WO2010017583A1 - Béton - Google Patents

Béton Download PDF

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Publication number
WO2010017583A1
WO2010017583A1 PCT/AU2009/001026 AU2009001026W WO2010017583A1 WO 2010017583 A1 WO2010017583 A1 WO 2010017583A1 AU 2009001026 W AU2009001026 W AU 2009001026W WO 2010017583 A1 WO2010017583 A1 WO 2010017583A1
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WO
WIPO (PCT)
Prior art keywords
particles
concrete
maximum dimension
dimension less
aggregate
Prior art date
Application number
PCT/AU2009/001026
Other languages
English (en)
Inventor
John Barry Moriarty
Original Assignee
Glosstone Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2008904098A external-priority patent/AU2008904098A0/en
Application filed by Glosstone Pty Ltd filed Critical Glosstone Pty Ltd
Priority to AU2009281698A priority Critical patent/AU2009281698A1/en
Publication of WO2010017583A1 publication Critical patent/WO2010017583A1/fr

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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
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5007—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing
    • C04B41/5015—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing containing phosphorus in the anion, e.g. phosphates
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • C04B41/65—Coating or impregnation with inorganic materials
    • C04B41/67—Phosphates
    • 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
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00293—Materials impermeable to liquids
    • 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
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/21—Efflorescence resistance
    • 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
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/25—Graffiti resistance; Graffiti removing
    • 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
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to concrete compositions and uses thereof.
  • Cement is a powdered material capable of setting and hardening.
  • hydraulic cements react with water to set and harden into concrete.
  • the term 'cement' is often used to refer to 'Portland cement' (a specific type of cement), but there are many other types of cements.
  • Portland cement is formed by calcination of a mixture of minerals containing calcium oxide, silicon oxide, aluminium oxide, ferric oxide and magnesium oxide (usually provided for by complex minerals, including limestone (predominantly calcite, CaCOs) and clays) to form clinker, a particulate version of cement powder.
  • Portland cement is then comprised of ground clinker and additional calcium sulphate, CaSO 4 (typically from gypsum).
  • the initial cement reaction with water is completed relatively quickly (eg over a few hours), at which point the concrete thus formed may be considered 'set'.
  • to form a 'hardened' concrete significantly more time is required (eg a few weeks), during which the concrete should be kept in ideal conditions (eg ideal temperature and high humidity).
  • the reaction of cement with water also known as hydration
  • 2Ca 3 OSiO 4 reacts with 6H 2 O to form
  • 3CaO.2SiO 2 .3H 2 O (hydration product) and 3Ca(OH) 2 (which is available for reaction with supplementary cementitious materials (such as pozzolans)).
  • Some reactions occur quickly during setting, while others are slower and occur during hardening.
  • Early hydration products are too small to fill the interparticle space (between cement particles), however as the hydration continues the hydration products (predominantly crystalline) grow in size and fill the interparticle space (pores), causing an increase in density, a decrease in permeability, and an increase in strength.
  • salts within the concrete, or salts from an external source are carried or diffuse through the concrete with any water that is able to permeate through the concrete as a salt solution.
  • the water evaporates, or the salt precipitates, leaving behind an unsightly crystalline material.
  • the gradation curve is a means to describe a sample comprised of non-uniformly sized particles. Typically, the proportion of the sample that is particles of less than a certain size is plotted against that size.
  • To prepare a gradation curve of a premixed sample of particles commercially available sieves of a range of aperture sizes are used; the proportion of the sample that is particles of less than a certain size being determined by the amount of sample that passes through the sieve apertures (ie that is less than the size of the sieve apertures).
  • a plot of 'percent passing' versus 'sieve size' is generally made.
  • a concrete including an aggregate, wherein the aggregate includes particles that are fractioned such that all or substantially all particles are less than about 7 mm, from about 69 to 92 w% of the particles have a maximum dimension less than about 2.36 mm, about 56 to 82 w% of the particles have a maximum dimension less than about 1.18 mm, about 30 to 62 w% of the particles have a maximum dimension less than about 0.6 mm, about 10 to 42 w% of the particles have a maximum dimension less than about 0.3 mm, about 1 to 32 w% of the particles have a maximum dimension less than about 0.15 mm, and about 0 to 2 w% of the particles are dust, to 100 w% in total.
  • the concrete further includes hydraulic cement and/or hydration products of the hydraulic cement.
  • the concrete also further includes a wetting agent / plasticiser.
  • a particularly suitable wetting agent / plasticiser is a polycarboxylic ether.
  • Glenium® 51 is a preferred wetting agent / plasticiser.
  • the concrete also further includes a silicate densifier.
  • a concrete composition including an aggregate, wherein the aggregate includes particles that are fractioned such that all or substantially all particles are less than about 7 mm, from about 69 to 92 w% of the particles have a maximum dimension less than about 2.36 mm, about 56 to 82 w% of the particles have a maximum dimension less than about 1.18 mm, about 30 to 62 w% of the particles have a maximum dimension less than about 0.6 mm, about 10 to 42 w% of the particles have a maximum dimension less than about 0.3 mm, about 1 to 32 w% of the particles have a maximum dimension less than about 0.15 mm, and about 0 to 2 w% of the particles are dust, to 100 w% in total; and wherein the concrete composition is for the manufacture of a concrete.
  • the concrete composition further includes hydraulic cement.
  • the concrete also further includes a wetting agent / plasticiser.
  • a particularly suitable wetting agent / plasticiser is a polycarboxylic ether.
  • Glenium® 51 is a preferred wetting agent / plasticiser.
  • the concrete also further includes a silicate densifier.
  • an aggregate when used in the manufacture of a concrete wherein the aggregate includes particles that are fractioned such that all or substantially all particles are less than about 7 mm, from about 69 to 92 w% of the particles have a maximum dimension less than about 2.36 mm, about 56 to 82 w% of the particles have a maximum dimension less than about 1.18 mm, about 30 to 62 w% of the particles have a maximum dimension less than about 0.6 mm, about 10 to 42 w% of the particles have a maximum dimension less than about 0.3 mm, about 1 to 32 w% of the particles have a maximum dimension less than about 0.15 mm, and about 0 to 2 w% of the particles are dust, to 100 w% in total.
  • the particles are fractioned such that all or substantially all particles are less than about 7 mm, from about 72 to 88 w% of the particles have a maximum dimension less than about 2.36 mm, about 60 to 78 w% of the particles have a maximum dimension less than about 1.18 mm, about 36 to 58 w% of the particles have a maximum dimension less than about 0.6 mm, about 15 to 38 w% of the particles have a maximum dimension less than about 0.3 mm, about 1 to 28 w% of the particles have a maximum dimension less than about 0.15 mm, and about 0 to 2 w% of the particles are dust, to 100 w% in total.
  • the particles are fractioned such that all or substantially all particles are less than about 7 mm, from about 80 to 88 w% of the particles have a maximum dimension less than about 2.36 mm, about 60 to 70 w% of the particles have a maximum dimension less than about
  • the particles are fractioned such that about 85 w% of the particles have a maximum dimension less than about 2.36 mm, about 65 w% of the particles have a maximum dimension less than about 1.18 mm, about 41 w% of the particles have a maximum dimension less than about 0.6 mm, about 16 w% of the particles have a maximum dimension less than about 0.3 mm, and about 1 w% of the particles have a maximum dimension less than about 0.15 mm, plus less than about 2 w% dust, to 100 w% in total.
