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AU633562B2 - Wear resistant concrete - Google Patents

Wear resistant concrete Download PDF

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Publication number
AU633562B2
AU633562B2 AU54807/90A AU5480790A AU633562B2 AU 633562 B2 AU633562 B2 AU 633562B2 AU 54807/90 A AU54807/90 A AU 54807/90A AU 5480790 A AU5480790 A AU 5480790A AU 633562 B2 AU633562 B2 AU 633562B2
Authority
AU
Australia
Prior art keywords
wear resistant
concrete
resistant concrete
coating
cement
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
AU54807/90A
Other versions
AU5480790A (en
Inventor
Finn Bindrup Nielsen
William Hugh Sanders
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sanders Shotcreting & Refractory Services Pty Ltd
Original Assignee
Sanders Shotcreting & Refractory Services Pty Ltd
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
Application filed by Sanders Shotcreting & Refractory Services Pty Ltd filed Critical Sanders Shotcreting & Refractory Services Pty Ltd
Priority to AU54807/90A priority Critical patent/AU633562B2/en
Publication of AU5480790A publication Critical patent/AU5480790A/en
Application granted granted Critical
Publication of AU633562B2 publication Critical patent/AU633562B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/14—Waste materials; Refuse from metallurgical processes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/06—Quartz; Sand
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/38—Fibrous materials; Whiskers
    • C04B14/48—Metal
    • 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
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0076—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials characterised by the grain distribution
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/08—Slag cements
    • 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
    • C04B32/00—Artificial stone not provided for in other groups of this subclass
    • C04B32/02—Artificial stone not provided for in other groups of this subclass with reinforcements
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/53—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • 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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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)

