Composition of cementitious binder and method for manufacturing the same

Abstract

[Solution] This disclosure relates to the composition of a cementitious material and a method for producing the same. The cementitious material may be a chemically activated concrete material utilizing industrial by-products and / or natural materials, and can provide an environmentally friendly alternative to Portland cement and other conventional cement materials. This cementitious material can form a construction material as a substitute for Portland cement or by adding it to Portland cement.

Description

Technical Field

[0005] ,

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 453,437, filed on March 20, 2023, the entire content of which is incorporated herein by reference.

[0002] This disclosure relates to the composition of a chemically activated cementitious material and a method for manufacturing the same.

Background Art

[0003] Cementitious materials are important components in building materials and other industries. One of the most common cementitious materials is Portland cement. Although Portland cement is widely used, there are environmental concerns such as greenhouse gas emissions and high energy consumption during manufacturing. Therefore, there is a need to provide cementitious materials with reduced environmental impact.

[0004] One such material is a chemically activated cementitious material, which is considered as an alternative to Portland cement. Chemically activated cementitious materials include industrial by-products or natural materials containing aluminosilicates such as slag, fly ash, waste ash, clay, natural pozzolan, granite, basalt, or zeolite, and offer the possibility of developing environmentally friendly building materials. The alternative material is ideally equipped with strength and durability equivalent to those of Portland cement and with further reduced energy costs. However, currently available chemically activated materials have problems such as low workability and limited strength. Therefore, it is advantageous to develop a composition of a chemically activated cementitious material having improved strength, durability, and other desirable properties, and such development is needed.

Summary of the Invention

Means for Solving the Problems

[0005] In some respects, the technologies described herein relate to cementitious materials comprising one or more chemical activators and industrial by-products or natural materials, wherein the chemical activators include one or more of the following: potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, or a combination thereof, and the industrial by-products The materials or natural materials include steel slag, non-ferrous slag, converter-type steelmaking slag, air-cooled slag, Solvay plant rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residues, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolanes, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAF) and lime kilns, general waste incineration ash, limestone, marble, gabbro, or combinations thereof.

[0006] In some respects, the technologies described herein relate to cementitious materials, which further include one or more of the following: sand, gravel, pH-adjusting admixtures, hardening accelerators, flocculating inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, high-performance water reducers, air entrainers, or combinations thereof.

[0007] In some respects, the technologies described herein relate to cementitious materials, which contain less than about 30% by weight of chemically active agents.

[0008] In some respects, the technologies described herein relate to cementitious materials, which contain less than about 15% by weight of a chemically active agent.

[0009] In some respects, the technologies described herein relate to cementitious materials, which contain less than about 10% by weight of a chemically active agent.

[0010] In some respects, the technologies described herein relate to cementitious materials, which contain less than about 5% by weight of chemically active agents.

[0011] In some respects, the techniques described herein relate to a method for producing cementitious materials, the method comprising the step of mixing a chemical activator and industrial by-products and / or natural materials with water to form a cementitious material, wherein the chemical activator includes potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, or a combination thereof. The aforementioned industrial by-products or natural materials include steel slag, non-ferrous metal slag, converter-type steelmaking slag, air-cooled slag, Solvay plant rinse slag, bauxite slag or bauxite residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residues, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolanes, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAF) and lime kilns, general waste incineration ash, limestone, marble, gabbro, or combinations thereof.

[0012] In some respects, the techniques described herein relate to methods in which the chemically active agent and the industrial by-product and / or natural material are mixed before being mixed with water.

[0013] In some respects, the techniques described herein relate to methods in which the chemically active agent and the industrial by-product and / or natural material are mixed in a grinder.

[0014] In some respects, the techniques described herein relate to methods, wherein the chemically active agent is dissolved in water before being mixed with the industrial by-product and / or the natural material.

[0015] In some respects, the techniques described herein relate to methods, which further include adding one or more of the following to the chemical activators and the industrial by-products and / or natural materials: sand, gravel, pH-adjusting admixtures, hardening accelerators, flocculating inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, high-performance water reducers, air entrainers, or combinations thereof.

[0016] In some respects, the technology described herein relates to cementitious materials, which are chemically active agents comprising one or more of the following: potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, and steel slag, non-ferrous steel slag, converter steelmaking slag This includes industrial by-products and / or natural materials, including one or more of the following: air-cooled slag, Solvay plant rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residues, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolanes, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Berterra clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and electric arc furnace (EAF) dust and lime kiln dust, or general waste incineration ash.