  • the particles are fractioned such that about 15 w% of the particles have a maximum dimension between about 7 and 2.36 mm, about 20 w% of the particles have a maximum dimension between about 2.36 and 1.18 mm, about 24 w% of the particles have a maximum dimension between about 1.18 and 0.6 mm, about
  • the particles include at least about 1 w% particles in each of the size ranges of from about 7 to 2.36 mm, about 2.36 to 1.18 mm, about 1.18 to 0.6 mm, about 0.6 to 0.3 mm, and about 0.3 to 0.15 mm.
  • the particles include at least about 3 w% particles in each of these size ranges.
  • the particles include at least about 5 w% particles in each of these size ranges.
  • a concrete including an aggregate having a gradation factor of about 2.56 to about 3.62 and including particles having a maximum dimension of less than about 7mm.
  • the gradation factor also known as a fineness modulus, may be calculated by adding the percentages by mass retained on the following sieves meeting AASHTO designation M92, and dividing by 100: 9.5 mm, 4.75 mm, 2.36 mm, 1.18 mm, 0.6 mm, 0.3 mm and 0.15 mm sieves.
  • a concrete composition including an aggregate having a gradation factor of about 2.56 to about 3.62 and including particles having a maximum dimension of less than about 7mm; and wherein the concrete composition is for the manufacture of a concrete.
  • an aggregate when used in the manufacture of a concrete having a gradation factor of about 2.56 to about 3.62 and including particles having a maximum dimension of less than about 7mm.
  • kits for the manufacture of a concrete including an aggregate having a gradation factor of about 2.56 to about 3.62 and including particles having a maximum dimension of less than about 7mm.
  • the gradation factor is about 2.92.
  • the concrete of the present invention preferably has a permeability to water of less than about 0.1 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003. More preferably, the concrete of the present invention has a permeability to water of less than about 0.05 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003. More preferably still, the concrete of the present invention preferably has a permeability to water of less than about 0.002 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003. In some embodiments, the concrete of the present invention has a permeability to water of about 0.0013 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003.
  • Another means for expressing the water permeability may be to conduct a measurement in accordance with the methods herein and with AS/NZS 4456.16:2003 to obtain a measure of water permeability in mm/min over a certain exposed area. Then, if the mm/min value (eg 0.0013 mm/min) is converted to a mm/hr value, divided by the exposed area, and multiplied by 100, a percentage value results (0.0002 % in the case of 0.0013 mm/min over an exposed area of 45240mm 2 ). To the best of the inventors knowledge, prior art un-sealed un-pressed concretes achieve a permeability calculated by this method of no better than about 2 to 3 %.
  • a concrete including an aggregate, the concrete having permeability to water of less than about 0.1 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003.
  • a concrete including an aggregate, the concrete having permeability to water of less than about 0.05 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003.
  • a concrete including an aggregate the concrete having permeability to water of less than about 0.002 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003.
  • a concrete including an aggregate the concrete having permeability to water of less than about 2 % as measured and calculated above.
  • the concrete includes hydraulic cement and a wetting agent / plasticiser.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • a concrete including an aggregate, an hydraulic cement and a wetting agent / plasticiser; the concrete having permeability to water of less than about 0.002 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003.
  • a concrete consisting essentially of an aggregate, an hydraulic cement and a wetting agent / plasticiser; the concrete having permeability to water of less than about 0.002 mm/min over an area of 45240mm 2 as measured in accordance with the methods herein and with AS/NZS 4456.16:2003.
  • a concrete of the prior art would require a sealant or the like in order to achieve low permeability (as in the concrete of the present invention).
  • the permeability level is achieved without the use of a sealant known in the art. Therefore, in these embodiments the concrete is not considered to include a sealant or like product as applied to the surface of the concrete.
  • an as-poured, non-sealed concrete there is provided an as-poured, non-sealed concrete.
  • the aggregate is in accordance with the size fractions of the above aspects of the invention.
  • a concrete including an aggregate, an hydraulic cement and a wetting agent / plasticiser; the concrete having a density of greater than about 2400 kg/m 3 .
  • a concrete consisting essentially of an aggregate, an hydraulic cement and a wetting agent / plasticiser; the concrete having a density of greater than about 2400 kg/m 3 .
  • the concrete has a density of greater than about 2500 kg/m 3 . In other embodiments still, the concrete has a density of greater than about 2550 kg/m 3 .
  • the aggregate is in accordance with the size fractions of the above aspects of the invention.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • An advantage of the concrete of the present invention is that it may be cured under atmospheric pressure and is not a pressed, compacted or vacuumed concrete. Thus, there is provided a non-pressed concrete.
  • the aggregate is in accordance with the size fractions of the above aspects of the invention.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • the concrete of the present invention may have, in some embodiments, an abrasion index as measured in accordance with AS/NZS 4456.9-2003 of less than about 1.0.
  • the concrete of the present invention has an abrasion index of less than about 0.9.
  • a concrete including an aggregate, an hydraulic cement and a wetting agent / plasticiser; the concrete having an abrasion index of less than about 1.0.
  • the aggregate is in accordance with the size fractions of the above aspects of the invention.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • a particularly suitable material for the aggregate is sand.
  • a method of making a concrete including the steps of: fractioning an aggregate including particles to form an aggregate in accordance with the size fractions of the above aspects; mixing the aggregate, a cement and an aqueous solution to form a concrete mixture; and curing the concrete mixture to form a concrete.
  • a method of making a concrete including the steps of: fractioning an aggregate including particles, wherein the particles are fractioned such that from about 69 to 92 w% of the particles have a maximum dimension less than about 2.36 mm, about 56 to 82 w% of the particles have a maximum dimension less than about 1.18 mm, about 30 to 62 w% of the particles have a maximum dimension less than about 0.6 mm, about 10 to 42 w% of the particles have a maximum dimension less than about 0.3 mm, about 1 to 32 w% of the particles have a maximum dimension less than about 0.15 mm, and about 0 to 2 w% of the particles are dust, to 100 w% in total; mixing the aggregate, a cement and an aqueous solution to form a concrete mixture; and curing the concrete mixture to form a concrete.
  • a method of making a concrete including the steps of: fractioning an aggregate including particles, wherein the particles are fractioned such that about 15 w% of the particles have a maximum dimension between about 7 and 2.36 mm, about 20 w% of the particles have a maximum dimension between about 2.36 and 1.18 mm, about 24 w% of the particles have a maximum dimension between about 1.18 and 0.6 mm, about 25 w% of the particles have a maximum dimension between about 0.6 and 0.3 mm, and about 15 w% of the particles have a maximum dimension between about 0.3 and 0.15 mm, plus about 1 w% dust, to 100 w% in total; mixing the aggregate, a cement and an aqueous solution to form a concrete mixture; and curing the concrete mixture to form a concrete.
  • a method of making a concrete including the steps of: fractioning an aggregate including particles to form an aggregate in accordance with the size fractions of the above aspects; mixing the aggregate, a cement and an aqueous solution to form a concrete mixture; curing the concrete mixture to form a concrete; and contacting a surface of the concrete with phosphoric acid.
  • a method of making a concrete including the steps of: fractioning an aggregate including particles, wherein the particles are fractioned such that from about 69 to 92 w% of the particles have a maximum dimension less than about 2.36 mm, about 56 to 82 w% of the particles have a maximum dimension less than about 1.18 mm, about 30 to 62 w% of the particles have a maximum dimension less than about 0.6 mm, about 10 to 42 w% of the particles have a maximum dimension less than about 0.3 mm, about 1 to 32 w% of the particles have a maximum dimension less than about 0.15 mm, and about 0 to 2 w% of the particles are dust, to 100 w% in total; mixing the aggregate, a cement and an aqueous solution to form a concrete mixture; curing the concrete mixture to form a concrete; and contacting a surface of the concrete with phosphoric acid.
