CA2327426A1 - Clay-free ready-mixed setting-type joint compound - Google Patents

Clay-free ready-mixed setting-type joint compound Download PDF

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Publication number
CA2327426A1
CA2327426A1 CA002327426A CA2327426A CA2327426A1 CA 2327426 A1 CA2327426 A1 CA 2327426A1 CA 002327426 A CA002327426 A CA 002327426A CA 2327426 A CA2327426 A CA 2327426A CA 2327426 A1 CA2327426 A1 CA 2327426A1
Authority
CA
Canada
Prior art keywords
joint compound
calcium
compound
total solids
sulfate hemihydrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002327426A
Other languages
French (fr)
Other versions
CA2327426C (en
Inventor
Therese A. Espinoza
Charles J. Miller
Richard B. Stevens
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
United States Gypsum Co
Original Assignee
United States Gypsum Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by United States Gypsum Co filed Critical United States Gypsum Co
Publication of CA2327426A1 publication Critical patent/CA2327426A1/en
Application granted granted Critical
Publication of CA2327426C publication Critical patent/CA2327426C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B22/00Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
    • C04B22/08Acids or salts thereof
    • C04B22/14Acids or salts thereof containing sulfur in the anion, e.g. sulfides
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0658Retarder inhibited mortars activated by the addition of accelerators or retarder-neutralising agents
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14Compositions 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 calcium sulfate cements
    • C04B28/145Calcium sulfate hemi-hydrate with a specific crystal form
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/10Accelerators; Activators
    • C04B2103/12Set accelerators
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/20Retarders
    • C04B2103/22Set retarders
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672Pointing or jointing materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/10Compositions or ingredients thereof characterised by the absence or the very low content of a specific material

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Sealing Material Composition (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)

Abstract

A two part joint compound which sets by hydration of calcium sulfate hemihydrate to gypsum and is clay-free. One part includes an in-situ acidic acrylate copolymer thickener (i.e., an associative thickener) with the calcium sulfate hemihydrate, along with a non-calcium bearing phosphate set preventer. The first part contains water, but remains unset for at least 175 days. The second part includes a set initiator compound having a cation with a log K value greater than calcium ions. The second part is mixed with the first part when setting is desired.

Claims (27)

