NZ524964A

NZ524964A - Mould release composition comprising a borate

Info

Publication number: NZ524964A
Application number: NZ524964A
Authority: NZ
Inventors: John Rosani
Original assignee: Rosmar Australia Pty Ltd
Priority date: 2000-09-27
Filing date: 2001-09-27
Publication date: 2003-08-29
Also published as: AUPR040900A0; WO2002026458A1

Abstract

An aqueous mould release composition including: i) A borate selected from the group consisting of calcium borate, aluminium borate (AIBO3), zinc borate (Zn2B6O11), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof. ii) At least one organic component with a melting point below 100oC selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof. The composition contains from 0.001 to 0.1 moles of borate per litre of composition. Also described is a method of improving the release of concrete from a surface including coating the surface with a composition including: i) A borate selected from the group consisting of calcium borate, aluminium borate (AIBO3), zinc borate (Zn2B6O11), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof. ii) At least one organic component with a melting point below 100oC selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof. The composition contains from 0.001 to 0.1 moles of borate per litre of composition.

Description

New Zealand Paient Spedficaiion for Paient Number 524964 52 WO 02/26458 PCT/AU01/01211 1 MOULD RELEASE COMPOSITION Field of the Invention The present invention relates to mould release compositions suitable for 5 use with concrete moulds and to methods of using these compositions as mould release agents for concrete moulds. In particular, the present invention relates to mould release compositions containing a boron containing component selected from Boric acid or a borate (a salt of boric acid) or a derivative thereof and mixtures thereof and hydrates thereof, with preferred borates containing 10 either 1, 2, 3 or 4 boron atoms and with the most preferred borate being borax (disodium tetraborate). It is found that compositions of this type have useful mould release properties whilst at the same time avoiding some of the difficulties associated with mould release compositions that are. currently available.

Background of the Invention Mould release compositions have been used for a number of years in the construction industry and in the housing and garden supply industries. Indeed, compositions of this type are widely used in any industry in which fabrication of 20 concrete articles is required. The mould release compositions are generally applied to solid surfaces such as form work, moulds, pallets or other surfaces that come into contact with fresh concrete before it has cured. Typically, in use, these mould release compositions are applied to the surface to be treated either by spraying or painting of the contact surface of the material prior to concrete 25 being bought into contact with the surface of the material (which occurs when concrete is poured into the mould). The mould release composition then typically forms a thin layer on the surface treated and provides a layer between, the pre-cured concrete and the material facilitating removal of the concrete from the material (or vis-versa) once the concrete has adequately cured.

It is therefore necessary that such mould release compositions provide acceptable release properties between the concrete and the material forming the mould (which is typically steel or another metallic substance although wooden, plastic and even concrete moulds may also be used).

WO 02/26458 PCT/AU01/01211 2 An ideal mould release agent would therefore theoretically produce a clean stripping action (removal of the cured concrete from the mould) with a minimum of surface defects on the hardened concrete surface thus produced. Unfortunately, many known mould release compositions lead to surface defects 5 on the finished surface of the concrete. Typical surface defects encountered with concrete moulds include stains, voids, bugholes and impaired concrete surface texture making it unsuitable for interfaced bonding.

Whilst, as expected, the mould release property (stripability) is the most 0 important property of any mould release composition, additional properties are also desirable. The ideal release composition, therefore, in addition to providing good mould release (stripability) should be a non-staining composition.' Unfortunately, many known mould release agents can, at times, produce staining or discoloration of the end product concrete which is particularly 5 undesirable in decorative applications.

Furthermore, due to the variety of applications in which these compositions are used, the release composition should be non-corrosive to the surfaces to be treated and any other materials it comes into contact with whilst :0 in use.

When these mould release compositions are applied, they are typically used in circumstances where a smooth exterior surface of the concrete material is required to be formed and further composition qualities are thus needed. 15 Thus, the composition should not promote the formation of air pockets or cause interference with concrete coating treatments as this will lead to bugholes or voids. Whilst in many instances a smooth finish is not required in the construction industry per se due to the proportions of the materials that are fabricated, this property of mould release compositions is typically important for 10 decorative concrete applications such as the use of concrete as a construction material for producing garden ornaments and the like. In these applications, the relative smoothness of the finished article is crucial to the ultimate product performance and, as such, the ability of the mould release composition to produce such a surface is important.

WO 02/26458 PCT/AU01/01211 3 In addition, as the material is typically applied manually, it should be environmentally friendly and non-toxic to the workers who deal with the composition. A number of the known mould release compositions typically contain, as a solvent or carrier, petroleum based hydrocarbon liquids. This is 5 undesirable as the hydrocarbon solvents are known to cause dermatological problems if they come into contact with the skin of sensitive subjects. Contact of these materials with the eyes of workers can also be undesirable. These agents may also be undesirable as potential run off of the composition can lead to environmental pollution.

Furthermore, as the most cost-effective manner of application of these compositions is by spraying, there is generally exposure of the workers applying the composition and others in the immediate vicinity to the mist thus produced. It is known that prolonged exposure to mist can, in such circumstances, lead to 15 respiratory problems if the composition contains materials that are irritants.

This problem is exacerbated where the composition has a high vapour pressure (typical of hydrocarbons) leading to excessive fuming of the applied layer. Unfortunately, in this regard many of the known mould release 20 compositions, in addition to hydrocarbons, contain environmentally unfriendly materials and are indeed hazardous in use. Thus, for example, many of the compositions contain salts of alkyl phosphonic acids and/or organic acids which can be severely irritating to the skin and eyes of any worker. This therefore potentially limits the ability to use these compositions especially where the 25 treating of components is conducted in a confined space.

It would therefore be desirable to provide a mould release composition that would overcome or ameliorate one or more of these disadvantages.

Surprisingly, the applicants of the present invention have found that certain boron containing components such as boric acid, borates and/or derivatives and mixtures thereof and hydrates thereof can be used as active ingredients in mould release compositions leading to the provision of environmentally friendly mould release compositions.

