BR112021003754A2 - wear-resistant concrete formulations and methods for their preparation - Google Patents

Abstract

WEAR RESISTANT CONCRETE FORMULATIONS AND METHODS FOR PREPARING THEM. It is a method for preparing concrete with improved wear resistance. The method involves using colloidal silica, which is added to a concrete mix after mixing, in conjunction with a concrete cutter, which is added to the concrete mix after the addition of colloidal silica.

Description

"WEAR RESISTANT CONCRETE FORMULATIONS AND METHODS FOR THE PREPARATION OF THEM" PRIORITY CLAIM

[0001] This application claims priority to Provisional Application 62/765,597, filed September 1, 2018, and incorporated by reference into the present document in its entirety for all it teaches, without exclusion.

[0002] The use of additional cementitious materials in concrete to improve the properties of concrete, such as, for example, water impermeability, compressive strength and abrasion resistance, is well known. Various types of particulate silica, eg silica fume, have been used in concrete as additional cementitious materials to improve water impermeability and compressive strength. A general problem with silica is that it can increase the water demand of a concrete formulation, so the likelihood of capillary and void formation during cure is increased due to the greater likelihood of significant purge water. In order to reduce purge water, water is commonly minimized, even when relatively large amounts of silica fume are used (often 5 to 10 percent by weight of cementitious materials). Water is often carefully rationed to be present in relative amounts below a water:cementitious materials ratio of about 0.5. (Design and Control of Concrete Mixtures, Sixteenth Edition, Second Edition (revised); Kosmatka, Steven H.; page 156). These low amounts of water are generally below what is recommended by the cement manufacturer and can significantly impair the rheology of the concrete mix, making pouring or working difficult. Materials such as superplasticizers may be needed with this low water content.

[0003] In the previously filed application (Application No. 16/501.232 filed on March 8, 2019, incorporated by way of reference for all it teaches, without exclusion), a concrete and method of preparation is disclosed comprising small size particles , high surface area amorphous silica, used in much smaller proportions for cement than generally used in industry for structural purposes: only about 2.83 to about 113.39 grams (0.1 to about 4 ounces) per one hundred weight of cementitious materials. In a further aspect, the improved concretes are prepared by a specific addition of the silica process. These improved concretes can be prepared using the standard amount of water recommended by the cement manufacturer, or even above the recommended amount of water, without significantly compromising the compressive strength. This result is really surprising. Despite the use of such amounts of water, little or no purge water is observed during curing. The formation of capillaries and voids is minimal or even essentially suppressed, and more water is retained in the concrete during cure, allowing more water to participate in the cure for a longer period of time and the compressive strength to be vastly improved.

[0004] Despite allowing relatively high amounts of water, concretes with low silica content described above have better compressive strength and abrasion resistance, among other improved characteristics. An improvement in compressive strength is surprising considering the small amounts of silica employed, whereas known methods use much larger amounts to obtain gains that are, in some cases, significantly smaller. Furthermore, there is generally no significant improvement in the abrasion resistance of concrete with the use of silicas such as silica fume, even in the largest quantities usually used (id, page 159). The low silica content concretes, described in the previous application (U.S. Provisional Order 62/761,064), provide a profound improvement in abrasion resistance as measured by the ASTM C944 test. (Note that, due to the previous standard, the version employing a load of 22 pd, 98 kg has been used in all references to the standard in this document.) Standard concretes (ie, not comprising surface area amorphous silica taught below) may have a value in the range of about 2.5 to about 4.0 grams of loss. The low silica concretes taught in this document can have an ASTM C944 value as low as 1.1 grams of loss or less.

[0005] Surprisingly, in the case of the present invention, it was found that the use of 1) amorphous silica, as disclosed in the above-indicated application; as well as 2) the use of a mixture by adding a mixture that comprises, counterintuitively, a concrete re-emulsifier (cutting agent), as disclosed below, can improve wear resistance, even in relation to cement that has been prepared with silica amorphous alone, particularly relative to typical cement (ie, cement that has not been prepared without amorphous silica or cutting agent). It has been found that abrasion resistance can be improved so that the loss in ASTM C944 can be as low as 0.6 grams or even less. Furthermore, it has been observed that the concrete of the present invention generally exhibits vastly reduced water absorption - both during and after curing. (Finish water absorption during curing, as well as water absorption in use, ie after curing, is largely a result of capillary formation during curing due to water migration to surface during curing). In some cases, water absorption during curing and/or after curing may be completely eliminated. This result is unexpected, as the mixture comprises a compound commonly

[0006] used to re-emulsify concrete. The concrete cutter has been used in the concrete industry to dissolve hardened (ie cured) concrete deposits from equipment used to prepare and work concrete, such as ready-mix concrete producer, electric trowels and the like. The presence of a re-emulsifier, which has the ability to destroy the structure (CSH matrix) of the cured concrete, could thin the concrete mixture, preventing cure, or negatively affecting the cured concrete structure, allowing water migration during the cure. However, when used in conjunction with silica, as described below, concrete not only cures, but little or no purge water is generally observed during curing of the concrete of the present invention. In addition, as indicated above, cured concrete has better abrasion resistance than even concrete prepared by mixing with silica addition alone, especially traditional concretes.

[0007] Unexpectedly, the high degree of impermeability to water can be obtained without subjecting the concrete to a finishing step (See Example 2, for example, which describes the preparation of a shoe that presents density and impermeability). Thus, the concrete of the present invention is particularly suitable for outdoor concrete applications. In general, concrete for outdoor use, such as sidewalks, curbs and parking lots, does not require extensive finishing, although some degree of flotation can be performed. Small surface imperfections usually remain and eventually the surface weathers and makes the issue of imperfections debatable. However, water damage during the life of concrete is an issue with outdoor concrete. A countermeasure taken is the application of a curing and sealing agent. The protection provided by these agents is usually short-lived. Another countermeasure is the use of aerated concrete so that damage caused by water absorbed during freezing is minimized. In practice, neither measure is a long-term solution to the problem of freeze damage. However, the cured concrete of the present invention generally has negligible or no water absorption. No additional finishing or sealant application is required. Additionally, concrete generally does not require air drag to resist freeze-thaw damage.

[0008] The normal water absorption of the external cement according to the Rilum test is about 1.5 to 3 ml in 20 minutes. The concrete surfaces of the present invention did not essentially absorb water, despite the lack of a finishing step. For example, the Rilum test is expected to provide an absorption in 20 minutes of from about 0 to about 1.0 ml in 20 minutes. Without wishing to be bound by theory, it is assumed that the concretes of the present invention may not develop the surface and capillary imperfections that are a problem with other concretes, or the inventive concretes may develop them to a very small degree.

[0009] Most notably, when the concrete of the present invention is subjected to finishing, the surface that develops can be similar to plastic (the extent of which can be controlled by details of the finishing process, as discussed below) having a very high amount of friction. reduced with respect to finishing blades, when compared to the finishing of standard concrete. Increased finishing speeds due to standard concrete finishing speeds generally favor obtaining a shiny surface that has a plastic consistency.

[0010] In general, the finish of concrete prepared by existing methods and formulations improves the smoothness and flatness of the surface, with longer finish times providing greater improvement, to some extent. This concrete can be finished either by hand or with an electrically driven trowel, where generally the electric trowel provides a faster, more uniform and higher quality finish than a manual trowel. However, regardless of the finishing method selected, the concretes of the present invention generally finish faster (ie, take less time to reach a certain degree of gloss) and have a higher gloss potential (as measured, for example, with a gloss meter) with regard to the finishing process. Due to the latter, it can be expected that the use of speeds higher than conventional ones (especially when the surface has reached a point where the lower speeds have stopped giving gloss gains) to result in gloss gains beyond what is possible with existing concretes. .

[0011] These high finishing speeds are generally easier to use with the concretes of the present invention due to reduced friction. Furthermore, throughout the entire finishing process, mixing as indicated in this document generally provides a concrete that requires less finishing effort to achieve a finished surface. Regardless of whether the finisher is working with a manual trowel or an electric trowel, the finisher can often feel a difference in the fact that the friction between the trowel or finishing blades and the floor surface is usually significantly less than it would be without use of the mixture of the present invention. In general, the amount of time required to finish a floor surface with a finishing machine to a certain degree of gloss is reduced for a certain finishing machine speed (rpm). In addition, although it may require higher finishing speeds (from about 190 to 210 rpm) than normally used in finishing (about 180 to about 190 rpm), the surface can generally be finished with a gloss greater than the traditional concrete surfaces. Within the industry, it is apparently thought that higher finishing speeds are not necessary and therefore newer finishing machines are capable of lower maximum speeds (180 rpm or 190 rpm) than older machines (200 rpm or 210 rpm). Thus, it may be necessary to use an older model machine to obtain the upper surface available with the concretes of the present invention.

[0012] Without wishing to be bound by theory, it is thought that the heat of cure promotes a reaction between the high surface area amorphous silica and the components of the "re-emulsifying" mixture to form a plastic-like component throughout the concrete. Finishing at high speeds promotes this reaction on the surface, where heat dissipation can prevent the reaction from occurring to the degree in the volume of the concrete. Without wishing to be bound by theory, it is thought that the formation of the plastic-like substance, promoted by the heat generated by finishing at high finishing speeds (i.e. generally 200 rpm and above), provides the surface with an improved gloss over the surface. possible with traditional concretes.

[0013] It should be noted that, in the technique, the finishing of concrete surfaces can have an effect on the water impermeability of the slab. “Slab closing”, that is, finishing a slab using a repetitive and directional application technique of finishing machinery, well known in the art, is a finishing method that can decrease water permeability. Such methods can be applied to the concretes of the present invention, however, the concretes of the present invention surprisingly exhibit high water impermeability, or even complete water impermeability even without a finishing step.

[0014] It should also be noted that the concrete surfaces of the present invention are generally harder than concrete from traditional methods and formulations. In general, most concretes increase in hardness with curing times. For example, about 28 days after concreting, most concretes prepared according to existing methods have a hardness in the range of about 4 to about 5 relative to the Mohs hardness scratch test. It is not uncommon for the concretes of the present invention to reach such hardness after periods of time in the range of about 3 to about 8 days (about 72 to about 192 hours) after pouring. After about 28 days, it is not uncommon for the concretes of the present invention to have a hardness in the range of about 6 to about 9, or in many cases, to have a hardness in the range of about 7 to about 8.