  • a method of making a concrete including the steps of fractioning an aggregate including particles, wherein the particles are fractioned such that about 15 w% of the particles have a maximum dimension between about 7 and 2.36 mm, about 20 w% of the particles have a maximum dimension between about 2.36 and 1.18 mm, about 24 w% of the particles have a maximum dimension between about 1.18 and 0.6 mm, about 25 w% of the particles have a maximum dimension between about 0.6 and 0.3 mm, and about 15 w% of the particles have a maximum dimension between about 0.3 and 0.15 mm, plus about 1 w% dust, to 100 w% in total; mixing the aggregate, a cement and an aqueous solution to form a concrete mixture; curing the concrete mixture to form a concrete; and contacting a surface of the concrete with phosphoric acid.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • the concrete also further includes a silicate densifier.
  • a method of making a concrete including the steps of: mixing an aggregate and a cement to form a dry mixture; contacting the dry mixture with an aqueous solution to form a wet mixture; mixing the wet mixture to form a concrete mixture; and curing the concrete mixture to form a concrete.
  • a method of making a concrete including the steps of: mixing an aggregate and a cement to form a dry mixture; contacting the dry mixture with an aqueous solution to form a wet mixture; mixing the wet mixture to form a concrete mixture; curing the concrete mixture to form a concrete; and contacting a surface of the concrete with phosphoric acid.
  • a method of making a concrete including the steps of: mixing an aggregate, a cement, and an aqueous solution including a wetting agent / plasticiser to form a concrete mixture; and curing the concrete mixture to form a concrete.
  • a method of making a concrete including the steps of: mixing an aggregate, a cement, and an aqueous solution including a wetting agent / plasticiser to form a concrete mixture; curing the concrete mixture to form a concrete; and contacting a surface of the concrete with phosphoric acid.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • the concrete also further includes a silicate densifier.
  • a method of making a concrete including the steps of: mixing an aggregate and a cement to form a dry mixture; contacting the dry mixture with an aqueous solution including a wetting agent / plasticiser to form a wet mixture; mixing the wet mixture to form a concrete mixture; and curing the concrete mixture to form a concrete.
  • a method of making a concrete including the steps of mixing an aggregate and a cement to form a dry mixture; contacting the dry mixture with an aqueous solution including a wetting agent / plasticiser to form a wet mixture; mixing the wet mixture to form a concrete mixture; curing the concrete mixture to form a concrete; and contacting a surface of the concrete with phosphoric acid.
  • the step of contacting the surface of the concrete with phosphoric acid is conducted at a concentration sufficient to form a calcium phosphate material at or beneath the surface of the concrete.
  • the calcium phosphate material formed is of sufficient quantity to result in a substantial sealing of the pores of the concrete surface.
  • the wetting agent / plasticiser is a polycarboxylic ether, such as that in the product Glenium® 51.
  • the mixing step preferably further includes the mixing of a polycarboxylic ether as a wetting agent / plasticiser.
  • Glenium® 51 is a preferred wetting agent / plasticiser.
  • the concrete also further includes a silicate densifier.
  • the present invention provides a method of forming a concrete structure having a concrete core and a finished facade provided by at least one concrete building panel, the or each concrete building panel including an outer surface and an opposed inner surface from which an integrally cast anchoring arrangement extends, the method including: positioning the at least one concrete building panel such that the outer surface of the at least one building panel defines the finished facade of the concrete structure, and the inner surface of the at least one building panel contributes to defining a void, and pouring concrete into the void to form the core of the concrete structure, the poured concrete setting about the anchoring arrangement of the at least one building panel to secure it in place.
  • the anchoring arrangement may include at least one latticework arrangement.
  • the void may be partially or wholly defined by inner surfaces of building panels.
  • the at least one building panel Prior to being secured in place by the setting of the concrete core, the at least one building panel may be held in position by scaffolding.
  • the concrete building panel may be made from concrete according to any of the above embodiments of the invention.
  • the present invention provides a method of manufacturing a concrete building panel, the method including: casting a concrete panel into a mould; inserting an anchoring arrangement into the concrete panel such that an inner volume of the anchoring arrangement is embedded in the concrete and an outer volume of the anchoring arrangement extends from an inner surface of the concrete panel; and allowing the concrete panel to dry about the inner volume of the anchoring arrangement thereby securing the anchoring arrangement to the concrete panel; wherein an outer surface of the building panel is a finished surface.
  • the anchoring arrangement may include at least one latticework arrangement.
  • the anchoring arrangement may include a concrete impervious membrane separating the inner and outer volumes.
  • the method of manufacturing a concrete building panel may further include the step of injecting an insulation layer into a middle volume of the anchoring arrangement such that the outer volume of the anchoring arrangement extends from the insulation layer.
  • the concrete cast into the mould may be concrete according to any of the embodiments of the invention described above.
  • a further aspect of the invention provides a building panel including a concrete panel and an anchoring arrangement, the concrete panel having a finished outer surface and opposed inner surface, wherein the anchoring arrangement is cast into the concrete panel such that an inner volume of the anchoring arrangement is embedded and secured within the concrete panel and an outer volume of the anchoring arrangement extends from the inner surface of the concrete panel.
  • the anchoring arrangement may include at least one latticework arrangement.
  • the anchoring arrangement may include a membrane separating the inner and outer volumes.
  • the building panel may further include an insulation layer adjacent the inner surface of the concrete panel, the insulation layer injected into a middle volume of the anchoring arrangement such that the outer volume of the anchoring arrangement extends from the insulation layer.
  • the concrete panel may be made from concrete according to any of the embodiments of the invention described above.
  • the invention extends to the embodiments as exemplified in the examples.
  • Figure 1 provides a chart showing gradation curves for the 0.45 power curve of the prior art, and for the upper and lower limits of the aggregate particles of the present invention.
  • Figures 2 (a) and (b) provide a scanning electron microscopy image (a) and associated elemental analysis (b) of the surface of the concrete of an embodiment of the present invention as described in Example 1.
  • Figures 3 (a) and (b) provide a scanning electron microscopy image (a) and associated elemental analysis (b) taken at 1 mm into a fractured surface of the concrete of an embodiment of the present invention as described in Example 1.
  • Figures 4 (a) and (b) provide a scanning electron microscopy image (a) and associated elemental analysis (b) taken at 0.5 mm into a fractured surface of the concrete of an embodiment of the present invention as described in Example 6 treated by a phosphoric acid wash.
  • Figures 5 (a) and (b) provide a scanning electron microscopy image (a) and associated elemental analysis (b) taken at 0.5 mm into a fractured surface of the concrete of an embodiment of the present invention as described in Example 6.
  • Figure 6A provides a perspective view of a building panel in accordance with an embodiment of the invention.
  • Figure 6B provides a sectional view of the building panel of Figure 6A along line II - II;
  • Figure 6C provides a front perspective view of the building panel of Figure 6A;
  • Figure 7A provides a perspective representation of the anchoring arrangement used in the building panel of Figure 6A;
  • Figure 7B provides a perspective view of a plastics material from which the support grid depicted in Figure 7A may be constructed;
  • Figure 7C provides a perspective representation of an alternative anchoring arrangement for use in the building panel of Figure 6A;
  • Figure 8A provides a perspective view of a building panel including a bar stool
  • Figure 8B provides a perspective view of a building panel including an insulation layer
  • Figure 8C provides a perspective view of a building panel including an insulation layer and plasterboard sheet
  • Figure 9 provides a flowchart depicting the steps involved of manufacturing a concrete building panel in accordance with a second embodiment of the invention.