[0017] In some respects, the technologies described herein relate to cementitious materials, which further include one or more of the following: sand, gravel, pH-adjusting admixtures, hardening accelerators, flocculating inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, high-performance water reducers, air entrainers, or combinations thereof.

[0018] In some respects, the technologies described herein relate to cementitious materials, which contain less than about 30% by weight of the chemically active agent.

[0019] In some respects, the technologies described herein relate to cementitious materials, wherein the cementitious materials contain less than about 15% by weight of the chemically active agent.

[0020] In some respects, the technologies described herein relate to cementitious materials, which contain less than about 10% by weight of the chemically active agent.

[0021] In some respects, the technologies described herein relate to cementitious materials, wherein the cementitious materials contain less than about 5% by weight of the chemically active agent.

[0022] In some respects, the technologies described herein relate to cementitious materials, which further comprise a pigment admixture in an amount of about 0.1% to about 3% by weight of the cementitious material, wherein the pigment admixture comprises one or more of red iron oxide, black iron oxide, chromium oxide, and cobalt oxide.

[0023] In some respects, the technologies described herein relate to cementitious materials, which further comprise admixtures in an amount of about 0.5% to about 5% by weight of the cementitious material, the admixtures including pH-adjusting admixtures, hardening accelerators, flocculating inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, high-performance water reducers, air entrainers, or combinations thereof.

[0024] In some respects, the technologies described herein relate to cementitious materials having a compressive strength of at least 1000 psi upon hardening.

[0025] In some respects, the technologies described herein relate to cementitious materials that can be cured at a temperature of at least about 23°C in cast-in-place or precast applications.

[0026] In some aspects, the technology described herein relates to a method of manufacturing a cementitious material, the method comprising contacting an industrial by-product and / or a natural material with one or more of a chemical activator or water, and mixing the industrial by-product and / or the natural material with one or more of the chemical activator or the water to form a cementitious material, the chemical activator comprising one or more of potassium silicate, potassium carbonate, potassium phosphate, potassium hydrogen carbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium hydrogen carbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, calcium aluminosilicate, calcium silicate hydrate, calcium aluminosilicate hydrate, the industrial by-product and / or the natural material comprising one or more of steel slag, non-ferrous steel slag, converter steelmaking slag, air-cooled slag, Solvay plant rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag fine powder, ladle slag, copper slag, mine residue, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gas, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolan, main ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Berterra clay), fine pulverized waste concrete powder derived from construction / demolition waste or rubble, and dust from an electric arc furnace (EAF) and dust from a lime kiln, or general waste incineration ash.

[0027] In some aspects, the technology described herein relates to a method in which both the water and the chemical activator are mixed with the industrial by-product and / or the natural material, and the chemical activator is mixed with the industrial by-product and / or the natural material before the water is mixed with the industrial by-product and / or the natural material.

[0028] In some aspects, the technology described herein relates to a method, and the mixing step is performed by a pulverizer.

[0029] In some aspects, the technology described herein relates to a method, and the chemical activator is dissolved in water before being mixed with the industrial by - product and / or the natural material.

[0030] In some aspects, the technology described herein relates to a method, and this method further includes a step of pulverizing one or more of the industrial by - product and / or the natural material, and the chemical activator.

[0031] In some aspects, the technology described herein relates to a method, and the pulverizing step is performed for up to 50 hours.

[0032] In some aspects, the technology described herein relates to a method, and this method further includes a step of mixing one or more of sand, gravel, pH - adjusting admixture, curing accelerator, flocculation inhibitor, curing retarder, strength enhancer, corrosion inhibitor, shrinkage reducer, crack reducer, viscosity reducer, high - performance water - reducing agent, air - entraining agent with the chemical activator and the industrial by - product and / or the natural material.

[0033] In some aspects, the technology described herein relates to a method, and the chemical activator to be mixed is less than about 30% by weight.

[0034] In some aspects, the technology described herein relates to a method, and the chemical activator to be mixed is less than about 15% by weight. In some aspects, the technology described herein relates to a method, and the chemical activator to be mixed is less than about 5% by weight.

[0035] In some aspects, the technology described herein relates to a method, and this method further includes a step of curing the cementitious material by contacting it with moisture.

[0036] In some respects, the techniques described herein relate to methods, wherein the cementitious material hardens at temperatures above 0°C.

[0037] In some respects, the techniques described herein relate to methods, wherein the chemically active agent is mixed in an amount of at least 0.5% by weight.

[0038] In some respects, the techniques described herein relate to methods, which further include the step of curing the cementitious material at a temperature of at least about 23°C to form a product for cast-in-place or precast applications.

