Ultra-High Performance Concrete Binder Mixture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High carbon dioxide emissions from traditional cement manufacturing processes pose an environmental and economic challenge, particularly in the production of high and ultra-high performance concretes, which require significant amounts of cement.
Innovation Solution
A binder mixture comprising ultrafine particles, selected Portland cement, and specific particle size classes of aggregates, with reduced cement content, is used to produce high or ultra-high performance concrete, achieving lower CO2 emissions while maintaining mechanical resistance and corrosion resistance comparable to conventional concretes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cement manufacturing processes are used to produce high or ultra-high performance concrete, then mechanical strength requirements are met, but carbon dioxide emissions increase significantly
Solution Approach 1:
The patent changes the chemical composition parameters of the binder mixture by reducing cement content to 8-25% and incorporating alternative materials such as fly ash (10-30%), slag (10-30%), and limestone powder (5-20%). This parameter modification allows achieving the required mechanical strength while significantly reducing CO2 emissions from cement manufacturing processes
Solution Approach 2:
The patent creates a composite binder mixture combining multiple materials with different properties: cement provides strength, fly ash and slag contribute to strength and durability, limestone powder improves workability and reduces permeability. This composite approach enables meeting mechanical requirements with lower cement content, thereby reducing carbon dioxide emissions
2Object-generated harmful factors
If cement content is reduced to lower CO2 emissions, then environmental impact decreases, but mechanical resistance may be compromised
Solution Approach 1:
The patent uses alternative materials (fly ash, slag, limestone powder) that can replicate or complement the binding and strengthening functions of cement. These materials undergo similar hydration reactions and contribute to matrix formation, allowing them to copy cement's mechanical functions while avoiding its carbon emissions
Solution Approach 2:
By formulating a composite binder mixture with multiple components, the patent achieves the required mechanical resistance through synergistic effects. The combination of cement (8-25%), fly ash (10-30%), slag (10-30%), and limestone powder (5-20%) creates a multi-functional binding system that maintains strength despite reduced cement content
3Strength
If conventional concrete formulations with high cement content are used, then mechanical performance is achieved, but porosity and permeability increase
Solution Approach 1:
The patent modifies the binder composition parameters by incorporating limestone powder (5-20%) and optimizing the ratios of fly ash and slag. These parameter changes result in a denser matrix structure with reduced porosity and permeability, thereby improving corrosion resistance while maintaining mechanical performance
Solution Approach 2:
The patent utilizes the pozzolanic properties of fly ash and slag to create a denser, less porous matrix. These materials react with calcium hydroxide to form additional calcium silicate hydrate, filling voids and reducing permeability. This approach maintains mechanical strength while improving durability against corrosion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves high mechanical resistance, reduced CO2 emissions, and comparable corrosion resistance and porosity to conventional high or ultra-high performance concretes, making it suitable for various industries with lower cement usage.
Implementation Method 1
a binder mixture comprising from 0.2 to 25% of a material of an ultrafine particle size class whose individual particles have a D90 less than 1 μm
Implementation Method 2
from 8 to 25% of selected Portland cement whose particles have a D90 less than 30 μm
Implementation Method 3
from 25 to 40% of a material, other than cement, of a fine particle size class whose particles have a D10 and a D90 of 1 μm to 120 μm
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a bonding pre-mixture containing: 0.2% to 63% of a material of an ultrafine granulometric class that contains individual D90 particles of less than 1 µm and/or of a specific BET surface area greater than 5 m2/g; 8% to 63% of selected Portland cement that contains D90 particles of less than 30 µm; and 25% to 85% of a material, other than the cement, of a fine granulometric class that contains particles, the D10 and D90 of which are 1 µm to 120 µm and of a specific BET surface area greater than 5 m2/g. The invention also relates in particular to a bonding mixture that contains particles, the D10 and D90 of which are 120 µm to 5 mm, in addition to the pre-mixture of a material of a medium granulometric class.