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Claims  |
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What is claimed is:
1. A process for the preparation of a cement composition, said process
comprising:
(a) combining a silicon dioxide containing sorbent with a water reducer or
high range water reducer solution to form a mixture;
(b) processing the mixture formed in step (a) to a dry or partially dry
particulate or granular admixture; and
(c) combining said admixture with a portland cement component, in a ratio
of cement component to admixture of about 100:1 to 2:1, to form a cement
composition.
2. The process of claim 1 wherein step (c) comprises combining said
admixture with said cement component by mixing or grinding.
3. The process of claim 1, wherein said portland cement component is
selected from the group consisting of:
(i) portland cement clinker containing one or more combinations of calcium
silicates and/or calcium aluminates and one or more types of calcium
sulfate; and
(ii) portland cement.
4. The process according to claim 2, wherein said cement composition
includes mineral components.
5. The process according to claim 4, wherein said mineral components are
selected from the group consisting of pozzolans, volcanic glasses,
diatomaceous earth, perlite, tuff, pumice, natural sand, quartz, marble,
limestone, burnt gaize, burnt clay, burnt shale, rice hull ash, bentonite
activated kaolin, granulated blast furnace slag, fly ash, silica fume,
catalytic and alum waste, broken glass, broken ceramic, and calcium
sulfate.
6. The process according to claim 4, wherein a mass ratio of said mineral
components to said admixture is from about 100:1 to about 1:1.
7. The process according to claim 4, wherein step (c) comprises separately
grinding said portland cement component and said mineral components and
subsequently intergrinding or mixing with said admixture.
8. The process according to claim 7, wherein said intermixing or grinding
step is carried out in apparatus selected from the group consisting of
conventional mixers, high speed mixers, vibrating mixers or mills, air jet
mixers or mills, ball mills, and tube ball mills.
9. A dry mix composition comprising a cement composition made according to
the process of claim 2 and dry aggregates.
10. A dry mix composition according to claim 9, wherein a mass ratio of
said dry aggregates to said cement composition is from about 10:1 to about
1:2.
11. A process for producing the dry mix composition according to claim 9,
comprising mixing said cement composition and said dry aggregates in
conventional mixers, high speed mixers, vibrating mixers, or air jet
mixers.
12. A concrete or mortar incorporating a cement composition produced
according to the process of claim 2.
13. A concrete or mortar incorporating a dry mix composition produced
according to the process of claim 11.
14. A concrete or mortar incorporating the dry mix composition according to
claim 10.
15. The concrete or mortar of claim 12 further including additional fillers
or aggregates selected from the group consisting of materials having
chemicals, thermal or abrasion resistance, thermal expansion or electric
conductivity properties, fibrous materials, and materials that increase
the density of the concrete or mortar.
16. The concrete or mortar of claim 13, further including additional
fillers or aggregates selected from the group consisting of materials
having chemical, thermal or abrasion resistance, thermal expansion or
electric conductivity properties, fibrous materials, and materials that
increase the density of the concrete or mortar.
17. The concrete or mortar of claim 14, further including additional filler
or aggregates selected from the group consisting of materials having
chemical, thermal or abrasion resistance, thermal expansion or electric
conductivity properties, fibrous materials, and materials that increase
the density of the concrete or mortar.
18. A cement composition prepared according to the process of claim 2,
wherein said portland cement component is selected from the group
consisting of:
(i) portland cement clinker comprising one or more combinations of calcium
silicates and/or calcium aluminates and one or more types of calcium
sulfate; and
(ii) portland cement.
19. The cement composition according to claim 18, further comprising
mineral components.
20. The cement composition according to claim 19, wherein said mineral
components are selected from the group consisting of pozzolans, volcanic
glasses, diatomaceous earth, perlite, tuff, pumice, natural sand, quartz,
marble, limestone, burnt gaize, burnt clay, burnt shale, rice hull ash,
bentonite, activated kaolin, granulated blast furnace slag, fly ash,
silica fume, catalytic and alum wastes, broken glass, broken ceramic, and
calcium sulfate.
21. The cement composition according to claim 19, wherein a mass ratio of
said mineral components to said admixture is from about 100:1 to about
1:1.
22. The process of claim 2, wherein said sorbent is a fine alkali reactive
non-crystalline silicon dioxide containing material, and wherein said
water reducer or high range water reducer is selected from the group
consisting of sulphonated melamine, naphthalene formaldehyde, polyacrylate
containing admixtures, and mixtures thereof.
23. The process of claim 22, wherein a mass ratio of said sorbent to water
reducer or high range water reducer is from about 5:1 to 100:1.