[0015] The methods of the present invention are preferably used as a mixture with the concrete formulations comprise amorphous silica (such concrete formulations prepared as described in

[0016] section below entitled “New Compositions for Improved Concrete Performance”). The use of the admixture by addition with the composition of the above mentioned section is described in this document, its mode of use in these formulations fully described. Without wishing to be bound by theory, the use of silica that is not described in this document, such as having larger particle sizes than those described in this document, may provide some limited benefits of the invention, but will likely be more difficult to pour, work, and finalize than concretes prepared with low particle size and high surface area amorphous silica.

DESCRIPTION OF DRAWINGS

[0017] Figure 1 shows a concrete slab that contains 113.39 grams (4 ounces) per hundred weights of E5 INTERNAL CURE, with E5 Finish used topically as a finish at rates of 24.54 square meters per liter (1,000 square feet per gallon). The polishing process was started right after the completion of the finishing step. Figure 1 shows the undamaged surface despite the 68 centimeter (27 inch) polisher operating at 2,500 rpm. While the photo is of E5 Finish applied topically, the same result is obtained for E5 Finish additive applications as indicated.

[0018] Figure 2 shows the surface conversion from approximately Grade 1 to approximately Grade 2. While the photo is of E5 Finish applied topically, the same result is obtained for the E5 Finish additive applications as indicated.

DETAILED DESCRIPTION OF THE INVENTION

The following is a detailed description of the addition mix formulations that can be used in the present invention. Although the invention disclosed in this provisional application refers to the Korkay Concrete Dissolver ("Korkay") formulation available for sale March 20, 2017, available from Tate's Soaps and Surfactants, one skilled in the art will recognize that Korkay and water dilutions of the same are chemical formulations, and such chemical formulations may be prepared by various different sources and/or methods and be suitable for use in the present invention, in order to obtain the benefits of the present invention. In one embodiment, the admixture composition by addition comprises or consists essentially of a dilution in Korkay water.

[0020] It should be recognized that formulations comprising the same chemical components as Korkay or water dilutions thereof, but in which concentrations of one or more components, not including water, deviate from the concentration relative to Korkay or a dilution of water thereof, respectively, for less than 50, 40, 30, 20, 10 or 5% by weight, relative to the weight of Korkay or its water dilutions, respectively, may be useful in the present invention. Such chemical compositions can be used in the amounts and rates recommended above.

[0021] In further embodiments, the admixture by addition comprises or consists essentially of water; an alpha-hydroxy acid, an alkyl ether glycol, and a polyethylene glycol having an average molecular weight in the range of about 500 to about 1,500 µm. In additional embodiments, the alpha-hydroxy acid contains in the range of about 5 to about 1 carbons, with glycolic acid being preferred. Glycolic acid is available from Chemsolv. The glycol alkyl ether is preferably a polypropylene glycol methyl ether, with dipropylene glycol methyl ether being preferred. Dipropylene glycol methyl ether is available from many sources, for example, Dow Chemical, Lyondell Bassell and Shell. Polyethylene glycol having an average molecular weight in the range of about 500 to about 1,500 molecular weight is preferably polyethylene glycol having an average molecular weight in the range of about 750 to about 1,250 molecular weight, and even more preferably, in the range of from about 950 to about 1050 molecular weight. An example of a suitable polyethylene glycol is PEG (1000).

In additional embodiments, the alpha-hydroxy acid is preferably present in the mixture by addition in the range of about 5 to about 20 percent by weight, with a percentage by weight in the range of about 10 to about 15 percent. by weight more preferred. The glycol alkyl ether weight percent is preferably in the range of about 5 to about 20 percent by weight, with a range of about 10 to about 15 percent by weight being more preferred. The weight percent of polyethylene glycol is preferably in the range of about 1 to about 15 weight percent, with a ratio in the range of about 1 to about 9 weight percent is more preferred. Water is present in the range of about 70 to about 80 percent by weight, with a range of about 71 to about 77 percent by weight being more preferred.

[0023] In other embodiments, the admixture by addition comprises, consists or consists essentially of a water dilution of the following four-part mixture:

[0024] 1) 74% water;

2) 13% glycolic acid;

3) 8% dipropylene glycol methyl ether (DPM glycol ether);

4) 5% polyethylene glycol (type PEG 1000);

[0028] wherein the dilution preferably comprises, consists or consists essentially of one part of the mixture between about 4 and about 20 parts of water, with a more preferred dilution between about 5 and about 12 parts of water, with an even more preferred dilution being from about 6 to about 8 parts water, with a range from about 6.5 to about 7.5, or even from about 6.8 to about 7.2 being particularly suitable. The component equivalent to such a dilution; where "equivalent component" means that the mixture comprises, consists or consists essentially of the same components and relative proportions as above, but the mixture was not prepared by the prescribed dilution.

[0029] In other modalities, the mixture to be added to the concrete mixture (such as, for example, adding to a Ready-Made Concrete Producer that contains a concrete mixture, prepared by and comprising amorphous silica in quantities as described in the provisional order US 62/765,597 or otherwise recited herein) comprises, consists or consists essentially of one part by weight of Korkay between about 4 and about 20 parts by weight of water, with a more preferred dilution of between about 5 and about 12 parts by weight of water, an even more preferred dilution being from about 6 to about 8 parts by weight of water. (Finish E5 formulation can be formed by creating a mixture comprising about 7 parts water to about 1 part Korkay). In some embodiments, the addition blending comprises the Finish E5 formulation. In other embodiments, the admixture by addition comprises a water dilution or dewatered concentration of the E5 finish or a chemically identical preparation of the above. In other embodiments, the addition mixture comprises or consists essentially of Finish E5. In other embodiments, the above addition mix is added to the Ready-mix Concrete Maker in amounts ranging from about 14.17 to about 226.79 grams per 45 kilograms (from about 0.5 to about 8 ounces per 100 pounds) of cement, with from about 56.69 to about 141.74 grams per 45 kilograms (about 2 to about 5 ounces per 100 pounds) of preferred cement, and from about 70.8 to about 99, 22 grams per 45 kilograms (from about 2.5 to about 3.5 ounces per 100 pounds) of cement is even more preferred, with about 79.37 to about 90.71 grams per 45 kilograms (about 2, 8 to about 3.2 ounces per 100 pounds of cement being most preferred.

[0030] For amounts of E5 Finish greater than about 141.74 grams (5 ounces) of E5 Finish per 100% by weight cementitious materials, or for amounts of amorphous silica greater than about 141.74 grams (5 ounces) by 100% by weight cementitious materials, the observed benefits of the invention may begin to diminish in such increased brittleness and the decrease in compressive strength may, in some cases, be observed. For a given amorphous silica (or E5 INTERNAL CURE) and Korkay (or E5 Finish) content within the preferred (or broader) ranges indicated herein, a change in the amount of amorphous silica of about 113 can generally be expected. .39 grams (4 ounces) per hundredth of weight or the amount of E5 Finish away from about 85.04 grams (3 ounces) per hundredth of weight provides some reduction in abrasion resistance, water tightness, and compressive strength.

[0031] Note that formulations are generally employed as a mixture and therefore are prepared in prescribed proportions and added to a bulk concrete mix, such as adding to a ready-mixed concrete producer containing a concrete mix comprising silica small particle size amorphous, such as the concrete mixes described below. This blending addition is most preferred. However, separate addition of the mixture components by addition may be permissible. For example, it may be permissible to add some or all of one or more of the components of water, glycolic acid, dipropylene glycol methyl ether or polyethylene glycol to the concrete mixture, particularly after the mixture has been thoroughly mixed, before adding the balance of the mixture by addition . For example, the concrete mix could be prepared with at least some of the water allocated to the mix by addition. It should be understood that in such a situation, when calculating the amounts of water in the concrete mix and in the addition mix, the total amount of water must be considered as the sum of two sub-quantities: one that is within the limits of the total amount of water allowed for the concrete mix and the second within the total amount of water allowed for the addition mix. Such separate addition of components may provide some effect to the present invention. However, for optimal results, it is strongly preferred to use the addition mixing modality as described herein, in which a mixture of components, where the mixture comprises an alpha-hydroxy acid, an alkyl ether glycol, a polyethylene glycol and water, is added to a ready-mix Concrete Maker that contains a concrete mix comprising amorphous silica, as described below.

[0032] Without wishing to be bound by theory, it is thought that the heat generated during the curing of concrete assists in the formation of a resistant plastic-like matrix throughout the concrete during curing, as a result of the components of the mixture interacting with amorphous silica in concrete (as a result of using the additive in concrete preparation). This result is indicated by experiments in which E5 Internal Cure is mixed directly with E5 Finish, in a container, with heat, providing a translucent or transparent substance, as thought to be the matrix substance.

[0033] The addition mix is blended into a concrete mix comprising amorphous silica, which can be added as an E5 Internal cure if desired. In general, the concrete mix comprises amorphous silica having particles with an average particle size less than about 55 nm and, in some embodiments, an average particle size less than about 7.8 nm, or, in other embodiments. an average particle size of between about 5 and about 55 nm, or between about 5 and about 7.9 nm; and having a surface area in the range of about 430 to about 900 m2 /g; and present in concrete at a weight ratio in the range of about 2.83 to about 113.39 grams per 45 kilograms (about 0.1 to about 4 ounces of amorphous silica per 100 pounds) of cement (ie. , not including water, aggregate, sand or other additives).

[0034] Amorphous silica from other sources may be suitable, as long as it is characterized by the above particle size parameters. Non-limiting examples of suitable amorphous silica include colloidal silica, precipitated silica, silica gel and fumed silica, in which colloidal silica or silica gel are preferred. It is more preferred to use particles with an average particle size of less than about 25 nm, with an average particle size of less than about 7.9 nm being even more preferred. A more preferred weight ratio in concrete is from about 2.84 to about 85.04 grams (from about 0.1 to about 3 ounces) of amorphous silica per 45 kilograms (100 pounds) of cement (not including water, aggregate, sand or other additives). An even more preferred weight ratio in concrete is from about 2.83 to about 28.35 grams (from about 0.1 to about 1 ounce) of amorphous silica per 45 kilograms (100 pounds) of cement (again , not including water, aggregate, sand or other additives).

[0035] In still other embodiments, amorphous silicas with surface areas in the range of about 50 to about 900 m2/gram are preferred, where about 150 to about 900 m2/gram is more preferred, and about about 400 to about 900 m2/gram is even more preferred. Amorphous silica with an alkaline pH is preferred, with a pH in the range of 8 to 11 being most preferred.