  • Figure 10 provides a flowchart depicting the steps involved in building a concrete structure in accordance with a third embodiment of the invention.
  • Figure 11 provides a perspective view of building panels according an embodiment of the present invention arranged to form a concrete structure.
  • w/w% as used herein is to be taken to mean g / 10Og cement unless otherwise specified. This is not inconsistent with the use of w% in relation to the aggregate composition, where w% describes the proportion of the total that is a certain size or size fraction. Curing as used herein is taken to mean both setting and hardening.
  • the inventors believe that the gradation curve of the particles used as the aggregate is important to attaining the desirable properties of the concrete of the present invention.
  • the aggregate for forming the concrete of the present invention is prepared by fractioning the aggregate particles by size, and then recombining them in the desired proportions.
  • a suitable gradation for the aggregate is in the area bound by the upper and lower limit lines in Figure 1.
  • the gradation curve for this aggregate is shown in Figure 1 as the upper and lower limit lines.
  • the aggregate is one where about 85 w% of the particles have a maximum dimension less than about 2.36 mm, about 65 w% of the particles have a maximum dimension less than about 1.18 mm, about 41 w% of the particles have a maximum dimension less than about 0.6 mm, about 16 w% of the particles have a maximum dimension less than about 0.3 mm, and about 1 w% of the particles have a maximum dimension less than about 0.15 mm, plus less than about 2 w% dust, to 100 w% in total.
  • substantially all particles have a maximum dimension less than about 7 mm. More preferably, all of the particles have a maximum dimension less than about 7 mm.
  • the aggregate preferably contains at least some particles from each of the size ranges. That is, the aggregate has at least about 1 w% particles in each of the size ranges from about 7 to 2.36 mm, about 2.36 to 1.18 mm, about 1.18 to 0.6 mm, about 0.6 to 0.3 mm, and about 0.3 to 0.15 mm.
  • a particularly preferred aggregate is one where about 15 w% of the particles have a maximum dimension between about 7 and 2.36 mm, about 20 w% of the particles have a maximum dimension between about 2.36 and 1.18 mm, about 24 w% of the particles have a maximum dimension between about 1.18 and 0.6 mm, about 25 w% of the particles have a maximum dimension between about 0.6 and 0.3 mm, and about 15 w% of the particles have a maximum dimension between about 0.3 and 0.15 mm, plus about 1 w% dust, to 100 w% in total.
  • the material that constitutes the particles may be any currently known in the art.
  • the material may be sand (pure sand, river sand, beachfront sand), natural gravel, crushed stone, blast furnace slag, furnace bottom ash (a residue generated in the combustion of coal), recycled aggregates, or recycled glass.
  • the aggregate need not be dry when used in the manufacture of concrete, but it is preferable that the aggregate not be wet to such a degree that it comprises more than about 50 % of the water needed for the concrete (see below for discussion of suitable w/c ratios).
  • the type of cement may be any currently known in the art.
  • the cement may be Portland cement, a Portland cement blend (eg blended with fly ash or silica fume), or other non- or mostly non-Portland cements (eg pozzolan-lime cement, slag- lime cement, supersulfated cements (mainly blast furnace slag, gypsum, and Portland clinker), calcium aluminate cements (mainly limestone and bauxite) or calcium sulfoaluminate cements).
  • a Portland cement blend eg blended with fly ash or silica fume
  • other non- or mostly non-Portland cements eg pozzolan-lime cement, slag- lime cement, supersulfated cements (mainly blast furnace slag, gypsum, and Portland clinker)
  • calcium aluminate cements mainly limestone and bauxite
  • calcium sulfoaluminate cements mainly limestone and bauxite
  • the weight ratio of the aggregate particles to the cement particles may be less than about 4:1.
  • a particularly suitable range for this weight ratio is from about 2:1 to about 3:1.
  • Most preferably, the weight ratio of the aggregate particles to the cement particles is 3:1.
  • the w/c ratio (w/w%, g water per 100 g cement) may be any that provides sufficient hydration and workability (ie the viscosity of the unset concrete is such that it may be handled with sufficient ease). It is not necessary (to obtain the increased resistance to permeability) for the w/c ratio to be kept as low as possible (eg to be between 21 and 25 w/w%).
  • suitable w/c ratios range from about 20 to about 50 w/w%.
  • the w/c is from about 25 to about 40 w/w%. More preferably, the w/c ratio is about 30 w/w%.
  • the concrete of the present invention further includes a wetting agent (variably referred to as a plasticiser, superplasticiser or hyperplasticiser).
  • a wetting agent (variably referred to as a plasticiser, superplasticiser or hyperplasticiser).
  • the wetting agent / plasticiser assists with bonding between aggregate particles and cement particles.
  • Particularly suitable wetting agents / plasticisers include BASF Glenium® 51 (a polycarboxylic ether having long lateral chains), which may be added in amounts of from about 1.5 w/w% to about 2 w/w%, and propylene or polyethylene oxide carboxylate comb polymer, which may be added in amounts of from about 1.5 w/w% to about 40 w/w%.
  • the wetting agent / plasticiser is a polycarboxylic ether.
  • the concrete may include supplementary cementitious materials.
  • the concrete of the present invention may further include a pozzolan; a material which exhibits cementitious properties, typically when combined with calcium hydroxide.
  • pozzolans are primarily vitreous siliceous materials which, when reacted with calcium hydroxides, form calcium silicates.
  • the most commonly used pozzolan is fly ash (a light residue generated in the combustion of coal), though silica fume (a by-product of the reduction of high-purity quartz with coke in electric arc furnaces in the production of silicon and ferrosilicon alloys), high-reactivity metakaolin (a calcined, dehydroxylated form of the clay mineral kaolin), volcanic ash, and ground granulated blast furnace slag (the by-product of smelting ore to purify metals).
  • Suitable pozzolans also include calcium silicates and aluminosilicates, which may be added in a concentration of from 0 - 55 w/w% and also serve as suppressants of efflorescence.
  • the concrete (or cement) may include still further additives (known to the skilled person as admixtures), as is known in the art, including:
  • curing agents eg methyl cellulose, added in amounts of from about 0 w/w% to about 5 w/w%;
  • water repellants / waterproofing agents to reduce water permeability
  • BASF 790 silanes, and siloxanes, added in amounts of from about 0 w/w% to about 2 w/w%;
  • densifiers potassium, sodium and/or lithium silicate, added in amounts of from about 0 w/w% to about 25 w/w%;
  • efflorescence suppressants eg propylene or polyethylene oxide carboxylate comb polymer added in amounts of from about 0 w/w% to about 40 w/w%, calcium aluminuosilicate pozzolan added in amounts of from about 0 w/w% to about 55 w/w%, glycol added in amounts of from about 0 w/w% to about 10 w/w%, silanes or siloxanes added in amounts of from about 0 w/w% to about 10 w/w%, fatty acid metal stearates added in amounts of from about 0 w/w% to about 20 w/w%.
  • efflorescence suppressants eg propylene or polyethylene oxide carboxylate comb polymer added in amounts of from about 0 w/w% to about 40 w/w%
  • calcium aluminuosilicate pozzolan added in amounts of from about 0 w/w% to about 55 w/w%
  • glycol added in amounts of from
  • colourings eg oxides
  • Particularly preferable conditions used to manufacture the concrete are described as follows: sand may be placed in a planetary concrete mixer with speed of from about 25 to about 45 rpm. Dry ingredients can then be added to the sand and mixed together, and then the wet chemical ingredients, preferably pre-mixed in a separate vessel, are added to the dry ingredients in the mixer. It is preferably that this step is done 'in bulk' as opposed to 'little by little', to ensure proper mixing. The mixing time should take about 5 to 7 minutes. The concrete mixture may then be placed into whatever 'mould' or 'conformation' is desired.
