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WO2012151657A1 - Compositions cimentaires utilisables en vue de la fabrication de revêtements en béton anti-sabotage et conduites ainsi revêtues - Google Patents

Compositions cimentaires utilisables en vue de la fabrication de revêtements en béton anti-sabotage et conduites ainsi revêtues Download PDF

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Publication number
WO2012151657A1
WO2012151657A1 PCT/CA2011/050293 CA2011050293W WO2012151657A1 WO 2012151657 A1 WO2012151657 A1 WO 2012151657A1 CA 2011050293 W CA2011050293 W CA 2011050293W WO 2012151657 A1 WO2012151657 A1 WO 2012151657A1
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WIPO (PCT)
Prior art keywords
composition
cement
approximately
concrete
aggregate
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Ceased
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PCT/CA2011/050293
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English (en)
Inventor
Philip Souza Zacarias
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Shawcor Ltd
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Shawcor Ltd
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Priority to PCT/CA2011/050293 priority Critical patent/WO2012151657A1/fr
Publication of WO2012151657A1 publication Critical patent/WO2012151657A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0038—Machines or methods for applying the material to surfaces to form a permanent layer thereon lining the outer wall of hollow objects, e.g. pipes
    • 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
    • C04B28/006—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 mineral polymers, e.g. geopolymers of the Davidovits type
    • 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
    • C04B28/02—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 hydraulic cements other than calcium sulfates
    • C04B28/04—Portland 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
    • C04B28/02—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 hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
    • F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
    • F16L58/04—Coatings characterised by the materials used
    • F16L58/06—Coatings characterised by the materials used by cement, concrete, or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/14—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
    • F16L9/153—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups comprising only layers of metal and concrete with or without reinforcement
    • 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
    • C04B2103/0041—Non-polymeric ingredients chosen for their physico-chemical characteristics
    • C04B2103/0043—Compounds chosen for their specific Moh's hardness
    • 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
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00706—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like around pipelines or the like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding

Definitions

  • the present disclosure relates to cementitious compositions, and in particular to cementitious compositions for making anti-tamper concrete (ATC) coatings and coated pipes made therefrom.
  • ATC anti-tamper concrete
  • the present disclosure provides ATC coatings for pipelines and cementitious compositions for making anti-tamper concrete coatings.
  • the ATC coatings are designed to be resistant to physical attack (e.g., from drilling, sawing and/or impact forces), chemicals and/or high temperatures depending on the composition selected.
  • the ATC coatings may be designed to be resistant to drilling with tungsten carbide masonry bits, sawing with fused aluminum oxide (FAO) concrete cutting blades, and/or impact forces from sledge hammers, chisels and the like.
  • FEO fused aluminum oxide
  • the ATC coatings may also be designed to be resistant to strong mineral acids such as hydrochloric, sulphuric and nitric acids, which attack the alkaline constituents of hydrated Portland cement (i.e., calcium silicate hydrate, and a by-product of Portland cement hydration, calcium
  • the ATC coatings may also be designed to be resistant to high temperatures caused, for example, by fires or torches.
  • the ATC coating of the present disclosure may be used to increase the time required to expose the underlying pipe compared to conventional concrete coatings.
  • the ATC coating may also serve to discourage tampering with the pipeline because of the time and cost required to access the underlying pipe.
  • the ATC coating in combination with tamper detection technologies, such as fiber optic sensors, may be used to increase the amount of time available to respond to and prevent access or damage to the pipeline.
  • the ATC coatings may, in some embodiments, increase the time required to expose the steel by up to 15 times the time required for conventional concrete coatings.
  • a cementitious composition comprising : a cement (also known as a binder), an aggregate or mixture of aggregates, and water.
  • the cement may be a Portland cement, a calcium aluminate cement or a geopolymer cement.
  • the aggregate consists of approximately 80 vol. % FAO and
  • the aggregate consists of approximately 50 vol. % FAO, approximately 30 vol. % emery, and approximately 20 vol. % fine siliceous concrete sand of the total composition by volume.
  • the size and hardness of the aggregate may be selected to provide resistance to physical attack such as that from drilling and sawing.
  • the aggregate includes a hard aggregate having a Mohs hardness of 8 or more.
