ZA200101577B - Settable composition. - Google Patents
Settable composition. Download PDFInfo
- Publication number
- ZA200101577B ZA200101577B ZA200101577A ZA200101577A ZA200101577B ZA 200101577 B ZA200101577 B ZA 200101577B ZA 200101577 A ZA200101577 A ZA 200101577A ZA 200101577 A ZA200101577 A ZA 200101577A ZA 200101577 B ZA200101577 B ZA 200101577B
- Authority
- ZA
- South Africa
- Prior art keywords
- silicate
- composition
- hardener
- carbonate
- cement
- Prior art date
Links
- 239000000203 mixture Substances 0.000 title description 59
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 31
- 239000004848 polyfunctional curative Substances 0.000 description 24
- 239000004568 cement Substances 0.000 description 16
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 15
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 12
- 239000002585 base Substances 0.000 description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 9
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 7
- 238000006243 chemical reaction Methods 0.000 description 7
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 7
- KMTRUDSVKNLOMY-UHFFFAOYSA-N Ethylene carbonate Chemical compound O=C1OCCO1 KMTRUDSVKNLOMY-UHFFFAOYSA-N 0.000 description 6
- 229910052910 alkali metal silicate Inorganic materials 0.000 description 6
- 239000000945 filler Substances 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 239000004115 Sodium Silicate Substances 0.000 description 5
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 5
- 150000005677 organic carbonates Chemical class 0.000 description 5
- 229910052911 sodium silicate Inorganic materials 0.000 description 5
- 235000019738 Limestone Nutrition 0.000 description 4
- 239000011398 Portland cement Substances 0.000 description 4
- 238000004873 anchoring Methods 0.000 description 4
- 239000002775 capsule Substances 0.000 description 4
- 239000006028 limestone Substances 0.000 description 4
- 150000007524 organic acids Chemical class 0.000 description 4
- 239000000377 silicon dioxide Substances 0.000 description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 4
- 239000002253 acid Substances 0.000 description 3
- 239000000440 bentonite Substances 0.000 description 3
- 229910000278 bentonite Inorganic materials 0.000 description 3
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- ZZXUZKXVROWEIF-UHFFFAOYSA-N 1,2-butylene carbonate Chemical compound CCC1COC(=O)O1 ZZXUZKXVROWEIF-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- 239000004606 Fillers/Extenders Substances 0.000 description 2
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 239000010881 fly ash Substances 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000011435 rock Substances 0.000 description 2
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 2
- 229910001948 sodium oxide Inorganic materials 0.000 description 2
- 239000000375 suspending agent Substances 0.000 description 2
- URAYPUMNDPQOKB-UHFFFAOYSA-N triacetin Chemical compound CC(=O)OCC(OC(C)=O)COC(C)=O URAYPUMNDPQOKB-UHFFFAOYSA-N 0.000 description 2
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- 239000004348 Glyceryl diacetate Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 239000004111 Potassium silicate Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- -1 for example Substances 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 239000003349 gelling agent Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 235000019443 glyceryl diacetate Nutrition 0.000 description 1
- 235000013773 glyceryl triacetate Nutrition 0.000 description 1
- 239000001087 glyceryl triacetate Substances 0.000 description 1
- 239000005001 laminate film Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000011505 plaster Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 description 1
- 229910052913 potassium silicate Inorganic materials 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 230000003019 stabilising effect Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229960002622 triacetin Drugs 0.000 description 1
Description
id wo 00/14026 PCT/GB99/02703
SETTABLE COMPOSITION
This invention relates to a composition which is settable by the reaction of a silicate with a hardener, more particularly to a composition provided in two parts to be mixed, each part formulated to have improved storage stability. When the parts are mixed the composition is useful for a variety of purposes for example anchoring anchor elements in the roofof a mine to secure the roof strata to overlying rock formations.
It has been previously proposed to provide hardenable silicate compositions in two part form and this is described in United States Patents Nos 5165958 which describes a method of sealing mine stoppings where an alkali metal silicate solution provided in one part is gelled by reaction with a weak acid or acid salt or ester that hydrolyses to release acid provided in . another part. United States Patent No 5330785 describes the use of a similar two part composition to seal rock strata.