[0039] In some respects, the technologies described herein relate to composite materials comprising the cementitious material and one or more aggregates. [Modes for carrying out the invention]

[0040] This disclosure describes cementitious materials comprising at least one chemically active agent and industrial by-products and / or natural materials, and methods for producing the same. In some embodiments, the compositions provide improved performance with reduced energy required for production compared to conventional Portland cement, thereby enabling a reduction in environmental costs. This disclosure describes methods and compositions for improving various properties of chemically activated materials. The compositions of the activated materials of the present invention include steel slag, non-ferrous slag, converter steelmaking slag, air-cooled slag, Solvay phosphorous slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residue, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, and silica fume gauze. This disclosure may include gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolanes, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAFs) and lime kilns, general waste incineration ash, limestone, marble, gabbro, or combinations thereof. This disclosure may include grinding processes to improve strength and other properties. The cementitious materials in this disclosure may refer to binders, chemically activated binders, chemically activated cementitious materials, etc.

[0041] In some embodiments, cementitious materials comprising a chemical activator and industrial by-products and / or natural materials are provided. The cementitious material may also be a chemically activated binder. The activator may include, but is not limited to, one or more of the following: potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, or a combination thereof. In some embodiments, industrial by-products and / or natural materials include iron slag, non-ferrous slag, converter-type steelmaking slag, air-cooled slag, Solvay mill rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residue, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fumes, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolanes, bottom ash, and fly-up ash. It comprises one or more of the following: sch, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAFs) and lime kilns, general waste incineration ash, limestone, marble, gabbro, or a combination thereof, and is used together with the various activators mentioned above, and admixtures to improve strength and durability, reduce moisture content, control color, and other properties.

[0042] In some embodiments, the cementitious material comprises an industrial by-product and / or natural material, a combination of two or more chemical activators, and admixtures for activation, improvement of strength and durability, reduction of moisture content, control of color, and improvement of other properties. In some embodiments, the chemically activated cementitious binder comprises an industrial by-product and / or natural material, a combination of two or more chemical activators and admixtures, and is pulverized for a certain period of time for mechanochemical activation, improvement of strength and durability, control of color, increase of surface area for effective reaction, and improvement of other properties thereafter.

[0043] In some embodiments, the cementitious material of this disclosure has a paste-like form, such as a paste-like binder, in which the components described herein are mixed with water. In some embodiments, the chemically activated cementitious binder described herein is mixed with water and is curable at room temperature.

[0044] In some embodiments, the cementitious material of this disclosure has a paste-like form, such as a paste-like binder, in which the components described herein are mixed with water. In some embodiments, the chemically activated cementitious binder described herein is mixed with water and can be cured under high temperature, high humidity, high pressure, or a combination thereof for the manufacture of precast products. In some embodiments, the chemically activated cementitious binder described herein hardens in several hours at high temperature and can be demolded.

[0045] In some embodiments, the curing temperature of the precast product is approximately 15°C to 100°C, and the curing time is approximately 1 hour to 24 hours.

[0046] In some embodiments, the cementitious material further includes sand, gravel, pH-adjusting admixtures, hardening accelerators, flocculating inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, high-performance water reducers, air entrainers, or combinations thereof. It may also include other additives well known to those skilled in the art.

[0047] In some embodiments, the cementitious materials described herein include a chemical activator, and as described above, the chemical activator may include various and / or multiple components. The chemical activator may be present in an amount of about 1% to about 30% by weight of the mixture and can be selected from one or more chemical activators described above. In some embodiments, the cementitious material comprises less than about 15% by weight of chemically active agents, or combinations thereof, including, for example, about 30% by weight, about 29% by weight, about 28% by weight, about 27% by weight, about 26% by weight, about 25% by weight, about 24% by weight, about 23% by weight, about 22% by weight, about 21% by weight, about 20% by weight, about 19% by weight, about 18% by weight, about 17% by weight, about 16% by weight, about 15% by weight, about 14% by weight, about 13% by weight, about 12% by weight, about 11% by weight, about 10% by weight, about 9% by weight, about 8% by weight, about 7% by weight, about 6% by weight, about 5% by weight, about 4% by weight, about 3% by weight, about 2% by weight, about 1% by weight, about 0.5% by weight, or any range or value included therein. In some embodiments, the remaining weight percent of the cementitious material is industrial by-products and / or natural materials, and other additives described herein. In some embodiments, the cementitious material comprises at least 80% by weight of industrial by-products and / or natural materials, with the remainder (approximately 20% by weight or less) being activators and / or admixtures. In some embodiments, the cementitious material comprises pigments, which in some embodiments are present in an amount of about 0.1 to 10% by weight of the binder and may include iron oxide pigments, cobalt oxide pigments, or chromium oxide pigments. In some embodiments, the cementitious material comprises pH-adjusting admixtures, hardening accelerators, flocculating inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, air entrainers, plasticizers, and high-performance water-reducing agents, one or more of which are present in an amount of about 0.1% to 5% by weight of the binder.