[0036] In yet another modality, amorphous silica is provided by the use of E5 INTERNAL CURE, a commercially available additive from Specification Products LLC. In one modality, the weight ratio of E5 INTERNAL CURE to cement is in the range of about 28.34 to about 566.99 grams (from about 1 to about 20 ounces) of E5 INTERNAL CURE to 45 kilograms ( 100 pounds) of cement (not including water, sand, aggregate or other additives). More preferably, the weight ratio of E5 INTERNAL CURE to cement is in the range of from about 28.34 to about 283.49 grams (from about 1 to about 10 ounces) of E5 INTERNAL CURE to about 45 kilograms (100 pounds) of cement (not including water, sand, aggregate or other additives). An even more preferred weight ratio of E5 INTERNAL CURE to cement is in the range of from about 28.34 to about 141.74 grams (from about 1 to about 5 ounces) of E5 INTERNAL CURE to about 45 kilograms (100 pounds) of cement (not including water, sand, aggregate or other additives). An ideal value is in the range of about 85.04 to 141.74 (about 3 to 5), or about 113.39 grams (4 ounces) per hundred by weight.

[0037] Surprisingly, the use of more than about 566.99 grams (20 ounces) of E5 INTERNAL CURE to about 45 kilograms (100 pounds) of cement (not including water, sand, aggregate or other additives), or the use of more than about 141.74 grams (5 ounces) of amorphous silica to about 45 kilograms (100 pounds) of cement (not including water, sand, aggregate or other additives) may cease to be beneficial because of the beneficial benefits of water or compressive strength may not be observed or may be observed minimally.

[0038] The order of addition of amorphous silica and admixture by addition (eg, without limitation, E5 Internal Cure and E5 Finish, respectively) is important to obtain maximum benefit from inventive processes, compositions and concretes. For example, it is strongly preferred to add the amorphous silica to the cement mix before adding the addition mix containing the cutter.

[0039] Amorphous silica is preferably combined with the cement mixture in accordance with the section below entitled "New Compositions for Improved Concrete Performance".

[0040] A concrete mix is created from components comprising amounts of a) a dry cement mix; b) water; c) amorphous silica; and d) aggregate and/or sand.

[0041] Dry cement mixes generally have a recommended water content that provides a water/cement ratio, providing a concrete mix that has a combination of desirable pouring and curing characteristics. In some cases, the recommended water content covers a range of water content. As indicated below, the initial water content of the concrete mix before pouring can give rise to problems during curing and finishing, which reduces the quality of the resulting concrete installation (slab, footing, etc.). It is common for water reduction measures such as the use of “water reducers” and superplasticizers to be employed in the interest of reducing water-mediated structural failures in cured concrete. It should be noted that while the benefits of the present invention should be evident in circumstances where the water content is being reduced below that recommended by the manufacturer, the present invention can be used to provide inventive concrete in situations where water is included. in the concrete mix is equal to or greater than the quantity specified by the manufacturer of the dry cement mix. Water reducers in the concrete mix are often unnecessary.

[0042] Thus, in a broad aspect, the mixture of cement and water are present in the concrete mixture in the following proportions:

[0043] An amount of water; and an amount of dry cement mix, wherein said cement mix is characterized by:

[0044] i) a water/cement ratio value suggested by the manufacturer; wherein said suggested ratio falls in the range of about 0.35 to about 0.65; and after which the combination with the amount of water, the water/cement ratio is greater than the value corresponding to about 10% less than the suggested value, but less than the value corresponding to about 30% greater than the suggested value ;

[0045] or

[0046] ii) a manufacturer suggested a range of water/cement ratio, having a higher value and a lower value, and after combining with the amount of water, the water/cement ratio is greater than the value corresponding to about 10 % less than the lower value and not greater than the value corresponding to approximately 30% more than the upper value;

[0047] or

[0048] iii) an amount such that, with the combination with the amount of water, the water/cement ratio is in the range of about 0.35 to 0.65.

[0049] The benefits of the invention are expected to generally manifest themselves with the use of commercially useful types of Portland cement. Cement mix is one or more of the types commonly used in construction, such as Portland cement Types 1, 11, III, IV and V.

[0050] The above amount of water is added to the cement mix. This amount includes all water that is combined with the concrete mix comprising at least the cement mix, except water introduced with the silica in the case of water-containing silica formulations such as colloids, dispersions, emulsions and the like; as well as water introduced with the mixture containing the cutter. As detailed below, the water can be combined with a concrete mix which comprises at least mixing cement in several portions, such as the addition of a second portion of water (eg "waste water") after a first portion of water be combined with the concrete mix and stirred for a while. Note that water is sometimes applied to the surface of the concrete after it has been partially cured to prevent premature drying of the surface, which can result in shrinkage, as well as further difficulties in working and finishing. This “finish” water is not included in the water quantity. In other modalities, the water/cement ratio is in the range of about 0.38 to 0.55 or, in more specific modalities, in the range of about 0.48 to about 0.52, or in the range of about 0.38 to about 0.42.

[0051] In a more preferred embodiment, in reference to i), ii) and iii) above, the mixture of water and cement is present in the concrete mixture in the proportions in which, after combining the amount of dry cement mixture with the amount of water, the water/cement ratio is:

[0052] equal to or greater than the suggested value, but not greater than the value corresponding to 30% more than the suggested value; or

[0053] equal to or greater than the upper value of the suggested range, but not greater than the value corresponding to approximately 30% more than the upper value; or

[0054] at least 0.35, but not greater than 0.65.

[0055] The size of the amorphous silica particles is particularly important. Larger particle sizes, such as those found in micronized silica, generally do not reduce capillary and void formation to the degree seen when amorphous silica sized as prescribed in this document is used in the prescribed amounts. The inventive concrete mix comprises an amount of amorphous nanosilica, which is preferably present in an amount in the range of from about 2.83 to about 198.44 grams (from about 0.1 to about 7.0 ounces) per one hundred percent cement (cwt) in a), and having particle sizes such that the silica particle size is in the range of about 1 to about 55 nanometers and/or where the surface area of the silica particles is in the range of from about 300 to about 900 m2/g, or in other modalities, from about 450 to about 900 m2/g.

[0056] Amorphous silica from various sources is generally suitable, as long as it is characterized by the above particle size and surface area parameters. Non-limiting examples of suitable amorphous silica include colloidal silica, precipitated silica, silica gel and fumed silica. However, amorphous colloidal silica and silica gel are preferred, and amorphous colloidal silica is most preferred.

[0057] In additional embodiments, the silica particle size is in the range of about 5 to about 55 nm. Preferred are particles with an average particle size less than about 25 nm, with an average particle size less than about 10 nm more preferred, and an average particle size less than about 7.9 nm even more preferred. A preferred weight ratio in concrete is from about 2.83 to about 85.04 grams (from about 0.1 to about 3 ounces) of amorphous silica per 45 kilograms (100 pounds) of cement (not including water , aggregate, sand or other additives). A more preferred weight ratio in concrete is from about 2.83 to about 28.34 grams (from about 0.1 to about 1 ounce) of amorphous silica per 45 kilograms (100 pounds) of cement (again, not including water, aggregate, sand or other additives). Even more preferred is about 12.75 to about 21.26 grams (from about 0.45 to about 0.75 ounces) of amorphous silica per 45 kilograms (100 pounds) of cement (again, not including water, aggregate, sand or other additives). Surprisingly, above about 85.04 to about 113.39 grams (from about 3 to about 4 ounces) of amorphous nanosilica per 45 kilogram (100 pounds) cement mix, concrete mixing can become difficult. from spilling or working, and the compressive strength can suffer greatly, even with controls without silica. Otherwise, amounts above about 28.34 grams (about 1 ounce) per 45 kilograms (100 pounds) of cement generally provide decreasing compressive strength gains over the preferred range of about 12.75 to about 21. 26 grams (from about 0.45 to about 0.75 ounces) of amorphous silica per 45 kilograms (100 pounds) of cement. The preferred range provided is the most economically viable, i.e., above that, the compressive resistibility gains are smaller per additional unit of silica, and the increase in the cost of silica per unit of compressive resistibility can cause the cost of concrete becomes prohibitive.

[0058] Amorphous silicas with surface areas in the range of about 50 to about 900 m2/gram are preferred, where about 150 to about 900 m2/gram is more preferred, and about 400 to about 900 m2/gram even more preferred, and 450 to 700 m2/gram or 500 to 600 m2/gram even more preferred. Amorphous silica having an alkaline pH (about pH 7 and above) is preferred, with a pH in the range of 8 to 11 being most preferred.

[0059] In yet another embodiment, amorphous silica is provided by using E5 INTERNAL CURE, a commercially available additive from Specification Products LLC, which contains about 15% by weight of amorphous silica in about 85% by weight of water . The silica particle characteristics are an average particle size of less than about 10 nm (measured by the BET method) and a surface area of about

550 m2/g. In one modality, the weight ratio of E5 INTERNAL CURE to cement is in the range of about 28.34 to about 566.99 grams (from about 1 to about 20 ounces) of E5 INTERNAL CURE to 45 kilograms ( 100 pounds) of cement (not including water, sand, aggregate or other additives). More preferably, the weight ratio of E5 INTERNAL CURE to cement is in the range of from about 28.34 to about 283.49 grams (from about 1 to about 10 ounces) of E5 INTERNAL CURE to about 45 kilograms (100 pounds) of cement (not including water, sand, aggregate or other additives). A more preferred weight ratio of E5 INTERNAL CURE to cement is in the range of from about 28.34 to about 141.74 grams (from about 1 to about 5 ounces) of E5 INTERNAL CURE to about 45 kilograms ( 100 pounds) of cement, with about 85.04 to about 141.74 grams (about 3 to about 5 ounces) of E5 INTERNAL CURE to about 45 kilograms (100 pounds) of cement (not including water, sand, aggregate or other additives) even more preferred. Surprisingly, using more than about 566.99 grams (20 ounces) of E5 for about 45 kilograms (100 pounds) of cement (again, not including water, sand, aggregate or other additives) may no longer be beneficial. where additional water benefits or compressive strength may not or may be observed minimally. The resulting concrete mix can be difficult to pour and any resulting concrete can be of poor quality. Note that concrete quality decreases with distance from the preferred range of about 85.04 to 141.74 grams (from about 3 to about 5 ounces) per 45 kilograms (100 pounds) of cement, but the compressive strength it can be further improved in relation to the absence of the E5 INTERNAL CURE amorphous colloidal silica. In preferred embodiments, colloidal silica added to the concrete mix is in the range of from about 40 to about 98% by weight silica, with 60 to 95% by weight preferred and 70 to 92% by weight more preferred, and 75 to 90% by weight even more preferred.