It is a problem with two part settable silicate compositions that they have only a limited shelf life, especially when they are stored under very hot or humid condtions which are sometimes found in mines. : A solution to this problem has now been invented in which the two parts of the settable silicate composition have an improved shelf life. , According to one aspect of the present invention there is provided a substantially water-free hardener composition suitable for admixture with a cement to give a product capable of reaction with a silicate to form a hardened mass, said hardener composition comprising: (a) from 50 to 99.9% of an organic carbonate hardener for the silicate {iL fiutii 6.61 10 28% of aii oiganic iclarasi pielciabiy an organic acid elaider for thie cement, the % being by weight based on the total weight of (a) and (b).
Preferably the amount of carbonate is from 75 to 99.8% and the amount of organic acid retarder is from 0.02 to 10%.
The carbonate may conveniently be ethylene carbonate, propylene carbonate, or butylene carbonate and is preferably a dry blend of ethylene carbonate (which is a solid at room temperature) in liquid propylene carbonate.
Preferably the organic carbonate hardener is a mixture of ethylene and propylene carbonates in proportions of from 3:1 to 1:3 by weight.
: WQ00/14026 PCT/GB99/02703 ™
The hardener composition preferably includes a cement.
Therefore according to a preferred embodiment of the invention a hardener composition for reaction with a silicate to form a hardened mass, comprises: a) from 10 to 60% of an organic carbonate hardener for the silicate b) from 0.05 to 5% of an organic retarder preferably an organic acid retarder for the cement and (c) from 20 to 85% of a cement capable of reacting with the silicate, the % being by weight based on the total weight of (a), (b) and (c). }
By adjusting the amounts of (a), (b) and (c) it is possible to form the composition as a stable paste ie where the solids do not settle out and also to achieve a storage life of at least 12 weeks at 35 degrees Centigrade,
Preferably the blend of carbonates makes up about 20% to about 40%, most preferably . about 25-35% by weight of the water free hardener composition.
In addition to the carbonate other organic hardeners for silicates may be employed, e.g. AGS esters, triacetin, diacetin; and the like.
It has been found experimentally that ethylene carbonate, propylene carbonate andbuylene carbonates result in different gel times. In the case of ethylene carbonate alone the gel time : is about 15 seconds whereas with buylene carbonate it is about 20 minutes. By emplying a mixture and adjusting the proportions of these carbonates it is possible to adjust the gel time . between about 5 seconds and 20 minutes.
It was initially expected that a dry mixture of organic carbonate and cementitious material would be stable but it was found by experiment to harden after about 3 weeks at 35° C.
However it was then found unexpectedly that the addition of an organic acid known as a retarder for the reaction of cements with water, produced a stable composition that was usable after storage for 12 weeks at 35°C.
The cement is preferably Ordinary Portland Cement (OPC) which makes up the major constituent. Other cements may also be present in addition to, or in substitution for theOPC, e.g. calcium sulphoaluminate (CSA, high alumina cement (HAC), plaster, ground granulated blast furnace slag (GGBFS), pulverised fuel ash (PFA) and the like.
The hardener composition may include other ingredients, for example, suspension agents such as bentonite, say up to 10%; retarders; extenders; accelerators; dispersants; and the like.
According to another aspect of the invention there is provided a silicate-containing composition for reaction with the hardener composition to form a hardened mass, said silicate composition comprising: a) from 50 to 85%, preferably 50 to 80% of a filler, (b) from 3 to 40%, preferably 5 to 25% of an alkali metal silicate (c) from 5 to 70%, preferably 10 to 50% water the percentages being by weight based on the total weight of (a), (b) and (¢) and the amount of alkali metal silicate being on a dry basis.
By adjusting the amounts of (a), (b) and (c) it is possible to produce the composition in the form of a stable paste ie where the solids do not settle out and also to achieve a storage life of at least 12 weeks at 35 degrees centigrade. . The composition may include other inorganic settable substance; fillers; and the like.
Preferably the composition includes an orthophosphate to act asretarder and/or dispersant; ] accelerators; extenders; and the like.
The silicate may be an alkali metal silicate for example sodium or potassium silicate and may ’ have a silica to alkali metal oxide molar ratio of from 2: to 4:1. Alkali metal silicates are usually associated with water and the silicate may have a solids content of from 10 to 60% . by weight, typically about 30 to 50%, the balance being water.