[0048] A method for producing cementitious material is provided, the method comprising the step of mixing a chemical activator and an industrial by-product or natural material with water. In some embodiments, the chemical activator may include one or more of the following: potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, or a combination thereof. In some embodiments, industrial by-products and / or natural materials may include one or more of the following: iron slag, non-ferrous slag, converter-type steelmaking slag, air-cooled slag, Solvay plant rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residues, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolanes, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAF) and lime kilns, general waste incineration ash, limestone, marble, gabbro, or combinations thereof. The sources and composition of industrial by-products and / or natural materials are not particularly limited. A paste-like binder is formed by mixing a chemical activator with water, thereby activating the industrial by-products and / or natural materials.

[0049] In some embodiments, the activator and industrial by-products and / or natural materials are mixed before being mixed with water. In some embodiments, the activator and industrial by-products and / or natural materials may be mixed in a dry state by mixing in a grinder or ball mill. Although not bound by theory, mixing the activator and industrial by-products and / or natural materials can result in the mechanochemical activation of the industrial by-products, followed by the addition of water to form a paste-like binder. In some embodiments, the chemically activated material mixture is ground for about 0.1 hours to about 10 hours, about 1 hour to about 10 hours, about 1 hour to about 20 hours, about 1 hour to about 40 hours, about 1 hour to about 50 hours, and about 1 hour to about 100 hours.

[0050] In some embodiments, the chemotherapeutic is dissolved in water (in some embodiments, hot water) before being mixed with industrial by-products and / or natural materials. The chemotherapeutic dissolved in water can then be mixed with industrial by-products and / or natural materials.

[0051] In some embodiments, the cementitious materials described herein, and the cementitious materials produced by the methods described herein, are used directly as cementitious materials in any way well known to those skilled in the art, for example, to form concrete. In other embodiments, the cementitious materials of the Disclosure are mixed with Portland cement or other cementitious materials before use. The cementitious materials in any embodiment described herein can be used for cast-in-place or precast construction applications.

[0052] In some embodiments, the cementitious material offers improved performance compared to Portland cement. Improved performance may include, but is not limited to, increased strength and durability, reduced moisture content, color control, or a combination thereof. The cementitious material of this disclosure is more environmentally friendly and less expensive than conventional Portland cement.

[0053] This specification provides chemically activated material compositions, such as chemically activated cementitious materials and chemically activated cementitious binders, comprising one or more admixtures. Furthermore, a method for preparing a chemically activated material comprising one or more admixtures is disclosed. Although not bound by theory, the chemical activators and admixtures described herein activate the reaction of a chemically activated binder and improve one or more properties of the binder. It is also possible to improve one or more properties of a chemically activated binder by performing a grinding process for different durations. In one embodiment, the size of the chemical activator or admixture can be coarse, fine, or ultrafine.

[0054] In some embodiments, a chemically activated cementitious binder is provided, comprising a base material such as an industrial by-product and / or natural material activated with one or more chemical activators, the activators of which may include potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, or a combination thereof, and the combination of one or more admixtures may include pigment admixtures, pH adjusting admixtures, hardening accelerators, flocculation inhibitors, hardening retarders, strength enhancers, corrosion inhibitors, shrinkage reducers, crack reducers, viscosity reducers, air entrainers, water reducers, plasticizers, high-performance water reducers, or a combination thereof.

[0055] The chemically activated cementitious binders of this disclosure may include industrial by-products and / or natural materials having average particle sizes of about 1 μm to about 10 μm, about 1 μm to about 20 μm, about 1 μm to about 50 μm, about 1 μm to about 100 μm, about 1 μm to about 150 μm, or about 1 μm to about 200 μm. The admixtures described herein may have average particle sizes of about 1 μm to about 10 μm, about 1 μm to about 20 μm, about 1 μm to about 50 μm, about 1 μm to about 100 μm, about 1 μm to about 150 μm, and about 1 μm to about 200 μm. The admixtures are mixed with the material in a solid or semi-solid state, partially or completely dissolved in water.

[0056] In some embodiments, the chemically activated cementitious binder comprises one chemical activator or a combination of two or more chemical activators, which may include compounds such as potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, or combinations thereof.