1. A clay-free ready-mixed joint compound comprising:
(a) about 20 to about 99 wt.% (based on total solids) of calcium sulfate hemihydrate;
(b) about 0.025 to about 0.5 wt.% (based on total solids) of an associative thickener;
(c) about 0.1 to about 10 wt.% (based on total solids) of a non-calcium bearing phosphate set preventer sufficient to prevent setting of the calcium sulfate hemihydrate of (a) until setting is initiated by addition of a set initiator; and (d) sufficient water to achieve the desired consistency.
2. A joint compound of Claim 1, wherein said associative thickener is an in-situ acidic acrylate copolymer thickener.
3. A joint compound of Claim 1, wherein said non-calcium bearing phosphate set preventer is selected from the group consisting of zinc hexametaphosphate, potassium tripolyphosphate, tetra sodium pyrophosphate, sodium tripolyphosphate, monoammonium phosphate, and monobasic potassium phosphate.
4. A joint compound of Claim 1, wherein said non-calcium bearing phosphate set preventer is tetra sodium pyrophosphate.
5. A joint compound of Claim 1, wherein said calcium sulfate hemihydrate is the alpha crystalline form.
6. A joint compound of Claim 1, wherein said calcium sulfate hemihydrate is the beta crystalline form.
7. A joint compound of Claim 1, further comprising calcium carbonate.
8. A joint compound of Claim 1, further comprising a latex binder.
9. A joint compound of Claim 1, wherein said set initiator comprises a compound having a cation with a log K value greater than that of calcium ions.
10. A joint compound of Claim 9, wherein said set initiator compound is zinc sulfate.
11. A joint compound of Claim 9, wherein said set initiator compound is added in an amount of about 0.01 to 0.03 wt.%, based on the amount of (a), (b), and (c).
12. A joint compound of Claim 1, further comprising additives selected from the group consisting of cellulose thickeners, resin microspheres, talc, mica, perlite, fibers, citric acid, fungicides, and bactericides.
13. A joint compound of Claim 1, wherein the amount of components (a), (b) and (c) are 60 to 80 wt.%, 0.05 to 0.15 wt.%, and 0.25 to 0.5 wt.%, respectively.
14. A joint compound of Claim 13, further comprising about 10 to 20 wt.% calcium carbonate, about 2 to 5.5 wt.% of a latex binder, and about 5 to wt.% perlite, based on total solids.
15. A two part joint compound system comprising:
(a) a first part comprising:
(1) about 20 to about 99 wt.% (based on total solids) of calcium sulfate hemihydrate;
(2) about 0.025 to about 0.5 wt.% (based on total solids) of an associative thickener;
(3) about 0.1 to about 10 wt.% (based on total solids) of a non-calcium bearing phosphate set preventer sufficient to prevent setting of the calcium sulfate hemihydrate of (1) until setting is initiated by addition of a set initiator;
(4) sufficient water to achieve the desired consistency; and (b) a second part comprising a set initiator compound having a cation with a log K value greater than that of calcium ions in an amount sufficient to set the hemihydrate of (a)(1).
16. A joint compound of Claim 15, wherein said associative thickener of (a)(2) is an in-situ acidic acrylate copolymer thickener.
17. A joint compound of Claim 15, wherein said non-calcium bearing phosphate set preventer of (a)(3) is selected from the group consisting of zinc hexametaphosphate, potassium tripolyphosphate, tetra sodium pyrophosphate, sodium tripolyphosphate, monoammonium phosphate, and monobase potassium phosphate.
18. A joint compound of Claim 17, wherein said non-calcium bearing phosphate set preventer is tetra sodium pyrophosphate.
19. A joint compound of Claim 15, wherein said set initiator of (b) is zinc sulfate.
20 20. A joint compound of Claim 15, wherein said set initiator of (b) is added in an amount of about 0.01 to 0.03 wt.%, based on the amount of (a)(1)-(3).
21. A joint compound of Claim 15, wherein said calcium sulfate hemihydrate of (a)(1) is the alpha crystalline form.
22. A joint compound of Claim 15, wherein said calcium sulfate hemihydrate of (a)(1) is the beta crystalline form.
23. A joint compound of Claim 15, further comprising calcium carbonate.
24. A joint compound of Claim 15, further comprising a latex binder.
25. A joint compound of Claim 15, further comprising additives selected from the group consisting of cellulose thickeners, resin microspheres, talc, mica, perlite, fibers, citric acid, fungicides, and bactericides.
26. A joint compound of Claim 15, wherein the amounts of components (a)(1), (a)(2) and (a)(3) are 60 to 80 wt.%, 0.05 to 0.15 wt.%, and 0.25 to 0.5 wt.%, respectively.
27. A joint compound of Claim 26, further comprising about 10 to 20 wt.% calcium carbonate, about 2 to 5.5 wt.% of a latex binder, and about 5 to wt.% perlite, based on total solids.
CA2327426A 1999-12-29 2000-12-04 Clay-free ready-mixed setting-type joint compound Expired - Lifetime CA2327426C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/474485 1999-12-29
US09/474,485 US6228163B1 (en) 1999-12-29 1999-12-29 Clay-free ready-mixed setting-type joint compound

Publications (2)

Publication Number Publication Date
CA2327426A1 true CA2327426A1 (en) 2001-06-29
CA2327426C CA2327426C (en) 2010-02-09

Family

ID=23883726

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2327426A Expired - Lifetime CA2327426C (en) 1999-12-29 2000-12-04 Clay-free ready-mixed setting-type joint compound

Country Status (9)

Country Link
US (1) US6228163B1 (en)
KR (1) KR100713255B1 (en)
AU (1) AU779883B2 (en)
CA (1) CA2327426C (en)
MX (1) MXPA00012508A (en)
MY (1) MY120648A (en)
NZ (1) NZ508632A (en)
PL (1) PL201386B1 (en)
SA (1) SA00210634B1 (en)