Received 11 December 2002 Summary of the Invention 1 In one aspect the present invention provides an aqueous mould release composition including: (a) a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B60n), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; and (b) at least one organic component with a melting point below 100°C 10 selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, 15 animal derived polyesters, vegetable derived polyesters or mixtures thereof; wherein the composition contains from 0.001 to 0.1 moles of borate per litre of composition.

In a further aspect the present invention provides an aqueous mould release 20 composition including: (a) a borate selected from the group consisting of calcium borate, aluminium borate (AIBO3), zinc borate (ZnaBeOn), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; (b) at least one organic component with a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, 30 glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; and (c) an alcohol or polyol.

W:\clska\nkl\specles\PCTAU01 01211 (12-2002).doc Received 11 December 2002 The exact amount of borate to be utilised will be dependent on the other ingredients in the composition. On a molar scale, the composition preferably contains 0.001 to 0.5 moles of borate per litre of composition, more preferably 5 0.001 to 0.1 moles, more preferably 0.006 to 0.1 moles, even more preferably 0.006 to 0.05 moles, more preferably 0.02 to 0.04 moles, most preferably 0.024 to 0.034 moles per litre of composition. Particularly preferred amounts of borate are 0.033 moles, 0.026 moles, and 0.025 moles. The preferred borate is disodium tetraborate or a hydrate thereof. On a weight percentage basis, these 10 amounts correspond to the amount of borate present in the composition being preferably in the range 0.038 to 19 wt.% (w/w), more preferably in the range 0.2 to 3.8 wt.%, even more preferably 0.2 to 1.9 wt.%, more preferably 0.75% to 1.5%, even more preferably 0.9% to 1.3% of the total weight of the mould release composition.

As stated above, the composition contains at least one organic component having a melting point below 100°C. Examples of suitable organic components are alcohols and polyols. Preferred alcohols and polyois for use in the mould release compositions of the present invention include glycol, 20 propylene glycol, and glycerol.

Preferred other organic components also include oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty 25 acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters and mixtures and derivatives thereof. Particularly preferred organic components are vegetable oil, tallow and lanolin.

In an even further aspect the present invention provides a method of improving the release of concrete from a surface including coating said surface with a composition including: W:\clska\nki\spacles\PCTAU01 01211 (12-2002).doc Received 11 December 2002 6 (a) a borate selected from the group consisting of calcium borate, aluminium borate (AIBO3), zinc borate (Zn2B60ii), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; and 5 (b) at least one organic component with a melting point below 100°C is selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, 10 glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; wherein the composition contains from 0.001 to 0.1 moles of borate per litre of composition; prior to contacting said surface with concrete.

In yet an even further aspect the present invention provides a method of improving the release of concrete from a surface including coating said surface with a composition including: (a) a borate selected from the group consisting of calcium borate, 20 aluminium borate (AIBO3), zinc borate (Zn2B60n), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; (b) at least one organic component with a melting point below 100°C is selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; 30 and (c) an alcohol or Polyol prior to contacting said surface with concrete.

W:\clska\nW\specl8s\PCTAU01 01211 (12-2002).doc Received 11 December 2002 7 In yet a further aspect the invention relates to a method for producing a concrete article, said method including the steps of a) providing a mould for said concrete article; b) applying a mould release composition of the invention to said mould; c) bringing concrete into contact with said mould; d) allowing said concrete to cure; e) removing the cured concrete article from said mould.

In another aspect the present invention provides a method of producing a mould release composition, said method including the step of combining (a) an aqueous solution of a borate selected from the group consisting of calcium borate, aluminium borate (AIBO3), zinc borate (ZnaBeOn), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; with (b) at least one organic component having a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; wherein the amount of the borate is sufficient to provide from 0.001 to 0.1 moles of borate per litre of the final composition.

In yet another aspect the present invention provides a method of producing a mould release composition, said method including the step of combining (a) an aqueous solution of a borate selected from the group consisting of calcium borate, aluminium borate (AIBO3), zinc borate (Z^BeOn), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; with (b) at least one organic component having a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable W:\ciska\nW\spoclas\PCTAU01 01211 (12-2D02).doc PCT/AUO1/01211 Received 11 December 2002 8 oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, 5 polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; and (c) an alcohol or Polyol.

It is particularly preferred that the boron containing component is first 10 dissolved in water to form an aqueous solution prior to combining it with the organic component. It is also preferred that said step of combining occurs at elevated temperatures, preferably between 50°C to 100°C, more preferably 70°C to 90°C, most preferably about 80°C. It is also preferred that said combining takes place with agitation, preferably sufficient agitation to produce 15 an emulsion.

Definitions: As used herein, the following terms have the following meanings: Concrete: A building material typically composed of stone, sand, cement and water.

Cement: Nominally any bonding material. An example of a well-known cement is Portland cement. Portland cement and allied cements are made from 25 materials containing lime, aluminium and silica (e.g. limestone and clay) which are heated strongly in a kiln to form a clinker (consisting mainly of calcium silicates and aluminates). The finely ground clinker undergoes complex hydration processes when mixed with water, setting and hardening to a glovelike material.

Tallow: This term designates the fat from the fatty tissue of animals particularly cattle and sheep. It is generally available as beef tallow and as sheep or mutton tallow. It is also available as horse tallow although this is rarely available. Oleo stock is the highest grade of beef tallow. Whilst the exact W:\clska\nW\spocl0s\PCT ALI01 01211 (12-2002).doc PCT/AUO1/01211 Received 11 December 2002 9 composition of tallow may vary, it is generally seen as being (as glycerides): Oleic acid (37-43%), palmitic (24-32%), stearic (20-25%), myristic (3-6%), linoleic (2-3%). Minor constituents are generally seen as cholesterol, arachidonic, elaidic, and vaccenic acids.