[0060] Aggregate and sand can generally be used in inventive concrete in amounts known in the art for construction purposes. In one embodiment, an amount of aggregate and/or an amount of sand is used so that they total an amount in the range of about 400 to about 700% by weight of cement. In general, a concrete mix is prepared with components comprising a mixture of cement, water and preferably a quantity of aggregate and sand (sometimes called in the technique "large aggregate" and "small aggregate", respectively). The concrete mix is allowed to comprise only one of the two, such as just sand or just aggregate, but it is preferable that the mix comprises at least a quantity of each. Sand and aggregate can contribute to the silica content of the cement mix and therefore can affect (ie slightly increase) the water requirement of the concrete mix. Generally, most types of aggregates that are suitable for the use in which the concrete will be placed can be used. These include larger aggregates such as coarse and crushed limestone gravel, larger grades of clean crushed rock and the like, as well as smaller aggregates such as smaller grades of clean crushed rock, finely crushed limestone and the like. Likewise, many types of sand can be used, such as pit sand (coarse), river sand and the like. Generally, in concrete applications, “coarse sand” is preferred over “soft sand”, which is known to be more suitable for use in mortar. However, you can generally expect soft sand to have a different water requirement than coarse sand when used in concrete preparation. As is known in the art, weight bearing applications may require a larger aggregate such as coarse ground limestone. This larger aggregate is preferred for hollow concrete applications, particularly for use in hollow building slabs and larger aggregates such as coarse crushed limestone gravel and higher grades of clean crushed stone and pit sand.

[0061] The ratio of aggregate to sand, taken together, based on the weight of cement (bwoc) is preferably in the range of about 992 to about 1,984 kilograms per meter (from about 2,000 to about 4,000 pounds per yard) of dry cement mix (in the range of from about 257 to about 302 kilograms per meter (from about 520 to about 610 pounds per yard), or more preferably from about 277 to about 282 kilograms per meter (from about 560 to about 570 pounds per yard), even more preferably, about 279 kilograms per meter (564 pounds per yard) Most preferred is a combined aggregate to sand ratio in the range of about 1,339 to about from 1,636 kilograms per meter (from about 2,700 to about 3,300 pounds per yard) of dry cement mix. Most preferred is a range from about 1,438 to about 1,537 kilograms per meter (from about 2,900 to about 3,100 pounds per yard) of dry cement mixture. In another modality, op The weight of aggregate and sand is between 50 and 90% by weight based on the weight of the concrete, with a range of about 70 to about 85% by weight preferred. The relative amounts of aggregate and sand are not critical, but are preferably in the range of about 20% by weight to about 70% by weight sand based on the combined weight of sand and aggregate, with about 40 % by weight to about 50% by weight sand preferred.

[0062] It has been found, especially in commercial scale pouring, that even the small amounts of amorphous nanosilica necessary to effect the disclosed benefits, when added to the cement mixture before water, can be detrimental to the fluidity of the concrete mixture, as well. as the quality of the resulting concrete, making the concrete even inadequate. The process of the present invention generally includes the situation where at least a portion of the amount of water is added prior to the addition of the amount of amorphous nanosilica, with at least a period of agitation time between the additions to distribute the water prior to the addition of the amorphous silica. In practice, some water can be added later in the preparation process if desired. For example, it is known to add water in two (or more) portions, as is the practice of adding one portion as "waste water" after adding and stirring a first portion. In one embodiment, the amorphous silica is added as a colloidal silica with a second portion of water. In a preferred embodiment, colloidal silica is added after the addition of water which has been added in two portions, with stirring after the addition of each portion.

[0063] Thus, more generally, the amount of water can be added in its entirety or added in portions that comprise an initial portion, comprising in the range of about 20% by weight to about 95% by weight of the amount of water and a portion of waste water, which comprise the remainder; wherein the initial portion of water is combined with the amount of cement mix and aggregate/sand components to form a first mix; and wherein the amorphous silica is added to a mixture comprising the amount of cement mixture, the aggregate/sand components and the initial portion of water to form a second mixture. Even more preferred is an initial portion comprising the range of 35 to about 60% by weight of the amount of water.

[0064] (The three situations below (i.e. "situation 1", "situation 2" and "situation 3") correspond, respectively to i) the addition of silica after addition of waste water; ii) addition of silica before addition of waste water; and iii) the co-addition of the silica with the waste water).

[0065] In split water addition arrangements, wherein the waste water is 1) added to the first mixture; or 2) added to the second mixture; or 3) co-added with the amorphous silica to the first mixture, wherein the amorphous silica and waste water are optionally inter-combined; and wherein 1) the first mixture is stirred for a time t11 before the addition of the residual water, for a time t12 after the addition of the residual water but before the addition of the amorphous silica, and for a time t13 after the addition of the silica amorphous, but before the addition of the mixture; or 2) the second mixture is stirred for a time t21 before adding the amorphous silica, for a time t22 after adding the amorphous silica but before adding the residual water, and for a time t23 after adding the residual water, but before adding the mixture; or 3) the second mixture is stirred for a time t31 before the co-addition of the amorphous silica and the residual water, and,

in that case, the concrete mix is then stirred for a time t32 after the addition of the silica, but before the addition of the mix by addition.

[0066] In situation 1), in which the second portion of water (waste water) is added to a concrete mixture comprising a first portion of water, the amount of cement mixture and the sand/aggregate components, t11 is preferably in the range of about 2 to about 8 minutes, where about 3 to about 6 minutes is more preferred, and at a mixing speed (as, for example, in a ready mix), preferably in the range from about 2 to about 5 rpm. Time t 12 is preferably in the range of about 0.5 to about 4 minutes, with a more preferred range of about 1 to 2 minutes, at a mixing speed in the range of about 2 to about 5 rpm. Time t13 is preferably in the range of about 2 to about 10 minutes, with a range of about 5 to about 10 minutes more preferred, with a relatively high mixing speed at a rate in the range of about 12 at about 15 rpm before adding the addition mix. After the mixture is added and mixed as described below, the rate can be reduced to a rate in the range of about 2 to about 5 rpm for a time, such as, for example, a transit time to a pouring site. . Transit time standards are set by the American Concrete Institute. For example, concrete must be poured within 60 minutes of the end of the high-rate mix if the temperature is 32 °C (90 F) or more, and within 90 minutes if the temperature is less than 32 °C (90 F).

[0067] In situation 2), in which the second portion of water (waste water) is added to a concrete mixture comprising a first portion of water, the amount of cement mixture and the sand/aggregate components and the silica amorphous, t21 is preferably in the range of about 2 to about 8 minutes, with about 3 to about 6 minutes more preferred, and at a mixing speed (such as in a ready mix) preferably in the range of about 2 to about 5 rpm. Time t22 is preferably in the range of about 0.5 to about 2 minutes,

with a more preferred range of about 0.5 to 1 minute, at a mixing speed in the range of about 2 to about 5 rpm. Time t 23, the time just before adding the mixture, is preferably in the range of about 2 to about 10 minutes, with a range of about 5 to about 10 minutes, more preferably, with a speed of relatively high mixing at a rate in the range of about 12 to about 15 rpm. After the mixture is added and mixed as described below, the rate can be reduced to a rate in the range of about 2 to about 5 rpm for a time, such as, for example, a transit time to a pouring site. . As noted above, transit time standards are set by the American Concrete Institute.

[0068] In situation 3), wherein the wastewater is co-added with the amorphous silica to the first mixture, wherein the amorphous silica and the wastewater are optionally inter-combined, t31 is preferably in the range of about 2 to about 8 minutes, where about 3 to about 6 minutes is most preferred, and at a mixing speed (such as in a ready mix) preferably in the range of about 2 to about 5 rpm. Time t32, the time immediately prior to addition of the mixture, is preferably in the range of about 2 to about 10 minutes, with a range of about 5 to about 10 minutes, more preferably, with a speed of relatively high mixing at a rate in the range of about 12 to about 15 rpm. After the mixture is added and mixed as described below, the rate can be reduced to a rate in the range of about 2 to about 5 rpm for a time, such as, for example, a transit time to a pouring site. . As noted above, transit time standards are set by the American Concrete Institute.

[0069] In another modality, the entire amount of water is added to the amount of cement mixture and the aggregate/sand components to form a mixture, after said mixture is stirred for a time t before adding the amorphous silica, in that the concrete mix mix is then stirred for a while before adding the mix by addition. Adding the entire amount of water at once is useful in case of wet batch processes. The time ta is preferably in the range of about 2 to about 8 minutes, where about 3 to about 6 minutes is most preferred, and at a mixing speed (as, for example, in a ready mix ), preferably in the range of about 2 to about 5 rpm. Time tb is preferably in the range of about 2 to about 10 minutes, with a range of about 5 to about 10 minutes, more preferably, with a relatively high mixing speed at a rate in the range of about from 12 to about 15 rpm. After the mixture is added and mixed as described below, the rate can be reduced to a rate in the range of about 2 to about 5 rpm for a time, such as, for example, a transit time to a pouring site. . As noted above, transit time standards are set by the American Concrete Institute. Although the benefits of the invention are generally seen in the case of a single addition of water, in practice the division of water into two portions is generally respected. After agitating a concrete mix comprising a first portion, the use of a second portion has the advantage of drawing the remaining ready mix of insufficiently mixed cement mix close to the mouth of the barrel.

[0070] The mixture is preferably added at a point where the mixture comprises the silica, and the mixture comprising the silica has been thoroughly mixed prior to adding the mixture by addition. Thus, in addition to the above recommendations regarding the addition of silica, there are similarly recommendations before and after adding the addition mix that contains the cutter, but before pouring. These conditions are consistent with the conditions above. In preferred embodiments, the mixture comprising silica is mixed for a total time of at least 3 minutes at one or more speeds greater than about 6 RPM. In more preferred embodiments, the mixture comprising silica is mixed for a time in the range of about 5 to about 15 minutes, and more preferably in the range of about 5 to about 10 minutes, at one or more speeds in the range. from about 7 RPM to about 15 RPM, and more preferably in the range of from about 12 to about 15 RPM. After the previous mixing step, the addition mix containing the cutter is added. In preferred embodiments, the blend containing the addition blend containing the cutter is blended for a total time of at least 3 minutes at one or more speeds greater than about 6 RPM. In more preferred embodiments, the addition mix containing the cutter is mixed for a time in the range of about 5 to about 15 minutes, and more preferably in the range of about 5 to about 10 minutes, in one or more speeds in the range of about 7 RPM to about 15 RPM, and more preferably in the range of about 12 to about 15 RPM.

