggregate was 1850 kg/m 2 .
  • the slag, fly ash, calcium carbonate, carbon and water reducing agent (methyl cellulose) were added together and mixed until a consistent blend was achieved.
  • the water was added to the sodium hydroxide and allowed to cool to room temperature.
  • the resultant solution was then added to the metakalin, calcium lignosulphonate, polysaccharide and carbon and mixed using a high speed mixer until a consistent blend was achieved (3 minutes) .
  • the components A, B, C, D and E were added in the proportions indicated above to a concrete mixer and mixed until a consistent blend was achieved (approximately 5 minutes) .
  • the components were added to the mix in the order: A, B, C, D and E.
  • the resultant mixture was shaped into 200 mm hollow concrete masonry units, and air cured at ambient temperatures .
  • the units were tested for compressive strength at days 3, 7, 14, 31 and 60 in accordance with Australian Standard AS 4456.4. The units were also tested for potential to effloresce in accordance with Australian Standard AS 4456.6. The units were also tested for water absorption properties in accordance with Australian Standard AS 4456.14. The results of these tests are shown in Table 1.
  • results are generally consistent with the performance of a conventional pressed hollow concrete masonry unit made using Portland cement.
  • a binding composition was prepared by mixing together the components B, D and E as described below. All the percentages referred to below in relation to the components B, D and E are percentages by volume.
  • fly ash The fly ash, slag, calcium carbonate, water reducing agent (methyl cellulose) and carbon were added together and mixed until a consistent blend was achieved.
  • the water was added to the sodium hydroxide and allowed to cool to room temperature.
  • the resultant solution was then added to the calcium lignosulphonate and polysaccharide and mixed using a high speed mixer until a consistent blend was achieved (3 minutes) .
  • the resultant mixture was vibrated into a 50 mm cube mould until self levelled. Specimens were moist cured in lime- saturated water.
  • a binding composition was prepared by mixing together the components B, D and E as described below. All the percentages referred to below in relation to the components B, D and E are percentages by volume.
  • fly ash, slag, calcium carbonate, methocel and carbon were added together and mixed until a consistent blend was achieved.
  • the water was added to the magnesium hydroxide and allowed to cool to room temperature.
  • the resultant solution was then added to the calcium lignosulphonate and polysaccharide and mixed using a high speed mixer until a consistent blend was achieved (3 minutes) .
  • the resultant mixture was vibrated into a 50mm cube mould until self levelled. Specimens were moist cured in lime- saturated water.
  • the same process can be carried out replacing the magnesium hydroxide with potassium hydroxide, ammonium hydroxide or aluminium hydroxide .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
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  • Environmental & Geological Engineering (AREA)
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  • Geochemistry & Mineralogy (AREA)
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  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention porte sur une composition liante comprenant une matière pouzzolanique et une solution aqueuse d'un ou plusieurs parmi l'hydroxyde de sodium, l'hydroxyde de potassium, l'hydroxyde d'ammonium, l'hydroxyde de magnésium et l'hydroxyde d'aluminium. La composition liante peut être utilisée pour lier des agrégats afin de coffrer du béton. L'invention porte également sur des compositions et des procédés de coffrage de béton.
PCT/AU2008/000548 2007-04-20 2008-04-18 Composition liante WO2008128287A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2007902102 2007-04-20
AU2007902102A AU2007902102A0 (en) 2007-04-20 Lightweight concrete

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WO2008128287A1 true WO2008128287A1 (fr) 2008-10-30

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Cited By (9)