The amount of water in tallow varies greatly depending on the source of the tallow. In general, the tallow can have a moisture content of up to 10% by weight although the tallow used herein was tested to have a moisture content of 1.15%. As used herein, reference to an amount of tallow refers to the amount 10 on a dry mass basis (anhydrous basis).

Therefore, whilst it is possible to produce a formulation of the invention using tallow containing moisture, the amount used must be increased to provide comparable amounts of tallow on a dry mass basis. The calculation of how to 15 adjust the amount of tallow to be used would be clear to one skilled in the art. Nevertheless, for clarity we include the following example calculation.

Amount of tallow required on a dry mass basis = 5g.

Tallow available has a moisture content of 15%.

.-.Tallow provided by tallow available on a dry mass basis = 85% of 20 actual amount (100% - H20 content).

Amount of 15% H2O content tallow required = 5/0.85 = 5.88g ^ The amount of H20 required will be reduced by the increase in moisture provided by the additional tallow.

Lanolin: Lanolin is the "fat-like" secretion of the sebaceous glands of sheep which is deposited onto the wool fibers. Chemically it is a wax rather than a fat, being a complex mixture of esters and polyesters of 33 high-molecular-weight alcohols and 36 fatty acids. The alcohols are of three types: aliphatic alcohols, steroid alcohols, and triterpenoid alcohols; the acids are also of three W:\clska\nkl\specles\PCT AU01 01211 {12-2002).cJoc Received 11 December 2002 types: saturated nonhydroxylated acids, unsaturated nonhydroxylated acids and hydroxylated acids. Liquid lanolin is rich in low molecular weight, branched aliphatic acids and alcohols while waxy lanolin is rich in high molecular weight, straight-chain acids and alcohols. Lanolin contains a variable water content 5 which can be as high as 25-30%. The lanolin employed in the present formulations had a water content of 1.7%. As for the tallow, the amounts of lanolin referred to herein refer to the amount of lanolin required on a dry mass basis (anhydrous). It is a yellowish-white unctuous mass with a slight odor. It is practically insoluble in water but is soluble in chloroform or ether with the 10 separation of the water. Where an amount of lanolin is referred to herein, reference is made to the amount on a dry mass basis. Accordingly, as for tallow, whilst lanolin containing moisture can be used, the amount must be adjusted to provide comparable amounts of lanolin on a dry mass basis.

Fats: The fats are esters of fatty acids with glycerol having the general formula: (RiCOO)CH2.CH(OOCR2)CH2(OOCR3). In the formula Ri, R2 and R3 may be the same fatty acid residue but, in general, the fats are mixed glycerols with each residue being different. The fatty acids present in the greatest quantity are typically oleic, palmitic and stearic acid. A number of fats (glycerols 20 of fatty acids) occur naturally in plants and animals. Fats are generally seen as having a melting point of greater than 20°C at atmospheric pressure.

Oils: There are glycerides of fatty acids as described for fats but having a melting point of less than 20°C at atmospheric pressure.

Vegetable Oil: Vegetable oils are oils obtained from the leaves, fruit or seeds of plants.

Animal Oil: Oils derived from animals.

Waxes: Fatty acid esters with monohydric alcohols.

W:\ciska\nkl\specles\PCTAU01 01211 {12-2002).doc Received 11 December 2002 11 Fatty Acids: Monobasic acids containing only the elements carbon, hydrogen and oxygen and consisting of an alkyl radical attached to the carboxyl group. Examples of fatty acids are palmitic acid, stearic acid, and linoleic acid.

Borates: Borates are salts of boric acid (H3BO3). They typically contain either trigonal BO3 or tetrahedral BO4 either of which may be discrete or linked and in which additional hydroxyl groups may be linked to the boron. Examples of borates are pyroborates and polyborates. Pyroborates such as C02B2O5 contain two BO3 linked together through one oxygen. Polyborates contain 10 infinite chains or rings, e.g. B3O3 rings in [B306]3" metaborates or linear [B02]' in LiB02.

Detailed Description of the Invention The mould release composition of the present invention contains a boron 15 component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, and mixtures thereof and hydrates thereof.

Chemistry of Borates Borates are a family of ionic compounds containing negative ions consisting of boron and oxygen. They are usually formed from boric acid (H3BO3) by dehydration and the simple borates contain 1, 2, 3 of 4 boron atoms. Examples of borates include: Calcium Borate (CaB204) 2- °0-B/ SB-O0 V Ca2+ Aluminium borate (AIBO3) Zinc borate (Z^BeOn) Lithum meta borate (LiB02) 30 Copper metaborate Dipotassium tetraborate (K2(B407)) Borax (disodium tetraborate) W:\clskataki\specfes\PCTAU01 01211 (12-2002).doc Received 11 December 2002 12 The exact chemical formula of any borate will depend on the level of hydration of the borate compound. For example, disodium tetraborate (borax) may be present as Na2B407 (anhydrous), Na2B4C>7.5H20 (pentahydrate) or Na2B407.(10H20) decahydrate. As used herein, reference to disodium tetraborate is intended to be a reference to the decahydrate and the amount of borate is calculated on this basis. As will be clear to a skilled addressee, however, different levels of hydration could be utilised that would provide the suitable amount of borate.

Poly borates are also well known in the art and can be used as the borate in the composition of the present invention. The preferred borate to be used in the invention is borax as discussed above. It is preferred that it is used in the form of the decahydrate. The exact amount of borate to be utilised will be 15 dependent on the other ingredients in the composition. On a molar scale, the composition preferably contains 0.001 to 0.5 moles of borate per litre of composition, more preferably 0.001 to 0.1 moles of borate per litre of composition, even more preferably 0.006 to 0.1 moles, even more preferably 0.006 to 0.05 moles, more preferably 0.02 to 0.04 moles, most preferably 0.024 20 to 0.034 moles per litre of release agent. Particularly preferred amounts are 0.033 moles, 0.26 moles, and 0.25 moles. The preferred borate is disodium tetraborate. On a weight percentage, this corresponds to the amount of borate present in the composition being preferably in the range 0.038% to 19 wt.% (w/w), more preferably in the range 0.038% to 3.8 wt.%, even more preferably 25 0.2% to 1.9 wt.%, more preferably 0.75% to 1.5%, even more preferably 0.9% to 1.3% of the total weight of the mould release composition.