[0071] The concrete mix can be prepared in a wet batch (“central mix”) or dry (“transit mix”) situation. In wet batch mode, the dry components are mixed with the amount of water followed by the amorphous silica to provide the concrete mix, in one of the ways indicated above. The mixture is stirred as above or introduced into a ready mix and stirred as indicated above. Essentially, the wet and dry batch situations are similar, except that part of the procedure for a wet batch is carried out outside of the ready mix (eg at the factory). Dry batch ("transit mix") is somewhat preferred. For example, 40 plus or minus 20%, or in other embodiments plus or minus 10% of the total amount of water to be used in preparing the mix of concrete, sand and coarse aggregate used in the batch is loaded into a Ready Mix. The cement mixture, coarse aggregate and sand are mixed and loaded into the finished mix. The remaining water is loaded into the finished mix. Once the dry components and water are completely mixed, the amorphous silica is added and the mixture is mixed for 5 to 10 minutes. Mixing preferably takes place at relatively high drum rotation speeds, such as a speed in the range of about 12 to about 15 rpm. After high speed mixing takes place, the batch can then be poured. However, it is permissible to have a period of time between high speed mixing and pouring, such as transport time to the pouring site. In general, as long as the concrete is mixed at lower speeds, such as about 3 to about 5 rpm, a time between high speed mixing and pouring is in the range of about 1 to about 60 minutes is allowed.

[0072] In one modality, it is particularly convenient to add silica to a ready mix, which contains water, cement and other dry components, once the finished mix has reached the pouring site. It has further been found that after the amorphous silica has been added, the concrete/silica mixture should be mixed, prior to pouring, for a time, more preferably at least about 5 to about 10 minutes. However, other periods of time may be allowed with regard to obtaining, at least partially, the benefits of the invention.

[0073] The benefits of the invention can be expected in commercially used variants of the above process, provided that the amorphous silica is added at the end, after mixing the dry components and the first and second portions of water (or with the second portion of water ), and the added silica mixture is mixed for a time as specified in this document before being poured.

[0074] In a preferred embodiment, it is particularly convenient to add the silica to the finished mix, which contains the water, cement and other dry components, once the finished mix has reached the pouring site. It has further been found that after the amorphous silica has been added, the concrete/silica mixture should be mixed, such as, for example, with a ready-mix mixer, for a time, more preferably at least from about 5 to about 10 minutes, preferably at high speed, such as 12 to 15 rpm. Nonetheless,

other time periods and other speeds may be allowed with regard to obtaining, at least partially, the benefits of the invention.

[0075] The concrete mix can be prepared in a wet or dry batch situation, as desired. For example, 40 plus or minus 15%, or in additional modalities plus or minus 10%, of the water required to fully wet the cement, sand and coarse aggregate to be used in the batch is loaded into a ready mix. The cement mixture, coarse aggregate and sand are mixed and loaded into the finished mix. The remaining water is loaded into the finished mix.

[0076] Once the dry components and water are mixed, the amorphous silica is added and the mixture is mixed for a time in the range of about 3 to about 15 minutes and more preferably in the range of about 5 about 10 minutes; preferably, at relatively high drum rotation speeds, such as, for example, a speed in the range of about 8 to about 20 rpm, and more preferably about 12 to about 15 rpm. It is allowed to have a period of time between high speed mixing and the addition of silica, such as transport time to the pouring site. In general, as long as the concrete is mixed at slower speeds, such as about 3 to about 5 rpm, a time between high speed mixing and silica addition is in the range of about 1 to about 60 minutes is allowed. In one embodiment, the silica-containing cement mix is preferably thoroughly mixed prior to adding the mix by addition. Once high speed mixing has taken place, the mixture can then be added, as in ready mix. Since the silica has been added to the mixture and fully blended, it is preferred to add the mixture to the batch within 30 minutes, more preferably within 20 minutes and even more preferably within 10 minutes. Once the addition mix has been added to the concrete mix comprising a mixed amorphous silica component, the mix containing the addition mix can then be mixed at speeds in the range of about 1 to about 18 rpm, for a time in the range of about 2 to about 20 minutes.

[0077] As indicated above, it is common for concrete to be mixed with split water addition, that is, with a portion of the water added before the addition of the dry components and a portion added after the first portion and the dry components are mixed during a time. The benefits of the invention can be expected in all commercially used variants of the above process, provided that

[0078] 1) the amorphous silica is added after mixing the dry components and the water (regardless of whether the water is added in one portion or 2 or more portions), within about 60 minutes of dosing (i.e., complete mixing ) of water and other concrete components;

[0079] 2) the silica-containing mixture is mixed at relatively high drum rotation speeds (such as, for example, one or more speeds in the range of about 8 to about 20 rpm for a time in the range of about 3 to about 15 minutes;

3) the mixture is added to the mixture containing silica and the resulting mixture is mixed at one or more speeds in the range above about 1 rpm, for a time in the range of about 2 to about 20 minutes, which preferably includes a time period of at least 1 minute, but as long as 18 minutes, or even longer, at a speed above about 10 rpm, and more preferably in the range of about 12 rpm to about 15 rpm; and

[0081] 4) the concrete mix is poured in about 60 minutes after mixing 3).

[0082] The abrasion resistance of concrete formed from the compositions and methods of the invention is generally increased due to concrete that is formed from standard methods and compositions (ie, prepared without adding amorphous silica and the mixture). Subjecting inventive concrete to the ASTM C944 abrasion resistance test generally provides less weight loss resulting from the fact that standard concrete is prepared in substantially the same way, but in the absence of the amorphous silica and the mix. For example, as shown by Examples 1 and 3, standard concrete has a greater abrasion loss than the concrete of the present invention. The standard concrete of Example 3 exhibits an abrasion loss of 1.1 grams, while concrete formed from the compositions and methods of the present invention exhibits a loss of 0.6 grams. In general, the concrete of the present invention can cause abrasion losses that are reduced compared to standard concrete by up to fifty percent or even more. By standard concrete is meant concrete prepared by comparable methods, components and proportions of components, but without the addition of the disclosed amorphous silica and the disclosed addition mixture.

[0083] The following is a detailed description of the finishing step procedures through which the advantages of the present invention manifest themselves. Accompanying the detailed description of the procedure are visual descriptions of changes in surfaces as the steps progress, with an emphasis on differences due to inventive methods and formulations. Finishing concrete for indoor use generally involves three successive steps after starting to cure a poured slab: float, blend, and a final finishing step. Each is performed at specific stages of healing, and the determination of when to begin each stage is within the expert's qualified judgment. As many or most slabs are often the first element of a new construction, external elements such as temperature, relative humidity and wind speed play a role in determining it. As discussed in the section entitled “New Compositions for Improved Concrete Performance”, the use of a specific type of amorphous silica, in the context of a specific concrete preparation process, minimizes many of the effects of the external element on curing. This makes the standard three-step finishing process much easier, with each step often requiring less energy and less risk of damage to the concrete during finishing. For example, all three are generally required to obtain the standard finish on concrete building slabs, which are the foundation for most residential and commercial construction. In the context of the present invention, flotation is generally easier than with standard concrete due to the excellent water holding properties of the concrete described below. Floating can be done by methods known in the art, such as, for example, manual trowel, lawn mower, electric trowel or with the use of concrete mixers or floating shoes of 91, 122 or 152 centimeters (36, 48 or 60 inches) . Generally, because of the reduced friction between the blades and the surface, the effort required to float is reduced due to that required to float traditional concrete, and therefore machine speeds can be significantly lower than the speeds required for the floating concrete prepared by methods, minimizing the potential for damage to the concrete surface.

[0084] The combining step is then generally performed as known in the art, such as, for example, a displacement on an electric trowel or a lawn trowel trowel with combined blades. It is during this step that the plastic nature of the surface usually becomes most apparent and pronounced. The surface is, in general, distinctly different from the surface developed during blending by concretes that do not contain both of the following; 1) the inventive amorphous silica amounts, particle sizes and surface areas as disclosed herein, and 2) the inventive blend formulations as disclosed herein. The effect was described by the inventors as "plastic-like". The surface develops a smoother appearance, which generally increases, to some degree, with blending time, where the surface has a reduced incidence of large pores as well as improved flatness when compared to widely used staged concrete formulations. similar finishing materials that lack the inventive formula and process details as disclosed in this document. By "plastic-like" it is meant that the surface has at least the appearance of a coating, wherein said coating generally not of high clarity during blending, is obstructed to a degree that can be diminished, to some extent, with the progress of the combination and/or increase in the speed of the combined blade. Later, during blending, it may or may not take on a glassy texture and even greater clarity as in later finishing steps. Using higher blending speeds (above about 190 rpm) than using traditional concrete can provide an improved finish with regard to clarity and gloss, but not necessarily. (It should be noted that there may be situations where the combination is not performed or is considered unnecessary). Again, the greater amount of water held by the concrete on its surface generally results in less friction between the surface and the combined blades and therefore less energy is needed for the machine to maintain a given speed. The risk of damage to the machine's surface is generally greatly reduced.

[0085] The finishing step can then be performed. Methods known in the art can be used, such as, for example, an electric trowel or a lawn trowel with finishing blades. Those who have worked with inventive concretes indicate that, with the finishing step, the surface takes on more and more glassy characteristics, such as a clarity that is increased due to the concretes known in the art and prepared in the same way, although not as clear as usually it can be achieved with a polishing step. Without wishing to be bound by theory, the increase in clarity is thought to be a consequence of moisture retention on the concrete surface attributable to the inventive inclusion of silica as disclosed in this document. The clarity, shine and levelness achievable after the finishing step is usually sufficient to qualify as a “Grade 1” finish. With traditional concretes, (i.e., where the disclosed topical or blended addition use of the prescribed formulations and the disclosed amorphous silica are not used), the finishing step does not necessarily provide that glassy appearance, i.e., greater clarity and/ or gloss, with traditional superior finish speeds of around 190 rpm.

[0086] Most available finishing machines are limited to a maximum speed of around 190 rpm, but some older machines can reach maximum speeds of around 220 rpm. A characteristic often observed with the use of blending or topical use of inventive formulations is that the use of higher finish blade speeds (such as 200 to 220 rpm) than traditionally used (such as, for example, 180 to 200 rpm) can improve the finish compared to that obtained at traditional speeds, so that the surface acquires even more shine and clarity than obtained at lower speeds. The surface thus obtained is often still a "Grade 1" finish, but with greater clarity and gloss over surfaces of the invention that have not been finished at such increased speeds. To the best of the inventors' knowledge, such increased clarity at higher speeds is specific to concrete surfaces of the present invention.

[0087] Finishing time is until the surface has the desired appearance. For example, two passes may be needed to observe a finish with superior clarity, gloss and flatness. It is noteworthy that the finish can acquire a more matte appearance during the blending step, which, if desired, can be retained, not performing the final finishing step. To obtain a finish with a more glassy appearance and texture, it is often necessary to proceed to the final finishing step.