  • the hard aggregate has an average particle size of between 0.5 to 2 mm, preferably an average particle size of 1 mm.
  • the cementitious composition may include reinforcing materials to provide resistance to physical attack such as impact resistance.
  • the reinforcing materials may provide impact resistance by increasing the flexural and tensile of the resultant concrete.
  • the cementitious composition may include one or more additives, such as a friction reducing additive which reduces the friction between tools and the resultant concrete, a high range water reducer which reduces the water content, an additive which improves tensile and/or impact resistance of the resultant concrete, or any combination thereof.
  • a coated pipe comprising : a length of pipe; an ATC coating formed from a cementitious composition in accordance with the present disclosure, the ATC coating being applied to at least a portion of the exterior surface of the pipe.
  • the consistency of the concrete formed ranges from very stiff, with a slump less than approximately 0 mm, to very fluid, having a slump greater than approximately 180 mm .
  • the cement is a geopolymer cement
  • the consistency of the concrete formed ranges from very stiff, with a slump less than approximately 0, to a slump less than approximately 150 mm .
  • the cementitious composition has a total binder content greater than 350 kg/m 3 and a water/cement ratio less than 0.50.
  • the concrete has a void content less than
  • the concrete has a compressive strength of approximately 30 MPa or more, preferably approximately 60 MPa or more.
  • a pipeline comprising at least one section of coated pipe in accordance with the present disclosure.
  • Portland cement is made by heating a source of calcium carbonate (such as limestone) with small quantities of an aluminosilicate such as clay or similar material at a sintering temperature (typically about 1450 °C) in a kiln in a process known as calcination. During calcination a molecule of carbon dioxide is liberated from the calcium carbonate to form calcium oxide which is blended with the secondary materials. The resulting hard substance, called “clinker”, is ground with a small amount of gypsum (calcium sulfate dihydrate) and/or anhydrite into a powder. Portland cement reacts with water to form primarily calcium silicate hydrate.
  • gypsum calcium sulfate dihydrate
  • the strength of the resultant concrete results from a hydration reaction between the silicate phases of Portland cement and water to form calcium aluminate hydrate Ca 3 Si 2 0iiH 8 (3 CaO ⁇ 2 Si0 2 ⁇ 4 H 2 0, or C 3 S 2 H 4 in Cement chemist notation (CCN)) and calcium hydroxide (lime) as a by-product.
  • Portland cement-based ATC coatings may be manufactured with Portland cement meeting the requirements of ASTM C150 Type I, II, I/I I, III, IV or V or equivalent standard specifications.
  • Supplementary cementitious materials may be partially substituted for Portland cement to improve the durability and ultimate strength of the resultant concrete, react with calcium hydroxide, a by-product of Portland cement hydration to form additional binder which further increases durability and ultimate strength, reduce material costs, and provide resistance to acids which may be used to attack the alkaline constituents of hydrated Portland cement.
  • Supplementary cementitious materials also improve the resistance of concrete to chemical attack from soluble sulphate in soild and ground water.
  • the supplementary cementitious materials are silicate or
  • the supplementary cementitious materials may include one or any combination of ground granulated blast furnace slag (GGBFS) (ASTM C989), coal combustion ash (ASTM C618), silica fume (ASTM C1240), rice husk ash or any fine silicate or aluminosilicate material which exhibits pozzolanic properties. Fine silicate or aluminosilicate materials typically haave an average particle size of less than 15 microns.
  • ATC coatings based on Portland cement may be manufactured with or without supplementary cementitious materials.
  • the substitution range of Portland cement with the various supplementary cementitious materials will typically range between 5 and 70% by weight, preferably between 5 and 50% by weight to reduce the impact of lower strengths of caused by higher levels of supplementary cementitious materials and reduce the time before coated ATC pipes can be handled.
  • Calcium aluminate cements are hydraulic cements made primarily from limestone and bauxite.
  • the active ingredients are monocalcium aluminate CaAI 2 0 4 (CaO ⁇ Al 2 0 3 or "CA" in CCN) and mayenite Cai 2 Ali 4 0 33 (12 CaO ⁇ 7 Al 2 0 3 , or C12A7 in CCN). Strength of the resultant concrete results from hydration to calcium aluminate hydrates.