Description

-I L t S33562 COMMONWEALTH OF AUSTRALIA PATENTS ACT 1952 Form COMPLETE SPECIFICATION
(ORIGINAL)
FOR OFFICE USE Short Title: Int. Cl: Application Number: PJ4074 Lodged: 5 May 1989 *i Complete Specification-Lodged: Accepted: Lapsed: 9Published: Priority: Related Art: o 4660 3 7 3590 4O94 TO BE COMPLETED BY APPLICANT S Name of Applicant: SANDERS SHOTCRETING REFRACTORY SERVICES PTY LTD Address of Applicant: 37 Freya Street, Kareela, New South 9 Wales 2232, Australia Actual Inventor: Address for Service: GRIFFITH HACK CO 71 YORK STREET SYDNEY NSW 2000 Complete Specification for the invention entitled: WEAR RESISTANT CONCRETE The following statement is a full description of this invention, including the best method of performing it known to me/us:- 8328A/rs 1 This invention relates to wear resistant concrete and has been devised particularly though not solely as a lining or surface for concrete drains, hoppers, shutes, etc. used for the handling of abrasive materials.
There are many situations in industry and other applications such as power generation where abrasive materials must be handled in drains, hoppers, shutes or the like. An example is the handling of fly ash or other abrasive forms of ash from furnaces where concrete drains, hoppers or shutes are typically lined with basalt tiles to provide a wear resistant surface. The provision and installation of such basalt tiles is expensive and furthermore the tiles can cause problems when one or more tiles become loose or dislodged in service.
Attempts have been made to provide various forms of coatings which may be applied to the surface of concrete drains, hoppers or shutes in a liquid or paste form but none of these coatings have successfully combined the *oo. required wear resistant characteristics with durability S 20 and low cost.
The present invention therefore provides, in one
C
aspect, a wear resistant concrete comprising a mixture of "high alumina cement and copper slag aggregate.
Preferably the cement comprises Ciment Fondue (Registered Trade Mark), a cement composition which typically comprises 36.6% AL 2 0 3 and 38% CaO.
Alternatively the cement comprises bauxite cement.
454/S:20591A/25.11.92 -la Preferably the copper slag aggregate comprises the form of coper slag which is a typical by-product of copper smelters and normally used as sand blasting grit.
Preferably the concrete incorporates a spraying agent to give a sprayable mix suitable for application to the surface of structural concrete using an applicator gun.
Preferably the spraying agent comprises silica fume.
Alternatively the spraying agent comprises powdered shale.
Preferably the wear resistant concrete incorporates an epoxy bonding agent and typically a water-based epoxy such as Hydrepoxy (Registered Trade Mark).
Preferably, the concrete incorporates a mixture of metal a a.
oa, a pa ot 454/S:20591 A/25.1 1 .e fibres to increase the tensile and impact strength of the product. z refr ;aY -Yp peallyAthe aggregate and cement are mixed in a 3:1 ratio.
In a further aspect the invention consists in a method of applying a wear resistant coating to the surface of drains, hoppers, shutes or the like, said method comprising the steps of applying a coating of wear resistant concrete of the type defined in one or more of the preceding ten paragraphs in patches of prdeterm4incd size, allowing the concrete to partially cure, applying further patches to the surface to fill the gaps between the original patches to complete a wear resistant coating.
Preferably the method incorporates the additional step aico o15 of applying a coating of water-based epoxy such as Hydrepoxy (Registered Trade Mark) to the surface of the wear resistant o 0o S:00 coating to maintain the moisture level in the coating.
0o Preferably the wear resistant coating is applied to the of 0 surface of the required substrate by a gun application process such as the Gunite (Registered Trade Mark) process.
Notwithstanding any other forms that may fall within its scope, one preferred form of the invention will now be described.
In the preferred form of the invention a wear resistant 0 o25 concrete is formulated for application to the surface of structural concrete typically in the form of drains, hoppers or shutes, or other substrates, by a concrete gun application process such as the well known Gunite process.
The wear resistant concrete is mixed using a mixture of three parts copper slag aggregate to one part high alumina cement. The copper slag aggregate is typically the type of by-product of copper smelters which is commonly used as sand blasting grit and the high alumina cement typically comprises Ciment Fondue (Trade Mark). Other forms of high alumina cements such as bauxite cement can also be used.
The aggregate:cement mix is typically provided with spraying agents such as powdered shale or silica fume and an 77s/rs 2 epoxy bonding agent such as the water-based epoxy Hydrepoxy (Trade Mark) to give the desired spraying and bonding |characteristics.
Where required for high tensile or impact strength, metal fibres may also be incorporated into the mix.
The wear resistant concrete is then applied to the surface of the substrate using a well known gun application process such as the Gunite process.
It has been found that the application of the wear resistant concrete coating to large surfaces in a single operation can cause curling at the edges due to inherent shrinkage in the Ciment Fondue and it is therefore preferred to apply the coating in intermitent patches, allowing the 00 Soo. patches to part cure before returning to fill in the gaps °oooo 15 between the patches to complete the coating over the surface 0 0 of the substrate.
It has also been found desirable to apply a coating of 000o o00 Hydrepoxy of the surface of the wear resistant concrete to .0 a maintain the moisture level in the wear resistant coating.
If the Hydrepoxy coating is not used, the cure is not complete and the concrete may go to powder. The use of a oo"o Hydrepoxy coating has been found to be particularly effective as it has been found that normal concrete curing Ba agents are not successful.
So025 Although the invention has been described as a liquid or paste-like coating to be adapted by a gun process, it will be appreciated that the wear resistant concrete, mixed 000. as described above could be cast into tiles) as an alternative to being sprayed directly onto the surface ol the substrate.
0077s/rs 3

Claims (13)