  • the concrete may now be vibrated at an amplitude of from about 0.5 mm to about 1.5mm and at a rotation frequency of from about 2500 rpm to about 3500 rpm.
  • the concrete may be pressed at this stage to, among other things, remove further air and thus decrease the permeability and increase the density.
  • the concrete of the present invention does not require this pressing or compacting step to achieve its permeability results.
  • the mould may be cured for any requisite amount of time. For instance, the concrete in the mould may be cured at about 18 0 C to about 25 0 C for about 48 hrs. After this degree of curing, the concrete may be removed from the mould and wrapped or placed in air tight environment for a further 2 to 7 days of curing. Then, the concrete may be further cured still at for a further 3 to 7 days.
  • the concrete is then optionally washed with hydrochloric acid to provide a sandstone- like finish.
  • the concrete of the present invention is subjected to hydrochloric acid of concentration ranging from about 5 g per 100 g water to about 20 g per 100 g water.
  • the concrete of the present invention is subjected to a phosphoric acid wash treatment, to, without wishing to be bound by theory, reduce the permeability to water and suppress efflorescence.
  • This acid wash is different to that of the hydrochloric acid wash.
  • Acids suitable for this purpose may be phosphorous containing acids commonly known in the art, for instance H 3 PO 2 (hypophosphorous acid), H 3 PO 3 (Phosphorous acid), H 2 PO 3 (Hypophosphoric acid), H 3 PO 4 (Phosphoric acid), H 4 P 2 O 8 (Perphosphoric acid), H 3 PO 5 (Permonophosphoric acid), H 2 PO 3 + (Phosphonic acid) and Phytic acid.
  • a particularly preferred acid is phosphoric acid.
  • calcium hydroxide (CaOH) in the concrete reacts with the acid to form a calcium phosphate material.
  • This calcium phosphate material which may have properties similar to that of calcium phosphate bone cement, may be acting to seal the surface of the concrete (thus preventing the conversion of calcium hydroxide to calcium carbonate (CaCO 3 ), ie preventing efflorescence).
  • This calcium phosphate material is thought to form at or beneath the surface, as opposed to on the surface, which fills the pores / capillaries present in the concrete (often as a result of incomplete concrete crystal growth).
  • the phosphoric acid wash may be conducted at numerous points during concrete manufacture.
  • the phosphoric acid wash may be conducted (i) after an initial cure period of about 24 hr, (ii) after a further cure period, often conducted under wrapped conditions) of about 5 days, or (iii) after a further dry cure of about a further 5 days.
  • the acid wash step is conducted in accordance with scenarios (ii) or (iii) as applying the phosphoric acid earlier in the curing process may result in discolouration of the concrete surface.
  • the time frames discussed above are not to be taken as definitive of when the acid wash must be applied. More important is the consideration that the phosphoric acid wash is to be applied before the concrete substantially effloresces.
  • the concentration of acid suitable for the acid wash may range from about 0.5 g per
  • the concentration of acid required for the phosphoric acid wash step is significantly less than that required to remove efflorescence once it has formed, which avoids or minimises damage to the concrete surface by the acid (allowing the retention of smooth concrete faces).
  • the acid may contact the surface for at least about 10 to 5 minutes.
  • the exact length of time suitable for the acid wash step is then dependent on the properties of the concrete itself, including the surface roughness. That is, for a smooth surface a relatively short application of the acid, for instance by spray, will likely suffice; for a rough surface a relatively long application, for instance by a continuous flow of acid over the surface, may be necessary. There is no particular requirement for the other conditions of this acid wash step.
  • the concrete of the present invention may be used for any application in which concrete is currently used (provided it has the right structural integrity for the specific application), but is particularly suitable for use as thin slabs or tiles.
  • 1500 kg of aggregate (sand particles) having a composition as follows was used: 15 w% of the particles had a maximum dimension between 7 and 2.36 mm, 20 w% of the particles have a maximum dimension between 2.36 and 1.18 mm, 24 w% of the particles have a maximum dimension between 1.18 and 0.6 mm, 25 w% of the particles have a maximum dimension between 0.6 and 0.3 mm, and 15 w% of the particles have a maximum dimension between 0.3 and 0.15 mm, with the remainder dust to 100 w% in total.
  • the above ratios result in a sand gradation factor of 2.92 (as calculated by (15 +
  • the sand was then added to a planetary concrete mixer with rpm speed of at least 45 rotations per minute.
  • the sand was used washed, however did not contain more than 50% of the total water required.
  • 500 kg of general purpose Portland cement and 5 w/w% oxide (as a colouring) were added to the sand and mixed all together.
  • ABS acrylonitrile butadiene styrene
  • steel moulds which were then placed onto a flat vibrator table with 0.5 mm amplitude of vibration and a rotation frequency of 3000 rpm.
  • the moulds were removed from the vibrator table, and the concrete placed onto racks at a spacing of no less 50 mm for curing at 20 0 C for 24 hr.
  • the concrete was then removed from the moulds and wrapped / covered in plastic for a further 5 days of curing. At this time, the plastic wrap / cover was removed and the concrete aired in dry ambient conditions for a further 5 days.
  • This concrete was not subjected to a phosphoric or hydrochloric acid wash.
  • Shown in Figure 3 are scanning electron microscopy and elemental analysis results for a test carried out on a fracture surface (ie an approximately cross-sectional surface) of the concrete. The image was taken at about 1mm from the top surface. The SEM was operated at 20.00 kV and 430 times magnification.
  • Samples 1-4 were weighed and measured to determine the bulk volume and density. Sample 5 was analysed by Helium Pycnometry.
  • the abrasion resistance of a sample of concrete of work size 230 x 110 x 30 mm was measured by Boral in accordance with AS/NZS 4456.9-2003, with the results shown in Tables 7 and 8.
  • the abrasion index correlates with the amount of sample lost due to abrasion, thus, a lower abrasion index indicates a material relatively resistant to abrasion.
  • 1500 kg of aggregate (sand particles having salt levels less than 150ppm) having a composition as follows was used: 15 w% of the particles had a maximum dimension between 7 and 2.36 mm, 20 w% of the particles have a maximum dimension between 2.36 and 1.18 mm, 24 w% of the particles have a maximum dimension between 1.18 and 0.6 mm, 25 w% of the particles have a maximum dimension between 0.6 and 0.3 mm, and 15 w% of the particles have a maximum dimension between 0.3 and 0.15 mm, with the remainder dust to 100 w% in total.
  • the above ratios result in a sand gradation factor of 2.92
  • the sand was then added to a planetary concrete mixer with rpm speed of at least 45 rotations per minute.
  • the sand was used washed, however did not contain more than 50% of the total water required.
  • ABS acrylonitrile butadiene styrene
  • steel moulds which were then placed onto a flat vibrator table with a 0.5 mm amplitude of vibration and a rotation frequency of 3000 rpm.
  • the moulds were removed from the vibrator table, and the concrete placed onto racks at a spacing of no less than 50 mm for curing at 20 0 C for 24 hr.
  • the concrete was then removed from the moulds and wrapped / covered in plastic for a further 5 days of curing.
  • the plastic wrap / cover was removed from the concrete and the concrete was washed with a solution of 2.5 w/w% (g acid per 100 g water) phosphoric acid by weight of water, rinsed with fresh water, and then aired in dry ambient conditions for a further 5 days.
  • the properties of the concrete thus formed appeared at least as good as those of the concrete of Example 1.