  • Calcium aluminate cements are well-adapted for use in refractory (high-temperature resistant) concretes, such as in furnace linings.
  • Calcium aluminate cement-based ATC coatings typically have an Al 2 0 3 content between 39 and 80%.
  • Supplementary cementitious materials may also be added or partially substituted for Calcium aluminate cement to increase the durability and ultimate strength of the resultant concrete by reducing or preventing conversion (a change in the internal structure of the resultant concrete).
  • the supplementary cementitious materials may also be added or partially substituted for Calcium aluminate cement to increase the durability and ultimate strength of the resultant concrete by reducing or preventing conversion (a change in the internal structure of the resultant concrete).
  • cementitious materials may include one or any combination of fly ash, silica fume or possibly slag (e.g., GGBFS). Hydrated calcium aluminate cements are resistant to sulfate attack and therefore may be suitable when the soils that the pipeline is in contact with contain high levels of naturally occurring soluble sulfates. Calcium aluminate cements, which are used to manufacture refractories, are heat resistant up to temperatures between about 950°C and about 1540°C, depending on the particular concrete composition. Therefore, calcium aluminate cements may be used in the ATC coating when heat resistance is required. When supplementary cementitious materials are used, the substitution range of Calcium aluminate cement with the various supplementary cementitious materials is estimated to range between 5 and 15%.
  • Geopolymer cements are generally formed by reaction of an
  • the supplementary cementitious materials, described above, are the main or primary constituents of geopolymer cements and are blended to achieve a specific rates of reaction and strength.
  • Metakaolin is an aluminosilicate powder generated by thermal activation of kaolinite clay which is commonly used in geopolymer cements.
  • Geopolymer cements can also be made from natural sources of pozzolanic materials such as lava or fly ash from coal.
  • Geopolymer cements-based ATC coatings may comprise a binder system including metakaolin which is calcined at a sintering temperature (typically about 750°C).
  • Geopolymer cements manufactured without metakoalin may alternatively be used; however, the strength may be lower and may be slower to develop.
  • the silicate and aluminosilicate materials may include one or any combination of GGBFS, silica fume, fly ash (ASTM Class C or F), rice hull (husk) ash, cracking catalyst (an aluminosilicate used to process petroleum products) or natural pozzolan (trass or pumice).
  • GGBFS silica fume
  • fly ash ASTM Class C or F
  • rice hull husk
  • cracking catalyst an aluminosilicate used to process petroleum products
  • natural pozzolan trass or pumice
  • the particular geopolymer composition will vary depending on the composition and reactivities of the raw materials used.
  • the composition and reactivity of metakaolin is generally uniform but the compositions and reactivities of an aluminosilicate material such as GGBFS and fly ash can vary widely.
  • orthosilicate form may be added as a solution to the metakaolin and supplementary cementitious materials, typically in powder form, to produce the geopolymer cement.
  • the particular amount of sodium and/or potassium silicate will vary depending on the raw materials used. Through a process of alkaline hydrolysis and condensation a strong and heat resistant cementitious binder may be formed.
  • geopolymer cements may be used for the ATC coating instead of calcium aluminate cements when heat resistance is required.
  • Calcium aluminate cements and geopolymer cements also provide resistance to attack by strong mineral acids, such as hydrochloric, sulphuric and nitric acids which attack the alkaline constituents (i.e., calcium silicate hydrate and lime) of hydrated Portland cement which are susceptible to attack by organic and mineral acids which degrade the concrete rapidly.
  • Calcium aluminate cements and geopolymer cements do not include lime or large amounts of other alkalis which may react with acid applied or otherwise exposed to the concrete. Therefore, calcium aluminate and geopolymer cements may be used for the ATC coating when acid resistance is required. Aggregates
  • the aggregate includes a hard aggregate having a Mohs hardness of 8 or more (based on Mohs scale of mineral hardness).
  • the hard aggregate may be made from natural rock and/or artificial materials.
  • suitable hard aggregates include abrasives such as emery, corundum, fused aluminum oxide (FAO) and calcined bauxite.
  • the hard aggregate system may comprise emery, corundum, FAO or calcined bauxite, or a mixture of any two or more of emery, corundum, FAO or calcined bauxite in any proportion.
  • the aggregate may also include an aggregate having a Mohs hardness of less than 8.