24. The process of claim 22, wherein said silicon dioxide containing
materials are selected from the group consisting of fly ash, rice hull
ash, zeolite, silica fume, bentonite, activated kaolin, montmorillonite
and diatomaceous earth.
25. The process of claim 2, wherein said sorbent includes a water
accumulating component selected from the group consisting of porous
lightweight sand, volcanic pumice, tuff, expanded clay, expanded perlite,
expanded slag, and expanded glass.
26. The process according to claim 25, wherein a mass ratio of said sorbent
to said water accumulating component is from about 10:1 to about 1:1.
27. The process according to claim 2, wherein said sorbent includes
non-organic or organic salts or hydroxides of metals as an electrolytic
agent.
28. The process according to claim 27, wherein said electrolytic agent is
selected from the group consisting of metal alkali and alkali earth
aluminates, hydroxides and/or carbonates, sodium nitrite, Al, Na, K or Ca
sulphate, calcium chloride, and calcium formate.
29. The process according to claim 28, wherein a mass ratio of said sorbent
to said electrolytic agent is from about 10:1 to about 1000:1.
30. The process according to claim 2, wherein said sorbent includes
hydrates, partially hydrated and dehydrated salts or compounds that
combine with water as a water combining component of said sorbent.
31. The process according to claim 30, wherein said water combining
component is selected from the group consisting of calcium sulfate, high
alumina cement and Na sulphate.
32. The process according to claim 30, wherein a mass ratio of sorbent to
water combining component is from about 1:1 to about 100:1.
33. The process according to claim 2, wherein said admixture includes a
water-soluble polymer.
34. The process according to claim 33, wherein said water-soluble polymer
is selected from the group consisting of polyvinyl alcohol, polyvinyl
acetate, polyacrylamide, cellulose ethers, methylcellulose, carboxymethyl
celluose, and hydroxyethyl cellulose.
35. The process according to claim 34, wherein a mass ratio of said sorbent
to said water soluble polymer is from about 3:1 to about 100:1.
36. The process according to claim 22, wherein said admixture includes a
retarder of hydration, setting, and/or hardening of a cement composition.
37. The process according to claim 36, wherein said retarder is selected
from the group consisting of lignosulphonates, sugars, hydroxycarbonic
acids, and their salts, carboxylates, phosphonic or phosphoric acids, and
their ethers and salts.
38. The process according to claim 37, wherein a mass ratio of sorbent to
retarder is from about 50:1 to about 1000:1.
39. The process according to claim 2, wherein said admixture includes air
detraining, hydrophobic, air entraining, foaming and/or gas creating
components as structure formation components.
40. The process according to claim 39, wherein said air detraining
component is three-butyl phosphate.
41. The process according to claim 39, wherein said hydrophobic component
is selected from the group consisting of silicon-containing compounds
containing silicones, silanes, silanols and/or siloxanes groups.
42. The process according to claim 39, wherein said air entraining or said
foaming components are selected from the group consisting of neutralised
hydroaromatic and fatty carboxylic acid, tall oil, vinsol resin and
protein-containing mixtures.
43. The process according to claim 39, wherein said gas creating component
is metal powder and/or hydrogen peroxide.
44. The process according to claim 39, wherein a mass ratio of said sorbent
to said structure formation components is from about 10:1 to about
10000:1.
45. The process according to claim 2, wherein said admixture includes
grinding aid components.
46. The process according to claim 45, wherein said grinding aid components
are selected from the group consisting of triethanol amine, amine acetate
salts, EDTA, acetic acid, hydrocarbons, silanes, methyl chlorine and
fluorine silane.
47. The process according to claim 45, wherein a mass ratio of said sorbent
to said grinding aid components is from about 10:1 to about 10000:1.
48. The process according to claim 2, wherein step (a) comprises combining
said sorbent and said water reducer or high range water reducer in mixing
apparatus selected from the group consisting of conventional mixers, high
speed spindle or planetary mixers, vibrating mixers or mills, and air jet
mixers or mills.
49. The process according to claim 2, further comprising at least one of
granulating, drying, pressing, extrusion, crushing, and calendering of
said admixture.
50. A cement composition prepared according to the process of claim 2 and
comprising a dry or partially dry granular admixture of a silicon dioxide
containing sorbent and a water reducer or high range water reducer, and
said admixture combined with a portland cement component.
51. The composition of claim 50, wherein said sorbent is a fine alkali
reactive non-crystalline silicon dioxide containing material, and said
water reducer or high range water reducer is selected from the group
consisting of sulphonated melamine, naphthalene formaldehyde, polyacrylate
containing admixtures, and mixtures thereof.
