Methods of manufacture and use for low density hydraulically bonded cement compositions
AssigneeE. Khashoggi Industries
InventorsHamlin M. Jennings, Simon K. Hodson
Life of this patent
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Abstract
Incorporation of solid removable aggregates into powdered cement which later completely dissolve, evaporate, volatilize, or melt leaving voids in the cement composition is discussed. Cementitious articles are prepared by manipulating powdered hydraulic cement or cement paste compositions into mechanically self-supporting structures of a predetermined configuration and thereafter hydrating the hydraulic cement compositions without mechanical mixing of the cement and water.
Claims76
A method for preparing a hydraulically bonded article of low density from a hydraulic cement composition, the method comprising the steps of:
- applying pressure to a hydraulic cement composition having a solid removable aggregate dispersed therein within a mold, the pressure being sufficiently high to form a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a predetermined configuration of the hydraulically bonded article;
- removing the mechanically self-supporting structure from the mold;
- hydrating the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the aqueous solution and the hydraulic cement composition of the mechanically self-supporting structure;
- and
- removing the solid removable aggregate from the hydraulic cement composition by causing the solid removable aggregate to undergo a phase change, the removal of the solid removable aggregate leaving a predetermined level of porosity within the hydraulically bonded article, thereby forming the hydraulically bonded article of low density.
A method for preparing a hydraulically bonded article of low density comprising the steps of:
- applying pressure to a hydraulic cement composition comprising a meltable solid aggregate within a mold, the pressure being greater than about 10,500 psi to form a mechanically self-supporting structure of a predetermined configuration corresponding substantially to predetermined configuration of the hydraulically bonded article;
- removing the mechanically self-supporting structure from the mold;
- hydrating the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the aqueous solution and the hydraulic cement composition of the mechanically self-supporting structure;
- and
- removing the meltable solid aggregate from the hydraulic cement composition by causing the meltable solid aggregate to undergo a phase change, the removal of the meltable solid aggregate leaving a a predetermined level of porosity within the hydraulically bonded article, thereby forming the hydraulically bonded article of low density.
A method for preparing a hydraulically bonded article of low density comprising the steps of:
- applying pressure to a hydraulic cement composition comprising a volatile solid aggregate within a mold the pressure being sufficient to form a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a predetermined configuration of the hydraulically bonded article;
- removing the mechanically self-supporting structure from the mold;
- hydrating the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the aqueous solution and the hydraulic cement composition of the mechanically self-supporting structure;
- and
- removing the volatile solid aggregate from the hydraulic cement composition by causing the volatile solid aggregate to undergo a phase change, the removal of the volatile solid aggregate leaving a predetermined level of porosity within the hydraulic cement composition of the hydraulically bonded article, thereby forming the hydraulically bonded article of low density.
A method for preparing a hydraulically bonded article of low density comprising the steps of:
- applying pressure to a hydraulic cement composition comprising a dissolvable solid aggregate within a mold, the pressure being sufficient to form a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a predetermined configuration of the hydraulically bonded article;
- removing the mechanically self-supporting structure from the mold;
- hydrating the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the aqueous solution and the hydraulic cement composition of the mechanically self-supporting structure;
- and
- removing the dissolvable solid aggregate from the hydraulic cement composition by causing the dissolvable solid aggregate to undergo a phase change, the removal of the dissolvable solid aggregate leaving a predetermined level of porosity within the hydraulic cement composition of the hydraulically bonded cement article, thereby forming the hydraulically bonded article of low density.
Dependencies are inferred from the claim text.