AU2015201212A1 - Low carbon cement & concrete composition - Google Patents
Low carbon cement & concrete composition Download PDFInfo
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- AU2015201212A1 AU2015201212A1 AU2015201212A AU2015201212A AU2015201212A1 AU 2015201212 A1 AU2015201212 A1 AU 2015201212A1 AU 2015201212 A AU2015201212 A AU 2015201212A AU 2015201212 A AU2015201212 A AU 2015201212A AU 2015201212 A1 AU2015201212 A1 AU 2015201212A1
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- 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
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Abstract
The present invention provides a binding composition and a method for forming a binding composition comprising: a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive
Description
LOW CARBON CEMENT & CONCRETE COMPOSITION TECHNICAL FIELD
The invention relates to binding compositions and to compositions and methods for making concrete.
BACKGROUND ART
In the most general sense, a cement is a binder which is capable of uniting fragments or masses of solid matter to a compact whole.
In the building industry, most 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.
In the building industry, 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.
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/m3 to 2500 kg/m3. 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/m3. 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, bottom ash, 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/m3 to 2000 kg/m3. 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/m3 typically has moderate strength, while only low strengths are typically achieved with concrete having a density below 800 kg/m3.
It would be advantageous to provide alternative binding compositions that can be used to produce concrete products for building and structural purposes that do not require the calcining of limestone to produce the binding composition, and that can be used to make lightweight concrete products.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a binding composition comprising: a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive
In a second aspect, the present invention provides a method for forming a binding composition comprising mixing: a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive
Typically the method further comprising adding additional water .
Typically, the binding composition comprises 20 to 80% by weight pozzolanic material.
In some embodiments, the pozzolanic material is selected from fly ash and slag.
In some embodiments, the pozzolanic material comprises a mixture of slag and fly ash.
In some embodiments, the limestone material is selected from calcium carbonate and calcium hydroxide.
In some embodiments, the limestone material comprises a mixture of calcium carbonate and calcium hydroxide.
In some embodiments, the binding composition further comprises a zeolithic activator.
In some embodiments, the zeolithic activator is in the form of DMP additive.
Typically, the binding composition contains some Portland cement.
In some embodiments, 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 CO2 or an atmosphere containing steam during the curing of the binding composition.
In a third aspect, the present invention provides a composition for making concrete or building products, comprising: a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive; and/or e) clay; and/or f) sand; and/or g) crusher dust; and/or h) recycled glass; and/or i) aggregate; and/or j) bottom ash.
For convenience, a composition for making concrete comprising the third aspect is referred to below as the "concrete composition of the present invention".
In a forth aspect, the present invention provides a method for making concrete or building products, comprising mixing: a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive; and/or e) clay; and/or f) sand; and/or g) crusher dust; and/or h) recycled glass; and/or i) aggregate; and/or j ) bottom ash.
To form a composition according to the third aspect of the present invention, shaping the composition, and curing the composition to make concrete.
In another aspect, 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.
In another aspect, the present invention provides concrete made by the method of the forth aspect of the present invention.
In some embodiments, the binding composition comprises 0.5 to 20% by weight calcium carbonate.
Typically, the binding composition is substantially free of Portland cement.
In some embodiments, 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 CO2 or an atmosphere containing steam during the curing of the binding composition.
DETAILED DESCRIPTION OF THE INVENTION
The binding composition of the present invention comprises : a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive
The pozzolanic material may be any pozzolanic material.
Pozzolanic materials, or pozzolans, 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.
Examples of 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.
In the binding composition of the present invention, fly ash is typically used. In some embodiments, 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.
In some embodiments where the pozzolanic material is, or includes, slag, at least some of the slag is milled. For example, the slag may be milled to a particle size of between about 2 and about 75 μπι. In some embodiments, the slag is milled to between 2 and 20 pm. The milled slag may, for example, constitute 5 to 20% by weight of the total amount of slag in the binding composition.
In some embodiments where the pozzolanic material is, or includes, silica, at least some of the silica is milled. For example, basalt dust or sand may be milled to a particle size of between about 2 and about 75 pm. The milled silica may, for example, constitute 5 to 20% by weight of the total amount of silica in the binding composition.
The inventor has found that the inclusion of milled silica 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 silica in the binding composition it is possible to influence the early and final strength of concrete formed using the binding composition.
In some embodiments, the pozzolanic material constitutes 20 to 90% by weight of the binding composition.
The limestone material may be any limestone material.
