Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/02—Alcohols; Phenols; Ethers
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/02—Alcohols; Phenols; Ethers
  • C04B24/026—Fatty alcohols
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/28—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/32—Polyethers, e.g. alkylphenol polyglycolether
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
  • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
  • C04B40/0039—Premixtures of ingredients
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/0068—Ingredients with a function or property not provided for elsewhere in C04B2103/00
  • C04B2103/0075—Anti-dusting agents
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/56—Opacifiers
  • C04B2103/58—Shrinkage reducing agents
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/34—Non-shrinking or non-cracking materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/60—Flooring materials
  • C04B2111/62—Self-levelling compositions

Definitions

• the present invention relates to admixtures and methods for improving cementitious mixtures, and more particularly for minimizing or preventing dust on cement and concrete structures caused by shrinkage reduction additives.
• Hydraulic e.g., hydratable cementitious compositions, such as mortar (cement, small particulate, e.g., sand, and water), or concrete (cement, small particulate, large particulate, e.g., gravel, and water), are used extensively in forming, either alone as a concrete formation or in combination with other elements as a mortar and brick formation) architectural structural formations. These compositions have certain properties that substantially affect their durability, including shrinkage that occurs during drying and curing of the cement composition.
• the present inventors have discovered surprisingly that oxyalkylene compounds which provide shrinkage inhibition in cements and concretes have a tendency to generate dust particles on the surface of the resultant cement or concrete structure. This can create an undesired problem, for example, in applications such as self -leveling concrete or foundations, against which or upon which coatings or adhesives are applied to attach tiles, wood flooring, carpeting, or other surface treatments. The problem is caused by the dust which tends to defeat the ability of the coating or adhesive to attach to the resultant structure. Accordingly, the present invention provides a novel admixture, method, and cementitious composition wherein the formation of surface dust is prevented or minimized.
• the present invention is directed to a cement admixture, and to a method of forming a cementitious structure having a surface substantially free of dust, which is capable of inhibiting drying shrinkage.
• An exemplary admixture of the invention thus comprises at least one shrinkage reducing additive and at least one fatty alcohol.
• the admixture may comprise (i) at least one alkyl ether oxyalkylene glycol adduct operative to inhibit shrinking during drying of cement, the glycol adduct being represented by the formula R 1 0(AO) n H wherein R 1 represents hydrogen, a C1-C7 alkyl group, or C5-C.6 cycloalkyl group; O represents oxygen, A represents one or more C1-C4 alkylene adducts (and preferably AO represents ethylene oxide, propylene oxide, or mixture thereof), H represents hydrogen, and "n" represents an integer of 1-10 (and more preferably 1-5); and (ii) at least one fatty alcohol represented by the formula R 2 OH wherein R 2 represents a C8-C22 linear or branched alkyl group, and more preferably a C14- C22 linear or branched alkyl group.
• Cementitious compositions comprising the admixture, and methods involving the use of the admixture to minimize surface dust
• cement and "cement composition” (which is synonymous with “cementitious compositions”) may be used herein to refer to dry powders as well as to pastes, mortars, grouts such as oil well cementing grouts, and concrete compositions comprising a hydraulic cement binder.
• pastes are mixtures composed of a hydratable binder (usually, but not exclusively, Portland cement, masonry cement, or mortar cement and may also include gypsum, limestone, hydrated lime, fly ash, blast furnace slag, pozzolans, and silica fume or other materials commonly included in such cements) and water; mortars are pastes additionally including fine aggregate (e.g., sand), and concretes are mortars additionally including coarse aggregate (e.g., gravel, stone).
• the cement compositions tested in this invention may be formed by mixing required amounts of certain materials, e.g., a hydratable binder (such as cement), water, and fine and/ or coarse aggregate, as may be applicable to make the particular cement composition being formed.
• shrinkage reducing agent means and refers to admixtures which are used for inhibiting shrinkage of cementitious compositions.
• Preferred shrinkage reducing agents comprise an alkyl ether oxyalkylene glycol adduct represented by the formula R 1 0(AO) n H wherein R 1 represents hydrogen, a C1-C7 alkyl group, or Cs-C ⁇ cycloalkyl group; O represents oxygen; A represents one or more C_-C4 alkylene adducts (and preferably ethylene oxide, propylene oxide, or mixture thereof); H represents hydrogen, and "n" represents an integer of 1-10 (and more preferably an integer of 1-5).
• R 1 groups are methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, tertiary butyl, n-pentyl, isopentyl, cyclopentyl, cyclohexyl and the like.
• the preferred adducts have R 1 groups of C3-C5 alkyl, such as propyl, isopropyl, n-butyl, t-butyl, isopentyl and the like.
• the most preferred adducts have R 1 groups of butyl or cyclohexyl group.
• the symbol A in the above formula represents at least one C2-C4 alkylene group such as, for example,
• n an integer of 1-10 (and more preferably 1-5).
• the preferred compounds of these ether adducts are those wherein R 1 represents a butyl group, A represents an ethylene or propylene, and n is 2 or 3.
• Dipropylene glycol mon ⁇ - tertiary butyl ether has the structure:
• Such a composition may be used in combination, in further exemplary embodiments, with dipropylene glycol to further enhance shrinkage reduction properties.
• dipropylene glycol The formula of dipropylene glycol is provided below:
• a further exemplary shrinkage reducing admixture is an alkylene glycol having the formula H-O-R-O-H wherein R is a C3 through C_o group, and is most preferably hexylene glycol.