  • a particularly surprising and advantageous result relates to the efflorescence.
  • the concrete according to this example that is the concrete washed with phosphoric acid, did not effloresce immediately as would the concrete of Example 1. Instead, the concrete according to this example have resisted efflorescence for 2 years so far.
  • Example 3 Alternative acid wash procedure using hydrochloric acid to achieve sandstone-like finish
  • Example 2 the concrete was placed in a mould and wrapped while curing for 5 days, then the plastic wrap / cover was removed from the concrete and the concrete was washed with a solution of 2.5 w/w% (g acid per 10O g water) phosphoric acid by weight of water, before being aired in dry ambient conditions for a further 5 days.
  • the phosphoric acid wash step it is also possible for the phosphoric acid wash step to be conducted after the concrete is removed from the moulds and before it is wrapped / covered in plastic (although some discolouration may result), or after the concrete is aired in dry ambient conditions for the final period of about 5 days.
  • the phosphoric acid wash step must be conducted before the cured concrete is significantly exposed to moisture containing CO 2 , that is, it must be conducted before efflorescence is initiated. Moisture is important in efflorescence as the CaOH needs to be transported to the surface to effloresce. Thus, use of the phosphoric acid treatment does not preclude use of the CO2 curing method known in the art.
  • 1500 kg of aggregate (sand particles) having a composition as follows was used: 15 w% of the particles had a maximum dimension between 7 and 2.36 mm, 20 w% of the particles have a maximum dimension between 2.36 and 1.18 mm, 24 w% of the particles have a maximum dimension between 1.18 and 0.6 mm, 25 w% of the particles have a maximum dimension between 0.6 and 0.3 mm, and 15 w% of the particles have a maximum dimension between 0.3 and 0.15 mm, with the remainder dust to 100 w% in total.
  • the above ratios result in a sand gradation factor of 2.92.
  • the sand was then added to a planetary concrete mixer with rpm speed of at least 45 rotations per minute. The sand was used washed and dried. 500 kg of general purpose
  • ABS acrylonitrile butadiene styrene
  • steel moulds which were then placed onto a flat vibrator table with 0.5 mm amplitude of vibration and a rotation frequency of 3000 rpm.
  • the moulds were removed from the vibrator table, and the concrete placed onto racks at a spacing of no less 50 mm for curing at 20 0 C for 24 hr.
  • the concrete was then removed from the moulds and wrapped / covered in plastic for a further 5 days of curing. At this time, the plastic wrap / cover was removed and the concrete aired in dry ambient conditions for a further 5 days.
  • the concrete Prior to the final curing stage, the concrete may be subjected to an acid wash step using phosphoric acid.
  • 1500 kg of aggregate (sand particles) having a composition as follows was used: 15 w% of the particles had a maximum dimension between 7 and 2.36 mm, 20 w% of the particles have a maximum dimension between 2.36 and 1.18 mm, 24 w% of the particles have a maximum dimension between 1.18 and 0.6 mm, 25 w% of the particles have a maximum dimension between 0.6 and 0.3 mm, and 15 w% of the particles have a maximum dimension between 0.3 and 0.15 mm, with the remainder dust to 100 w% in total.
  • the above ratios result in a sand gradation factor of 2.92.
  • the sand was then added to a planetary concrete mixer with rpm speed of at least 45 rotations per minute. The sand was used washed and dried. 500 kg of general purpose Portland cement, 2 w/w% Ability Building Chemicals Efflorein MK2 (as a efflorescence suppressant) and 5 w/w% oxide (as a colouring) were added to the and all mixed together.
  • BASF Glenium® 51 (as a wetting agent / plasticiser), 2 w/w% potassium silicate (as a densifier), and 30 w/w% of water after mixing together is added in bulk to the dry ingredients in the planetary concrete mixer and mixed for around 5 to 7 minutes (until all the components appear well-mixed).
  • ABS acrylonitrile butadiene styrene
  • steel moulds which were then placed onto a flat vibrator table with 0.5 mm amplitude of vibration and a rotation frequency of 3000 rpm.
  • the moulds were removed from the vibrator table, and the concrete placed onto racks at a spacing of no less 50 mm for curing at 20 0 C for 24 hr.
  • the concrete was then removed from the moulds and wrapped / covered in plastic for a further 5 days of curing. At this time, the plastic wrap / cover was removed and the concrete aired in dry ambient conditions for a further 5 days.
  • the concrete Prior to the final curing stage, the concrete may be subjected to an acid wash step using phosphoric acid. Since this concrete did not include any waterproofing admixture, the hydrochloric acid wash may also be conducted.
  • a portion of a sample of the concrete of this Example was subjected to phosphoric acid treatment step. This portion, as well as a neat portion without the phosphoric acid treatment step, was subjected to scanning electron microscopy. After about 3 weeks of storing under dry conditions, a fracture surface of each test material was subjected to scanning electron microscopy and elemental analysis at a depth of 0.5 mm from the treated surface.
  • Figure 4 shows the results for the phosphoric acid treated material (the SEM was operated at 20.00 kV and 1400 times magnification), while Figure 5 shows the results for the neat material (no phosphoric acid treatment) (the SEM was operated at 20.00 kV and 3300 times magnification).
  • the amount of C detected at this depth was found to be about 6 times larger than that detected for the concrete made without the phosphoric acid treatment step. There was also a substantial amount of P and K detected in the treated sample.
  • Example 7 Alternative composition / method using the phosphoric acid step
  • 1500 kg of aggregate (sand particles) having a composition as follows was used: 15 w% of the particles had a maximum dimension between 7 and 2.36 mm, 20 w% of the particles have a maximum dimension between 2.36 and 1.18 mm, 24 w% of the particles have a maximum dimension between 1.18 and 0.6 mm, 25 w% of the particles have a maximum dimension between 0.6 and 0.3 mm, and 15 w% of the particles have a maximum dimension between 0.3 and 0.15 mm, with the remainder dust to 100 w% in total.
  • the above ratios result in a sand gradation factor of 2.92.
  • the sand was then added to a planetary concrete mixer with rpm speed of at least 45 rotations per minute.
  • the sand was used washed, however did not contain more than 50% of the total water required.
  • 500 kg of general purpose Portland cement, and 5 to 8 w/w% oxide (as a colouring), were added to the sand and mixed together.
  • ABS acrylonitrile butadiene styrene
  • steel moulds which were then placed onto a flat vibrator table with 0.5 mm amplitude of vibration and a rotation frequency of 3000 rpm.
  • the moulds were removed from the vibrator table, and the concrete placed onto racks at a spacing of no less 50 mm for curing at 20 0 C for 24 hr.
  • the concrete was then removed from the moulds and wrapped / covered in plastic for a further 3 to 5 days of curing. At this time, the plastic wrap / cover was removed from the concrete and the concrete aired in dry ambient conditions for a further 7 days.
  • the concrete was then washed with a solution of 2.5 w/w% (g acid per 100 g water) phosphoric acid and then rinsed with fresh water.
  • 1500 kg of aggregate (sand particles) having a composition as follows was used: 15 w% of the particles had a maximum dimension between 7 and 2.36 mm, 20 w% of the particles have a maximum dimension between 2.36 and 1.18 mm, 24 w% of the particles have a maximum dimension between 1.18 and 0.6 mm, 25 w% of the particles have a maximum dimension between 0.6 and 0.3 mm, and 15 w% of the particles have a maximum dimension between 0.3 and 0.15 mm, with the remainder dust to 100 w% in total.
  • the above ratios result in a sand gradation factor of 2.92.