[0088] Finishing can be done in varying degrees, based on the desired gloss and clarity of the concrete surface. Finishing with a finishing machine as described above and performed in industry at maximum speeds of 190 rpm generally results in a "Grade 1" finish, as is well known in the art. Further elevations in surface quality, i.e., increased gloss and clarity, can generally be achieved by using a polishing machine, also well known in the art, to develop a "Grade 2" or "Grade 3" finish . One skilled in the art can generally determine the degree of a finish by visually inspecting the finished surface. (Approximate RA reading (mean roughness) corresponding to various grades: Grade 1 generally corresponds to an RA from 50 to 20; Grade 2 generally corresponds to an RA from 19 to 11; Grade 3 generally corresponds to an RA from 5 to 0). It should be noted that the quality of the finish in polishing depends on the quality of the finish provided by the finishing step, which will generally provide a Grade 1 surface. High grade finishes obtained by polishing usually have a polished appearance. Note that, unlike traditional concretes, the shine of a polished floor of the present invention is achieved without the use of a protector or sealant.

[0089] As floor polishing machines operate at much higher speeds (rpm) than finishing machines, until now it was necessary to wait some time after finishing the finishing, such as at least about three or four days, and for up to 28 days or more before using a machine to polish a finished surface. It is known in the art that prior use generally risks significant damage, such as scratches (can be quite deep: 2 to 4 mm) and exposed aggregate, on the finished surface. Notably, concrete that has been prepared with amorphous silica, as disclosed and described in this document, as well as mixing by adding or using a topical finish of the formulations disclosed and described in this document, can be polished immediately after finishing, if desired, without damage to the surface of the concrete.

[0090] More specifically, concrete that has been prepared with the amorphous silica as described herein or in US Provisional Application 62/761,064 (incorporated by reference and included herein) and, additionally, having been prepared using Korkay Finish Mix or E5 which contains formulations described in this document, can be polished immediately after the finishing step without damaging the concrete surface.

[0091] For example, Figure 1 shows a concrete slab that contains 113.39 grams (4 ounces) per hundred of E5 Internal Cure, with E5 Finish used topically as a finish at rates of 24.54 square meters per liter (1,000 square meters) square feet per gallon). The polishing process was started right after the completion of the finishing step. Figure 1 shows the undamaged surface despite the 68 centimeter (27 inch) polisher operating at 2,500 rpm. Figure 2 shows the surface conversion from approximately Grade 1 to approximately Grade 2, although both Figures correspond to a topical use of the cutter, the effect is visually indistinguishable from that seen in the case of mixing use by adding the cutter.

[0092] Polishing machines generally come in three sizes (43, 50 and 68 centimeters (17, 20 and 27 inches) in diameter) with the larger diameter machines reaching speeds of up to 2,500 rpm. Higher speeds generally provide better clarity and brightness. A notable feature of the present invention is that concretes prepared by traditional methods generally require the application of a protector or sealant before polishing in order to achieve Grade 2 or Grade 3 gloss quality, with a wait of up to 28 days often required before starting polishing. The concretes of the present invention can be polished immediately after finishing without the application of protections or sealants, without damaging the concrete surface. Without wishing to be bound by theory,

The finishing and polishing steps are thought to cause the amorphous silica to react with the topical or blended formulation to create a glassy substance or phase, with a more complete reaction associated with higher finishing machine and polishing machine rpms. . It was also observed that, as in the finishing step, there is less friction between the machine and the floor, resulting in lower RA (Average Roughness) numbers and longer service life of the polishing pad.

[0093] The number of polishing passes used is usually simply enough to achieve clarity and gloss. The number of passes required to transform a Grade 1 finish to a Grade 2 finish can be as low as 3 to 4 or as high as 4 to 20. For every 93 square meters (1,000 square feet) of surface, approximately 20 minutes High speed polishing may be required to turn a Grade 1 into a Grade 2. It has been noted that if the floor has not developed a sheen during finishing, it is unlikely to pollute. Experience suggests that waiting some time after finishing, such as 1 to 24 hours or more, to start polishing can, in some circumstances, provide greater clarity when polishing.

[0094] Other advantages that are a consequence of the use of silica without the mixture (Application No. 16/501.232 filed on March 8, 2019, incorporated by reference for everything it teaches, without exclusion) in the present inventive method are generally not diminished with the use of the mixture. In preferred embodiments, the concrete mix is formed and agitated in the context of an industrial scale pouring, such as the preparation of slabs or slabs. In an additional modality, the concrete mix is created with and within equipment that holds the mix as it is being created, and which also has the ability to agitate the mix, such as a ready mix.

[0095] An advantage of the present inventive process is that the water in the formation of concrete, such as a plate,

formulated in accordance with the present invention, appears to be immobilized in formation rather than lost to evaporation. The likely fate of much of this water is to participate in hydration for long periods of time, rather than forming capillaries and voids. Thus, it is expected that, regardless of thickness, slabs, walls and other concrete formations present a reduction or absence of voids and capillaries, and a correlative gain in resistance to compression. Concrete formation with improved structure and compressive strength with thicknesses of up to about 6 meters (20 feet) can be formed with the concrete of the present invention.

[0096] An advantage of the present inventive process is that the poured concrete is less damaged by drying caused by environmental conditions such as temperature, relative humidity and air movement such as wind. For example, good quality concrete can be produced at wind speeds of up to 50 mph, temperatures as high as 48.88 °C (120 °F) and as low as -12 °C (10 °F), and relative humidities as low as 5% and as high as 85% or even higher.

[0097] The compressive strength of concrete formed by the method of the present invention is generally increased due to concrete formed by methods that are similar or, preferably, the same except for the addition of silica after water mixing, cement mixing and filling materials (aggregates, sand and the like). "Similar" or "the same" applies to environmental conditions such as wind speed, relative humidity and temperature profile, as well as other environmental factors such as shading or heat radiating environment in relation to the assessment of increased resistance to compression . Factors under the control of the pourer such as mixing times and parameters, pouring parameters (ie plate dimensions) are more easily accounted for. An increase in compressive strength is preferably evaluated from spillages that are identical except for the addition of amorphous silica. In a preferred embodiment, the evaluation is made from pours prepared from identical amounts of identical ingredients, simultaneously, but in separate ready-mixes, poured side by side at the same time but using separate ready-mixes. These spills are "substantially identical".

[0098] The increase in compressive strength may be in the range of about 5 to about 40% or even more, based on the compressive strength of the non-silica-containing spill of a pair of substantially identical spills. In most commonly observed modalities, the increase in compressive strength as assessed by substantially identical spillages is in the range of about 10 to about 30%.

[0099] The concrete of the present invention can generally be used in applications that require poured concrete, such as, for example, slabs, foundations and the like. An advantage of the present invention is that concrete prepared therefrom generally has increased resistance to water penetration and can thus be used in hollow applications that are particularly susceptible to exposure to moisture and associated damage, such as foundations.

[0100] As indicated below, the present invention includes the discovery that nanosilica, when added to a concrete mixture, preferably as a colloidal silica, after the addition of at least a portion of water, provides a cement with a improved compressive strength among other improved properties such as abrasion resistance and water permeability.

[0101] Concrete additive components, such as sand and sized aggregates that are used in the art, can generally be used in the concrete of the present invention without destroying the benefits provided by the present invention.

[0102] Thus, it is possible to use a concrete, composed of plenty of water for hydration, pouring and work, in the preparation of concrete that generally lacks the deficiencies otherwise associated with concrete concrete with large amounts of transport water. The compositions of the invention result in concrete that retains water so that exposed surfaces are less likely to dry out prematurely than concrete that has not had amorphous silica added. The relative effect of water retention is observed even under environmental conditions under which the surface would normally be predisposed to dehydrate. Concrete can therefore be poured under a wider range of environmental conditions than standard concrete. Surfaces can thus be finished with reduced amounts of surface water, or even, in some cases, without adding surface water.

[0103] Shrinkage is generally reduced relative to concrete that contains comparable amounts of water. Most notably, the compressive strength is increased. This result is generally obtained even if the concrete contains quantities of transport water that would jeopardize the formation of capillaries and voids in the absence of amorphous silica.

[0104] Without wishing to be bound by theory, it is assumed that amorphous silica can immobilize water during curing so that the water is prevented from migrating, delaying evaporation as well as the formation of capillaries and voids. Surprisingly, immobilization does not prevent water from participating in prolonged, long-term hydration, which provides the unexpected increase in resistance to compression.

[0105] A comprehensive benefit of the present invention is the ability to not use excess water in the curing reaction (hydration) due to the general loss of water through evaporation. Such benefit can be obtained even in the case of poured concrete with water levels below the theoretically required for the total hydration of the concrete, as well as in water levels higher than the theoretically required for the hydration.

[0106] A problem with existing concrete preparation and pouring processes is the risk taken when pouring is done in suboptimal conditions. As indicated below, relative humidity, wind speed and temperature, among other environmental factors, often compromise the shedding pattern because of their effects on water levels in various locations over and within concrete. This can occur even when the amount of water included is in accordance with the recommended amount of water specified by the cement mix manufacturer, be it a range of recommended values or a single specified optimal value. The present invention allows operation at the water content suggested by the cement manufacturer with a reduced risk of water-related problems. These suggested values generally correspond to the amount of water that would be needed to allow the hydration reaction to proceed to an acceptable degree or, in some cases, to completion. In the practice of this invention, the use of water in the amounts specified by the cement manufacturer is preferred. However, the present invention also reduces the risk of water problems due to other processes, even when the water content deviates from that specified by the manufacturer. Thus, in some embodiments, the water content is within the range of about -30% of the lowest value specified by the manufacturer's specifications and +30% of the highest value specified by the manufacturer's specifications, based on the weight of water added to the cement prior to addition of the amorphous colloidal silica or other silica described in this document.

[0107] Yet another benefit of the present invention stems from the ability of its formulations to retain Tvater for the benefit of prolonged hydration without the formation of capillaries and empty reservoirs. It is known in the art that the addition of aggregate, sand and other commonly included augmentation and reinforcement materials to cement to form concrete generally requires additional water to accommodate them in the concrete and can actually promote the formation of capillaries and especially empty reservoirs. These reservoirs are associated and located in relation to the surfaces of the included materials. In general, the most preferred aggregates and materials are of such quality that they closely associate with the concrete over their surface areas so that, during hydration, reservoir formation is minimized, as is the associated loss of compressive strength. However, these high quality included materials are generally uneconomical. Surprisingly, even in the presence of aggregates, the inclusion of amorphous silica particles can reduce or prevent the formation of empty reservoirs and capillaries. Without wishing to be bound by theory, the reduction of such imperfections, particularly empty reservoirs, and the associated increase in compressive strength tends to indicate that high surface area amorphous silica particles are participating in a direct association with the included material. , regardless of suboptimal material quality. This association can exclude water and strengthen the concrete's fixation to the included material.