Chemistry of Borax (The Preferred Borate of the Invention) Borax is the common name for sodium tetraborate which has a varying 30 chemical formula of Na2[B407].XH20 wherein X can vary from 0 to 10 depending on the level of hydration of the borax. Typical grades of commercially available borax include the anhydrous form (Na2B407), the pentahydrate (Na2B407.5H20) and the decahydrate (no2b4o7.ioh2o).

W:\clska\nkl\spscles\PCT AU01 01211 (12-2002).doc Received 11 December 2002 13 Borax is found to occur naturally as either kernite or tincal and it is also found to be present in the brines of Searle's Lake, United States of America. It has a number of uses including as a pesticide and has the advantage of not being very toxic to mammals. The anion is found to be strongly hydrogen 5 bonded to water and the compound can be used as a source of boron compounds in applications requiring this. In addition, borax has a mild antiseptic property.

As discussed above, the borax used in the present specification has 10 been sourced from a solution of sodium tetraborate decahydrate in water. In principle any source of borax can be used. In addition, suitable quantities of anhydrous disodium tetraborate (anhydrous) or disodium tetraborate pentahydrate could also be used to make up the solution. The important feature being that amounts used are equivalent to the total amount of anhydrous 15 disodium tetraborate provided by the decahydrate.

The exact amount of borate to be utilised will be dependent on the other ingredients in the composition. On a molar scale, the composition preferably contains 0.001 to 0.5 moles of borate per litre of composition, more preferably 20 0.001 to 0.1 moles of borate per litre of composition, more preferably 0.006 to 0.1 moles, even more preferably 0.006 to 0.05 moles, more preferably 0.02 to 0.04 moles, most preferably 0.024 to 0.034 moles per litre of release agent. Particularly preferred amounts are 0.033 moles, 0.26 moles, and 0.25 moles.

The preferred borate is disodium tetraborate or a hydrate thereof. On a weight percentage, this corresponds to the amount of borate present in the composition being preferably in the range 0.038% to 19 wt.% (w/w), more preferably in the range 0.038% to 3.8 wt.%, even more preferably 0.2% to 1.9 wt.%, more preferably 0.75% to 1.5%, even more preferably 0.9% to 1.3% of 30 the total weight of the mould release composition. The exact amount of borax to be used will depend on the application and the additional ingredients in the composition.

W:\clska\nKl\specles\PCT AU01 01211 (12-2002).doc Received 11 December 2002 14 In one preferred embodiment of the present invention the mould release agents of the invention include a borate and one or more alcohols or polyols.

Alcohols and Polyols A number of alcohols or polyols can be used in the mould release compositions of the invention. In general, any compound containing a free hydroxy group can be used although it is preferred that the alcohol or polyol is a low molecular weight organic alcohol or polyol. Preferred alcohols or polyols for use in the present invention are selected from the group consisting of glycol, 10 glycerol, propylene glycol, and Ci-s alcohols. It is further preferred that the alcohol is a diol and it is particularly preferred that the alcohol is glycerol or propylene glycol. Where an alcohol or polyol is present it is preferably present such that it represents at least 10 wt.% of the composition. It is particularly preferred that the alcohol is propylene glycol and is present at 10 wt.% of the 15 composition.

In a particularly preferred embodiment, the mould release composition contains a plurality of alcohols or polyols. Preferably said alcohol or polyol is selected from the group consisting of propylene glycol, glycerol and glycol.

In yet a further embodiment the mould release composition includes a borate and at least one organic component with a melting point below 100°C.

A number of organic compounds are suitable with preferred ones being 25 selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, 30 animal derived polyesters, vegetable derived polyesters or mixtures thereof.

Particularly preferred organic components are fats and oils with vegetable oils, tallow and lanolin being especially preferred.

W;\clska\nW\speclQs\PCT AUQ1 01211 (12-2002) .doc PCT/AUO1/01211 Received 11 December 2002 The total amount of the additional organic components utilised (if at all) can vary significantly with the preferred range being from 10% to 70% (w/w). If a viscous product is required, the amount of additional organic component is preferably in the range from 18% to 55% by weight, more preferably 35 to 55%, 5 most preferably 45% to 55%. When a less viscous composition is required, the amount of organic component is preferably present in the range 10% to 30%, more preferably 15% to 25%, most preferably 17.5% to 22.5%.

In relation to the vegetable oil, it is noted that any vegetable oil may be 10 used. Examples of suitable vegetable oils are canola oil and linseed oil. Canola oil is particularly preferred. Canola oil is rape seed oil which has a low erucic acid content. Whilst it is preferred that the vegetable oil is a single oil, it may be a mixture of vegetable oils.

When the mould release composition contains vegetable oil it is preferably present in the composition in an amount of 30% to 45% by weight of the composition. Particularly preferred amounts include 33.3%, 34.8%, 38.3% and 42.3%. It is preferred that the vegetable oil is recycled vegetable oil. In a particularly preferred embodiment, the vegetable oil is recycled, filtered 20 vegetable oil. If vegetable oil is used, it is preferably heated at its boiling point for approximately five minutes prior to use in the production of a formulation of the invention.

When tallow is present in the mould release composition, it is preferably 25 present in an amount of from 9.8% to 35% by weight of the composition, more preferably 11.8% to 32% by weight of the composition, most preferably 14.8% to 17.8% by weight of the composition.

When lanolin is present in the composition in addition to other organic 30 components, it is preferably present in an amount of from 0.5% to 7.5% by weight, more preferably 1.45% to 4.5% by weight, even more preferably 1.6% to 3.6%. If lanolin is the only organic component present, it is preferably present in the range of 30% to 60%, more preferably 40% to 50%, most preferably 44.2% by weight.