References to the amount of alkali metal silicate in the silicate base composition are calculated on a water-free basis. ‘
The silicate-containing composition may contain a filler provided it is non reactive and compatibie With thie silicate for jong teri stapiiity. Sich fillers incllide limestone, mica, cellulose fibre, glass fibre, and other reinforcing non reactive fibres, clay and kaolin.
It is an object of the invention to prolong the shelf life of the silicate base composition as well as that of the hardener composition. Generally the lower the molar ratiof silica to sodium oxide the shorter is the shelf life. When the molar ratio is raised to aboutabout 3.3:1 the shelf life is extended but the gel time is too short. However it has been discovered that if the molar ratio of silica to alkali metal oxide in a silicate is lowered from for example 3.3:1 to about 2.8:1 by the addition of sodium hydroxide or the like the gel time is extended without loss of shelf life.
For example, adding sufficient sodium hydroxide to sodium silicate having a molar ratio of silica: sodium oxide of 3.3:1 to give a molar ratio of 2.8:1 gives a shelf life greater than 12 weeks at 35°C.
According to one embodiment of the invention there is provided acompartmented container having two compartments impervious to air and water, one compartment containing a hardener composition as hereinbefore defined and the other compartment containing a silicate-containing composition as hereinbefore defined.
The relative amounts of amounts of reactive components are preferably chosen so that when the compositions in the two compartments are mixed the reactants will form a hardened mass.
Conveniently the relative amounts of ethylene carbonate, propylene carbonate andbutylene carbonate are adjusted to give a gel time of within 15 seconds and 20 minutes. .
The invention includes a method of reacting the two part composition for purposes other than anchoring an anchor element.
The cement may contain traces of moisture such as are found in commercially available forms of these materials and references to dry and substantially water-free should be : construed accordingly.
In order that the invention may be well understood it will now be described, by way of . illustration only, with references to the following examples in which parts are by weight and strengths are in MPa.
EXAMPLE 1
A silicate base composition and a dry hardener composition were prepared and stored separately. The ingredients used to prepare the two compositions are set out below:
SILICATE BASE % by weight
Graded limestone filler 66.5 sodium silicate* (Si0, : Na0 ratio 3.3:1) 27.0 tri-sodium orthophosphate retarder** 1.0 sodium hydroxide powder*** 0.5 china clay 5.0
Ng * solids content 38.1% by weight, the remainder being water.
Weight % of sodium silicate calculated on a water free basis was 10.29%. ** also acts as a dispersion agent for the limestone and silicate. = sodium hydroxide added to adjust the molar ratio to about 2.8:1
The silicate base was prepared by adding to the sodium silicate (which was a clear liquid) the sodium hydroxide powder and the sodium orthophosphate and mixed until dissolved.
Then the limestone and china clay were added and the stirred in a mixer to form a paste.
The paste was stable in that the components did not settle out.
The silicate base composition was stored in an airtight plastic container for 12 weeks at 350C after which time it was inspected and found to beuseable, thus demonstrating a shelf life of at least 12 weeks under these conditions.
CL HARDENER
Ordinary Portland Cement 67.8 ah propylene carbonate* and ethylene carbonate 30.0 ’ (50:50 blend by weight) bentonite suspending agent 2.0 : citric acid 0.2 * the organic carbonates employed were polyurethane grade materials ie extremely dry. the hardener composition was prepared by adding the citric acid to the mixture of ethylene and propylene carbonate and stirring until dissolved. Then the ordinary Portland cement and bentonite were added and mixed to form a paste. The paste was stable in that the components did not settle out.
The above hardener composition was stored in an airtight plastic container for 12 weeks at 350C after which time it was inspected and found to beuseable, thus demonstrating a shelf life of at least 12 weeks under these conditions.
It was expected that the dry mixture of cement and carbonates would be stable but it was found to set after about 3 weeks storage. The addition of citric acid produced a stable composition. It was surprising that the citric acid (which has previously been used as a retarder when water is employed to set the cement) was effective in stabilising the components in a dry system.
When the two compositions are mixed the main reactions are firstly between the carbonate with the silicate and secondly between the cement and the water associated with the silicate.
In addition the Portland cement being highly alkaline will act as a gelling agent for the silicate.