[0057] In certain embodiments, the mass ratio of the base material (e.g., slag or any industrial by-product and / or natural material described herein) to the activator is greater than 4.0, such as about 5 to about 99. In certain embodiments, the mass ratio is about 5 to about 99. In certain embodiments, the mass ratio is about 5 to about 50. In certain embodiments, the mass ratio is about 5 to about 10.

[0058] In certain embodiments, the mass ratio of one chemical activator to another is greater than 1, for example, about 1 to about 20. In certain embodiments, the mass ratio is about 1 to about 10. In certain embodiments, the mass ratio is about 1 to about 5. In certain embodiments, the mass ratio is about 1 to about 4.5. In certain embodiments, the mass ratio is about 1 to about 3.5. In certain embodiments, the mass ratio is about 1 to about 2.5. In certain embodiments, the mass ratio is about 1 to about 2. In certain embodiments, the mass ratio is about 1 to about 1.5. In certain embodiments, the mass ratio is about 1 to about 1.25. In certain embodiments, this ratio is about 1 to about 1.

[0059] In one embodiment, the chemically activated material comprises an admixture consisting of one or more pigments uniformly or non-uniformly dispersed in a bonding matrix. The pigments may be any suitable pigment of various metal oxides or salts, such as red iron oxide, black iron oxide, chromium oxide, or cobalt oxide. The pigments may be any color, such as black, gray, white, blue, green, red, yellow, or brown.

[0060] In certain embodiments, the mass ratio of the chemical activator to the pigment admixture is greater than 1, for example, about 1 to about 2. In certain embodiments, the mass ratio is about 1 to about 5. In certain embodiments, the mass ratio is about 1 to about 10. In certain embodiments, the mass ratio is about 1 to about 20.

[0061] In some embodiments, the chemically activated cementitious binder may contain a curing enhancer admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0062] In some embodiments, the chemically activated cementitious binder may contain an agglomeration reducer admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0063] In some embodiments, the chemically activated cementitious binder may contain a strength enhancer admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0064] In some embodiments, the chemically activated cementitious binder may contain a set retarder admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0065] In some embodiments, the chemically activated cementitious binder may contain a shrinkage reducer admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0066] In some embodiments, the chemically activated cementitious binder may contain a crack reducer admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0067] In some embodiments, the chemically activated cementitious binder may contain a viscosity reducer admixture in an amount of about 0.1% to about 5% by weight. In certain embodiments, the content is about 0.1% to about 4% by weight. In certain embodiments, the content is about 0.1% to about 3% by weight. In certain embodiments, the content is about 0.1% to about 2% by weight. In certain embodiments, the content is about 0.1% to about 1% by weight. In certain embodiments, the content is about 0.1% to about 0.5% by weight.

[0068] In some embodiments, the chemically activated cementitious binder may contain water-reducing agents (plasticizers and high-performance water-reducing agents). The efficiency of the plasticizers and high-performance water-reducing agents can be evaluated based on their water-reducing capacity in the binder mixture while maintaining the same consistency.

[0069] In certain embodiments, the chemically activated cementitious binder comprises at least 0.5% by weight of one or more chemical activators. In certain embodiments, the chemically activated cementitious binder comprises about 0.1% to about 3% by weight of a pigment admixture, the pigment admixture comprising red iron oxide, black iron oxide, chromium oxide, and cobalt oxide.

[0070] In some embodiments, the substrate is pre-mixed in water and then added to and mixed with one or more chemical activators, or one or more chemical activators are pre-mixed in water and then added to and mixed with the substrate, or one or more chemical activators and the substrate are added simultaneously and then mixed with water.

[0071] In some embodiments, a grinding step is performed on one or more substrates, one or more chemical activators, or a combination thereof.

[0072] In certain embodiments, the grinding time of the mixture is approximately 0 to 5 hours. In certain embodiments, the grinding time of the mixture is approximately 0 to 10 hours. In certain embodiments, the grinding time of the mixture is approximately 0 to 20 hours. In certain embodiments, the grinding time of the mixture is approximately 0 to 30 hours. In certain embodiments, the grinding time of the mixture is approximately 0 to 40 hours. In certain embodiments, the grinding time of the mixture is approximately 0 to 50 hours.

[0073] Any suitable aggregate can be used to form a composite material from a chemically activated cementitious binder, such as construction sand or gravel, trap rock, industrial waste, and other types of fillers. The average particle size of the aggregate can range from approximately 0.1 mm to approximately 30 mm. In certain embodiments, the average particle size of the aggregate can range from approximately 0.1 mm to approximately 15 mm, approximately 0.1 mm to approximately 10 mm, approximately 0.1 mm to approximately 5 mm, or approximately 0.1 mm to approximately 1 mm.

