MXPA01005777A

MXPA01005777A - Inorganic cementitious material

Info

Publication number: MXPA01005777A
Application number: MXPA/A/2001/005777A
Authority: MX
Inventors: William J Mcnulty Jr
Original assignee: William J Mcnulty Jr
Priority date: 1998-12-08
Filing date: 2001-06-08
Publication date: 2002-06-05

Abstract

A method of producing a new type of cement, hereafter called Conch-krete. Conch-krete is created by adding sodium carbonate (also known as soda ash, natron, etc.) and one or more minerals from the calcium carbonate group (including aragonite, limestone, calcite, marble, dolomite, etc.) and the addition of water to the mix that will harden into a cement-like material. The combination of sodium carbonate and calcium carbonate can be either layered or in a mixed state. An exothermic reaction starts after the addition of water. The composition of Conch-krete can vary between 20%sodium carbonate and 80%calcium carbonate to 80%sodium carbonate and 20%calcium carbonate. Conch-krete can be used in a variety of applications not inclusive of forming bricks, interior architecture, table or counter tops, ornaments, repairing damaged cement products, casting and other applications not mentioned above.

Description

MATERIAL CEMENTICIO INORGÁNICO BACKGROUND OF THE INVENTION i '1. Field of the Invention This invention relates to a new form of inorganic cementitious material, which finds utility as a binder for aggregate. The invention also relates to a method for forming the cementitious material by mixing an inorganic material with either fresh water or seawater, creating an exothermic reaction by which the inorganic material hardens. In some instances, the aggregate is added before, subsequent to, or simultaneous with the addition of water to create a concrete type material. 2. Description of the Related Art Hydraulic cements are known, the most widely found being Portland Cement, where an inorganic material is heat-treated at high temperatures, generally in a kiln to activate the cement. When it is subsequently mixed with water, this cement hardens. When aggregate is added to cement, it is generally known as concrete. The invention relates to a new type of cementitious material formed of inorganic substances that do not require the high temperature thermal treatment associated with Portland Cement.