  • the lower hardness aggregate may be sand (such as quartz or silica sand), concrete sand and/or pea gravel.
  • the low hardness aggregate may be added up to a maximum of 50% of the total aggregate by volume to optimize the particle size distribution and to improve particle packing of the aggregate mixture and reduce cost.
  • Fine siliceous concrete sand having the above-noted size distribution may be described as a sand which is substantially retained on the 0.075 mm sieve and passing the 0.600 mm sieve (or +0.75 - 0.060 mm).
  • the aggregate properties including compressive strength, Mohs hardness and modulus of elasticity, are given in Table 2 below.
  • the aggregate properties may vary somewhat according to the source from which the aggregate is extracted or acquired; however, the aggregate properties are generally similar between sources.
  • Emery has a variable composition
  • the compressive strength and moduli of the hard aggregates are significantly higher than the soft aggregates as shown in Table 2.
  • the compressive strengths of concretes prepared with hard aggregates also exhibit significantly higher compressive strengths relative to concrete prepared with soft aggregates.
  • Particle morphology and surface texture also play a role in the development of higher compressive strengths.
  • Hard aggregates are generally angular because of the crushing process used to manufacture them.
  • Siliceous sands used to manufacture conventional concrete are generally rounded due to
  • Concrete prepared with angular aggregates typically exhibit higher compressive strengths due to their higher surface areas and the greater ability to mechanically interlock under compressive stresses.
  • the chemical nature of the aggregate surface may also affect the strength of the bond between the cement paste and the aggregate.
  • the hard aggregate is FAO, calcined bauxite or emery or a mixture of any two or more of FAO, calcined bauxite or emery in any proportion.
  • the linear coefficient of thermal expansion of FAO, calcined bauxite and emery are given in Table 3.
  • ASTP169C entitled “Significance of Tests and Properties of Concrete and Concrete-Making Materials”.
  • FAO is a refractory material and has a linear coefficient of thermal expansion which is significantly less than siliceous sands (e.g., fine sand and quartz) as shown in Table 3.
  • siliceous sands e.g., fine sand and quartz
  • Table 3 At a temperature of 572.7°C, FAO expands 0.85% as described in American Society for Testing and Materials (ASTM) STP169C, entitled “Significance of Tests and Properties of Concrete and Concrete-Making Materials”.
  • ASTM American Society for Testing and Materials
  • STP169C entitled “Significance of Tests and Properties of Concrete and Concrete-Making Materials”.
  • FAO expands and contracts considerable less in response to high temperatures than siliceous sands. Excessive expansion of the aggregate degrades the structural integrity of the concrete due to the development of high internal tensile stresses in the concrete. Therefore, the use of FAO as an aggregate provides a measure of heat resistance to the concrete in which it is carried compared
  • the hard aggregate provides resistance to physical attack from drilling and sawing.
  • an average particle size of between 0.5 to 2 mm for the hard aggregate provides relatively effective resistance to physical attack from drilling and sawing, preferably an average particle size of 1 mm.
  • This particle size provides protection against drilling and sawing by concrete and masonry drill bits and saw blades, such as carbide-tipped masonry bits and blades.
  • the cementitious composition may also include reinforcing materials for reinforcement of the concrete in some embodiments.
  • the reinforcing materials provide resistance to impact by increasing the flexural and tensile strength of the concrete. Reinforcement increases the amount of energy required to cause rupture and complete failure. Reinforcing materials may be added to any of the cement compositions described herein.
  • the reinforcing materials provide strength when cracks form in the concrete as a result of sustained impacts. When a crack forms in the concrete, the reinforcing materials bridge the void created by the crack and allow the concrete to deform in a ductile manner.
  • the reinforcing material may comprise one or any combination of steel rebar, wire mesh, steel fibers, polypropylene fibers, nylon fibers or polyvinyl alcohol fibers.
  • the total content of the reinforcing material is between 0.25% and 2% of the cementitious composition by volume (of concrete), preferably between 0.6% and 2% of the cementitious composition by volume, and preferably 1% to 2% of the cementitious composition by volume.
  • the reinforcing material comprises one or any combination of wire mesh, steel fibers or polyvinyl alcohol fibers. Properties of suitable wire mesh, steel fibers or polyvinyl alcohol fibers are described in Table 4 below.