[0074] This specification provides a method for improving one or more properties of a chemically activated cementitious binder, the method comprising the steps of adding various activators and / or admixtures to a binder composition and / or grinding a mixture of chemically activated cementitious binders. In some embodiments, the step of adding a activator to a substrate (e.g., any industrial by-product and / or natural material described herein) includes the step of adding a solid activator. In some embodiments, the step of adding a activator to a substrate includes the step of adding a liquid activator. In some embodiments, the step of adding a activator includes the step of adding a mixture of a solid activator and a liquid activator. In some embodiments, the step of adding an admixture to a substrate includes the step of adding a solid admixture. In some embodiments, the step of adding an admixture to a substrate includes the step of adding a liquid admixture. In some embodiments, the step of adding an admixture to a substrate includes the step of adding a mixture of a solid admixture and a liquid admixture. In some embodiments, a mixture of a base material such as industrial by-products and / or natural materials, a chemical activator, and an admixture can be pulverized. The methods provided herein may include a curing step for forming a concrete product. In some embodiments, the chemically activated cementitious binder has a compressive strength of at least 1000 psi when cured. In some embodiments, the chemically activated cementitious binder can be cured at temperatures above about 0°C. In some embodiments, the chemically activated cementitious binder can be cured at room temperature or humid conditions, at room temperature or high temperatures, or a combination thereof.

[0075] In some embodiments, when multiple chemical activators are added, the activators can be added in any order. In certain embodiments, two or more chemical activators can be added simultaneously as a mixture.

[0076] This specification provides methods for improving one or more strength properties (compared to conventional materials) of a chemically activated cementitious binder by adding chemical activators and / or admixtures and / or grinding. Examples of strength properties that can be improved include compressive strength, torsional strength, tensile strength at fracture, tensile strength, flexural strength, and combinations thereof.

[0077] This specification provides a method for controlling the color of concrete products by adding different admixtures. In some examples, pigment admixtures described herein are added.

[0078] In some embodiments, activation of the substrates described herein (industrial by-products and / or natural materials) can form one or more phases of geopolymers such as calcium (alumino)silica hydrate (CASH), sodium (alumino)silica hydrate (NASH), or calcium silicate hydrate (CSH), carbonates, or combinations thereof.

[0079] The embodiments described herein can be combined in any way to form new embodiments.

[0080] This disclosure is not limited to the specific systems, apparatus, and methods described, and these may be modified. The terms used in the detailed description are intended to describe specific aspects or embodiments and are not intended to limit the scope of the claims.

[0081] As used herein, the singular forms "a," "an," and "the" include the plural forms unless the context clearly indicates a plural. Unless otherwise defined, all technical and scientific terms as used herein have the same meaning as those generally understood by those skilled in the art. Nothing in this disclosure should be construed as acknowledging that the embodiments described herein do not precede any prior art disclosures. As used herein, the term "comprising" means "including, but not limited to."

[0082] Where used herein, the term “about” means plus or minus 10% of the number in which the term is used. For example, “about 50%” means a range of 45% to 55%. The ranges disclosed herein include upper and lower limits.

[0083] As used herein, terms such as “cementaceous material,” “chemically activated cementitious material,” “chemically activated admixture,” “chemically activated material,” and “chemically activated cementitious binder” may be used to refer to the compositions or precursors described herein.

[0084] As used herein, terms such as “base material,” “industrial by-product,” “natural material,” and “slag” refer to the same common starting material activated by the chemical activators described herein.

[0085] This disclosure is not limited to the specific embodiments described in this application, which are intended to illustrate various aspects. As will be apparent to those skilled in the art, many modifications and variations are possible without departing from the spirit and scope of the invention. Those skilled in the art will consider, based on the foregoing, that functionally equivalent methods and apparatus within the scope of the disclosure are obvious in addition to those described herein. Such modifications and variations are included in the appended claims. This disclosure is limited only by the content of the appended claims and the entire scope of equivalents recognized as such claims. This disclosure is not limited to any particular method, reagent, compound, composition, or biological system, which may, of course, be different. Furthermore, the terminology used herein is intended solely to describe specific embodiments and is not intended to be limiting.

[0086] Wherever plural and / or singular terms are used herein, a person skilled in the art can interpret the plural as singular and / or the singular as plural, depending on the context and / or the situation in which they are applied. Various singular / plural substitutions may be explicitly stated herein for clarity.

