Compositions
Compositions such as concrete compositions are described for use in building materials and products. The composition may comprise an aggregate composition comprising a particulate suppressing component and a cement. The composition may have an impact resistance of at least Class 1 as measured under ANSI/FM 4473. Methods of preparing and using such compositions are also described.
1. A concrete composition comprising:
an aggregate composition comprising a particulate suppressing component, wherein the particulate suppressing component comprises an aggregate that has an average particle size (d 50 ) of 0.1 mm to 5 mm and a d 10 particle size greater than or equal to 200 mesh and less than or equal to 70 mesh; and
a hydraulic cement;
wherein dry machining of the concrete composition results in exposures under a Permissible Exposure Limit (PEL) of 50 micrograms of respirable crystalline silica per cubic meter of air (50 μg/m 3 ) as an 8-hour time-weighted average as defined by 29 CFR 1926.1153; and
wherein the composition has an impact resistance of at least Class 3 as measured under ANSI/FM 4473.
2. The concrete composition of claim 1 , wherein the aggregate comprises granite, gneiss, basalt, or a material that has a Mohs hardness less than 6; and wherein the particulate suppressing component further comprises an organic compound or admixture; a fiber material; or a combination thereof.
3. The concrete composition of claim 1 , wherein the aggregate has a d 90 particle size less than or equal to 4 mesh, greater than or equal to 7 mesh, or less than or equal to 4 mesh and greater than or equal to 7 mesh.
4. The concrete composition of claim 2 , wherein the material that has a Mohs hardness less than 6 comprises calcium carbonate, limestone, dolomite, clay, wollastonite, or a combination thereof.
5. The concrete composition of claim 2 , wherein the particulate suppressing component comprises the organic compound or admixture, and the organic compound or admixture comprises latex, a fatty acid, or a mixture thereof.
6. The concrete composition of claim 5 , wherein the particulate suppressing component further comprises the fiber material.
7. The concrete composition of claim 1 , wherein the aggregate has a roundness shape factor less than 0.8, a sphericity shape factor less than 0.8, or a roundness shape factor less than 0.8 and a sphericity shape factor less than 0.8.
8. The concrete composition of claim 1 , wherein the concrete composition comprises less than 25% by weight silica, less than 15% by weight silica, less than 10% by weight silica, less than 5% by weight silica, less than 1% by weight silica, or less than 0.1% by weight silica, with respect to the total weight of the concrete composition.
9. The concrete composition of claim 1 , wherein the aggregate composition is substantially devoid of siliceous sand.
10. The concrete composition of claim 1 , wherein the aggregate composition is present in an amount of 35% to 90% by weight, with respect to the total weight of the concrete composition.
11. The concrete composition of claim 1 , wherein the concrete composition has at least a Class C fire rating as measured under ASTM E 108.
12. The concrete composition of claim 1 , wherein the concrete composition is a roof tile.
13. A roof tile comprising:
an aggregate composition comprising a particulate suppressing component, wherein the particulate suppressing component comprises an aggregate that has an average particle size (d 50 ) of 0.1 mm to 5 mm and a d 10 particle size greater than or equal to 200 mesh and less than or equal to 70 mesh; and
a cement;
wherein the roof tile comprises less than 25% siliceous sand;
wherein dry machining of the roof tile results in exposures under a Permissible Exposure Limit (PEL) of 50 micrograms of respirable crystalline silica per cubic meter of air (50μg/m 3 ) as an 8-hour time-weighted average as defined by 29 CFR 1926.1153; and
wherein the roof tile has an impact resistance of at least Class 1 as measured under ANSI/FM 4473.
14. The roof tile of claim 13 , wherein an average thickness of the roof tile is 1 inch to 30 inches, an average weight of the roof tile is 5 pounds to 15 pounds, or wherein an average thickness of the roof tile is 1 inch to 30 inches and an average weight of the roof tile is 5 pounds to 15 pounds.
15. The roof tile of claim 13 , wherein a weight ratio of the aggregate composition to the cement is 2 to 5.
16. The roof tile of claim 13 , wherein a transverse break strength of the roof tile is 100 pounds force to 400 pounds force.
17. The roof tile of claim 13 , wherein:
(a) an average porosity of the roof tile is greater than an average porosity of a second roof tile comprising more than 25% silica; or
(b) an amount of dust generated during dry machining of the roof tile is less than an amount of dust generated during dry machining of a second roof tile comprising more than 25 % by weight silica;
wherein the second roof tile comprises the cement and an aggregate composition that includes siliceous sand.
18. The roof tile of claim 17 , wherein the amount of dust generated by the roof tile in (b) comprises less than 20% insoluble material as measured under ASTM D3042-17.
19. The roof tile of claim 13 , wherein the aggregate composition has a d 90 particle size less than or equal to 4 mesh.
20. The roof tile of claim 13 , wherein the aggregate composition comprises calcium carbonate, limestone, dolomite, clay, wollastonite, or a combination thereof.
21. A tile system, comprising:
at least one first tile comprising siliceous sand and a hydraulic cement; and
at least one second tile comprising (i) a polymer composite or (ii) the concrete composition of claim 1 ;
wherein the first tile and the second tile include complementary features; and
wherein each of the first tile and the second tile has an impact resistance of at least Class 3 as measured under ANSI/FM 4473.