Abstract:
Calcium silicate-based cements and concretes are disclosed, which result in concrete compositions that have an increased durability. A cement product includes a plurality of particles of a carbonatable calcium silicate cement and a hydrophobic organic acid, or a salt thereof, or a silane, or a polysiloxane.
Abstract:
A method of making a supplementary cementitious material is described that includes: forming a slurry comprising water and a carbonatable material powder, wherein a weight ratio of water to the carbonatable material powder is at least 1; and flowing a gas comprising carbon dioxide into the slurry for 0.5 to 24 hours while maintaining the slurry at a temperature of 1° C. to 99° C. to form a carbonated slurry comprising CaCO3 and amorphous silica. A method of forming cement or concrete using the supplemental cementitious material is also described.
Abstract:
A method of producing a carbonated composite material is described that includes: providing a carbonatable cementitious material in particulate form; mixing the carbonatable cementitious material with water to produce a mix; forming a predetermined shape with the mix, wherein the predetermined shape has an initial pore structure containing an initial pore solution having a first pH; pre-conditioning the predetermined shape to remove a predetermined amount of the water from the predetermined shape to produce a pre-conditioned shape; carbonating the pre-conditioned shape in an environment comprising carbon dioxide to produce a modified pore structure containing a modified pore solution having and a second pH, wherein the difference between the first pH and the second pH is represented by a ΔpH, and the ΔpH is 1.0 or less, 0.75 or less, 0.5 or less, 0.25 or less, or about 0.0. A calcium silicate composition including solid components and liquid components having improved pore solution pH stability is also disclosed.
Abstract:
The invention provides compositions and methods for controlling setting of carbonatable calcium silicate compositions that are contaminated with hydrating materials. These carbonatable calcium silicate cements are suitable for use as non-hydraulic cement that hardens by a carbonation process and may be applied in a variety of concrete components in the infrastructure, construction, pavement and landscaping industries.
Abstract:
The invention provides novel, microstructured clinker and cement materials that are characterized by superior grindability and reactivity. The disclosed clinker and cement materials are based on carbonatable calcium silicate and can be made from widely available, low cost raw materials via a process suitable for large-scale production. The method of the invention is flexible in equipment and processing requirements and is readily adaptable to manufacturing facilities of conventional Portland cement.
Abstract:
The invention provides a curing system that is useful for curing materials that consume carbon dioxide as a reagent. The system has a curing chamber that contains the material to be cured and a gas that contains carbon dioxide. The system includes apparatus that can deliver carbon dioxide to displace ambient air upon loading the system, that can provide carbon dioxide as it is needed and as it is consumed, that can control carbon dioxide concentration, temperature and humidity in the curing chamber during the curing cycle and that can record and display to a user the variables that occur during the curing process.
Abstract:
Carbonatable calcium silicate-based cements and concretes are presented, which result in concrete compositions that have an improved aesthetics. A cement product includes a plurality of particles of a carbonatable calcium silicate cement and a first additive; wherein, the first additive is a hydrophobic organic acid, or a salt thereof, or a silane, or a polysiloxane.
Abstract:
Methods for preparing a carbonated supplementary cementitious materials, including semi-wet carbonation, cyclic carbonation, non-slurry carbonation, high temperature carbonation and/or granular carbonation of a carbonatable material.
Abstract:
The invention provides novel aerated composite materials made from a carbonatable calcium silicate composition, and formulations and methods of manufacture and use thereof, in particular, the use of novel additive mineral compositions in the form of magnesium, magnesium salts or magnesium oxides, to improve physical chemical properties of low density concrete materials. The low density, aerated material is comprised of calcium carbonate (CaCO3) and silica (SiO2), as cured products of carbonatable calcium silicate compositions.
Abstract:
The invention provides novel aerated composite materials that possess excellent physical and performance characteristics of aerated concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.