1. A wear resistant concrete comprising a /imKa of high alumina cement and copper slag aggregate.
2. A wear resistant concrete as claimed in claim 1 wherein the cement comprises CIMENT FONDUE(reiS' -rc/ -rade. c rk9
3. A wear resistant concrete as claimed in claim 1 wherein the cement comprises a bauxite cement.
4. A wear resistant concrete as claimed in any one of the preceding claims wherein the copper slag aggregate comprises that form of copper slag which is a typical by-product of copper smelters, commonly used as sand blasting grit.
A wear resistant concrete as claimed in any one of the preceding claims incorporating spraying agents giving a o a sprayable mix suitable for application to the surface of structural concrete using an applicator gun. o
6. A wear resistant concrete as claimed in claim 5 wherein the spraying agent comprises silica fume.
7. A wear resistant concrete as claimed in any one of the preceding claims further incorporating an epoxy bonding agent.
8. A wear resistant concrete as claimed in claim 7 wherein the epoxy bonding agent comprises a water-based epoxy. *0
9. A wear resistant concrete as claimed in any one of the 0c 0 preceding claims further incorporating a mixture of metal o 25 fibres.
A wear resistant concrete as claimed in any one of the preceding claims wherein the aggregate and cement are mixed o in a ratio of approximately 3:1.
11. A method of applying a wear resistant coating to the surface of drains, hoppers, shutes or the like, said metLh. comprising the steps of applying a coating of wear resistant concrete as claimed in any one of the preceding claims in patches -f prcedeterrmianed size, allowing the concrete to partially cure and applying further patches to the surface to fill the gaps between the original patches to complete a wear resistant coating. .1 0 0rp~ 77s/rS 4 I c i I
12. A method as claimed in claim 11 incorporating the additional step of applying a coating of water-based epoxy to the surface of the wear resistant coating.
13. A method as claimed in either claim 11 or claim 12 wherein the wear resistant coating is applied to the surface of the required substrate by a gun application process. DATED this seventh day of MAY 1990 SANDERS SHOTCRETING REFRACTORY SERVICES PTY. LTD. By their Patent Attorneys GRIFFITH HACK CO. 4 4 4a 2 O 4 0077s/rs 5
AU54807/90A 1989-05-05 1990-05-07 Wear resistant concrete Ceased AU633562B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU54807/90A AU633562B2 (en) 1989-05-05 1990-05-07 Wear resistant concrete

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AUPJ4074 1989-05-05
AUPJ407489 1989-05-05
AU54807/90A AU633562B2 (en) 1989-05-05 1990-05-07 Wear resistant concrete

Publications (2)

Publication Number Publication Date
AU5480790A AU5480790A (en) 1990-11-08
AU633562B2 true AU633562B2 (en) 1993-02-04

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
AU54807/90A Ceased AU633562B2 (en) 1989-05-05 1990-05-07 Wear resistant concrete

Country Status (1)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104418564A (en) * 2013-08-19 2015-03-18 上海维乐耐磨材料有限公司 Anti-wear ceramic mortar and use method thereof

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU443460B2 (en) * 1970-07-06 1973-12-04 Australian Iron and Steel Pty. Ltd. The use of granulated blast furnace slag in refractory cements and castables
EP0312323A2 (en) * 1987-10-15 1989-04-19 Btg International Limited Cement compositions
AU589260B2 (en) * 1986-04-10 1989-10-05 Fosroc International Limited Capsules of high alumina cement composition

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU443460B2 (en) * 1970-07-06 1973-12-04 Australian Iron and Steel Pty. Ltd. The use of granulated blast furnace slag in refractory cements and castables
AU589260B2 (en) * 1986-04-10 1989-10-05 Fosroc International Limited Capsules of high alumina cement composition
EP0312323A2 (en) * 1987-10-15 1989-04-19 Btg International Limited Cement compositions

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104418564A (en) * 2013-08-19 2015-03-18 上海维乐耐磨材料有限公司 Anti-wear ceramic mortar and use method thereof
CN104418564B (en) * 2013-08-19 2016-04-13 上海维乐耐磨材料有限公司 A kind of wear-resistant ceramic mortar and using method thereof

Also Published As

Publication number Publication date
AU5480790A (en) 1990-11-08

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