• Shrinkage reducing admixtures which are believed suitable for the invention, are commercially available from Grace Construction Products under the ECLIPSE® brand name.
• Exemplary fatty alcohols useful in the present invention are represented by the formula
• fatty alcohols are generally known to those skilled in the art and are disclosed, for example, in US 3,486,916 and in PCT World Patent Application No. WO/ 04008 of Abdelrazig et al., both of which are incorporated herein by reference.
• Preferred fatty alcohols having from 14 to 22 carbon atoms in their hydrocarbon chains, include myristic alcohol, cetyl alcohol, stearyl alcohol (octadecanol), arachidic alcohol, all of which are solids at room temperature.
• Preferred fatty alcohols include octadecanol, eicosanol, and docosanol.
• the shrinkage reducing additive e.g., alkyl ether oxyalkylene glycol adduct
• the ratio of the shrinkage reducing additive to fatty alcohol components may be 99.99-95.0%/0.01-5.0%; and more preferably 99.5- 97.0%/0.5-3.0%; and most preferably 99-98%/l-2%, all percentages based on total dry weight of the two components in the admixture.
• An admixture comprising the SRA and fatty alcohol may be added to a cementitious composition in the amount of 0.5-5.0% by weight of cement in the composition, and more preferably 1-3% by weight.
• Various conventional ingredients may also be optionally used.
• the optional employable ingredients are water reducing agents, preferably superplasticizers, and most preferably polycarboxylate type comb polymers (a suitable superplasticizer is commercially available from Grace Construction Products under the ADVA® tradename).
• Other optional ingredients may include conventional hardening accelerators (such as metal chlorides such as calcium chloride and sodium chloride, metal sulfates such as sodium sulfate, and organic amines such as triethanolamine); ordinary hardening retarders (such as alcohols, sugars, starch, and cellulose); reinforcing-steel corrosion inhibitors (such as calcium nitrite and/ or calcium nitrate, sodium nitrate); and conventional water reducing agents and high-range water reducers (such as lignosulfonic acids and their salts and derivatives, hydroxylated carboxylic acids and their salts; condensation products of naphthalenesulfonic acids and formaline, sulfonated melamine polycondensation products, amines and their derivatives, alkanolamines, and inorganic salts such as borates, phosphates, chlorides and nitrates; super plasticizers; and the like).
• the quantity of such an optional ingredient or ingredients is usually 0.05-6
• At least one compound or composition capable of imparting air entrainment to the resultant cement (or concrete) structure is employed.
• this may be premixed as part of shrinkage reducing additive/ fatty alcohol admixture product, or separately introduced into the cement or concrete mixture to be treated.
• air entraining agents are well known, and include, for example, tall oil fatty acids and their esters, gum resins and rosins, sulfite liquors and the like.
• the air entraining agent can be used in amounts sufficient to impart from about 4 to 10 volume percent air voids (or more) in the resultant cement structure. The exact dosage needed for a particular agent to attain a particular degree of air can be readily determined.
• Exemplary cementitious compositions of the invention comprise a hydratable binder (such as Portland cement, gypsum, or any of the other binders previously mentioned above) in combination with the above- described fatty alcohol, a shrinkage reduction admixture, and optionally the conventional ingredients previously identified above.
• a hydratable binder such as Portland cement, gypsum, or any of the other binders previously mentioned above
• Particularly preferred cementitious compositions of the invention are mortars which are used in self -leveling concrete production and processes.
• Self-leveling concrete is made from combining water with a particular dry mortar mix involving dry cement with "fines" (e.g., limestone dust in amounts of 15-25% by weight) and optional colorants.
• the dry mortar and water are mixed and placed into a shallow mold (form) to form a floor slab. It is particularly appreciated in these applications to avoid drying shrinkage and the formation of dust on the surface of the resultant hardened slab.
• Mix 1 contained only a superplasticizer (a polycarboxylate type sold by Grace Construction Products under the ADVA® name), and in Mix 2 a shrinkage reducing additive (an alkyl ether oxyalkylene glycol type of SRA sold by Grace under the ECLIPSE® name). Only the sample with the SRA showed a significant amount of dust on the surface of the sample (and this was rated as a "5").
• Mix 3 contained a melanine sulfonate base superplasticizer in combination with the SRA and mix 4 contained a naphtalene based superplastizer in combination with the SRA. The resultant mixes in 3 and 4 showed both a high level of dust on the surface of the samples.
• a superplasticizer and a modified SRA were used.
• the SRA was modified by incorporating approximately 1% by weight of a fatty alcohol (octadecanol in this case).
• a fatty alcohol octadecanol in this case.
• the resultant mixes in 5 and 6 were stable (no segregation), and neither of the resultant hardened samples formed from the mixes showed dusting.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Aftertreatments Of Artificial And Natural Stones (AREA)

Priority Applications (7)

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• 2001
  • 2001-03-26 DE DE60143316T patent/DE60143316D1/de not_active Expired - Lifetime
  • 2001-03-26 EP EP01924336A patent/EP1358136B1/en not_active Expired - Lifetime
  • 2001-03-26 US US10/221,248 patent/US6849118B2/en not_active Expired - Fee Related
  • 2001-03-26 ES ES01924336T patent/ES2352319T3/es not_active Expired - Lifetime
  • 2001-03-26 JP JP2001572431A patent/JP4796730B2/ja not_active Expired - Fee Related
  • 2001-03-26 CA CA2402699A patent/CA2402699C/en not_active Expired - Fee Related
  • 2001-03-26 AU AU2001250998A patent/AU2001250998A1/en not_active Abandoned
  • 2001-03-26 WO PCT/US2001/009655 patent/WO2001074733A2/en not_active Ceased
  • 2001-03-26 AT AT01924336T patent/ATE485247T1/de not_active IP Right Cessation

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