W:\clska\nki\spocles\PCTAU01 01211 (12.2002).doc Received 11 December 2002 16 In a particularly preferred embodiment, the component comprises vegetable oil and at least component selected from the growth consisting of lanolin and tallow. When the composition includes both tallow and vegetable oil, it preferably contains either: (A) 10% to 20% (preferably 12.5% to 17.5%, most preferably 13% to 15%) tallow and 30% to 40% (preferably 33% to 37%) vegetable oil; or (B) 15% to 25% tallow (preferably 17.5% to 22.5%) and 0.5% to 5% (preferably 0.75% to 1.25%) vegetable oil.

In a further preferred embodiment, the composition includes both lanolin and tallow. It is preferred that the total amount of lanolin and tallow in such composition is in the range 12% to 22% (more preferably 14% to 19%). In compositions containing both lanolin and tallow, it is preferred that the tallow is 15 present in an amount of 10% to 18%, more preferably 11% to 17%. It is preferred that the lanolin is present in these compositions in an amount of 1.45% to 4.5%, more preferably 1.6% to 3.6%.

In a further preferred embodiment, the composition includes tallow, 20 lanolin and vegetable oil.

Additional Additives A number of other additives can be added to or incorporated in the mould release compositions of the invention. The composition may therefore contain 25 paraffin oils and the like as an example.

A particularly preferred additional ingredient is a water softening/emulsifying ingredient. A preferred water softener is sodium carbonate. If present, it is preferably present in an amount of 0% to 2% by 30 weight of the composition, more preferably 0.2% to 1.0%, preferably 0.2% by weight.

W:\clske\nkl\specles\PCTAU01 01211 (12-2002).doc Received 11 December 2002 17 The composition may also contain sources of acid and alkali to adjust the pH to a suitable level if required. Suitable alkali sources are sodium hydroxide and potassium hydroxide. Suitable acid sources are mineral acids such as hydrochloric acid or sulphuric acid. In general, the source of alkali or acid is only required to adjust the pH of the composition to an appropriate pH in applications where pH control is important. It is preferred that the pH of the composition is in the range 6.0 to 10.0, more preferably 7.0 to 9.0, more preferably 8.0 to 9.0, most preferably about 8.5.

A particularly preferred composition is as follows: a) 0.6 parts to 3.6 parts borax (based on the decahydrate) b) 0 parts to 45 parts vegetable oil c) 10 parts to 25 parts tallow d) Balance water to 100 parts The compositions of the invention contain a certain amount of water. The general compositions of the invention are produced by dissolving the appropriate boron-containing component in water. In circumstances where an organic component is required, the procedure varies slightly. In these cases, all organic components are blended (with heating if necessary) to produce a solution of the organic components. The solution is then preferably agitated rapidly with addition of an aqueous solution of the boron component being added at such a rate to ensure the temperature of the mixture stays constant, preferably within the range of 50°C to 100°C, more preferably 70°C to 90°C, most preferably about 80°C. Upon completion of addition the mixture is stirred for a further 10 minutes at the temperature of addition and allowed to cool to ambient temperature. It can then be filtered if desired and packaged into the appropriate size containers.

The present invention in a further aspect relates to a method of improving the release of concrete from a surface, said method including the step of coating said surface with a composition of the invention (as described hereinbefore) prior to contacting said surface with concrete.

W:\clska\nki\specl0s\PCTAUOI 01211 (12-2002).doc PCT/AUO1/01211 Received 11 December 2002 18 In the method of the invention it has been found that the composition can be used with any suitable surface used in shaping concrete with metallic, steel, wooden, plastic and concrete surfaces being particularly suitable. It is preferred that the surface is the surface of a mould.

The mould release compositions can be used in concentrated form as discussed above or can be diluted in part with water to form a less viscous emulsion if required.

The mould release composition can be coated onto the surface in a number of ways well known in the art. The compositions may be sprayed onto the surface or applied by mop, brush/roller and are suitable for internal/external vibrating mould systems. The application required is a thin film on the surface to be treated prior to contacting the surface with the pre-cured concrete blend. The 15 preferred thickness of the film is in the range of 0.25 micron to 1mm, preferably 0.25mm to 0.50 mm.

Preferably, the mould release composition is applied by a spraying technique. Such an application method has been found to produce a more 20 uniform coating leading to improved results in the finished concrete article as well as superior mould release. In addition, spraying techniques are found to be more economical in terms of the use of the material and the time taken to apply it.

With the compositions of the present invention it is noted that moderate- to-large over dosing does not cause detrimental effects of air entrapment/bug holes. There may however occur some compression of concrete in low regions of the mould. The appearance obtained typically shows uniform colour, which is also smooth to touch. This reduces finishing of the surface thus produced to be 30 reduced to a bare minimum in contrast to available products.

The amount of time between application of the agent and the concrete can vary significantly however, it is found that the best results are achieved W:\clske\nki\speclcs\PCT AU01 01211 (12-2002).doc StfEST Received 11 December 2002 19 where the composition is applied to the surface immediately prior to the concrete being bought into contact with the surface.

The invention also relates to a method for producing a concrete article, said method including the steps of a) providing a mould for said concrete article; b) applying a mould release composition of the invention (as hereinbefore described) to said mould; c) bringing concrete into contact with said mould; d) allowing said concrete to cure; e) removing said concrete article from said mould.

A number of moulds are suitable including wooden, steel, metallic, plastic or concrete moulds. The moulds used are the moulds typically used in the art. A number of mould shapes can also be utilized depending on the desired concrete article to be produced. The process of the present invention has been found to be suitable for ornamental moulds with high levels of detail as required for garden ornaments and figurines for example, as well as for large, relatively straightforward moulds for beam construction.

The mould release composition can be applied in a number of ways well known in the art. The compositions may be sprayed onto the mould or applied by mop, brush/roller and are suitable for internal/external vibrating mould systems. The application required is a thin film on the surface to be treated prior to contacting the surface with the pre-cured concrete blend. The preferred thickness of the film is in the range of 0.05 to 1mm, preferable 0.25mm.