The ancient Egyptians described using mud bricks or blocks to build many structures such as in mud-brick-forming scenes in the Rehkmire tomb in the Sheikh abd el-Qurna area of. Egypt. Other formulas for making structures, casting or casting, are detailed in the Famine Stele located on the island of Sehel, Egypt. However, the abandonment of this process would be applicable if this previous technique describes the use of a cementitious material created by adding sodium carbonate (also known as commercial soda, trona, etc.) and one or more materials for the calcium carbonate group (including aragonite, limestone, calcite, marble, dolomite, etc.) which, when mixed with water, harden. I've named this type of cement Conch-krete. The resistance and final setting of the product of this process depend on the combination of sodium carbonate, calcium carbonate and water. To achieve a long-lasting setting, additional water must be available to the product after the initial setting, since the product absorbs water after the initial setting, which will increase the setting time. SUMMARY OF THE INVENTION Thus, an object of the invention is to provide a new type of inorganic cementitious material that hardens upon the addition of water. A further object of the invention is to provide methods to use this new cementitious material as a binder for aggregate, to produce bricks, blocks, cast paving, artificial marble, retaining walls, pipes, concrete fill, mortar, shotcrete, stucco and similar products or others. These and other objects of the invention will be more fully understood in connection with the detailed description of the embodiments of the invention. DESCRIPTION OF THE PREFERRED MODALITIES In one embodiment, a cementitious material is formed by mixing a source of sodium carbonate with a calcium carbonate material, adding water and inducing an exothermic reaction to harden the cement. The amounts of components can vary between 20 and 80% by weight of sodium carbonate to 80-20% by weight of calcium carbonate, as active ingredients. Sodium carbonate can in the form of sodium carbonate or as sodium carbonate decahydrate, anhydrous sodium carbonate, etc. As sources of sodium carbonate can be commercial soda, trona, etc. Sources of calcium carbonate include calcium carbonate or • as one of the known forms or as a source such as aragonite, limestone, calcite, marble, dolomite, etc. When water is added to the mixture of inorganic materials, the hardening generally begins rapidly. The fineness and grain size of the components calcium carbonate and sodium carbonate, not only affects the overall appearance of the final product but also its resistance. • The calcium carbonate and sodium carbonate employed in the invention may vary in particle size from powder, common sand, even fine dust, pieces or large pieces of material. The particle size will normally be selected for the effect to be achieved in the finished product and mixtures of particle sizes can be used in combination. A coloring agent or dye can be introduced at the time of mixing the ingredients of the cementitious material that will affect the final color of the resulting product, thus allowing the ability to individually tailor the final appearance of the cementitious products. The following is a list of minerals and compounds that can be added to the cement mixture (less than 5% by weight of cement) that will improve the final product: halides, sodium chloride, borates, oxides, phosphates, silicates, sulfates, sulphides , fly ash, silica fume, sand, polycarbonate, mastics, thermoplastics, thermoset elastomers, epoxy, polyurethane, polysulphides, silicones, carbon polysulphide tars, thermoset sealers, neoprene, butyl rubber, lead, rubber, asphalt, rubber tar tarmac, acrylic, vinyl, oleo-resins, polybutene, asphalt, carbon steel, stainless steel, steel, copper, fluorosilicates, lime-free, hydrated lime, chlorinated rubber, bentonite, micro silicas, metakaolin, cuprovivant, wollastonite , magnesium carbonate, silicon dioxide, asphalt, copper salts, iron, iron oxide, potash, potassium carbonate, superplasticizers, bitumen or asphalt, synthetic fibers, straw, slag, glass fibers, steel galvanized, cellulose ethers, sulfonated copolymers, aluminum, aluminum salts, carbon, sulfuric acid, magnesium, magnesium salts, thiocyanic acids, alkanolamine, rodanides, urea, aldehydes, monomethylurea, triisopropanolamine, metal nitrates, metal thiocyanates, thiosulfates triethanolamine, gluconic acid, lignosulfonic acid, sodium nitrite, calcium formate, sodium benzoate, formaldehyde, if 1 icoaluminates, geopolymeric binders, zeolites, polyacrylates, geopolymers, ammonium salts, calcium oxide, borax, potassium hydroxide , potassium carbonate, sodium hydroxide, citric acid, carboxylic acid, lignosulfate, dehydrated gypsum, gypsum hemidrate, anhydrous gypsum, sodium bicarbonate, hydrogen peroxide, boric acid, lithium, lithium carbonate, calcium sulphate, bicarbonate alkaline, sulfonated lignin, lignosulfonates, fluoride, tricalcium silicates, tricalcium aluminate, chromium oxide, wood, natural fibers, synthetic textile fibers, anhydrite, titanium, sandstone, rhyolites, volcanic ash, dolomite, thiocyanates, calcium nitrite and mixtures that trap air, hydrogen sulphide, iron sulphide, ferrous sulfide, sulfur, magnesium silicate. As noted above, the resulting cementitious material can be used as a filler or filler, fill concrete, mortar, gunnite, masonry, bricks or blocks, decorative effect, architectural paving or casting, marble or ornamental or artificial granite, retaining walls, wall coverings, panels, counter walls, floor and ceiling tiles, paving materials, precast stone, boulders and chipboard, pipes, reinforced concrete products, including prestressed, extruded and molded and composite products. It can be used as an insulated lining, thermal insulation, packaging material and in products and household items, it can be used as a component of canoes, boats, kayaks, temporary hollows, tables and counters, bioabsorbable devices, etc. alone or with other materials. It also finds utility as temporary landfills, temporary roads, temporary facilities, temporary beaches, temporary barriers, temporary support, temporary scaffolding, temporary walls, docks or temporary berths, etc. Aggregates that may be included within the cement include bedrock, trapezoid rock, quartz and quartzite, granite, crisocola, malachite, biotite and feldspar. It can be formed of a mixed homogeneous material or it can take the form of a layered mixture. It will be understood that variations and improvements to the invention can be made without departing from the spirit and scope of the appended claims.