[0087] A person skilled in the art will understand that the terms used herein, in particular in the appended claims (e.g., the text of the appended claims), are generally intended to be "open" terms (for example, the term "including" should be interpreted as "including, but not limited to," the term "having" should be interpreted as "at least having," and the term "includes" should be interpreted as "including, but not limited to," etc.). Various compositions, methods, and apparatuses are described in terms of "comprising" (but not limited to) various components or processes, but these compositions, methods, and apparatuses may also "consist essentially of" or "consist of" various components or processes, and such terminology should be interpreted as defining essentially closed sets of components. Furthermore, it is expected that those skilled in the art will understand that if a claim is intended to introduce a particular numerical value, such intent will be explicitly stated in the claim, and if no such statement is made, such intent does not exist.

[0088] For example, as an aid to understanding, the attached claims below may use introductory phrases such as “at least one” and “one or more” to introduce the claim. However, the use of such phrases should not be interpreted as suggesting that a particular claim having such an introduction to the claim subject matter is limited to embodiments containing only one of the claim subject matter. This is true even if a single claim contains the introductory phrase “one or more” or “at least one” and an indefinite article such as “a” or “an” (for example, “a” and / or “an” should be interpreted as meaning “at least one” or “one or more”). This is also true when a definite article is used to introduce the claim subject matter.

[0089] Furthermore, even if a specific number is specified in the description of an introduced claim, it is reasonable to assume that a person skilled in the art would recognize that such description should be interpreted as meaning at least the number specified (for example, if it is simply stated as "two" without other modifiers, it means at least two descriptions, or two or more descriptions). In addition, when a notation similar to "at least one of A, B, and C" is used, such notation is usually intended to have the same meaning as a person skilled in the art would understand (for example, "a system having at least one of A, B, and C" includes (but is not limited to) a system having only A, a system having only B, a system having only C, a system having A and B, a system having A and C, a system having B and C, and / or a system having A, B and C). When a notation similar to "at least one of A, B, or C" is used, such notation is usually intended to have the same meaning as a person skilled in the art would understand (for example, "at least one of A, B, or C"). A “system having at least one” includes (but is not limited to) systems having only A, only B, only C, A and B, A and C, B and C, and / or systems having A, B and C. Furthermore, a person skilled in the art should understand that any disjunction and / or disjunction that presents two or more alternative terms in the specification, claims, or drawings substantially assumes the possibility of including one of those terms, either of those terms, or both of those terms. For example, the phrase “A or B” is understood to include the possibility of “A” or “B,” or “A and B.”

[0090] Furthermore, if any feature or aspect of the disclosure is described using the Markush group, a person skilled in the art will likely recognize that the disclosure also describes any individual component or subgroup of components of the Markush group.

[0091] As those skilled in the art will understand, for any purpose, such as providing a written explanation, the entire scope of the disclosure herein encompasses all possible sub-scopes and combinations of sub-scopes. It can be readily recognized that any scope described herein adequately describes and enables the implementation of the same scope divided into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each scope described herein can be readily divided into the lower third, middle third, upper third, etc. Furthermore, as those skilled in the art will understand, all expressions such as “maximum” and “at least” include numerical values ​​and refer to scopes that can be subdivided into further sub-scopes, as described above. Finally, as those skilled in the art will understand, one scope includes individual components. For example, the group containing compounds 1-3 refers to the group containing compounds 1, 2, or 3.

[0092] The various features and functions disclosed above, other features and functions, or alternative forms thereof, can be incorporated into many other different systems or applications. Furthermore, various alternative forms, modifications, variations, or improvements that are not currently anticipated or conceived by those skilled in the art may be made, all of which are intended to be included within the disclosed embodiments.

Claims

1. Cementaceous material, A chemical activator containing one or more of the following: potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, aluminum calcium silicate hydrate, Industrial by-products and / or natural materials including one or more of the following: iron slag, non-ferrous metal slag, converter-type steelmaking slag, air-cooled slag, Solvay plant rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residues, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolann, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAF) and lime kilns, or general waste incineration ash. A cementitious material having [ceramic properties].

2. In the cementitious material according to claim 1, further, A cementitious material comprising one or more of the following: sand, gravel, pH-adjusting admixture, hardening accelerator, flocculation inhibitor, hardening retarder, strength enhancer, corrosion inhibitor, shrinkage reducer, crack reducer, viscosity reducer, high-performance water-reducing agent, air-entraining agent, or a combination thereof.

3. A cementitious material according to claim 1, wherein the cementitious material contains less than about 30% by weight of the chemically active agent.

4. A cementitious material according to claim 1, wherein the cementitious material contains less than about 15% by weight of the chemically active agent.

5. A cementitious material according to claim 1, wherein the cementitious material contains less than about 10% by weight of the chemically active agent.