  • the sand was then added to a planetary concrete mixer with rpm speed of at least 45 rotations per minute. The sand was used washed, however did not contain more than
  • ABS acrylonitrile butadiene styrene
  • steel moulds which were then placed onto a flat vibrator table with 0.5 mm amplitude of vibration and a rotation frequency of 3000 rpm.
  • the moulds were removed from the vibrator table, and the concrete placed onto racks at a spacing of no less 50 mm for curing at 20 0 C for 24 hr.
  • the concrete was then removed from the moulds and wrapped / covered in plastic for a further 3 to 5 days of curing. At this time, the plastic wrap / cover was removed from the concrete and the concrete aired in dry ambient conditions for a further 7 days.
  • the concrete was then washed with a solution of 2.5 w/w% (g acid per 100 g water) phosphoric acid and then rinsed with fresh water.
  • Example 1 The materials and procedures of Example 1 , except for use of a sand having 15 w% of the particles having a maximum dimension between 7 and 2.5 mm, 20 w% of the particles having a maximum dimension between 2.5 and 1.25 mm, 24 w% of the particles having a maximum dimension between 1.25 and 0.63 mm, 25 w% of the particles having a maximum dimension between 0.63 and 0.315 mm, and 15 w% of the particles having a maximum dimension between 0.315 and 0.14 mm, with the remainder dust to 100 w% in total, were followed and the resultant concrete did not have the desirable properties, for instance water impermeability, of the concrete of Example 1. In particular, the water absorption was greater, and the strength less, than the concrete of Example 1.
  • An advantage of the building panels according to the invention is that they can be made thinner than building panels made according to the prior art. This has the consequent advantages that more panels (ie with more surface area, m 2 ) can be transported per unit volume (eg of the truck), on-sire erection is easier as each building panel is lighter, and hence the time required for construction is reduced.
  • a concrete building panel 100 in accordance with the present embodiment of the invention includes a concrete panel 101 cast into an anchoring arrangement 106.
  • a particularly suitable concrete for the concrete panel 101 is the concrete material described above.
  • the concrete panel 101 has an outer surface 102 (which is the outer surface of the building panel 100) and an opposed inner surface 104.
  • the concrete panel 101 is cast into the anchoring arrangement 106 such that an outer volume 108 of the anchoring arrangement 106 extends from the inner surface 104 of the concrete panel 101.
  • the building panel 100 is manufactured such that the outer surface 102 is a finished surface. As will be appreciated, the precise nature of this surface will be determined according to the requirements of a structure to be built with the concrete building panel 100, and may (for example) be coloured, textured and/or polished as desired.
  • FIG 7A provides a perspective representation of an anchoring arrangement 106 used in the concrete building panel 100.
  • the anchoring arrangement 106 is a latticework formed of a plurality of walls/supports 202 which define therebetween a plurality of interstices 204.
  • the latticework 106 also includes a concrete impervious membrane 206 which divides the latticework 106 into an inner volume 208 and an outer volume 108.
  • membrane 206 prevents concrete from the building panel 100 itself from occupying the outer volume 108 of the latticework 106.
  • the anchoring arrangement 106 may be a typical plastics injection moulded grid as provided by many plastic injection moulding companies, and may be injection moulded from a number of different hard plastics materials such as ABS.
  • Figure 7B provides a perspective view of a plastics material 209 from which the anchoring arrangement 106 may be constructed. It will be appreciated that different types of materials may be used for the anchoring arrangement 106, and that the specific shape and configuration of the support grid as depicted in the Figures of this application are by way of general representation only.
  • the walls/supports 202 of the anchoring arrangement 106 provide a series of anchors about which concrete poured into the interstices 204 of the anchoring arrangement 106 sets thereby securing the latticework 106 in the concrete.
  • the concrete of the building panel sets about the inner volume 208 of the latticework 106 to secure the panel and latticework 106 together.
  • the latticework 106 also serves to reinforce the concrete building panel 100.
  • the concrete core of the structure sets about the outer volume 108 of the anchoring arrangement 106, thereby securing the building panel 100 in place on the structure.
  • building panels 100 may, of course, be manufactured of a variety of different dimensions depending on their intended use, dimensions of a typical building panel may be as follows:
  • distance anchoring arrangement106 extends into concrete panel 101 : 20mm • distance anchoring arrangementi 06 extends out of concrete panel 101 : 20mm
  • anchoring arrangement 106 is a single latticework embedded in the building panel 100 it would be possible to provide a alternative or multiple anchoring arrangements 106, such as (for example) a plurality of latticeworks (each of an appropriate shape/size) embedded at appropriate positions (e.g. the corners and/or centre) of the building panel 100.
  • the anchoring arrangement 210 may include a plurality of elongate members 212, each member 212 including a strut 214 joining two spherically shaped anchors 216.
  • the individual members 212 are shown as being joined by a grid 218.
  • Grid 218 may be a sheet (thus providing a concrete impermeable membrane as discussed above) or may be a net only.
  • the members 212 of the anchoring arrangement 210 may be unconnected (i.e. the anchoring arrangement 210 not provided with grid 218).
  • Each strut 214 is of sufficient length to allow the member 212 of the anchoring arrangement 210 be cast into the building panel 100 and extend away from the inner surface 104 thereof.
  • Each anchor 216 is shaped to allow the member to be securely cast in place either in the building panel 100 or in the concrete core of a structure with which the building panel 100 is to be used.
  • the anchoring arrangement 106 may be formed by an injection moulding process using, for example, ABS plastics material. Alternative materials (such as steel) may be used.
  • Figures 8A to 8C depict variations of a concrete building panel 300 which, while similar to the building panel 100 described above, have been provided with further features.
  • the concrete building panel 300 includes an outer surface 302 and an opposed inner surface 304, and is cast into an anchoring arrangement 306 such that the anchoring arrangement 306 extends from the inner surface 304.
  • the building panel 300 further includes an insulating layer 308 adjacent the inner surface 304.
  • the insulating layer 308 is, in this instance, a foam layer such as polystyrene, polyurethane, or polyethylene.
  • an inner volume 310 of the anchoring arrangement 306 is cast into the building panel 300, a middle volume 312 of the anchoring arrangement 306 is moulded into the insulating layer 308, and an outer volume 314 of the anchoring arrangement 306 extends out of the insulating later 308.
  • the building panel 300 has been further provided with a plasterboard finish 316.
  • the inner volume 310 of the anchoring arrangement 306 is cast into the building panel 300
  • the middle volume 312 of the anchoring arrangement 306 is moulded into the insulating layer 308, and the outer volume 314 of the anchoring arrangement 306 is cast into the plasterboard 316.
  • the middle volume 312 could, of course, be left vacant to allow for air flow and/or wiring.
  • a building panel may, for example, be used as partition walls in office buildings or external house/building walls.
  • the building panel 300 is provided with a bar stool 320.
  • the bar stool 320 is secured to the anchoring arrangement 306 by means of a mechanical fastener such as a clip or similar.
  • the bar stool 320 may be secured to a reinforcing bar or similar placed in the void into which the concrete core of the structure is to be poured. This may be particularly advantageous where the panels are to be placed on a vertical wall or the underside of a ceiling/roof and need to be held in place while the concrete core dries.
  • step 402 concrete is cast into a mould, the mould being the desired dimensions of the building panel.
  • the concrete used will ideally be relatively light weight and able to provide the finished surface desired.
  • the concrete should be of that colour.
  • the finished surface of the building panel i.e. the outer surface 102 which is the surface which, during manufacture, will lie on the bottom surface of the mould
  • the mould should be provided with that pattern so as to impart it to the cast concrete.