[0108] Yet another benefit of the present invention is that the concrete formulations prepared from it can be pourable and/or worked without the use of so-called "superplasticizers". Non-limiting examples of such superplasticizers include ligninsulfonate, sulfonated naphthalene formaldehyde polycondensates, sulfonated melamine formaldehyde polycondensates, polycarboxylate ethers and other superplasticizer components whether they are emulsions, dispersions, powders or other chemical forms. In one embodiment, the concrete formulations of the present invention are pourable without the inclusion of superplasticizers and are free of superplasticizers or essentially free of superplasticizers. “Essentially superplasticizer free” means that the superplasticizer content is in residual amounts of less than about 0.1% based on the weight of the cement.

[0109] Below is a non-limiting list of addition blends that can be used with the present invention.

Alternatively, the concrete mix of the present invention may be free of any or all of the additives below, or other additives. The list below is sorted by ASTM C 494 categories. These include ASTM C-494 certified and non-certified additives.

[0110] Addition mixtures can be added as a powder or liquid.

[0111] • Normal water reducers and retarders (Type A, B, D)

[0112] • Nominal dosage range: 59.91 to 71.89 mg/ml (0.5 to 6 OZ/C)

[0113] • Superplasticizers: Normal and delay setting (Type F, G)

[0114] • Nominal dosage range: 239.65 to

4,793.05 mg/ml (2 to 40 OZ/C)

[0115] • Acceleration addition mixtures: water-reducing or non-water-reducing (Type C, E)

[0116] • Nominal dosage range: 239.65 to

5,392.18 mg/ml (2 to 45 OZ/C)

[0117] • Type S addition mixtures as defined in ASTM C 494:

[0118] • Medium range water reducers and retarders

[0119] • Nominal dosage range: 239.65 to

5,392.18 mg/ml (2 to 45 OZ/C)

[0120] • Corrosion inhibitors

[0121] • Nominal dosage range: 1.03 to 20.69 l/m (0.25 to 5 gallons/yard)

[0122] • MVRA (Moisture Vapor Reducing Addition Mixtures)

[0123] • Nominal dosage range: 599.13 to

2,875.83 mg/ml (5 to 24 OZ/C)

[0124] • SRA (mixtures by addition of shrinkage reducers)

[0125] • Nominal dosage range: 1.03 to 20.69 l/m (0.25 to 5 gallon/yard)

[0126] • Hydration stabilizers

[0127] • Nominal dosage range: 59.91

2,875.83 mg/ml (0.5 to 24 OZ/C)

[0128] • Viscosity modifiers

[0129] • Nominal dosage range: 29.95 to 958.61 mg/ml (0.25 to 8 OZ/C)

[0130] • Mixtures by adding air builders;

[0131] • Nominal dosage range: Grams (ounce), as required, to enter air: 11.98 to 4,313.75 mg/ml (0.1 to 36 OZ/C)

[0132] • Color agents; liquid and solid

[0133] • Nominal dosage range: 0.04 to 9.92 Kg/m (0.1 to 20 lb/yard) EXAMPLE 1

PREPARATION OF AN INTERIOR SLABS WITH MIXTURE

BY ADDITION ABRASION RESISTANCE MEASURED WITH ASTM-C944

[0134] Shed Size: 37 square meters (400 square feet)

[0135] Weather conditions: 52 to 78 degrees; humidity about 60%; Sunny.

[0136] The pouring started at approximately 7:00 am and the finishing finished at 1:00 pm.

[0137] The concrete was placed in accordance with normal practice (ACI 302). The mix design was standardized (ie a standard 6 bag mix described in Step 1 was used. The amorphous silica used was reported as E5 INTERNAL CURE. The mix used was introduced as E5 Finish. The slab was prepared as indicated in steps 1 through 8 below.

[0138] 1 - A traditional Class A concrete design of 6 bags (255 kg (564 lb)) of cement to 117 liters (31 gallons) of water (SSD - Saturated Dry Surface) per 0.76 cubic meter (yard) cubic) (7 cubic meters (9 cubic yards) total) was used to lay a 0.1 meter (4 inch) thick interior concrete slab with an unaerated concrete. Approximately 45 liters (12 gallons) of water per 0.76 cubic meter (cubic yard) were added to the finished mix, followed by the dry cement mix (255 kg per 0.76 meter (564 pounds per yard) as well as the aggregate. and sand (566 kilograms (1250 pounds) of sand and 793 kilograms (1,750 pounds) of rock per 0.91 meter (yard)). The water and dry components were mixed for 1 to 2 minutes and about 71 liters (19 gallons) of additional water per 0.91 meter (yard) was then added to the finished mix. The mix was mixed (in a concrete drum which has a high speed of 12 to 15 RPM for concrete mixing) by a additional time of 5 to 10 minutes When the driver was ready to transport the concrete to the job site, he reduced the concrete barrel speed to 3 to 5 RPM.

[0139] 2- 5,754.95 grams (203 ounces) total of E5 INTERNAL CURE (113.39 grams/45 kg (4 ounces/100 pounds) of cement was added after 8 meters (9 yards) loaded and grouped. there were 255 kilograms (564 pounds) of cement and 117 liters (31 gallons) of water per 0.76 cubic meter (cubic yard).

[0140] 3- The team allowed the ready mix driver to mix the batch for 5 minutes at a speed of 12 to 15 rpm.

[0141] 4- The E5 Finish was then added to the ready-mixed concrete producer truck (85.04 grams (3 oz) per hundred cement weight) and mixed for approximately 12 to 15 minutes. Mixing started with the truck idling the drum (3 to 5 RPM) for 2 minutes.

The drum speed was then increased to 12 to 15 RPM for the rest of the time.

[0142] 5- The slab was placed (cast) and after a waiting time of 3 hours, the finishing process was started.

[0143] 6- A concrete mat behind the trowel was used to carry out the dredging (floating) process. The float process tank speed was 80 to 130 revolutions per minute. The process is carried out for an hour and a half, at which time the texture of the slab surface indicated that it was ready for the next power pass on the trowel.

[0144] 7- The manual trowel was equipped with combined blades and the combination process was started. After about 2 passes at the beginning of the slab, the surface developed a plastic appearance. Blade speed was about 100 to 165 revolutions per minute. It was noted that the surface was even easier to finish than the situation where E5 Finish is applied topically after pouring, another finding by the same inventors with the present application. The surface exhibited very little friction compared to the combined blades. The finisher, extremely experienced in concreting and finishing concrete, noted the low friction, commenting that “it felt like it was finishing on a ball bearing surface, with practically no resistance on the machine”. As is known in the art and verifiable to a person skilled in the art, an opaque haze that would be identifiable to a person skilled in the art indicated that the surface was ready for the finishing step.

[0145] 8- The lawn troller was equipped with finishing blades, and the surface was submitted to finishing at a speed of about 165 rpm. The finisher noted that "the surface started to look a little like glass" and "the more I finished it, the lighter the finish." The finished surface appeared to have a coating that was somewhat similar to glass, though not as clear as glass, and the slab appeared denser, more consolidated throughout the matrix than typical concretes. Abrasion resistance was measured in accordance with ASTM-C944, and a loss of 0.6 grams was observed. It was expected from experience that a polishing step could be carried out without waiting and that the clarity of the surface layer could be greatly improved by polishing. EXAMPLE 2

PREPARATION OF A MIXED SHOE BY ADDITION

[0146] Footings are a common use of cast concrete in the construction industry. Spilled concrete is generally exposed to constant moisture exposure due to contact with the ground during curing. This constant contact can also provide a source of moisture in the case of cured concrete. A footing was made to observe the characteristics of the poured concrete under these conditions. The intent was to observe the resulting concrete density (ie, lack of capillaries and voids) in the footing and determine whether the strength of the concrete was affected.

[0147] Shed Size: 15 meters (50 feet) long by 0.61 meter (2 feet) wide and 0.76 meter (30 inches) thick

[0148] Conditions: 60 degrees

[0149] The pouring started at 1:00 h and was completed at 13:00 h.

[0150] Five bags (215 kilograms (475 pounds)) of cement were used for 117 liters (31 gallons) of water (SSD-saturated dry surface) per 0.76 cubic meter (cubic yard) (5.73 cubic meters ( 7.5 cubic yards) in total). Approximately 45 liters (12 gallons) of water per cubic yard were added to the finished mix, followed by dry cement mix (279 kilograms per meter (564 pounds per yard)), as well as coarse aggregate (stone) and fine aggregate ( sand) with 566 kilograms (1250 pounds) of sand, and

793 kilograms (1,750 pounds) of stone used per 0.91 meter (yard) of concrete. The water and dry components were mixed for 1 to 2 minutes and approximately 71 liters (19 gallons) of additional water per 0.91 meter (yard) was then added to the finished mix. All of the above took place at a drum speed of 3 to 5 RPM. E5 Internal Cure was then added to the ready-mixed concrete maker truck at 85.04 grams (3 ounces) for every hundred weight of cement. The mixture was then blended at a high speed of 12 to 15 RPM for an additional type of 5 to 10 minutes. The driver then slowed the concrete barrel to 3-5 RJPM and drove 5-10 minutes to the test site. E5 Finish was then added to the ready-mix truck at a rate of 85.04 grams (3 ounces) per hundred weight of cement. The drum speed is increased to about 12 to 15 RPM for about 5 to 10 minutes and the mixture is poured.

[0151] About 35 to 45 minutes after the pouring, a plastic-like surface was observed. Purge channels were not apparent. After 24 hours, the shoe showed no evidence of shrinkage as no stress cracks were observed. It is thought that the lack of shrinkage can be attributed to the closing or blocking of any channels. The surface was then observed to be extremely dense, which was verified by the compression breaks in the cylinder. This result tended to indicate that concrete could be used both indoors and outdoors.

[0152] ASTM C39\Cl23 L cylinder compression break results indicated that the compressive strength reached or exceeded 206.84 MPa (30,000 psi) in 28 days, with 25% or more of that achieved in 7 days. EXAMPLE 3

PREPARATION OF Slab WITHOUT MIXING BY ADDITION RESISTANCE TO ABRASION MEASURED WITH ASTM-C944

[0153] Location: Shelbyville, Indiana at Shelby Materials' ready-mix plant.

