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The country that was earliest, most experienced in the research, production, and use of aluminate cement is France. Aluminate cement, also known as high alumina cement, is made from bauxite and limestone, which are melted or sintered to form clinker primarily composed of calcium aluminate and dicalcium aluminate. The clinker is then finely ground to form this hydraulic cementing material, code CA. If needed, appropriate amounts of α-Al2O3 powder can be added to cement with an Al2O3 content greater than 68% during grinding. Aluminate cement, with its unique hydration characteristics and long-term stability, demonstrates excellent performance in various types of dry-mix mortar applications.
In the early days, aluminate cement was only used in regular mortar to achieve rapid setting and early strength properties. As the dry-mix mortar industry developed, practical engineering requirements for mortar performance increased. The rapid setting and hardening, high temperature and thermal shock resistance, chemical resistance (especially to acids), microbial resistance (especially in sewage pipeline systems), impact, and wear resistance properties of aluminate cement provided many special mortars with excellent performance, meeting various high-standard industrial requirements.
For instance, ultra-rapid hardening mortars for quick leak plugging need very short setting times; repair mortars for concrete road patching demand quick availability, high strength, no cracking, and good bonding with the substrate; non-shrink grouts for precise installation of heavy machinery must exhibit high fluidity, minimal shrinkage, high early strength, and good long-term stability. Special mortars can use aluminate cement to achieve adjustable working time, setting time, rapid hardening, early strength, and shrinkage control.
Self-leveling mortars are also a very important application area for aluminate cement. Among various dry-mix mortar products, self-leveling mortars are recognized as the most complex product system. They must meet many restrictive conditions during application and use, such as good fluidity and appropriate hardening rate during application, as well as high strength, hardness, wear resistance, and bonding strength with the substrate after hardening.
Additionally, good dimensional stability and no cracking are also essential requirements for base layer self-leveling mortars. Surface layer self-leveling mortars, typically used for industrial flooring, require even higher standards for wear resistance, impact resistance, and hardness. Sometimes the surface mortar needs to have stable, uniform color and not be prone to efflorescence. To meet these requirements, selecting high-quality, stable aluminate cement is a fundamental and crucial step. Proficient application of aluminate cement combined with other cements and various additives can produce high-performance self-leveling mortars.
