CA2478319A1 - Sprayable machinable media - Google Patents

Sprayable machinable media Download PDF

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Publication number
CA2478319A1
CA2478319A1 CA002478319A CA2478319A CA2478319A1 CA 2478319 A1 CA2478319 A1 CA 2478319A1 CA 002478319 A CA002478319 A CA 002478319A CA 2478319 A CA2478319 A CA 2478319A CA 2478319 A1 CA2478319 A1 CA 2478319A1
Authority
CA
Canada
Prior art keywords
mixture
slurry
weight
binder
calcium sulfate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002478319A
Other languages
French (fr)
Other versions
CA2478319C (en
Inventor
Dennis Mark Lettkeman
Eldon L. Whiteside
Raymond A. Ii Kaligian
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
United States Gypsum Co
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2478319A1 publication Critical patent/CA2478319A1/en
Application granted granted Critical
Publication of CA2478319C publication Critical patent/CA2478319C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
    • C04B22/08—Acids or salts thereof
    • C04B22/14—Acids or salts thereof containing sulfur in the anion, e.g. sulfides
    • C04B22/142—Sulfates
    • C04B22/143—Calcium-sulfate
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
    • C04B28/147—Calcium sulfate hemi-hydrate with a specific crystal form beta-hemihydrate
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/12—Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/02—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing
    • B28C5/026—Mixing guns or nozzles; Injector mixers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/10—Accelerators; Activators
    • C04B2103/12—Set accelerators
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures
    • C04B2111/00155—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/32—Expansion-inhibited materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility
    • C04B2111/802—White cement

Abstract

In conjunction with water, a mixture can be used to prepare a sprayable slurry that hydrates to form a machinable plaster composition. The mixture includes from about 80% to about 98% by weight calcium sulfate hemihydrate, from about 1 % to about 5% by weight adhesive binder for adhering said plaster mixture to a substrate and from about.001 % to about 10% of a polysaccharide. The mixture is made into a slurry by the addition of from 10% to about 50 weight water based on the weight of the mixture.

Claims (22)

1. A mixture to be employed in conjunction with water for preparing a sprayable slurry that hydrates to form a machinable plaster composition, said mixture comprising:
from about 80% to about 98% by weight calcium sulfate hemihydrate;
from about 1 % to about 5% by weight adhesive binder for adhering said plaster mixture to a substrate; and from about 0.001 % to about 10% of a polysaccharide.
2. The mixture according to claim 1 further comprising an internal binder.
3. The mixture according to claim 2 wherein said internal binder is a polyethylene glycol).
4. The mixture according to claim 2 wherein said internal binder is a polyethylene glycol) having a molecular weight of approximately 8,000 Daltons.
5. The mixture according to claim 2 wherein said internal binder is a polyethylene glycol), and said adhesive binder is an ethylene/vinyl acetate copolymer.
6. The mixture according to claim 1 wherein said adhesive binder is a water redispersible composition having adhesive properties.
7. The mixture according to claim 1 wherein said adhesive binder is an ethylene/vinyl acetate copolymer.
8. The mixture according to claim 1, further comprising a polymeric resin.
9. The mixture according to claim 8 wherein said polysaccharide has a molecular weight greater than 2,000,000 Daltons.
10. The mixture according to claim 1 wherein said mixture comprises approximately 80% to 90% by weight of said calcium sulfate hemihydrate, approximately between 0.01 % and 1 by weight of said polysaccharide, and approximately between 1 and 5 percent by weight of said adhesive binder.
11. The mixture according to claim 10 wherein said internal binder is polyethylene glycol), and said adhesive binder is ethylene/vinyl acetate copolymer.
12. The mixture according to claim 10 further including less than 1 % of a defoamer.
13. The mixture according to claim 11 wherein said mixture comprises from about 6% to about 9% by weight of said poly(ethylene glycol).
14. A sprayable slurry that hydrates to form a machinable plaster, said slurry comprising:
a dry mixture comprising:
calcium sulfate hemihydrate;
an adhesive binder; and polysaccharide; and from about 10% to about 50% water based on the weight of said dry mixture.
15. The slurry according to claim 14 wherein said slurry comprises less than 32 weight % water based on the weight of the dry mixture.
16. The slurry according to claim 15 wherein said slurry comprises less than 25 weight % water based on the weight of the dry mixture.
17. The slurry according to claim 14 wherein said calcium sulfate hemihydrate is alpha-calcium sulfate hemihydrate.
18. The slurry according to claim 14, further comprising a defoamer.
19. The slurry according to claim 18 wherein said defoamer comprises from about 0.2% to about 0.8% by weight of said mixture.
20. The slurry according to claim 14 further including a setting rate retarder comprising one or more of sodium citrate, citric acid, tartaric acid, sodium tartrate, a proteinaceous material, or a phosphate.
21. A method of making a shaped plaster article comprising:
mixing a slurry comprising calcium sulfate hemihydrate, an adhesive binder for adhering said slurry to a substrate, 0.01 to 10%
by weight polysaccharide and water;
spraying said slurry onto a substrate;
allowing said slurry to set forming a hardened plaster;
and machining the hardened plaster to a desired shape with machine tools.
22. A shaped gypsum article on a substrate comprising:
an article shaped by machining the set and dried product of a slurry sprayed onto and adhering to a substrate, said slurry comprising calcium sulfate hemihydrate, an adhesive binder for adhering said plaster mixture to a substrate, 0.001 % to 10% by weight polysaccharide and water.
CA2478319A 2002-03-27 2003-03-27 Sprayable machinable media Expired - Lifetime CA2478319C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US36792002P 2002-03-27 2002-03-27
US60/367,920 2002-03-27
PCT/US2003/009569 WO2003082767A1 (en) 2002-03-27 2003-03-27 Sprayable machinable media

Publications (2)

Publication Number Publication Date
CA2478319A1 true CA2478319A1 (en) 2003-10-09
CA2478319C CA2478319C (en) 2010-12-21

Family

ID=28675420

Family Applications (3)

Application Number Title Priority Date Filing Date
CA2478323A Expired - Lifetime CA2478323C (en) 2002-03-27 2003-03-27 High strength flooring compositions
CA2478319A Expired - Lifetime CA2478319C (en) 2002-03-27 2003-03-27 Sprayable machinable media
CA2477709A Expired - Lifetime CA2477709C (en) 2002-03-27 2003-03-27 High molecular weight additives for calcined gypsum and cementitious compositions

Family Applications Before (1)

Application Number Title Priority Date Filing Date
CA2478323A Expired - Lifetime CA2478323C (en) 2002-03-27 2003-03-27 High strength flooring compositions

Family Applications After (1)

Application Number Title Priority Date Filing Date
CA2477709A Expired - Lifetime CA2477709C (en) 2002-03-27 2003-03-27 High molecular weight additives for calcined gypsum and cementitious compositions

Country Status (10)

Country Link
US (2) US7056964B2 (en)
EP (3) EP1485330B1 (en)
JP (3) JP2005521622A (en)
AT (2) ATE496013T1 (en)
CA (3) CA2478323C (en)
DE (2) DE60335791D1 (en)
ES (3) ES2432640T3 (en)
HK (1) HK1072592A1 (en)
MX (3) MXPA04009326A (en)
WO (3) WO2003082765A1 (en)

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