Preferably, the mould release composition is applied by a spraying technique. Such an application produces a more uniform coating leading to improved results in the finished concrete article as well as superior mould release. In addition, spraying techniques are found to be more economical in terms of the use of the material and the time taken to apply the same.

W:\clska\nki\specle5\PCT AU01 01211 (12-2Q02).doc PCT/AUO1/01211 Received 11 December 2002 A concrete formulation is then applied to said mould and allowed to cure. The process of the invention has been found to be applicable to any number of concrete formulations known in the art. The curing time will vary depending on the concrete composition chosen and will be within the skill of a skilled addressee to determine. Additives that increase this rate of cure may be incorporated in the concrete formulation and physical techniques that are known to facilitate curing, e.g. steaming, may also be used. Once the concrete has cured sufficiently, the concrete article is removed from the mould. As would be clear to a worker skilled in the art, there are a number of ways in which this can be achieved.

In an even further aspect the present invention provides a method of producing a mould release composition, said method including the step of combining (a) an aqueous solution of a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B60n), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; with (b) at least one organic component having a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; wherein the amount of the borate is sufficient to provide from 0.001 to 0.1 moles of borate per litre of the final composition.

In yet an even further aspect the present invention provides a method of producing a mould release composition, said method including the step of combining (a) an aqueous solution of a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B60ii), W:\clsko\nkl\speclos\PCT AU01 01211 <l2-2002).doc PCT/AUO1/01211 Received 11 December 2002 21 lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; with (b) at least one organic component having a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures 10 thereof; and (c) an alcohol or Polyol.

It is particularly preferred that the boron containing component is first dissolved in water to form an aqueous solution prior to combining it with the 15 organic component. It is also preferred that said step of combining occurs at elevated temperatures, preferably between 50°C to 100°C, more preferably 70°C to 90°C, most preferably about 80°C. It is also preferred that said combining takes place with agitation, preferably sufficient agitation to produce an emulsion.

The manufacture and use of these compositions will now be demonstrated by reference to the following non-limiting examples.

EXAMPLE 1 The following is a production procedure for the preferred mould release compositions of the invention. The batch size is 1000 litres.

The organic compounds are admixed and if any of the components are not liquids at room temperature, the admixture is heated to provide a solution of 30 the organic component(s). The solution thus formed is agitated and the temperature increased to 80°C. Once the mixture has reached 80°C the solution of the boron containing component in water is added at a rate of approximately 10 litres per minute with constant stirring whilst maintaining the temperature at approximately 80°C (preferably between 70 - 90°C). Upon W:\clska\nkl\speclBS\PCT AU01 01211 (12-20D2).doc PCT/AUO1/01211 Received 11 December 2002 22 completion of addition of the boron containing solution, stirring is continued until the mixture reaches 80°C and agitated at this temperature for 10 minutes. The mixture is then allowed to cool to ambient temperature, filtered and packed.

EXAMPLE 2 The following ingredients were blended in order with mild heating (approximately 50°C) and agitation. After each addition, the solution was allowed to equilibrate prior to the addition of the next ingredient. The time taken to reach equilibrium was typically of the order of 5-15 minutes for each addition.

Ingredient % by weight Recycled vegetable oil 57% Paraffin oil 3% Borax solution (2.4% w/v) 10% Sodium hydroxide solution (4% w/v) 20% Propylene glycol 10% The admixture was allowed to stand at ambient temperature for 24 hours then diluted with stirring with equivalent quantities of water and the pH adjusted 20 to be in the range 8-8.5. The composition had the following physical properties.

Appearance Odour Specific Gravity @ 20°C Flash Point 25 Solubility PH Opaque emulsion Pleasant 0.92-0.98 Not applicable Semi-soluble 8.5 EXAMPLE 3 The following ingredients were blended in order with mild heating and 30 agitation. After each addition, the solution was allowed to equilibrate prior to the addition of the next ingredient. The time taken to reach equilibrium was typically of the order of 5-15 minutes for each addition.

Component % by weight Lanolin 5% W:\ctskfl\nkltepocies\PCT AU01 01211 (12-20D2i.doc JPISA/AU Received 11 December 2002 23 Recycled vegetable oil 52% Paraffin Oil (Ondina oil) 3% Borax solution (2.4% w/v) 10% Sodium hydroxide solution (4% w/v) 20% Propylene glycol 10% Total 100% The mixture was allowed to sit for a minimum 24 hours then diluted with the same quantity of water and the pH adjusted to be between (8-8.5).

Appearance Odour Specific Gravity @ 20°C Flash point Solubility pH Opaque emulsion liquid Pleasant 1.0 Not applicable Semi-soluble 8.5 EXAMPLE 4 The following ingredients were blended: Component Propylene glycol Glycerol Borax solution (2.4% w/v) Total % by weight 32.68% 3.32% 64.00% 100% This was then allowed to stand at ambient temperature.

EXAMPLE 5 The composition of Example 2 was diluted with water to produce a composition having a water content of 60%.

This composition was applied as a thin film to a concrete mould prior to the concrete pour as a thin film. On removal of the concrete from the mould, the concrete surface was smooth to touch and displayed a uniform colour on the surface.

W:\ctska\nki\specJQS\PCTAU01 01211 (12-2002).doc SHEHT 24 Received 11 December 2002 EXAMPLES 6 - 7 The following compositions listed in Table 1 were also prepared using the method outlined in Example 1.

Table 1 Ingredient 6 Amount (wt%) 7 Amount (wt%) Tallow 11.3% 13.3% Recycled Vegetable Oil 34.8% 33.3% Lanolin 3.5% nil 2.4% Sodium Tetraborate + 0.2% sodium carbonate in water 50.4% 53.4% TOTAL 100% 100% EXAMPLES 8-10 The following compositions listed in Table 2 were prepared using the method outlined in Example 1.