[0154] Ambient conditions: Spill start time was 7:30 am with an initial temperature of approximately 15 °C (60 °F). The ambient temperature reached a high peak at 80 s during the day. Relative humidity was in the range of 18% to 67%. The wind speed range was from 3 to 18 mph.

[0155] Steps and results:

[0156] 1 - A traditional Class A concrete design of 6 bags (255 kg (564 lbs)) of cement to 117 liters (31 gallons) of water (SSD - Saturated Dry Surface) per 0.76 cubic meter (yard) cubic) (7 cubic meters (9 cubic yards) total) was used to lay a 0.1 meter (4 inch) thick interior concrete slab with an unaerated concrete. Approximately 45 liters (12 gallons) of water per 0.76 cubic meter (cubic yard) were added to the finished mix, followed by the dry cement mix (279 kilograms per meter (564 pounds per yard)) as well as the fine aggregate ( sand) and coarse aggregate (566 kilograms (1,250 pounds) of sand, and 793 kilograms (1,750 pounds) of stone (coarse aggregate per 0.91 meter (yard)). The water and dry components were mixed for 1 to 2 minutes and approximately 71 liters (19 gallons) of additional water per 0.91 meter (yard) were then added to the finished mix.The mix was mixed (in a concrete drum at 12 to 15 RPM for an additional time of 5 to 10 minutes. When the driver was ready to transport the concrete to the job site, he then slowed down the concrete barrel to 3 to 5 RPM. The transport time to the pour site was approximately 5 to 10 min.

[0157] 2- total 10,792 grams (380.7 ounces) of E5 INTERNAL CURE (212.6 grams/45 kg (7.5 ounces/100 pounds) of cement) was added after the 8 meters (9 yards) loaded and grouped. Again, there were 255 kilograms (564 pounds) of cement and 117 liters (31 gallons) of water per 0.76 cubic meter (cubic yard).

[0158] 3- The team allowed the ready mix driver to mix the batch for 5 minutes at 12 to 15 rpm.

[0159] 4- The concrete was then poured into the slab forms.

[0160] 5- After the pouring, the slab was leveled. A “bull float” type leveler was then used to close the surface. Once the surface was hard enough to start the mechanical finishing process, proper methods were used to complete the finish.

[0161] 6- During the bull-type leveling process for surface closing, it was noticed that the concrete was much easier to close than the one prepared by the traditional ready-mix process.

[0162] 7- During the finishing process where purge water is usually present, this process did not present purge water. However, the surface remained wet. Unlike concrete prepared from traditional ready-mix products, water surprisingly was retained on the concrete surface under conditions which, with ready-mixes in the absence of E5 INTERNAL CURE, would likely result in a much drier surface.

[0163] 8- The team then spent 4 hours completing the concrete finishing process. Unlike concrete prepared from traditional ready mixes, the finishing process could be carried out with the machines running at half speed because of the moisture still present on the concrete surface. This led to a much easier finishing process than concrete without E5 INTERNAL CURE. Traditional concrete requires machines to run at 100% acceleration and is a more labor intensive process that involves a greater risk of surface damage during finishing.

[0164] 9- Abrasion resistance was measured by subjecting associated cylinders to ASTM-C944, and a loss of 1.1 gram was observed.

Claims (21)

1. Process for preparing a concrete installation, said process being characterized by the fact that it comprises the steps of: A) creating a concrete mixture from components, wherein said components comprise each of the following : a) an amount of dry cement mix, wherein said cement mix is defined by: i) a water/cement ratio value suggested by the manufacturer; wherein said suggested ratio is in the range of about 3.5 to about 6.5; and, after combining with b), the water/cement ratio is greater than the value corresponding to about 10% less than the suggested value and not greater than the value corresponding to about 30% greater than the value suggested; or ii) the range of water/cement ratio suggested by the manufacturer with a higher value and a lower value and, after combining with b) below, the water/cement ratio is greater than the value corresponding to approximately 10% lower than the that the lower value is less than the value corresponding to about 30% greater than the upper value; or iii) an amount such that, after combining with b) below, the water/cement ratio is in the range of about 0.35 to 0.65; b) an amount of water, c) an amount of amorphous silica in the range of about 2.83 to about 198.44 grams (from about 0.1 to about 7.0 ounces) per yard of cement in a ); wherein the average silica particle size is in the range of 1 to 55 nanometers and/or wherein the surface area of the silica particles is in the range of about 300 to about 900 m 2 /g; d) an amount of aggregate and/or an amount of sand in the range of about 400 to about 700% by weight of cement; and B) wherein the water from b), which is added in its entirety or in portions comprising an initial portion, comprises at least about 20% by weight of the amount of water and a portion of waste water; wherein the initial portion of water is combined with a) and the components of d) to form a first mixture; and wherein the amorphous silica is added to a mixture comprising a), d) and the initial portion of b) to form a second mixture; And wherein the waste water is 1) added to the first mixture or 2) added to the second mixture; or 3) is co-added with the amorphous silica to the first mixture, wherein the amorphous silica and waste water are optionally added optionally inter-combined; and wherein 1) the first mixture is stirred for a time t11 before the addition of the residual water, for a time t12 after the addition of the residual water and for a time t13 after the addition of the amorphous silica, or 2) the second mixture is stirred for a time t21 before the addition of the amorphous silica, for a time t22 after the addition of the amorphous silica but before the addition of the residual water and for a time t23 after the addition of the residual water; or 3) the second mixture is stirred for a time t31 before the co-addition of the amorphous silica and the residual water and, after this, the concrete mixture is then stirred for a time t32; OR C) wherein the amount of water is added to aa) and to the components of d) to form a mixture, whereupon said mixture is stirred for a time t before adding the amorphous silica, and after which, the concrete mixture is then stirred for a time tb; wherein, meeting the restrictions of B) or C), a mixture comprising silica results in B) or C), wherein said mixture comprising silica is mixed for a time greater than about 5 minutes at a speed of mixing at least 7 RPM; D) an addition mix is added after step B) or step C) to form an addition mix comprising the mix, and wherein said 'addition mix comprising the mix' is mixed for a total time of at least minus 3 minutes at one or more speeds greater than about 6 RPM. E) pouring the concrete mix from D) to form a concrete installation. 2. Process according to claim 1, characterized in that the initial portion of water comprises at least 30, 40, 50, 60, 70, 80, 90 or 99% by weight of the amount of water. 3. Process according to claim 1, characterized in that, by combining the mixture of dry cement from a) with the water from b), the water/cement ratio is: equal to or greater than the value suggested in i), but less than the value corresponding to 30% greater than the suggested value; or equal to or greater than the superior value of the range suggested in ii), but not greater than the value corresponding to 30% greater than the superior value; or with respect to iii), at least 0.35, but not greater than 0.65. 4. Process according to claim 1, characterized in that the amorphous silica is introduced into the first mixture as a colloidal silica solution and wherein the solution comprises between about 50 and about 95% by weight of silica and between about 5 to about 50% by weight of water. 5. Process according to claim 4, characterized in that the silica comprises between about 75 and about 90% by weight of silica and between about 10 and about 25% by weight of water. Process according to claim 5 characterized by the fact that amorphous silica is added in an amount in the range of about 70.87 to about 155.92 grams (from about 2.5 to about 5.5 ounces) per yard of cement. 7. Process according to claim 6, characterized in that the amorphous silica is added in an amount ranging from about 99.22 to about 127.53 grams (from about 3.5 to about 4 .5 ounces) per cement yard. 8. Process characterized by the fact that colloidal silica is added after the waste water. 9. Process according to claim 1, characterized in that the concrete is poured into a slab or a footing. 10. Process according to claim 1, wherein the process is characterized by the fact that it is conducted in a ready mix; wherein the residual water is added to the first mix after the first mix is stirred at a speed in the range of about 2 rpm to about 18 rpm for a time in the range of 15 seconds to 5 minutes; wherein, after the addition of residual water, the mixture is stirred at a speed in the range of about 5 rpm to about 18 rpm, for a time in the range of about 1 minute to about 18 minutes, after which the silica is added, as colloidal silica, to the finished mixture, and the mixture is stirred for a time in the range of about 1 to about 15 minutes at a speed in the range of about 2 to about 18 rpm. 11. Process according to claim 4, wherein process A, according to claim 1, is characterized by the fact that the process is conducted in a ready mix; wherein the residual water is added to the first mix after the first mix is stirred at a speed in the range of about 2 rpm to about 18 rpm for a time in the range of 15 seconds to 5 minutes; wherein, after the addition of residual water, the mixture is stirred at a speed in the range of about 5 rpm to about 18 rpm, for a time in the range of about 1 minute to about 18 minutes, after which the silica is added, as colloidal silica, to the finished mixture, and the mixture is stirred for a time in the range of about 1 to about 15 minutes at a speed in the range of about 2 to about 18 rpm. 12. Process according to claim 1, characterized in that the addition mixture comprising the mixture is mixed for a time in the range of about 5 to about 15 minutes at one or more speeds in the range of about 7 RPM to about 15 RPM, and more preferably in the range of about 12 to about 15 RPM. 13. Process according to claim 12, characterized in that the addition mixture comprising the mixture is mixed for a time in the range of about 5 to about 10 minutes. 14. Process according to claim 13, characterized in that the addition mixture comprising the mixture is mixed at one or more speeds in the range of about 7 RPM to about 15 RPM. 15. Process according to claim 14, characterized in that the addition mixture comprising the mixture is mixed at one or more speeds in the range of about 12 to about 15 RPM. 16. Process according to claim 15, characterized in that said mixture comprising silica is mixed for a total time in the range of about 5 to about 15 minutes. 17. Process according to claim 16, characterized in that said mixture comprising silica is mixed for a total time in the range of about 5 to about 10 minutes. 18. Process according to claim 17, characterized in that said mixture comprising silica is mixed at one or more speeds in the range of about 7 RPM to about 15 RPM 19. Process according to claim 18, characterized in that said mixture comprising silica is mixed at one or more speeds in the range of about 12 to about 15 RPM. 20. Process according to claim 1, characterized in that the mixture by addition is the E5 finish and it is added in an amount in the range of about 14.17 to about 226.79 grams per 45, 35 kg (from about 0.5 to about 8 ounces per 100 pounds) of cement. 21. Method for preparing concrete with improved wear resistance, said method being characterized by the fact that it comprises the following steps: 1) pouring a concrete slab comprising concrete comprising internal curing E5, wherein said slab is defined by an upper surface; 2) make the top surface float; 3) apply a diluted Korkay water solution on the upper surface; 4) perform a combination on the top surface so that the top surface is defined by a glossy appearance of non-glossy and opaque plastic type; 5) optionally perform top surface finish to improve shine.