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US20050028979A1 (en) * 1996-11-27 2005-02-10 Brannon Harold Dean Methods and compositions of a storable relatively lightweight proppant slurry for hydraulic fracturing and gravel packing applications
CA2407607C (en) * 2000-04-26 2010-09-21 National Gypsum Properties, Llc Joint compound and method of making same
US6884830B1 (en) * 2000-09-06 2005-04-26 Air Products Polymers, L.P. Flexible setting joint compound and method for making flexible joints
US7105587B2 (en) * 2001-03-07 2006-09-12 Innovative Construction And Building Materials Method and composition for polymer-reinforced composite cementitious construction material
WO2003039713A1 (en) * 2001-10-19 2003-05-15 Innovative Construction And Building Materials, Llc Anti-pathogenic air filtration media and air handling devices having protective capabilities against infectious airborne microorganisms
US6846856B1 (en) 2002-05-20 2005-01-25 Innovative Construction And Building Materials Mixed organic and inorganic composites with intermingled facial layers
US6955844B2 (en) * 2002-05-24 2005-10-18 Innovative Construction And Building Materials Construction materials containing surface modified fibers
ZA200306629B (en) * 2002-09-20 2004-05-06 Rohm & Haas Polymer modified gypsum composition.
EP1403227B1 (en) * 2002-09-20 2010-11-24 Rohm And Haas Company Polymer modified gypsum composition
US6790277B2 (en) * 2002-10-01 2004-09-14 National Gypsum Properties, Llc Lightweight joint treatment formulation
US6902797B2 (en) * 2002-11-12 2005-06-07 Innovative Construction And Building Materials Gypsum-based composite materials reinforced by cellulose ethers
US6841232B2 (en) * 2002-11-12 2005-01-11 Innovative Construction And Building Materials Reinforced wallboard
EP1594813B1 (en) * 2003-01-23 2016-04-20 Saint-Gobain Placo Inorganic composite structures enhanced by organic compounds
US6805741B1 (en) * 2003-03-27 2004-10-19 United States Gypsum Company Ready-mixed setting-type composition and related kit
DE102004040879B3 (en) * 2004-08-24 2006-05-04 Bk Giulini Gmbh Use of a composition for setting retardation of gypsum and gypsum preparations and compositions containing this composition
TWI321554B (en) 2004-08-25 2010-03-11 Rohm & Haas Composition for forming a composite material
US20070150352A1 (en) * 2005-12-23 2007-06-28 Mastercard International Incorporated Techniques for transaction data coordination
US20080023129A1 (en) * 2006-07-15 2008-01-31 Bergevin Marcel Artificial decorative masonry and manufacturing process thereof
US7754006B2 (en) * 2007-03-20 2010-07-13 United States Gypsum Company Process for manufacturing ready-mixed setting alpha-calcium sulphate hemi-hydrate and kit for same
CL2008001639A1 (en) * 2007-06-08 2009-01-16 United States Gypsum Co A composition comprising a filler material comprising calcium carbonate, calcium sulfate dihydrate or hemidrate, a binder and optionally a biocide, the composition is free of formaldehyde after curing; and method of filling board surface crack.
CA2641234A1 (en) * 2007-10-23 2009-04-23 Jig-A-World Inc. Sprayable surface repair compound
FR2925042B1 (en) * 2007-12-14 2010-10-22 Lafarge Platres ADJUVANT FOR HYDRAULIC BINDER
US8563139B2 (en) * 2008-04-22 2013-10-22 United States Gypsum Company Non-hydrating plaster composition and method
US20100083879A1 (en) * 2008-10-08 2010-04-08 Georgia-Pacific Gypsum Llc Low voc joint composition
US9174881B2 (en) * 2009-11-05 2015-11-03 United States Gypsum Company Ready mixed setting type joint compound and set initiator in chambered pouch
GB201019841D0 (en) 2010-11-23 2011-01-05 Bpb Ltd Calcium sulphate-bases products and methods for the manufacture thereof
US8668087B2 (en) 2011-12-22 2014-03-11 United States Gypsum Company Two-phase packaging of ready mix joint compound
US8925677B2 (en) 2012-06-27 2015-01-06 Usg Interiors, Llc Gypsum-panel acoustical monolithic ceiling
US8684134B2 (en) 2012-06-27 2014-04-01 Usg Interiors, Llc Gypsum-panel acoustical monolithic ceiling
PT2971391T (en) 2013-03-15 2018-10-19 Usg Interiors Llc Gypsum-panel for acoustical monolithic ceiling
US9731879B2 (en) 2015-01-05 2017-08-15 United States Gypsum Company Container lid with functional additive chambers
US10928286B2 (en) 2016-02-24 2021-02-23 United States Gypsum Company System and method for evaluating joint compound specimen
US20180148220A1 (en) 2016-11-28 2018-05-31 United States Gypsum Company Lid with hinged compartments for joint compound container
KR20190088995A (en) 2016-11-28 2019-07-29 유나이티드 스테이츠 집섬 컴파니 Package for delivery of additive for powder composition
CA3208725A1 (en) 2021-02-19 2022-08-25 Knauf Gips Kg High solids, sprayable setting type joint compound

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Also Published As

Publication number Publication date
PL201386B1 (en) 2009-04-30
MY120648A (en) 2005-11-30
NZ508632A (en) 2002-07-26
SA00210634B1 (en) 2006-11-13
CA2327426C (en) 2010-02-09
KR20010070350A (en) 2001-07-25
MXPA00012508A (en) 2003-04-25
KR100713255B1 (en) 2007-05-02
US6228163B1 (en) 2001-05-08
PL344736A1 (en) 2001-07-02
AU7203600A (en) 2001-07-12
AU779883B2 (en) 2005-02-17

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Effective date: 20201204