Table 2 Ingredient 8 9 Tallow 17.7% 16.2% .8% Recycled Vegetable Oil 0.9% 2.0% 1.1% Lanolin nil 1.8% nil 1.2% Sodium Tetraborate + 0.2% sodium carbonate in water 81.4% 80.0% 78.1% TOTAL 100% 100% 100% EXAMPLE 11 The following formulation was prepared using the procedure outlined in Example 1.

W:\clsko\nkl\specles\PCTAU01 01211 (12.2002).doc AftWEP e'r!EET fPEftfAU Received 11 December 2002 Table 3 Ingredient Amount wt./% Vegetable oil 42.3% Lanolin 6.6% Ondina oil 15 1.8% 2.4% Sodium tetraborate in water 49.3% TOTAL 100% * Ondina oil is a paraffin oil.

EXAMPLE 12 A formulation was prepared using the procedure from Example 1 with the following composition: Table 4 Ingredient Amount wt./% Vegetable oil 38.3% Tallow .8% 2.4% sodium tetraborate and 0.2% sodium carbonate in water 45.9% TOTAL 100% EXAMPLE 13 A vegetable oil free formulation was prepared as follows: Table 5 Ingredient Amount Lanolin 45% 2.4% sodium tetraborate in water 55% TOTAL 100% AMENP®®?®1 W:\clske\nkUspoc1os\PCTAU01 01211 (12-2002).doc m

Claims

PCT/AU01/01211 Received 11 December 2002 26 EXAMPLE 14 The product of Example 7 was applied to a panel mould for the production of concrete paving by a paint approach. A concrete mixture was then applied to the panel mould and allowed to cure, and removed from the mould. 5 The article thus formed was found to have a smooth surface with no surface imperfections. The colour of the surface was the natural concrete colour. It was also notable that the moulds were easily stripped from the concrete and the surface thus produced was free of any bug holes and air entrapment. 10 EXAMPLE 15 The composition of Example 8 was applied to the main shutter moulds of a "T" Beam. The mould was then filled with a concrete mixture and steam cured to facilitate rapid curing. Upon completion of curing, the mould was removed, leaving the completed beam. The concrete surface was found to have produced 15 a beam with a high class finish free of any surface imperfections. The concrete surface was smooth to the touch and did not contain any bug holes or other surface imperfection. In addition, the colour of the surface was that of natural concrete. The testers handling the composition found the composition easy to apply, was free of any nasal or eye irritation and facilitated demoulding of the 20 beam upon curing. EXAMPLE 16 The composition of Example 7 was applied to a "baking tin" type mould. The control agent used was an existing mineral oil. After application of the 25 agents to the test and control moulds, a concrete formulation was poured into each mould and allowed to cure overnight. Upon completion of the curing time, the moulds were removed to produce the finished articles. The trial product provided easy mould release and a product with no surface imperfections and was a natural colour. The control mould had surface imperfections and bug 30 holes noted. EXAMPLE 17 The products referred to in Example 16 were trialled again in "trough" shaped moulds. In this example, the moulds were treated with the agents and IUENDED SHEET W:\clska\nkl\species\PCTAUQ1 01211 (12-2002).doc §r> 1 1 PCT/AUO I/O 1211 Received 11 December 2002 27 then a concrete mixture was added. Upon completion of addition of the concrete, a trough-shaped tap mould was added and vibrated to the finished mould position. The concrete was allowed to cure overnight and removed from the mould. The surface was found to be free from imperfections and to have a smooth, natural color. In contrast, the control product produced several surface imperfections. Various modifications can be made to the invention described above without departing from the spirit of the invention. It is to be understood that the invention is not to be limited by the previous disclosure. AMENDED SHEET IPE^iAU W:\ciska\nkl\spodes\PCT AU01 01211 (12-2002).doc PCT/AU01/01211 Received 11 December 2002 28 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An aqueous mould release composition including: (a) a borate selected from the group consisting of calcium borate, 5 aluminium borate (AIB03), zinc borate (ZnaBeOn), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; and (b) at least one organic component with a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, 10 animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; 15 wherein the composition contains from 0.001 to 0.1 moles of borate per litre of composition.

2. A mould release composition according to claim 1, wherein said borate is disodium tetraborate (borax) or a hydrate thereof. 20

3. A mould release composition according to claim 1, wherein the amount of borate present in the composition is from 0.006 to 0.1 moles per litre of composition. 25

4. A mould release composition according to claim 1, wherein the amount of borate present in the composition is from 0.02 to 0.04 moles per litre of composition.

5. A mould release composition according to claim 1 wherein the amount of 30 organic component(s) is from 10% to 70% (w/w) of the composition.

6. A mould release composition according to claim 5 wherein the amount of organic component(s) is from 18% to 55% (w/w) of the composition. W:\clska\nkJ\specles\PCTAU01 01211 (12-2002).doc 10 PCT/AU01/01211 Received 11 December 2002 29

7. A mould release composition according to claim 6 wherein the amount of organic component(s) is from 35% to 55% (w/w) of the composition.

8. A mould release composition according to claim 1 wherein said organic component includes at least one member selected from the group consisting of vegetable oil, tallow, and lanolin.

9. A mould release composition according to claim 8 wherein the organic component includes vegetable oil and at least one of tallow and lanolin.

10. A mould release agent according to claim 1, further including a water softening agent.

11. A mould release composition according to claim 10, wherein the water 15 softening agent is sodium carbonate.

12. A mould release composition according to claim 1, wherein the pH is in the range 6.0 to 10.0. 20

13. A mould release composition according to claim 8, wherein the composition includes an alcohol or polyol.

14. A mould release component according to claim 13, wherein the polyol is propylene glycol. 25

15. An aqueous mould release composition including: (a) a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B6011), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures 30 and hydrates thereof; (b) at least one organic component with a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty W:\cfska\nkl\species\PCTAU01 01211 (12-2002).doc /\W1EMDEP S'rlSST PCT/AU01/01211 Received 11 December 2002 30 acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; and 5 (c) an alcohol or polyol.