In some embodiments of the present invention, the limestone material is calcium carbonate and/or calcium hydroxide .
In some embodiments of the present invention, the limestone material constitutes 5 to 50% by weight of the binding composition.
In preferred embodiments, the binding composition comprises : a) 10 to 70% by weight Portland cement; and b) 30 to 90% by weight fly ash; and c) 20 to 60% by weight of slag; and d) 1 to 20% by weight calcium hydroxide; and e) 1 to 20% by weight of calcium carbonate; and f) 0.01 to 15% by weight of DMP additive
The binding composition of the present invention may be used to bind sand, crusher dust, recycled glass and aggregate together to form concrete.
The strength of concrete products formed using the binding composition is typically increased if less water is included in the binding composition. Accordingly, 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 as part of the concrete composition.
The inventor has found that 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. Accordingly, in some embodiments, the binding composition comprises carbon. Typically, the carbon is in the form of carbon black, soot or graphite.
In some embodiments, 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 of the present invention can be prepared by mixing together the components of the binding composition. Typically, the binding composition is prepared shortly before use. The binding composition of the present invention is mixed in the following order: a) calcium hydroxide is then added and blended until consistent. b) calcium carbonate is then added and blended until consistent. c) DMP is then added and blended until consistent. d) fly ash is then added and blended until consistent. e) slag is then added and blended until consistent, d) Portland cement is then added and blended until consistent.
The binding composition of the present invention is suitable for binding aggregate together to make concrete. By using 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 composition of the present invention may be prepared by mixing a binding composition of the first aspect of the present invention with the aggregate. Alternatively, 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) 8 to 25% by weight a binding composition comprising; (i) 10 to 70% by weight Portland cement; and (ii) 30 to 90% by weight fly ash; and (iii) 20 to 60% by weight of slag; and (iv) 1 to 20% by weight calcium hydroxide; and (v) 1 to 20% by weight of calcium carbonate; and (vi) 0.01 to 15% by weight of DMP additive b) 5 to 30% by weight sand; and/or c) 5 to 30% by weight crushed glass; and/or d) 5 to 30% by weight crusher dust; and/or e) 20 to 55% by weight aggregate; and/or f) 0 to 80% by weight bottom ash.
In some embodiments, the binding composition further comprises carbon, for example, carbon black.
In some embodiments, the concrete composition 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.
In some embodiments, the concrete composition comprises a clay material. The clay material may be any clay material.
Clay is a naturally occurring material composed primarily of fine-grained minerals, which show plasticity through a variable range of water content, and which can be hardened when dried or fired. There are three or four main groups of clays: kaolinite, montmorillonite-smectite, illite and chlorite. There are approximately 30 different types of "pure" clays in these categories, but most "natural" clays are mixtures of these different types, along with other weathered minerals.
Examples of clay materials include kaolin and bentonite.
In some embodiments, 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 CO2 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.
In some embodiments, 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, crushed glass, slag or recycled crushed concrete. In some embodiments, 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.
Typically 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 For forming the following concrete products, the typical weight ratio of dry weight of binding composition: fine aggregate: course aggregate is as follows:
The weight ratio of dry weight of the binding composition to total weight of aggregate is typically about 1:2 to 1:9.
The composition of the third aspect of the present invention may be used to form concrete for similar purposes to conventional concrete.
In some embodiments, the concrete formed using the binding composition of the present invention has a density lower than 2000 kg/m3. In some embodiments, the density is less than about 1850 kg/m3. In some embodiments, the density is between about 800 to about 1850 kg/m3.
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/m3) 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/m3 and a strength of 18MPa after 28 days can be prepared.
Specific embodiments of the invention are described below by reference to the following non-limiting examples .
In some embodiments, the binding composition comprises a powder product mixing calcium oxide and an aqueous solution named Active08.
Typically, the hydroxide powder is formed by filling a mixing apparatus with 4m3 of water with agitation in operation. One tonne of calcium oxide is added to the mixing apparatus then immediately after an additional 2m3 of water is added to create a slurry. Residence time of slurry mixing is 15min. The calcium oxide slurry is passed through a screen for removal of impurities of calcium oxide with particles >150 micron. Next the aqueous solution named Activate08 is filled into a mixing apparatus then the calcium oxide solution is added at the ratio of 1:1 by weight. Residence time of slurry mixing is 4hrs. The mixed calcium oxide/Activate08 solution is then dried through a computer controlled spray drier to moisture and particle size specification to produce a free flowing powder with the following properties: pH at 10% solid = 13.4 PSD (dry screening of powder): • +500 micron 1.19% • +180 micron 22.81% • +150 micron 16.94% • -150 micron 56.32%
Typically, the binding composition comprises 0.5% to 20% by weight of the powder hydroxide.