  • polypropylene fibers and/or polyvinyl alcohol fibers may be used as the reinforcing material .
  • the polypropylene fibers and/or polyvinyl alcohol fibers melt and decompose, opening channels in the concrete.
  • the channels allow water vapour (e.g., steam), which is generated from the decomposition of hydrated cements to escape from the concrete, reducing and/or preventing the cracking and spalling of concrete due to generation of high internal tensile forces.
  • Friction reducing additives may be added to the cementitious composition to reduce the friction between tools (e.g., drill bits, saw blades, etc.) and the concrete. Friction reducing additives increase drilling time and may increase sawing time.
  • the friction reducing additives may comprise one or any combination of granulated polyethylene (such as Ultra-High Molecular Weight Polyethylene (UHMWPE)), graphite or Teflon®. Properties of friction reducing additives are described in Table 5 below.
  • a high range water reducer may be added to the cementitious compositions.
  • use of a high range water reducer is limited to a Portland cement or calcium aluminate cement.
  • a water reducer reduces the water content (e.g., the water/cement ratio), decreases the concrete porosity, increases the concrete strength as less water is required for the concrete mixture to remain workable, increases the workability (assuming the amount of free water remains constant), reduces the water permeability (due to a reduction in connected porosity), and reduces the diffusivity of aggressive agents in the concrete and thereby improves the durability of the concrete.
  • a high range water reducer is an admixture which has the ability to reduce the water/cement of concrete over a wide range, for example 5 to 15% as per ASTM C494, compared with conventional water reducers are typically limited to 5 to 8%.
  • the high range water reducer may be, but is not limited to, a polycarboxylate superplasticizer or other material which is functionally equivalent and meets ASTM C494, Type F and G requirements.
  • additives may be added to the cementitious composition to modify the properties of the concrete, such as acrylic or styrene butadiene latex, or emulsified epoxy to improve tensile and impact resistance.
  • acrylic or styrene butadiene latex or emulsified epoxy to improve tensile and impact resistance.
  • styrene butadiene latex is limited to a Portland cement or calcium aluminate cement.
  • Wollastonite a processed fiberous calcium inosilicate mineral (CaSi0 3 ) having an aspect ratio of 9 : 1 to 15 : 1 (length to diameter) may be added as a component in the geopolymer cement to improve the tensile and flexural properties of the resultant concrete (i.e., as a form of micro-reinforcement) and as a secondary source of calcium ions for the geopolymer binder system.
  • Cementitious compositions in accordance with the present disclosure may have a total binder content between 350 kg/m 3 and 550 kg/m 3 and a water/cement ratio between 0.5 and 0.25. Cementitious compositions having these properties are believes, based on limited testing, to achieve an effective balance between concrete strength and drill/impact resistance. As the amount of the binder content is reduced, the strength of the ultimate concrete is reduced. As the amount of the binder content is increased, the volume of aggregate will be lower and drill resistance will be impacted of the ultimate concrete is reduced.
  • supplementary cementitious materials may be partially substituted for Portland cement between 5% and 50% by weight.
  • a Portland or calcium aluminate cement are used, the consistency of concrete formed is expected to range from very stiff, with a slump less than 0 mm, to very fluid, having a slump greater than 180 mm .
  • a geopolymer cement is used, the consistency of the concrete formed is expected to range from very stiff, with a slump less than 0, to a slump less than 150 mm .
  • the void content of the concrete is preferably less than 15% by volume, more preferably less than 10% by volume, and more preferably less than 5% by volume.
  • the compressive strength of the concrete is at least 30 MPa, preferably 60 MPa or greater. The compressive strength up to approximately 120 MPa are possible but very expensive and difficult to manufacture consistently. Accordingly, a compressive strength of approximately 80-90 MPa may be the practical upper limit for ATC coatings.
  • the ATC coating may be bonded to an anti-corrosion coating (e.g., fusion bonded epoxy, polyethylene or polypropylene) of the steel pipe with an epoxy-based or latex-modified cement slurry adhesive.
  • an anti-corrosion coating e.g., fusion bonded epoxy, polyethylene or polypropylene
  • the bonding of the ATC coating to the steel pipe creates a composite and increases the impact resistance of the ATC coating.