* Cited by examiner, † Cited by third party
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US20110287198A1 (en) * 2009-01-30 2011-11-24 Industry Foundation Of Chonnam National University Alkali-activated binder, alkali-activated mortar, concrete products and wet red clay paving material using binder
CN105153352A (zh) * 2015-08-09 2015-12-16 深圳市嘉达高科产业发展有限公司 无机改性丙烯酸树脂及其制备方法、水泥预制构件
CN105669055A (zh) * 2016-01-31 2016-06-15 西安建筑科技大学 电导率可调控碱激发钢渣基半导体胶凝材料的制备
CN105731895A (zh) * 2016-01-31 2016-07-06 西安建筑科技大学 电导率可调控碱激发高硅铝土矿基胶凝材料制备
CN105753342A (zh) * 2016-01-31 2016-07-13 西安建筑科技大学 电导率可调控碱激发赤泥基半导体胶凝材料的制备
CN108689625A (zh) * 2018-06-19 2018-10-23 王然 混凝土掺合料及其制备方法和混凝土
CN110964531A (zh) * 2018-09-26 2020-04-07 广东清大同科环保技术有限公司 一种脱硫石膏颗粒土壤及其制备方法
CN111592287A (zh) * 2020-05-21 2020-08-28 南昌航空大学 一种碳酸钙型废渣地质聚合物的制备方法
WO2022051744A1 (fr) * 2020-09-01 2022-03-10 Lithic Industries Holding Co. Unité de maçonnerie polymère et procédé associé

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US4640715A (en) * 1985-03-06 1987-02-03 Lone Star Industries, Inc. Mineral binder and compositions employing the same
WO1989005284A1 (fr) * 1987-12-11 1989-06-15 Lone Star Industries, Inc. Ciment hydraulique et composition l'utilisant
WO1996025369A1 (fr) * 1995-02-17 1996-08-22 Drexel University Materiau de type ciment contenant des cendres volantes
WO2004101137A1 (fr) * 2003-05-16 2004-11-25 James Hardie International Finance B.V. Methodes de production de produits de faible densite
WO2005049522A1 (fr) * 2003-11-19 2005-06-02 Rocla Pty Ltd Ciment en geopolymeres et procede de preparation et de coulage
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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110287198A1 (en) * 2009-01-30 2011-11-24 Industry Foundation Of Chonnam National University Alkali-activated binder, alkali-activated mortar, concrete products and wet red clay paving material using binder
US8617307B2 (en) * 2009-01-30 2013-12-31 Industry Foundation Of Chonnam National University Alkali-activated binder, alkali-activated mortar, concrete products and wet red clay paving material using binder
CN105153352A (zh) * 2015-08-09 2015-12-16 深圳市嘉达高科产业发展有限公司 无机改性丙烯酸树脂及其制备方法、水泥预制构件
CN105153352B (zh) * 2015-08-09 2019-02-19 深圳市嘉达高科产业发展有限公司 无机改性丙烯酸树脂及其制备方法、水泥预制构件
CN105731895B (zh) * 2016-01-31 2017-09-01 西安建筑科技大学 电导率可调控碱激发高硅铝土矿基胶凝材料制备
CN105753342A (zh) * 2016-01-31 2016-07-13 西安建筑科技大学 电导率可调控碱激发赤泥基半导体胶凝材料的制备
CN105731895A (zh) * 2016-01-31 2016-07-06 西安建筑科技大学 电导率可调控碱激发高硅铝土矿基胶凝材料制备
CN105669055A (zh) * 2016-01-31 2016-06-15 西安建筑科技大学 电导率可调控碱激发钢渣基半导体胶凝材料的制备
CN108689625A (zh) * 2018-06-19 2018-10-23 王然 混凝土掺合料及其制备方法和混凝土
CN110964531A (zh) * 2018-09-26 2020-04-07 广东清大同科环保技术有限公司 一种脱硫石膏颗粒土壤及其制备方法
CN111592287A (zh) * 2020-05-21 2020-08-28 南昌航空大学 一种碳酸钙型废渣地质聚合物的制备方法
CN111592287B (zh) * 2020-05-21 2022-04-15 南昌航空大学 一种碳酸钙型废渣地质聚合物的制备方法
WO2022051744A1 (fr) * 2020-09-01 2022-03-10 Lithic Industries Holding Co. Unité de maçonnerie polymère et procédé associé

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