Typically 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. Typically the liquid silicate is an aqueous solution of sodium silicate, or an aqueous solution of potassium silicate, or a mixture thereof. In some embodiments, the liquid silicate has a silicate concentration of about 34 to 38% by weight.
Typically 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 of silicate. In some embodiments, the binding composition comprises less than 0.1% by weight of 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 of 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.
In preferred embodiments, the binding composition comprises : a) 70 to 95% by weight pozzolanic material; b) 5 to 15% by weight of an aqueous solution named Active08; or c) 0.01 to 20% by weight hydroxide powder; and d) 0.01 to 3% by weight silicate in the form of a liquid silicate.
Hydroxide solutions, particularly concentrated hydroxide solutions, are corrosive. The inventor has found that 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. Accordingly, in some embodiments, 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 inventor has found that the strength of concrete formed using the binding composition of the present invention may be increased by including calcium carbonate in the binding composition. Accordingly, in some embodiments, the binding composition further comprises calcium carbonate. When the binding composition includes calcium carbonate, the calcium carbonate is typically included in the binding composition in an amount of about 1 to 20% by weight of the binding composition, for example 1 to 4%, 1 to 4.5%, 1 to 3% or 1 to 2% by weight of the binding composition. In other embodiments, the binding composition is free, or substantially free, of calcium carbonate. In some embodiments, 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. Suitable agents include refined clays such as calcined kaolin, for example metakalin.
The strength of concrete products formed using the binding composition is typically increased if less water is included in the binding composition. Accordingly, 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.
Typically, the binding composition is free or substantially free of Portland cement.
In some embodiments, 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.
In some embodiments, the binding composition consists essentially of: a) pozzolanic material; and b) calcium oxide;and c) an aqueous solution named Activate08; or d) hydroxide powder; and e) 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. Typically, the binding composition is prepared shortly before use.
The binding composition of the present invention is suitable for binding aggregate together to make concrete.
By using 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.
Typically, the concrete is prepared by mixing pozzolanic material, an aqueous solution named Activate08, 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. Alternatively, the various constituents of a binding composition of the fifth aspect of the present invention and the aggregate may be mixed in any order to form a mixture of a binding composition of the fifth aspect of the present invention and aggregate.
The concrete composition of the present invention comprises : (a) a binding composition comprising: (i) pozzolanic material; and (ii) calcium oxide; and (iii) an aqueous solution named Activate08; or (iv) hydroxide powder; and (b) aggregate.
Typically, the binding composition comprises 70 to 95% by weight pozzolanic material.
In some embodiments, 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.
In some embodiments, 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.
In some embodiments, the binding composition comprises 0.5 to 5% by weight calcium carbonate.
Typically, the binding composition is substantially free of Portland cement.
In some embodiments, the concrete composition of the present invention comprises: a) a binding composition consisting essentially of: (i) pozzolanic material; and (ii) calcium oxide; and (iii) an aqueous solution named Activate08; or (iv) hydroxide powder; and (v) optionally one or more agents selected from liquid silicates, carbon, calcium carbonate, water reducing agents, agents capable of reacting with excess hydroxide, and water retention agents; and b) aggregate.
In some embodiments, 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 CO2 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.
In some embodiments, 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. In some embodiments, 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.
EXAMPLES EXAMPLE 1
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. A) Aggregate 58.4% of overall mix volume
Fine aggregates (0-1 mm) 26%
Coarse aggregate (1-4 mm) 74% B) Binder Composition 13.6% of overall mix volume a) 58.1% by weight Portland cement; and b) 41.1% by weight fly ash; and
c) 0.8% by weight DMP C) Water 19.6% of overall mix volume
Water 34.4%
Air 56.5% Ά'
The aggregate used was Bayswater bottom ash produced by the Bayswater power station. The bulk density of the aggregate was 1850 kg/m2. λΒ' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components A, B and C were added in this order, in the proportions indicated above to a concrete mixer.
The components were mixed until a consistent blend was achieved (approximately 5 minutes).