  • the adhesive further makes it difficult to remove the ATC coating from the steel pipe, which makes attaching connections to the steel pipe, such as nipples, more difficult and time consuming.
  • the ATC coating may be applied to bare steel pipe.
  • Two processes are contemplated for use in the manufacture of the ATC coating although other processes may be used : (1) a (compression) wrapping process and (2) a form and pour/pump process.
  • the wrapping process uses concrete which is relatively dry (similar to damp sand which holds together when compressed by hand pressure).
  • the form and pour/pump process uses concrete which is fluid.
  • the concrete used in the wrapping process will likely have a void content between approximately 10 and 25% and the concrete used in the form and pour/pump process will likely have a void between approximately 2 to 4%.
  • cement content can be low if the void content are low and vice versa.
  • Table 6 below shows the relative penetration resistance of ATC coatings relative to conventional Portland cement concrete with a compressive strength of 30-50 MPa.
  • the impact drill resistance results are presented as relative resistance and are based on the rate of penetration with a 25 mm tungsten carbide bit in mm/second using a proprietary testing method.
  • the saw resistance results are presented as relative resistance and are based on rate of penetration in mm/second with a 229 mm diameter FAO masonry blade using a proprietary testing method.
  • Impact resistance is a relative resistance based on Joules required to penetrate 50 mm using proprietary testing method, and time to penetrate 50 mm with an electric impact hammer using a proprietary testing method.
  • Temperature resistance is based on published literature rather than experimental data.
  • the predicted acid resistance is based on published literature and the binder chemistry rather than experimental data.
  • % to 2 vo. % increases the current density significantly.
  • Concrete mixtures containing 430 kg/m 3 cement with dry or plastic consistencies exhibited low electrical resistivities; however, high strength concrete mixtures having 500 or 550 kg/m 3 cement (e.g., Portland cement) exhibited higher electrical resistivities.
  • Steel fibres significantly reduce resistivity by providing low resistance pathways through the concrete coating. Generally, the electrical resistivity is lowered as the content of steel fibres increases.
  • Table 7 illustrates Portland cement mixture range and properties based in accordance with examples of the present disclosure.
  • Steel fibers and wire mesh are provided for reinforcement in the examples in Table 7.
  • Polyvinyl alcohol or other suitable reinforcing materials may be used in addition, or instead of steel fibers and wire mesh in other examples.
  • Some of the examples in Table 6 include friction reducing additives, which may include one or any combination of Teflon, UHMWPE or graphite in the proportions specified.
  • the Examples identified as Type 1-2 and Type 1-3 show improved heat resistance owing, at least in part, to the inclusion of FAO as a hard aggregate and its refractory properties.
  • Examples of Portland cement compositions for use in forming the ATC coatings of the present disclosure are provided in Tables 8 to 12 shown below.
  • the compositions in Table 8 below include reinforcement and aggregate in the form of fine and coarse siliceous concrete aggregate. No hard aggregates are present. Cements formed using the compositions in Table 8 were found to have low drill and saw resistance, moderate impact resistance, and are expected to have low
  • compositions in Table 9 below include no reinforcement but include aggregates in the form of FAO, emery and fine siliceous concrete sand.
  • FAO and emery are considered hard aggregates; however, fine siliceous concrete sand is considered a low hardness aggregate based on Mohs Hardness, as described above.
  • Cements formed using the compositions in Table 9 were found to have high drill and saw resistance, low impact resistance, and a predicted moderate resistance to high temperatures and low resistance to acid. Table 9
  • compositions in Table 10 below include no reinforcement but include aggregates in the form of FAO and fine siliceous concrete sand. Cements formed using the compositions in Table 10 were found to have high drill and saw resistance, low impact resistance, and are predicted to have a moderate resistance to high temperatures and low resistance to acid attack.
  • compositions in Table 11 include steel reinforcement but include aggregates in the form of FAO, emery and fine siliceous concrete sand.
  • FAO and emery are considered hard aggregates but fine concrete sand is considered a soft aggregate based on Mohs hardness, as described above.
  • Cements formed using the compositions in Table 11 were found to have high drill and saw resistance, high impact resistance, moderate resistance to high temperatures and low resistance to acid attack.