16. - A mould release composition according to claim 15, wherein said borate is disodium tetraborate (borax) or a hydrate thereof. 10

17. A mould release composition according to claim 15, wherein the amount of borate present in the composition is from 0.001 to 0.1 moles per litre of composition.

18. A mould release composition according to claim 15, wherein the amount 15 of borate present in the composition is from 0.006 to 0.1 moles per litre of composition.

19. A mould release composition according to claim 15, wherein the amount of organic component(s) is from 10% to 70% (w/w) of said composition. 20

20. A mould release composition according to claim 19, wherein the amount of organic component(s) is from 18% to 55% (w/w) of the composition.

21. A mould release compound according to claim 20, wherein the amount of 25 organic component(s) is from 35% to 55% (w/w) of the composition.

22. A mould release composition according to claim 15, wherein such alcohol or polyol is selected from the group consisting of propylene glycol, glycerol and glycol. 30

23. A mould release composition according to claim 22 including vegetable oil. AMEM0ED SHEET W:\clsks\nkl\speclos\PCTAU01 01211 <12-2002).doc PCT/AU01/01211 Received 11 December 2002 31

24. A method of improving the release of concrete from a surface including coating said surface with a composition including: (a) a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B60ii), lithium metaborate, copper 5 metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; and (b) at least one organic component with a melting point below 100°C is selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived 10 fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; wherein the composition contains from 0.001 to 0.1 moles of borate per 15 litre of composition; prior to contacting said surface with concrete.

25. A method according to claim 24, wherein the borate in the composition used in the method is disodium tetraborate (borax) or a hydrate thereof. 20

26. A method according to claim 24, wherein the composition contains from 0.006 to 0.1 moles of borate per litre of composition.

27. A method according to claim 24, wherein the composition contains from 25 10% to 70% (w/w) organic component(s).

28. A method according to claim 24, wherein the composition contains from 18% to 55% (w/w) organic component(s). 30

29. A method according to claim 24, wherein the composition contains from 35% to 55% (w/w) organic component(s). W.\clska\nkl\specles\PCTAU01 01211 (12-2002).doc AMENDED SHEET ro/MJ PCT/AUO1/01211 Received 11 December 2002 32

30. A method according to claim 24, wherein said organic component includes at least one member selected from the group consisting of vegetable oil, tallow, and lanolin. 5

31. A method according to claim 24, wherein the composition includes sodium carbonate as a water softening agent.

32. A method of improving the release of concrete from a surface including coating said surface with a composition including: 10 (a) a borate selected from the group consisting of calcium borate, aluminium borate (AlB03), zinc borate (Zn2B60n), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; (b) at least one organic component with a melting point below 100°C 15 is selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, 20 animal derived polyesters, vegetable derived polyesters or mixtures thereof; and (c) an alcohol or Polyol prior to contacting said surface with concrete. 25

33. A method according to claim 32, wherein the borate in the composition is disodium tetraborate (borax) or a hydrate thereof.

34. A method according to claim 32, wherein the composition contains from 0.006 to 0.1 moles of borate per litre of composition. 30

35. A method according to claim 32, wherein the composition contains from 10% to 70% (w/w) organic component(s). W:\clskatnkilspecles\PCT AUOi 01211 {t2'2002).aoc awiemdeo sheet {PEA/MI PCT/AU01/01211 Received 11 December 2002 33

36. A method according to claim 32, wherein the amount of organic component(s) in the composition used in the method is from 18% to 55% (w/w).

37. A method according to claim 32, wherein the composition contains from 5 35% to 55% (w/w) organic component(s).

38. A method according to claim 32, wherein said organic component includes at least one member selected from the group consisting of vegetable oil, tallow, and lanolin. 10 iFV

39. A method of producing a mould release composition, "saia method including the step of combining (a) an aqueous solution of a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B6On), 15 lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; with (b) at least one organic component having a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable 20 derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; 25 wherein the amount of the borate is sufficient to provide from 0.001 to 0.1 moles of borate per litre of the final composition.

40. A method according to claim 39 wherein said step of combining is carried out at a temperature in the range of 50°C to 100°C. 30

41. A method according to claim 39 wherein said step of combining is carried out at a temperature in the range of 70°C to 90°C. W:\clska\nkl\spoclos\PCTAU01 01211 <12-2002).doc AMEMDED SHEET wmm PCT/AU01/01211 Received 11 December 2002 34

42. A method according to claim 39 wherein said step of combining is carried out at about 80°C.

43. A method according to claim 39 wherein said organic component 5 includes at least one member selected from vegetable oil, tallow and lanolin.

44. A method according to claim 39 wherein said borate is disodium tetraborate or a hydrate thereof.

45. A method of producing a mould release composition, said method including the step of combining (a) an aqueous solution of a borate selected from the group consisting of calcium borate, aluminium borate (AIB03), zinc borate (Zn2B60n), lithium metaborate, copper metaborate, disodium tetraborate (borax), dipotassium tetraborate and mixtures and hydrates thereof; with (b) at least one organic component having a melting point below 100°C selected from the group consisting of alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof; and (c) an alcohol or Polyol.

46. A method according to claim 45 wherein said step of combining is carried out at a temperature in the range of 50°C to 100°C.

47. A method according to claim 45 wherein said step of combining is carried 30 out at a temperature in the range of 70°C to 90°C.

48. A method according to claim 45 wherein said step of combining is carried out at about 80°C. W:\clska\nkl\spocles\PCT AU01 01211 (12-2Q02).doc 10 15 20 25 PCT/AU01/01211 Received 11 December 2002 •> 35

49. A method according to claim 45 wherein said organic component includes at least one member selected from vegetable oil, tallow and lanolin.

50. A method according to claim 45 wherein said borate is disodium tetraborate or a hydrate thereof.

51. A method according to claim 45 wherein said polyol is propylene glycol. W;\clska\nkl\specles\PCT AU01 01211 (12-2002).doc amended sheet ipm/MJ