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 4456.1. The results of these tests are shown in Table 1. TABLE 1 - Testing of Units in accordance with Australian Standard 4456 "Masonry Units and Segmental Pavers and Flags - Methods of Test" 1) Compressive Strength - Part 4
2) Potential to Effloresce - Part 6
3) Water Absorption - Part 14
The results are generally consistent with the performance of a conventional pressed hollow concrete masonry unit made using Portland cement. EXAMPLE 2 A binding composition was prepared by mixing together the components B and C as described below. B) Binder Composition 80% of overall mix volume a) 48.75% by weight Portland cement; and b) 49.25% by weight fly ash; and
c) 2% by weight DMP C) Water 20% of overall mix volume
Water 95.0%
Air 5.0% 'B' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components B and C were added in this order, in the proportions indicated above to a mixing bowl. The components were 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.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 2. TABLE 2 - Testing of cured cubes in accordance with Australian Standard 4456.4
EXAMPLE 3 (Standard Binder) A binding composition was prepared by mixing together the components B and C as described below. B) Binder Composition 80% of overall mix volume a) 21.5% by weight Grey Portland cement; and b) 15% by weight fly ash; and c) 38.5% by weight slag; and d) 19% by weight calcium carbonate; and e) 6% by weight DMP; C) Water 20% of overall mix volume
Water 95.0%
Air 5.0% 'B' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components B and C were added in this order, in the proportions indicated above to a mixing bowl. The components were 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.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 3. TABLE 3 - Testing of cured cubes in accordance with Australian Standard 4456.4
EXAMPLE 4 (Off White) A binding composition was prepared by mixing together the components B and C as described below. B) Binder Composition 80% of overall mix volume a) 21.5% by weight Off White Portland cement; and b) 15% by weight fly ash; and c) 38.5% by weight slag; and d) 19% by weight calcium carbonate; and e) 6% by weight DMP; C) Water 20% of overall mix volume
Water 95.0%
Air 5.0% 'B' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components B and C were added in this order, in the proportions indicated above to a mixing bowl. The components were 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.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 4. TABLE 4 - Testing of cured cubes in accordance with Australian Standard 4456.4
EXAMPLE 5 (LRC/Ceramic Cement) A binding composition was prepared by mixing together the components B and C as described below. B) Binder Composition 80% of overall mix volume a) 4% by weight Grey Portland cement; and b) 26.5% by weight fly ash; and c) 38.5% by weight slag; and d) 17% by weight calcium carbonate; and e) 14% by weight DMP; C) Water 20% of overall mix volume
Water 95.0%
Air 5.0% 'B' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components B and C were added in this order, in the proportions indicated above to a mixing bowl. The components were 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.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 5. TABLE 5 - Testing of cured cubes in accordance with Australian Standard 4456.4
EXAMPLE 6 (40MPa Gunlake mix - ICL) A concrete composition was prepared by mixing together the components A, B, C, D and E as described below. The resultant mixture was then placed by someone skilled in the art of placing traditional concrete. All the percentages referred to below in relation to the components A, B, C, D and E are percentages by volume. a) Aggregate 59.7% of overall mix volume 7/1Omm 12.7% 14/20mm 38.4%
Sand 24.6%
Cracker Dust 24.3% b) Binding Composition 16.5% of overall mix volume (i) Portland cement 48.75% (ii) Fly ash 49.25% (iii) DMP 2.0% c) Water 22.0% of overall mix volume d) Air 1.7% of overall mix volume e) Poz370 0.1% of overall mix volume
The resultant mixture was vibrated into a 50 mm cube mould until self levelled. Specimens were moist cured in lime-saturated water.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 6. TABLE 6 - Testing of cured cubes in accordance with Australian Standard 4456.4
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as described in the Examples without departing from the spirit or scope of the invention as broadly described. The Examples are, therefore, to be considered in all respects as illustrative and not restrictive. EXAMPLE 7 (40MPa Gunlake Mix - Gunlake Dust) A concrete composition was prepared by mixing together the components A, B, C, D and E as described below. The resultant mixture was then placed by someone skilled in the art of placing traditional concrete. All the percentages referred to below in relation to the components A, B, C, D and E are percentages by volume. a) Aggregate 59.7% of overall mix volume 7/1Omm 12.7% 14/20mm 38.4%
Sand 24.6%
Cracker Dust 24.3% b) Binding Compositionl6.5% of overall mix volume
Portland cement 48.75%
Fly ash 49.25% DMP 2.0% c) Water 22.0% of overall mix volume d) Air 1.7% of overall mix volume e) Poz370 0.1% of overall mix volume
The resultant mixture was vibrated into a 50 mm cube mould until self levelled. Specimens were moist cured in lime-saturated water.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 7. TABLE 7 - Testing of cured cubes in accordance with Australian Standard 4456.4
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as described in the Examples without departing from the spirit or scope of the invention as broadly described. The Examples are, therefore, to be considered in all respects as illustrative and not restrictive. EXAMPLE 8 (Hanson LWC) A concrete composition was prepared by mixing together the components A, B, C, D and E as described below. The resultant mixture was then placed by someone skilled in the art of placing traditional concrete. All the percentages referred to below in relation to the components A, B, C, D and E are percentages by volume. a) Aggregate 45.2% of overall mix volume
Bayswater Bottom Ash 100% b) Binding Composition 37.9% of overall mix volume
Portland cement 90.9%
Fly ash 5.7% DMP 3.4 % c) Water 22.0% of overall mix volume d) Air 1.7% of overall mix volume e) Poz370 0.1% of overall mix volume
The resultant mixture was vibrated into a 50 mm cube mould until self levelled. Specimens were moist cured in lime-saturated water.