  • compositions in Table 12 below include no reinforcement but include aggregates in the form of FAO and fine siliceous concrete sand. Cements formed using the compositions in Table 12 were found to have high drill and saw resistance, high impact resistance, and predicted moderate resistance to high temperatures and low resistance to acid attack. Table 12
  • Table 13 shown below provides a comparison of the example Portland cement compositions in Tables 7 through 11 in terms of various types of anti- tamper resistance.
  • Table 14 illustrates calcium aluminate cement mixture ranges and properties based in accordance with examples of the present disclosure.
  • Steel fibers and wire mesh are provided for reinforcement in the examples in Table 14.
  • Polyvinyl alcohol or other suitable reinforcing materials (such as those described above) may be used in addition, or instead of steel fibers and wire mesh in other examples.
  • Some of the examples in Table 14 include friction reducing additives, which may include one or any combination of Teflon, UHMWPE or graphite in the proportions specified.
  • the calcium aluminate cements in Table 14 show improved heat and acid resistance owing, at least in part, to the refractory properties of the calcium aluminate binder.
  • the calcium aluminate binder allows even further improved heat and acid resistance compared to Portland cement mixtures which utilize refractory aggregates.
  • Table 15 illustrates geopolymer cement mixture range and properties based in accordance with examples of the present disclosure.
  • Steel fibers and wire mesh are provided for reinforcement in the examples in Table 15.
  • Polyvinyl alcohol or other suitable reinforcing materials (such as those described above) may be used in addition, or instead of steel fibers and wire mesh in other examples.
  • Some of the examples in Table 15 include friction reducing additives, which may include one or any combination of Teflon, UHMWPE or graphite in the proportions specified.
  • the geopolymer cements in Table 15 show improved heat and acid resistance owing, at least in part, to the refractory properties of the geopolymer binder.
  • the geopolymer binder allows even further improved heat and acid resistance compared to Portland cement mixtures which utilize refractory aggregates.

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Abstract

La présente invention concerne des revêtements en béton anti-sabotage pour conduites et des compositions cimentaires utilisables en vue de la fabrication desdits revêtements en béton anti-sabotage. Conformément à un mode de réalisation, la présente invention concerne une composition cimentaire contenant un ciment choisi parmi un ciment Portland, un ciment à base d'aluminate de calcium ou un ciment géopolymère ; un granulat comprenant un granulat dur présentant une dureté, sur l'échelle de Mohs, supérieure ou égale à 8 ; et de l'eau.
PCT/CA2011/050293 2011-05-11 2011-05-11 Compositions cimentaires utilisables en vue de la fabrication de revêtements en béton anti-sabotage et conduites ainsi revêtues Ceased WO2012151657A1 (fr)

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Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140339745A1 (en) * 2013-05-17 2014-11-20 Stuart URAM Molds for ceramic casting
CN104197119A (zh) * 2014-09-19 2014-12-10 新兴铸管股份有限公司 一种具有复合防腐涂层的球墨铸铁管及其制备方法
CN104867576A (zh) * 2015-04-21 2015-08-26 安徽埃克森科技集团有限公司 一种电缆护套用防腐喷涂复合材料及其制备方法
WO2017085688A1 (fr) * 2015-11-19 2017-05-26 Cementos Argos S.A. Formulation de matériau de liant hydraulique pour l'obtention de mortiers avec une réaction alcali-silice réduite