Claims

CLAIMS r 1. A cementitious product that is formed by reacting an uncalcined cementitious mixture, which consists of a source of sodium carbonate and a source of calcium carbonate and water, where the content of sodium carbonate is 20 to 80. % by weight and the content of calcium carbonate is from 80 to 20% by weight and water is present in an amount sufficient to harden the cementitious product.
2. The cementitious product according to claim 1, characterized in that the source of calcium carbonate includes at least one material selected from the group consisting of calcium carbonate, aragonite, limestone, calcite, marble and dolomite.
3. The cementitious product according to claim 1, characterized in that it also includes at least one aggregate selected from the group consisting of bedrock, trapezium rock, quartz, quartzite, granite, marble, limestone, dolomite, sandstone, crisocola, malachite, biotite and feldspar.
4. The cementitious product according to claim 1, characterized in that it is subjected to an exothermic reaction before the addition of water to the cementitious mixture in the presence or absence of a hardener.
5. The cementitious product according to claim 1, characterized in that it also comprises a coloring agent or dye.
6. The cementitious product according to claim 1, characterized in that the source of calcium carbonate is present in the form of a material selected from the group consisting of powder, fine powder, sand, lumps and combinations thereof.
7. A method for forming a cementitious product characterized in that it comprises: providing a mixture of a source of 20 to 80% by weight of calcium carbonate and 80 to 20% by weight of sodium carbonate in uncalcined form, mixing with water in the. presence or absence of aggregate, induce an exothermic reaction in the resulting mixture and recover a hardened product.
The method according to claim 7, characterized in that the method further includes shaping the mixture before hardening.
The method according to claim 7, characterized in that the exothermic reaction is induced in the presence or absence of a hardener.
10. The method according to claim 7, characterized in that the product is at least one selected from the group consisting of filling, concrete fill, mortar, gunnite, stucco, masonry, decorative or architectural paving, bricks, blocks, tiles for roof and floor, pebbles and paving materials.
The method according to claim 7, characterized in that the product is at least one selected from the group consisting of artificial marble, panels, retaining walls, wall coverings, counter-panels, floor masonry, pipe, reinforced concrete and prestressed concrete.
12. The method according to claim 7, characterized in that the water is fresh water or seawater.
The method according to claim 7, characterized in that the mixture further includes adding up to 5% by weight of a synthetic resin or other petroleum-based residue.
The method according to claim 7, characterized in that the mixture further includes adding at least one inorganic additive to the mixture,
15. The method according to claim 7, characterized in that the formation includes the step of shaping the cementitious product at least by a selected formation step of molding, spraying and casting.
16. The cementitious product according to claim 1, characterized in that the source of sodium carbonate is present in the form of a material selected from the group consisting of fine powder, powder, sand, lumps and their combinations.
17. The cementitious product according to claim 1, characterized in that it also comprises a mixture that traps air in an amount of up to 5% by weight.
18. A bioabsorbable device comprising a hardened cementitious product according to claim 1.
19. The method according to claim 7, characterized in that the mixture further includes adding at least one organic additive to the mixture.
20. The cementitious product according to claim 1, characterized in that it also comprises up to 5% by weight of at least one substance selected from the group consisting of halides, sodium chloride, borates, oxides, phosphates, silicates, sulfates, sulphides, fly ash, fumes of silica, sand, pozzolans,. mastics, thermoplastics, thermoset elastomers, epoxy, polyurethane, polysulphides, silicones, carbon polysulphide tars, thermosetting sealants, neoprene, butyl rubber, lead, rubber, asphalt, coal tar -hule, acrylic, vinyl, oleo-resins, polybutene, asphalt, carbon steel, stainless steel, steel, copper, fluorosilicates, free lime, hydrated lime, chlorinated rubber, bentonite, micro silicas, metacaolíri, cuprovivant, wollastonite, magnesium carbonate, silicon dioxide, copper salts, iron , iron oxide, potash, potassium carbonate, super-plasticizers, bitumen or asphalt, synthetic fibers, straw, slag, glass fibers, galvanized steel, cellulose ethers, sulfonated copolymers, aluminum, aluminum salts, carbon, sulfuric acid , magnesium, magnesium salts, thiocyanic acids, alkanolamine, rhodanides, urea, aldehydes, monomethylurea, triisopropanolamine, metal nitros metal thiocyanates, thiosulfates, triethanolamine, ac gluconic acid, lignosulfonic acid, sodium nitrite, sodium formate, sodium benzoate, formaldehyde, silicoaluminates, geopolymeric binders, zeolites, polyacrylates, geopolymers, ammonium salts, calcium oxide, borax, potassium hydroxide, potassium carbonate, hydroxide sodium, citric acid, carboxylic acid, lignosulfate, dehydrated gypsum, hemidrated plaster, anhydrous gypsum, sodium bicarbonate, hydrogen peroxide, boric acid, lithium, lithium carbonate, calcium sulfate, alkaline bicarbonate, sulfonated lignin, lignosulfonates, fluoride, tricalcium silicates, tricalcium aluminate, chromium oxide, wood, natural fibers, synthetic textile fibers, anhydrite, titanium, sandstone, rhyolites, volcanic ash, dolomite, thiocyanates, calcium nitrite and air-entraining mixtures, hydrogen sulphide, iron sulfide, ferrous sulfur, sulfur and magnesium silicate.
21. The cementitious product according to claim 1, characterized in that the sodium carbonate and calcium carbonate appear as discrete layers in the product.