PERLITE-BASED CEMENTITIOUS MATERIALS, CONCRETE, AND RELATED TECHNIQUES
Treated perlite-based cementitious materials, concrete, and related techniques are disclosed. In accordance with some embodiments, a treated perlite-based cementitious material may be produced by intergrinding raw perlite ore, polyvinyl alcohol (PVA) powder, a polycarboxy late material, and (optionally) at least one of calcium sulfate (CaSO 4 ) and calcium sulfite (CaSO 3 ). In accordance with some embodiments, expanded perlite wastes and/or expanded perlite also may be included in the cementitious material. In accordance with some embodiments, raw perlite ore, expanded perlite wastes, and expanded perlite may be combined in providing a cementitious material. In at least some cases, the cementitious material may be provided as an all-in-one powder blend. In accordance with some embodiments, concrete may be produced by mixing the cementitious material with ordinary Portland cement (OPC), sand, rock, and water.
1 . A method comprising:
producing a treated perlite-based cementitious mixture comprising:
raw perlite ore;
polyvinyl alcohol (PVA) powder; and
a polycarboxylate material.
2 - 3 . (canceled)
4 . The method of claim 1 , wherein producing the treated perlite-based cementitious mixture involves intergrinding the raw perlite ore, the PVA powder, and the polycarboxylate material until a D90 particle size distribution of about 38 μm is achieved for the treated perlite-based cementitious mixture.
5 . The method of claim 1 , wherein producing the treated perlite-based cementitious mixture involves intergrinding the raw perlite ore, the PVA powder, and the polycarboxylate material until a D90 particle size distribution of about 28 μm is achieved for the treated perlite-based cementitious mixture.
6 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises at least one of calcium sulfate (CaSO 4 ) and calcium sulfite (CaSO 3 ).
7 . The method of claim 6 , wherein producing the treated perlite-based cementitious mixture involves intergrinding the raw perlite ore, the PVA powder, the polycarboxylate material, and the at least one of calcium sulfate and calcium sulfite.
8 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises at least one of expanded perlite waste and expanded perlite.
9 . The method of claim 8 , wherein producing the treated perlite-based cementitious mixture involves intergrinding the raw perlite ore, the PVA powder, the polycarboxylate material, and the at least one of expanded perlite waste and expanded perlite.
10 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises expanded perlite waste and expanded perlite.
11 . The method of claim 10 , wherein producing the treated perlite-based cementitious mixture involves intergrinding the raw perlite ore, the PVA powder, the polycarboxylate material, the expanded perlite waste, and the expanded perlite.
12 . A method comprising:
producing a concrete comprising:
the treated perlite-based cementitious mixture produced according to claim 1 ;
ordinary Portland cement (OPC);
water; and
at least one of rock and sand.
13 . The method of claim 12 , wherein the treated perlite-based cementitious mixture and the OPC are provided in a 50-50 blend.
14 . A concrete product comprising concrete produced according to claim 12 .
15 . A composition of matter comprising:
raw perlite ore;
polyvinyl alcohol (PVA) powder; and
a polycarboxylate material.
16 . (canceled)
17 . The composition of matter of claim 15 , wherein the composition of matter has a D90 particle size distribution of about 38 μm±3 μm.
18 . The composition of matter of claim 15 , wherein the composition of matter has a D90 particle size distribution of about 28 μm±3 μm.
19 - 21 . (canceled)
22 . The composition of matter of claim 15 , further comprising ordinary Portland cement (OPC).
23 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises expanded perlite waste, wherein the expanded perlite waste constitutes about 6 wt % or less of the treated perlite-based cementitious mixture.
24 - 28 . (canceled)
29 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises expanded perlite, wherein the expanded perlite constitutes about 1 wt % or less of the treated perlite-based cementitious mixture.
30 - 32 . (canceled)
33 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises:
expanded perlite waste, wherein the expanded perlite waste constitutes about 5 wt % of the treated perlite-based cementitious mixture; and
expanded perlite, wherein the expanded perlite constitutes about 0.5 wt % of the treated perlite-based cementitious mixture.
34 . The method of claim 33 , wherein at least one of:
the expanded perlite waste has a D90 particle size distribution of about 40 μm;
the expanded perlite has a D90 particle size distribution of about 25 μm;
the PVA powder constitutes about 0.05 wt % of the treated perlite-based cementitious mixture; and
the polycarboxylate material constitutes about 0.2 wt % of the treated perlite-based cementitious mixture.
35 - 37 . (canceled)
38 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises:
expanded perlite waste, wherein the expanded perlite waste constitutes about 6 wt % of the treated perlite-based cementitious mixture; and
expanded perlite, wherein the expanded perlite constitutes about 0.5 wt % of the treated perlite-based cementitious mixture.
39 . The method of claim 38 , wherein at least one of:
the expanded perlite waste has a D90 particle size distribution of about 20 μm
the expanded perlite has a D90 particle size distribution of about 20 μm;
the PVA powder constitutes about 0.15 wt % of the treated perlite-based cementitious mixture; and
the polycarboxylate material constitutes about 0.3 wt % of the treated perlite-based cementitious mixture.
40 - 42 . (canceled)
43 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises calcium sulfite (CaSO 3 ), wherein the calcium sulfite constitutes 1.5-3 wt % of the treated perlite-based cementitious mixture.
44 - 46 . (canceled)
47 . The method of claim 1 , wherein the treated perlite-based cementitious mixture further comprises calcium sulfate (CaSO 4 ), wherein the calcium sulfate constitutes 0.1-1.5 wt % of the treated perlite-based cementitious mixture.
48 - 50 . (canceled)
51 . The composition of matter of claim 15 , further comprising expanded perlite waste, wherein the expanded perlite waste constitutes about 6 wt % or less of the composition of matter.
52 - 56 . (canceled)
57 . The composition of matter of claim 15 , further comprising expanded perlite, wherein the expanded perlite constitutes about 1 wt % or less of the composition of matter.
58 - 60 . (canceled)
61 . The composition of matter of claim 15 , further comprising:
expanded perlite waste, wherein the expanded perlite waste constitutes about 5 wt % of the composition of matter; and
expanded perlite, wherein the expanded perlite constitutes about 0.5 wt % of the composition of matter.
62 . The composition of matter of claim 61 , wherein at least one of:
the expanded perlite waste has a D90 particle size distribution of about 40 μm;
the expanded perlite has a D90 particle size distribution of about 25 μm;
the PVA powder constitutes about 0.05 wt % of the composition of matter; and
the polycarboxylate material constitutes about 0.2 wt % of the composition of matter.
63 - 65 . (canceled)
66 . The composition of matter of claim 15 , further comprising:
expanded perlite waste, wherein the expanded perlite waste constitutes about 6 wt % of the composition of matter; and
expanded perlite, wherein the expanded perlite constitutes about 0.5 wt % of the composition of matter.
67 . The composition of matter of claim 66 , wherein at least one of:
the expanded perlite waste has a D90 particle size distribution of about 20 μm;
the expanded perlite has a D90 particle size distribution of about 20 μm;
the PVA powder constitutes about 0.15 wt % of the composition of matter; and
the polycarboxylate material constitutes about 0.3 wt % of the composition of matter.
68 - 70 . (canceled)
71 . The composition of matter of claim 15 , further comprising calcium sulfite (CaSO 3 ), wherein the calcium sulfite constitutes 1.5-3 wt % of the composition of matter.
72 - 74 . (canceled)
75 . The composition of matter of claim 15 , further comprising calcium sulfate (CaSO 4 ), wherein the calcium sulfate constitutes 0.1-1.5 wt % of the composition of matter.
76 - 78 . (canceled)