US10071934B1 (en) * 2017-02-22 2018-09-11 Nano And Advanced Materials Institute Limited High performance fire resistant concrete containing hybrid fibers and nano particles
US10150703B2 (en) 2016-06-28 2018-12-11 King Fahd University Of Petroleum And Minerals Cementitious blend and concrete mix compositions resistant to high temperatures and alkaline conditions
WO2018231044A1 (fr) * 2017-06-16 2018-12-20 Gutierrez Obeso Orlando Composite cimentaire activé mécaniquement pour l'arrêt d'impact d'arme à feu
EP2229241B1 (fr) * 2007-12-04 2019-06-05 Oerlikon Metco (US) Inc. Revêtement anticorrosif multicouche
EP3370962A4 (fr) * 2015-11-04 2019-06-12 Imerys Filtration Minerals, Inc. Compositions et procédés de fabrication additive
CN110015853A (zh) * 2019-01-23 2019-07-16 同济大学 超高韧性地聚合物及其制备方法
CN110922108A (zh) * 2019-12-09 2020-03-27 大连理工大学 一种基于稻壳灰-赤泥复合胶凝材料的城市生活垃圾焚烧飞灰固化方法
RU2762216C1 (ru) * 2020-11-12 2021-12-16 Владимир Эдуардович Карташян Соединительная деталь трубопровода с наружным утяжеляющим бетонным покрытием
CN114426436A (zh) * 2022-01-25 2022-05-03 湖南大学 一种高吸水率的内养护材料及其应用
IT202100005723A1 (it) * 2021-03-11 2022-09-11 Daniel Pinter Pannello isolante
CN117142811A (zh) * 2023-09-20 2023-12-01 齐齐哈尔大学 一种秸秆地聚物墙体材料的制备工艺
WO2024105460A1 (fr) * 2023-07-05 2024-05-23 Rasekhisahneh Alireza Ciment d'aluminate de calcium respectueux de l'environnement mélangé à de la zéolite et de la pierre ponce

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2229241B1 (fr) * 2007-12-04 2019-06-05 Oerlikon Metco (US) Inc. Revêtement anticorrosif multicouche
US20140339745A1 (en) * 2013-05-17 2014-11-20 Stuart URAM Molds for ceramic casting
CN104197119A (zh) * 2014-09-19 2014-12-10 新兴铸管股份有限公司 一种具有复合防腐涂层的球墨铸铁管及其制备方法
CN104867576A (zh) * 2015-04-21 2015-08-26 安徽埃克森科技集团有限公司 一种电缆护套用防腐喷涂复合材料及其制备方法
EP3370962A4 (fr) * 2015-11-04 2019-06-12 Imerys Filtration Minerals, Inc. Compositions et procédés de fabrication additive
WO2017085688A1 (fr) * 2015-11-19 2017-05-26 Cementos Argos S.A. Formulation de matériau de liant hydraulique pour l'obtention de mortiers avec une réaction alcali-silice réduite
US11479507B2 (en) 2016-06-28 2022-10-25 King Fahd University Of Petroleum And Minerals Concrete mix composition
US10150703B2 (en) 2016-06-28 2018-12-11 King Fahd University Of Petroleum And Minerals Cementitious blend and concrete mix compositions resistant to high temperatures and alkaline conditions
US11485684B2 (en) 2016-06-28 2022-11-01 King Fahd University Of Petroleum And Minerals Water cured concrete mix composition
US10071934B1 (en) * 2017-02-22 2018-09-11 Nano And Advanced Materials Institute Limited High performance fire resistant concrete containing hybrid fibers and nano particles
WO2018231044A1 (fr) * 2017-06-16 2018-12-20 Gutierrez Obeso Orlando Composite cimentaire activé mécaniquement pour l'arrêt d'impact d'arme à feu
CN110015853A (zh) * 2019-01-23 2019-07-16 同济大学 超高韧性地聚合物及其制备方法
CN110922108A (zh) * 2019-12-09 2020-03-27 大连理工大学 一种基于稻壳灰-赤泥复合胶凝材料的城市生活垃圾焚烧飞灰固化方法
CN110922108B (zh) * 2019-12-09 2021-08-10 大连理工大学 一种基于稻壳灰-赤泥复合胶凝材料的城市生活垃圾焚烧飞灰固化方法
RU2762216C1 (ru) * 2020-11-12 2021-12-16 Владимир Эдуардович Карташян Соединительная деталь трубопровода с наружным утяжеляющим бетонным покрытием
IT202100005723A1 (it) * 2021-03-11 2022-09-11 Daniel Pinter Pannello isolante
CN114426436A (zh) * 2022-01-25 2022-05-03 湖南大学 一种高吸水率的内养护材料及其应用
WO2024105460A1 (fr) * 2023-07-05 2024-05-23 Rasekhisahneh Alireza Ciment d'aluminate de calcium respectueux de l'environnement mélangé à de la zéolite et de la pierre ponce
CN117142811A (zh) * 2023-09-20 2023-12-01 齐齐哈尔大学 一种秸秆地聚物墙体材料的制备工艺

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