Rapid setting material for improved processing and performance of carbonating metal silicate cement

Abstract

Cementitious compositions and methods for producing the cementitious compositions are described herein. The methods can include mixing a compound of the general formula MaSibXcOd, MaSibXcOd(OH)e, MaSibXc(OH)e, or MaSibXc(OH)e, (H2O)f, wherein M comprises a metal that can react with carbon dioxide in a carbonation reaction to form a carbonate, Si forms an oxide during the carbonation reaction, X is an element other than M or Si, a, b, d, e, and f are greater than zero, and c is zero or greater, with a rapid setting hydraulic cement to produce a cementitious mixture. The methods can further include hydrating the cementitious mixture and carbonating the cementitious mixture. Carbonating the cementitious mixture can occur simultaneously with hydrating the cementitious mixture or subsequent to hydrating the cementitious mixture. In some embodiments, the non-hydraulic cement can comprise wollastonite. The hydraulic cement can be in an amount of from 5 wt % to 80 wt % of the cementitious composition.

1 - 20 . (canceled) 
     
     
         21 . A cementitious composition comprising:
 a non-hydraulic cement comprising a compound of the general formula M a Si b X c O d , M a Si b X c O d (OH) e , M a Si b X c (OH) e , M a Si b X c (OH) e (H 2 O) f , or mixtures thereof, wherein M is an alkaline earth metal selected from the group consisting of calcium, magnesium, and sodium; X is an element other than M or Si; a, b, d, e, and f are greater than zero, and c is zero or greater; and   a rapid setting hydraulic cement selected from the group consisting of calcium aluminate cement, calcium phosphate cement, calcium sulfate hydrate cement, calcium aluminate sulfonate cement, magnesium oxychloride cement, magnesium oxysulfate cement, magnesium phosphate cement, and combinations thereof.   
     
     
         22 . The cementitious composition of  claim 21 , wherein the compound is from the wollastonite group. 
     
     
         23 . The cementitious composition of  claim 21 , wherein the non-hydraulic cement includes wollastonite. 
     
     
         24 . The cementitious composition of  claim 21 , wherein the non-hydraulic cement further comprises Ca(OH) 2 . 
     
     
         25 . The cementitious composition of  claim 21 , wherein the cementitious composition comprises 10 wt % to 75 wt % of the hydraulic cement and 25 wt % to 90 wt % of the non-hydraulic cement, based on the total weight of the cementitious composition. 
     
     
         26 . The cementitious composition of  claim 21 , wherein the cementitious composition further comprises an aggregate. 
     
     
         27 . The cementitious composition of  claim 26 , wherein the aggregate comprises ash. 
     
     
         28 . The cementitious composition of  claim 26 , wherein the aggregate comprises a lightweight aggregate. 
     
     
         29 . The cementitious composition of  claim 21 , wherein the cementitious composition further comprises inorganic fibers or organic fibers. 
     
     
         30 . The cementitious composition of  claim 29 , wherein the cementitious composition comprises polyvinyl alcohol fibers, polypropylene fibers, polyacrylonitrile fibers, polyester fibers, or carbon fibers. 
     
     
         31 . A cementitious product prepared by:
 hydrating the cementitious composition of  claim 21 ; and   carbonating the cementitious composition.   
     
     
         32 . The cementitious product of  claim 31 , wherein the cementitious product has a compressive strength of at least 1000 lbs/in 2 . 
     
     
         33 . A building material comprising the cementitious product of  claim 31 , wherein the building material is a tile, a brick, a paver, a panel, a synthetic stone, or an underlay. 
     
     
         34 . A cementitious composition comprising:
 a non-hydraulic cement comprising a compound from the wollastonite group, and   15 wt % to 70 wt %, based on the total weight of the cementitious composition, of a rapid setting hydraulic cement selected from the group consisting of calcium aluminate cement, calcium phosphate cement, calcium sulfate hydrate cement, calcium aluminate sulfonate cement, magnesium oxychloride cement, magnesium oxysulfate cement, magnesium phosphate cement, and combinations thereof; and   an aggregate.   
     
     
         35 . The cementitious composition of  claim 34 , wherein the non-hydraulic cement further includes Ca(OH) 2 . 
     
     
         36 . The cementitious composition of  claim 34 , wherein the cementitious composition further comprises inorganic fibers or organic fibers. 
     
     
         37 . A cementitious product prepared by:
 hydrating the cementitious composition of  claim 34 ; and   carbonating the cementitious composition;   wherein the cementitious product has a compressive strength of at least 1000 lbs/in 2 .   
     
     
         38 . A cementitious product prepared by:
 hydrating a cementitious composition comprising:
 a non-hydraulic cement comprising a compound of the general formula M a Si b X c O d , M a Si b X c O d (OH) e , M a Si b X c (OH) e , M a Si b X c (OH) e (H 2 O) f , or mixtures thereof, wherein M is an alkaline earth metal selected from the group consisting of calcium, magnesium, and sodium; X is an element other than M or Si; a, b, d, e, and f are greater than zero, and c is zero or greater; 
 10 wt % to 75 wt % of a rapid setting hydraulic cement selected from the group consisting of calcium aluminate cement, calcium phosphate cement, calcium sulfate hydrate cement, calcium aluminate sulfonate cement, magnesium oxychloride cement, magnesium oxysulfate cement, magnesium phosphate cement, and combinations thereof; and 
 an aggregate; and 
 carbonating the cementitious composition. 
   
     
     
         39 . The cementitious product of  claim 38 , wherein the non-hydraulic cement comprises wollastonite, and the hydraulic cement comprises calcium sulfate hydrate cement. 
     
     
         40 . A building material comprising the cementitious product of  claim 38 , wherein the building material is a roofing tile, a ceramic tile, or architectural stone.