The base and hardener were mixed in a weight ratio of 9:1 and the composition gelled within about 90 seconds. Different samples were made and tested under different conditions of cure.
The following results were obtained;
The dry tests were carried out by mixing the silicate base and hardener and adding the . mixture to a mould and allowing the mixture to set in the mould. The samples were then demoulded and allowed to stand in the air in the laboratory.
DRY CURE AT 20°C
Time Strenath ; mins 11.8 1 hour 12.2 . 1 day 14.3 7 days 23.5 28 days . 32.4
DRY CURE AT 35°C
Time Strength 1 day 15.0 7 days 20.3 28 days 28.4 v WO 00/14026 PCT/GB99/02703
DRY CURE AT 50°C
Time Strength 1 day 21.0 7 days 29.6 28 days 32.6
The wet cure samples were demoulded after one hour, placed under water and then tested.
WET CURE AT 20°C
Time Strength 1 day 12.5 7 days 20.5 . 28 days 21.0 ] WET CURE AT 35°C
Time Strength 1 day 12.8 ¢ 7 days 18.6 28 days 19.0
WET CURE AT 50°C
Time Strength 1 day ) 11.1 7 days i6Y 28 days 17.3
These results show that at different storage conditions of humidity and temperature the composition could still be set to provide high early and long term compressive strength.
The advantages of the compositions illustrated in the above Example are: (i) both compositions are stable pastes in that the solids do not settle out which makes them suitable for use in a two part capsule of the type used in mining operations (ii) both compositions have a storage life of at least 12 weeks when stored at 35 degrees
Centigrade.
(iii) the carbonates serve as a carrier for the cement and the water serves as a carrier for the silicate and in addition the carbontes react with the silicate and the water with the cement.
Thus each carrier, whilst inert in its composition, will when mixed react with a component in the other composition.
EXAMPLE lI
A roof bolt of 20mm diameter was anchored in a hole which was 28mm in diameter and 229mm in depth using a composition according to Example | and the load applied was measured over time. The results are shown in the graph of the accompanying Figure 1 from which it will be seen that the load increased with time and stabilised after 30 minutes. The early high strength is useful in anchoring.
The invention is not limited to the examples: for instance different cements and fillers may be used and in different proportions: the carbonate hardener may be butylene carbonate either . alone or in combination with other hardeners.
EXAMPLE {li
The silicate base and hardener compositions of example 1 were packed into separate } compartments of a capsule having two compartments made oftri-laminate film at a ratio by weight of 9 parts silicate base to 1 part hardener. Three 24mm diameter, 450mm long capsules were made. These were pneumatically inserted into a 1.85m deep, 28mm diameter hole in a Polish copper mine. A 20mm rebar was spun through the capsules to break the film and mix the contents. 10 minutes after installation the anchor was found to exceed the anchoring requirements of the Polish regulations for copper mines. These regulations state that the bolt must be capable of taking a load of greater than 10 tonnes 10 minutes after installation with a maximum movement of 10mm.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB9819066.3A GB9819066D0 (en) | 1998-09-02 | 1998-09-02 | Anchoring |
Publications (1)
Publication Number | Publication Date |
---|---|
ZA200101577B true ZA200101577B (en) | 2001-08-30 |
Family
ID=10838183
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
ZA9905637A ZA995637B (en) | 1998-09-02 | 1999-09-01 | Anchoring. |
ZA200101577A ZA200101577B (en) | 1998-09-02 | 2001-02-26 | Settable composition. |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
ZA9905637A ZA995637B (en) | 1998-09-02 | 1999-09-01 | Anchoring. |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB9819066D0 (en) |
ZA (2) | ZA995637B (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB0608177D0 (en) * | 2006-04-25 | 2006-06-07 | Minova Int Ltd | Cement-Containing Compositions And Method Of Use |
-
1998
- 1998-09-02 GB GBGB9819066.3A patent/GB9819066D0/en not_active Ceased
-
1999
- 1999-09-01 ZA ZA9905637A patent/ZA995637B/en unknown
-
2001
- 2001-02-26 ZA ZA200101577A patent/ZA200101577B/en unknown
Also Published As
Publication number | Publication date |
---|---|
ZA995637B (en) | 2001-04-17 |
GB9819066D0 (en) | 1998-10-28 |
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