The cured cubes were tested for compressive strength at days 3, 7, 14 and 28 in accordance with Australian Standard AS 4456.4. The results of these tests are shown in Table 8. TABLE 8 - Testing of cured cubes in accordance with Australian Standard 4456.4
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as described in the Examples without departing from the spirit or scope of the invention as broadly described. The Examples are, therefore, to be considered in all respects as illustrative and not restrictive.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. EXAMPLE 9
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. QLD MASONRY Based on l/2m3 mix: 7mm + CD 250kg QLD Bottom Ash 270kg Calcium Agg 150kg OPC 80kg FA 90kg DMP 6.25kg
Water 80-90kg Ά'
The aggregate used was Bayswater bottom ash produced by the Bayswater power station. The bulk density of the aggregate was 1850 kg/m2. λΒ' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components A, B and C were added in this order, in the proportions indicated above to a concrete mixer.
The components were mixed until a consistent blend was achieved (approximately 5 minutes).
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 4456.1. The results of these tests are shown in Table 1. EXAMPLE 10
Pressed and extruded brick units were prepared by mixing together the components A, B, C, D and E as described below. The resultant mixture was then shaped into bricks and cured. All the percentages referred to below in relation to the components A, B, C, D and E are percentages by volume.
Unfired Brick
Clay 17.50%
Agg 25.00%
Descrete Ceramic Cement 57.50% a) Clay 17.5% of overall mix volume b) Calcium Aggregate 25% of overall mix volume c) Ceramic Cement 57.5% of overall mix volume a. 4% by weight Grey Portland cement; and b. 26.5% by weight fly ash; and c. 38.5% by weight slag; and d. 17% by weight calcium carbonate; and e. 14% by weight DMP; c) Water 22.0% of overall mix volume d) Air 1.7% of overall mix volume 'A'
The clay used was sourced from the Selkirk quarry in Ballarat. 'B' Mix Process
Ingredients of the binder composition were added together in any order and mixed until a consistent blend was achieved.
OVERALL PROCESS
The components A and B were added in this order, in the proportions indicated above to a pan mixer. The components were mixed until a consistent blend was achieved (approximately 5 minutes).
The resultant mixture was shaped into 76 mm high x 230 mm long x 110 mm wide, and air cured at 80QC.
The units were tested for compressive strength at days 3, 7, 14, 31 and 60 in accordance with Australian Standard AS 1617.