52. The composition of claim 51, wherein a mass ratio of said sorbent to
water reducer or high range water reducer is from about 5:1 to about
100:1.
53. The composition according to claim 51, wherein said silicon dioxide
containing material is selected from the group consisting of fly ash, rice
hull ash, zeolite, silica fume, bentonite, activated kaolin,
montmorillonite and diatomaceous earth.
54. The composition according to claim 50, wherein said sorbent includes
porous lightweight sand, volcanic pumice, tuff, expanded clay, expanded
perlite, expanded slag, and/or expanded glass as a water accumulating
component.
55. The composition according to claim 54, wherein a mass ratio of said
sorbent to said water accumulating component is from about 10:1 to about
1:1.
56. The composition according to claim 50, wherein said sorbent includes
non-organic or organic salts or hydroxides of metals as an electrolytic
agent.
57. The composition according to claim 56, wherein said electrolytic agent
is selected from the group consisting of metal alkali and alkali earth
aluminates, hydroxides and/or carbonates, sodium nitrite, Al, Na, K or Ca
sulphate, calcium chloride, and calcium formate.
58. The composition according to claim 57, wherein a mass ratio of said
sorbent to said electrolytic agent is from about 10:1 to about 1000:1.
59. The composition according to claim 50, wherein said sorbent includes
hydrated, partially hydrated and dehydrated salts or combinations thereof
that combine with water as a water combining component of said sorbent.
60. The composition according to claim 59, wherein said water combining
component is selected from the group consisting of calcium sulfate, high
alumina cement and Na sulphate.
61. The composition according to claim 59, wherein a mass ratio of sorbent
to water combining component is from about 1:1 to about 100:1.
62. The composition according to claim 50, wherein said admixture further
comprises a water-soluble polymer.
63. The composition according to claim 62, wherein said water-soluble
polymer is selected from the group consisting of polyvinyl alcohol,
polyvinyl acetate, polyacrylamide, cellulose ethers, methylcellulose,
carboxymethyl cellulose, and hydroxyethyl cellulose.
64. The composition according to claim 62, wherein a mass ratio of said
sorbent to said water soluble polymer is from about 3:1 to about 100:1.
65. The composition according to claim 50, wherein said admixture further
comprises a retarder of hydration, setting, and/or hardening of a cement
composition.
66. The composition according to claim 65, wherein said retarder is
selected from the group consisting of lignosulphonates, sugars,
hydroxycarbonic acids and their salts, carboxylates, phosphonic or
phosphoric acids, and their ethers and salts.
67. The composition according to claim 65, wherein a mass ratio of sorbent
to retarder is from about 50:1 to about 1000:1.
68. The composition according to claim 50, wherein said admixture further
comprises air detraining, hydrophobic, air entraining, foaming and/or gas
creating components as structure formation components.
69. The composition according to claim 68, wherein said air detraining
component is three-butyl phosphate.
70. The composition according to claim 68, wherein said hydrophobic
component is selected from the group consisting of silicon-containing
compounds containing silicones, silanes, silanols and/or siloxanes groups.
71. The composition according to claim 68, wherein said air entraining or
said foaming components are selected from the group consisting of
neutralized hydroaromatic and fatty carboxylic acid, tall oil, vinsol
resin and protein-containing mixtures.
72. The composition according to claim 68, wherein said gas creating
component is metal powder and/or hydrogen peroxide.
73. The composition according to claim 68, wherein a mass ratio of said
sorbent to said structure formation components is from about 10:1 to about
10000:1.
74. The composition according to claim 50, further comprising grinding aid
components.
75. The composition according to claim 71, wherein said grinding aid
components are selected from the group consisting of triethanol amine,
amine acetate salts, EDTA, acetic acid, hydrocarbons, silanes, methyl
chlorine and fluorine silane.
76. The composition according to claim 74, wherein a mass ratio of said
sorbent to said grinding aid components is from about 10:1 to about
10000:1.
77. The process of claim 38 wherein said portland cement comprises at least
one of moderate heat of hardening cements, high early strength cements,
low heat cements, sulfate resisting cements, white portland cements,
blended hydraulic cements, portland blast furnace slag cements,
portland-pozzolan cements, expanding cements, high alumina cements and
oil-well cements.
78. The cement composition of claim 18 wherein said portland cement
comprises at least one of moderate heat of hardening cements, high early
strength cements, low heat cements, sulfate resisting cements, white
portland cements, blended hydraulic cements, portland blast furnace slag
cements, portland-pozzolan cements, expanding cements, high alumina
cements and oil-well cements. |
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Claims |
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