  • step 404 the anchoring arrangement 106 is inserted into the concrete cast into the mould such that the inner volume 208 of the anchoring arrangement 106 is immersed in the concrete.
  • the precise depth of insertion will depend on the depth of the concrete cast in the mould, the depth of the anchoring arrangement 106, and the intended use of the panel, however the anchoring arrangement 106 will typically be inserted to occupy approximately 66% of the depth of the cast concrete.
  • the anchoring arrangement 106 is provided with a concrete impervious membrane 206, the anchoring arrangement 106 need only be inserted into the concrete until the membrane 206 prevents further insertion.
  • Step 406 is an optional step which is only performed if an insulating layer 308 is to be provided. In this step the insulation is injected into the mould (which is of sufficient depth to contain the concrete and insulating material) prior to the concrete being set.
  • step 408 the cast concrete is allowed to set, thereby securing the anchoring arrangement 106 into the concrete.
  • the building panel is removed from the mould in step 410. Depending on the desired finish of the building panel this may be the final step in its manufacture.
  • finishing will depend on the finish desired but may, for example, include:
  • the concrete structure to be formed is a structure of the type having a poured concrete core and a finished outer surface.
  • formation of a column will be described, however other structures such as walls, ceilings or floors could also be formed.
  • the method 500 for forming a concrete structure 600 will be described with reference to a plurality of building panels, each building panel having the features of building panel 100 as depicted in Figure 6 and described above.
  • step 502 the building panels 100 are positioned such that the outer surfaces 102 of the building panels 100 define the outer surface of the structure 600.
  • the outer volume 108 of the anchoring arrangement 106 of each concrete panel 100 extends into the void 604 defined by the positioned panels 100.
  • the structure is a column with only 8 building panels 100 illustrated. Further panels 100 could, of course, be added to increase the height/width/depth of the column as desired.
  • scaffolding 602 or other supporting means may be required. If so this is provided in step 504.
  • the structure could be provided with one or more reinforcing bars (not depicted) and panels with bar stools 320 (as described above) could be supported in place by connection of the bar stools 320 to the reinforcing bars.
  • the building panels 100 may be provided with a hole (e.g. by drilling) to allow the panels 100 to be tied to a holding down treaded rod as is known in the art. In this case, once the concrete has set the ties can be removed and the holes filled with pre- made plugs of the same material and finish of the panel 100.
  • step 506 the core of the structure is poured into the void 604.
  • the poured concrete occupies the outer volumes 108 of the anchoring arrangements 106 of the concrete panels 100.
  • step 508 the concrete core sets, thereby securing the concrete panels in place (via the outer volumes 108 of the anchoring arrangements 106 which extend into the core and about which the concrete sets). If any scaffolding 602 was used this is removed.
  • concrete building panels 100 have been manufactured with outer surfaces 102 corresponding to the desired outer surface of the structure, no further finishing (such as painting, rendering, attachment of further panels etc) of the structure is required. In this case the concrete building panels 100 have, effectively, been used in their own right as the formwork for the concrete core.
  • method 500 is one of many possible methods by which a concrete structure may be formed using the building panels of various embodiments of the present invention.
  • concrete building panels would be positioned to define that surface and the remainder of the walls of the void (into which the concrete core is to be poured) could be provided by traditional formwork.
  • concrete building panels with an insulating layer as shown in Figure 8A may be appropriate to aid in insulation of the structure.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)

Abstract

L’invention concerne un béton qui comprend un agrégat. L’agrégat comprend des particules qui sont fractionnées de manière à ce que toutes ou sensiblement toutes les particules soient inférieures à environ 7 mm, d’environ 69 à 92 % en poids des particules ont une dimension maximale inférieure à environ 2,36 mm, d’environ 56 à 82 % en poids des particules ont une dimension maximale inférieure à environ 1,18 mm, d’environ 30 à 62 % en poids des particules ont une dimension maximale inférieure à environ 0,6 mm, d’environ 10 à 42 % en poids des particules ont une dimension maximale inférieure à environ 0,3 mm, d’environ 1 à 32 % en poids des particules ont une dimension maximale inférieure à environ 0,15 mm, et d’environ 0 à 2 % en poids des particules sont de la poussière, pour 100 % en poids au total.
PCT/AU2009/001026 2008-08-11 2009-08-11 Béton WO2010017583A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2009281698A AU2009281698A1 (en) 2008-08-11 2009-08-11 Concrete

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
AU2008904098A AU2008904098A0 (en) 2008-08-11 A building panel and method of building
AU2008904098 2008-08-11
AU2008904104A AU2008904104A0 (en) 2008-08-12 Concrete composition 2
AU2008904104 2008-08-12

Publications (1)

Publication Number Publication Date
WO2010017583A1 true WO2010017583A1 (fr) 2010-02-18

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AU (1) AU2009281698A1 (fr)
WO (1) WO2010017583A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013173636A (ja) * 2012-02-24 2013-09-05 Ube Industries Ltd グラウト組成物の施工方法
JP2013173634A (ja) * 2012-02-24 2013-09-05 Ube Industries Ltd グラウト組成物、グラウトスラリー及びグラウト硬化体

Citations (7)

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Publication number Priority date Publication date Assignee Title
JPS5397019A (en) * 1977-02-07 1978-08-24 Nippon Steel Corp Method for production of water slag block
JPH0558688A (ja) * 1991-09-02 1993-03-09 Ohbayashi Corp モルタル・コンクリートの施工方法
US5306344A (en) * 1992-12-02 1994-04-26 Edward C. Levy Company Mixture of portland cement concrete materials for freeze/thaw resistance
KR100465887B1 (ko) * 2004-07-14 2005-01-13 석성기업주식회사 폐도자기를 골재로 한 콘크리트 배합 조성물
US20050274295A1 (en) * 2004-04-16 2005-12-15 University Of Iowa Research Foundation Multi-function construction material, system, and method for use around in-ground foundations
EP1832561A2 (fr) * 2006-03-08 2007-09-12 Wethmar, Herbert, Dipl.-Kaufm. Ciment minéral
WO2008049642A2 (fr) * 2006-10-27 2008-05-02 Geodur International Ag Améliorations relatives aux résidus

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5397019A (en) * 1977-02-07 1978-08-24 Nippon Steel Corp Method for production of water slag block
JPH0558688A (ja) * 1991-09-02 1993-03-09 Ohbayashi Corp モルタル・コンクリートの施工方法
US5306344A (en) * 1992-12-02 1994-04-26 Edward C. Levy Company Mixture of portland cement concrete materials for freeze/thaw resistance
US20050274295A1 (en) * 2004-04-16 2005-12-15 University Of Iowa Research Foundation Multi-function construction material, system, and method for use around in-ground foundations
KR100465887B1 (ko) * 2004-07-14 2005-01-13 석성기업주식회사 폐도자기를 골재로 한 콘크리트 배합 조성물
EP1832561A2 (fr) * 2006-03-08 2007-09-12 Wethmar, Herbert, Dipl.-Kaufm. Ciment minéral
WO2008049642A2 (fr) * 2006-10-27 2008-05-02 Geodur International Ag Améliorations relatives aux résidus

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DATABASE DERWENT ABSTRACT L02; Database accession no. 90/305752/41 *
DATABASE WPI Derwent World Patents Index; Class L02, AN 0000-69744A *
PATENT ABSTRACTS OF JAPAN *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013173636A (ja) * 2012-02-24 2013-09-05 Ube Industries Ltd グラウト組成物の施工方法
JP2013173634A (ja) * 2012-02-24 2013-09-05 Ube Industries Ltd グラウト組成物、グラウトスラリー及びグラウト硬化体

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