Process for the Preparation of Cement, Mortars, Concrete Compositions Containing a Calcium Carbonate - Based Filler Treated with an Ultrafine Filler and a Superplasticizer, Compositions and Cement Products Obtained and Their Applications

Abstract

PROCESS for the preparation of cement/mortar/concrete compositions or systems, (for simplicity hereafter “cement” compositions or systems or even “cements”), of a generally known type containing low or medium (standard) “filler(s)”, and/or optionally HP filler(s), as carbonate-based filler(s), namely coarse low or medium calcium carbonate(s), namely coarse marble(s); Product comprising, or consisting of, the pre-blend (A) of coarse, low or medium (or optionally HP) “calcium carbonate-based filler” pre-blended with at least an UF; Aqueous compositions (B) obtained by mixing the above pre-blend (A) of coarse filler(s) with UF(s) with an aqueous system such as mix water, aqueous mix fluid; Product (C) consisting of, or comprising, the pre-blend (A) or the compositions (B), treated or pretreated with at least one superplastifier or aqueous system containing superplastifier(s); Cement and Use of cement.

1 . A product comprising a blend of a course calcium carbonate-comprising filler and an ultrafine filler, wherein the blend is treated with at least one treating agent comprising at least one superplastifier. 
     
     
         2 . The product according to  claim 1 , wherein the calcium carbonate-comprising filler is ground natural calcium carbonate, precipitated calcium carbonate, modified calcium carbonate, or any mixture thereof. 
     
     
         3 . The product according to  claim 1 , wherein the course calcium carbonate-comprising filler has particles having a d 50 >6 microns. 
     
     
         4 . The product according to  claim 1 , wherein the course calcium carbonate-comprising filler is selected from the group consisting of (i) calcium carbonate having a d 50  of 7 to 9 microns and a Blaine of 462 to 690 m 2 /g, (ii) calcium carbonate having d 50  of 10.4 to 10.8, and (iii) calcium carbonate having a d 50  of 18 microns and a Blaine of about 365 m 2 /g. 
     
     
         5 . The product according to  claim 1 , wherein the ultrafine filler has a d 50  from 1 to 6 microns and a Blaine of greater than 1000 m 2 /kg. 
     
     
         6 . The product according to  claim 1 , wherein the ultrafine filler has a d 50  from 1 to 5 microns and a Blaine of greater than 1000 m 2 /kg and of less than 2000 m 2 /kg. 
     
     
         7 . The product according to  claim 1 , wherein the ultrafine filler is selected from the group consisting of: (i) a silica fume having a d 50  of 1 to 2 microns, (ii) metakaolin having a d 50  of 3 to 5 microns, (iii) metakaolin having a d 50  of 3 to 6 microns, a chalk having a d 50  of 1 to 5 microns, (iv) a calcite having a d 50  of about 1 micron; (v) white limestone having a d 50  of about 2 microns, (vi) a marble having a d 50  of 1 to 6 microns, (vii) a marble having a d 50  of 1 to 5 microns, (viii) ultrafine calcium carbonate having a d 50  of 1-2 microns, (ix) ultrafine calcium carbonate from microcrystaline whiting having a d 50  of about 2.4 micron, (x) an utrafine siliceous product having a d 50  of about 1.86 microns, (xi) modified calcium carbonate having a d 50  of about 2.29 microns, and (xii) precipitated calcium carbonate having a d 50  of about 1.52 microns. 
     
     
         8 . The product according to  claim 1 , wherein the ultrafine filler is selected from the group consisting of: (i) ultrafine calcium carbonate having a d 50  of about 2.4 microns, (ii) silica fume, (iii) metakaolin, and (iv) ultrafine calcium carbonate having a d 50  of 1 to 2 microns. 
     
     
         9 . The product according to  claim 1 , which further comprises water. 
     
     
         10 . The product according to  claim 1 , wherein the at least one treating agent comprising at least one superplastifier is a superplastifier. 
     
     
         11 . The product according to according to  10 , wherein superplastifier is a polycarboxylate, a polycarboxylate ether, or a product manufactured from sulfonated naphthalene condensate or sulfonated melamine formaldehyde. 
     
     
         12 . The product according to  claim 10 , wherein the superplastifier is a polycarboxylate ether. 
     
     
         13 . A cement composition comprising the product according to  claim 1 . 
     
     
         14 . The cement composition according to  claim 13 , wherein the superplastifier is present in an amount of from 0.3 to 3 kg for 100 kg of the cement composition, on a dry to dry basis. 
     
     
         15 . The cement composition according to  claim 13 , wherein the superplastifier is present in an amount of from 0.3 to 2 kg for 100 kg of the cement composition, on a dry to dry basis. 
     
     
         16 . The cement composition according to  claim 13 , wherein the at least one treating agent comprises a superplastifier only, or a superplastifier and a plasticizer. 
     
     
         17 . The cement composition according to  claim 13 , wherein the at least one treating agent comprises a superplastifier and a plasticizer in a ratio of from 95/5 to 85/15 on a dry weight basis. 
     
     
         18 . The cement composition according to  claim 13 , further comprising one or more of a fluidifier, a setting accelerator, a setting retarder and an air entrainment agent. 
     
     
         19 . The cement composition according to  claim 13 , wherein the course calcium carbonate-comprising filler is dry calcium carbonate, the at least one treating agent is a superplastifier, and the cement composition further comprises one or more additives, and optionally water and aggregates selected from the group consisting of sand and gravel. 
     
     
         20 . A cement product made from the cement composition of  claim 13 .