6. A cementitious material according to claim 1, wherein the cementitious material contains less than about 5% by weight of the chemically active agent.

7. In the cementitious material according to claim 1, further, The cementitious material contains a pigment admixture in an amount of approximately 0.1% to approximately 3% by weight, The aforementioned pigment admixture contains one or more of the following: red iron oxide, black iron oxide, chromium oxide, and cobalt oxide, in a cementitious material.

8. In the cementitious material according to claim 1, further, The cementitious material contains an admixture in an amount of approximately 0.5% to approximately 5% by weight, The admixture is a cementitious material having a pH adjusting admixture, a hardening accelerator, a flocculation inhibitor, a hardening retarder, a strength enhancer, a corrosion inhibitor, a shrinkage reducer, a crack reducer, a viscosity reducer, a high-performance water reducer, an air entrainer, or a combination thereof.

9. A cementitious material according to claim 1, wherein the cementitious material has a compressive strength of at least 1000 psi when hardened.

10. A cementitious material according to claim 1, wherein the cementitious material is capable of hardening at a temperature of at least about 23°C for use in cast-in-place or precast applications.

11. A method for producing cementitious material, A step of bringing industrial by-products and / or natural materials into contact with one or more of a chemically active agent or water, A step of mixing the industrial by-product and / or the natural material with one or more of the chemical activator and / or water in order to form a cementitious material. It has, The aforementioned chemical activator includes one or more of the following: potassium silicate, potassium carbonate, potassium phosphate, potassium bicarbonate, potassium nitrate, potassium hydroxide, potassium oxide, potassium sulfate, sodium silicate, sodium carbonate, sodium phosphate, sodium bicarbonate, sodium nitrate, sodium hydroxide, sodium oxide, sodium sulfate, calcium nitrate, calcium silicate, calcium hydroxide, calcium oxide, calcium aluminate, calcium sulfate, aluminum calcium silicate, calcium silicate hydrate, and aluminum calcium silicate hydrate. The aforementioned industrial by-products and / or natural materials include one or more of the following: steel slag, non-ferrous metal slag, converter steelmaking slag, air-cooled slag, Solvay plant rinse slag, bauxite slag / residue, zinc slag, lead slag, electric arc furnace (EAF) slag, blast furnace slag powder, ladle slag, copper slag, mining residues, zeolite, clay, volcanic lava, tuff, metakaolin, calcined shale, silica fume gauze, biomass ash, halloysite, calcined clay, basalt, granite, pumice, natural pozzolann, bottom ash, fly ash, cement kiln dust, fine waste glass powder derived from waste glass, mining waste (e.g., Bertera clay), finely ground waste concrete powder derived from construction and demolition waste or rubble, and dust from electric arc furnaces (EAF) and lime kilns, or general waste incineration ash. method.

12. In the method according to claim 11, Both the water and the chemical activator are mixed with the industrial by-product and / or the natural material. The chemical activator is mixed with the industrial by-product and / or natural material before the water is mixed with the industrial by-product and / or natural material. method.

13. The method according to claim 12, wherein the mixing step is performed by a grinder.

14. A method according to claim 11, wherein the chemical activator is dissolved in water before being mixed with the industrial by-product and / or the natural material.

15. A method according to claim 11, further comprising the step of grinding one or more of the industrial by-products and / or the natural materials and the chemical activators.

16. A method according to claim 15, wherein the grinding step is performed for a maximum of 50 hours.

17. In the method according to claim 11, further, A method comprising the step of mixing one or more of the following with a chemical activator and the industrial by-products and / or natural materials: sand, gravel, pH adjusting admixture, hardening accelerator, flocculation inhibitor, hardening retarder, strength enhancer, corrosion inhibitor, shrinkage reducer, crack reducer, viscosity reducer, high-performance water reducer, and air entrainer.

18. The method according to claim 11, wherein the amount of the chemically active agent to be mixed is less than about 30% by weight.

19. The method according to claim 11, wherein the amount of the chemically active agent to be mixed is less than about 15% by weight.

20. The method according to claim 11, wherein the amount of the chemically active agent to be mixed is less than about 5% by weight.

21. A method according to claim 11, further comprising the step of hardening the cementitious material by bringing it into contact with moisture.

22. The method according to claim 21, wherein the cementitious material hardens at a temperature above 0°C.

23. The method according to claim 11, wherein the chemical activator is mixed in an amount of at least 0.5% by weight.

24. In the method according to claim 11, further, A method comprising the step of curing the cementitious material at a temperature of at least about 23°C in order to form a product for cast-in-place or precast applications.

25. A composite material comprising a cementitious material according to any one of claims 1 to 10 and one or more aggregates.

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