Other Examples also include:
CLAIMS 1) A binding composition comprising: i) Portland cement; and/or ii) pozzolanic material; and/or iii) limestone material; and/or iv) DMP additive 2) The binding composition according to claims 1 and 2, wherein the binding composition comprises 20 to 90% by weight pozzolanic material. 3) The binding composition according to any one of claims 1 and 2, wherein the pozzolanic material is selected from fly ash, amorphas silica and slag. 4) The binding composition according to any one of claims 1 and 2, wherein the pozzolanic material comprises fly ash. 5) The binding composition according to claim 1, wherein the binding composition comprises 10 to 70% by weight of Portland cement. 6) The binding composition according to claim 1, wherein the binding composition comprises 1 to 20% by weight of limestone. 7) The binding composition according to claim 1, comprising 0.01 to 10% by weight DMP. 8) A binding composition according to claim 2, wherein the binding composition comprises 5 to 15% by weight of an aqueous solution named Activate08. 9) The binding composition according to claim 2, further comprising liquid silicate. 10) The binding composition according to claim 2, wherein the binding composition comprises less than 3% by weight silicate. 11) The binding composition according to claim 2, wherein the binding composition comprises less than 0.2% by weight silicate. 12) The binding composition according to any one of claim 2, wherein the binding composition comprises 0.5 to 5% by weight calcium carbonate. 13) The binding composition according to any one of claim 2, wherein the binding composition is substantially free of Portland cement. 14) A binding composition comprising: a) 10 to 70% by weight Portland cement; and b) 30 to 90% by weight fly ash; and c) 20 to 60% by weight of slag; and d) 1 to 20% by weight calcium hydroxide; and e) 1 to 20% by weight of calcium carbonate; and f) 0.01 to 15% by weight of DMP additive 15) A method for forming a binding composition comprising mixing: a) Portland cement; and b) fly ash; and c) slag; and d) limestone; and e) DMP additive 16) A composition for making concrete, comprising: i) 8 to 25% by weight a binding composition comprising; a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive ii) 5 to 30% by weight sand; and iii) 5 to 30% by weight crusher dust; and/or iv) 3-30% by weight crushed glass; and/or v) 20 to 55% by weight aggregate; and/or vi) 0 to 80% by weight of bottom ash. 17) The composition according to claim 15, comprising a binding composition according to any one of claims 3 to 14 .
Claims (17)
- CLAIMS 1) A binding composition comprising: i) Portland cement; and/or ii) pozzolanic material; and/or iii) limestone material; and/or iv) DMP additive
- 2) The binding composition according to claims 1 and 2, wherein the binding composition comprises 20 to 90% by weight pozzolanic material.
- 3) The binding composition according to any one of claims 1 and 2, wherein the pozzolanic material is selected from fly ash, amorphas silica and slag.
- 4) The binding composition according to any one of claims 1 and 2, wherein the pozzolanic material comprises fly ash.
- 5) The binding composition according to claim 1, wherein the binding composition comprises 10 to 70% by weight of Portland cement.
- 6) The binding composition according to claim 1, wherein the binding composition comprises 1 to 20% by weight of limestone .
- 7) The binding composition according to claim 1, comprising 0.01 to 10% by weight DMP.
- 8) A binding composition according to claim 2, wherein the binding composition comprises 5 to 15% by weight of an aqueous solution named Activate08.
- 9) The binding composition according to claim 2, further comprising liquid silicate.
- 10) The binding composition according to claim 2, wherein the binding composition comprises less than 3% by weight silicate .
- 11) The binding composition according to claim 2, wherein the binding composition comprises less than 0.2% by weight silicate .
- 12) The binding composition according to any one of claim 2, wherein the binding composition comprises 0.5 to 5% by weight calcium carbonate.
- 13) The binding composition according to any one of claim 2, wherein the binding composition is substantially free of Portland cement.
- 14) A binding composition comprising: a) 10 to 70% by weight Portland cement; and b) 30 to 90% by weight fly ash; and c) 20 to 60% by weight of slag; and d) 1 to 20% by weight calcium hydroxide; and e) 1 to 20% by weight of calcium carbonate; and f) 0.01 to 15% by weight of DMP additive
- 15) A method for forming a binding composition comprising mixing: a) Portland cement; and b) fly ash; and c) slag; and d) limestone; and e) DMP additive
- 16) A composition for making concrete, comprising: i) 8 to 25% by weight a binding composition comprising; a) Portland cement; and/or b) pozzolanic material; and/or c) limestone material; and/or d) DMP additive ii) 5 to 30% by weight sand; and iii) 5 to 30% by weight crusher dust; and/or iv) 3-30% by weight crushed glass; and/or v) 20 to 55% by weight aggregate; and/or vi) 0 to 80% by weight of bottom ash.
- 17) The composition according to claim 15, comprising a binding composition according to any one of claims 3 to 14.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015201212A AU2015201212A1 (en) | 2015-03-09 | 2015-03-09 | Low carbon cement & concrete composition |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015201212A AU2015201212A1 (en) | 2015-03-09 | 2015-03-09 | Low carbon cement & concrete composition |
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| Publication Number | Publication Date |
|---|---|
| AU2015201212A1 true AU2015201212A1 (en) | 2016-09-29 |
Family
ID=56979815
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2015201212A Abandoned AU2015201212A1 (en) | 2015-03-09 | 2015-03-09 | Low carbon cement & concrete composition |
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| Country | Link |
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| AU (1) | AU2015201212A1 (en) |
-
2015
- 2015-03-09 AU AU2015201212A patent/AU2015201212A1/en not_active Abandoned
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