WO2015198178A1 - Produit coulage de béton à revêtement et procédé de sa production - Google Patents

Produit coulage de béton à revêtement et procédé de sa production Download PDF

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Publication number
WO2015198178A1
WO2015198178A1 PCT/IB2015/054314 IB2015054314W WO2015198178A1 WO 2015198178 A1 WO2015198178 A1 WO 2015198178A1 IB 2015054314 W IB2015054314 W IB 2015054314W WO 2015198178 A1 WO2015198178 A1 WO 2015198178A1
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WO
WIPO (PCT)
Prior art keywords
additive
concrete casting
concrete
casting
coating
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Application number
PCT/IB2015/054314
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English (en)
Other versions
WO2015198178A4 (fr
Inventor
Israel PAYCZER
Original Assignee
Payczer Israel
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
Application filed by Payczer Israel filed Critical Payczer Israel
Publication of WO2015198178A1 publication Critical patent/WO2015198178A1/fr
Publication of WO2015198178A4 publication Critical patent/WO2015198178A4/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

Definitions

  • Embodiments of the invention relate to a coated concrete casting and a method for forming the coated concrete casting, and in particular to a monolithic type casting.
  • Concrete is a composite material typically composed of ingredients such as water, coarse granular material and cement consisting of a mixture of oxides such as calcium, silicon and aluminum. Production of concrete typically consists of a process including mixing together the ingredients, possibly with additives.
  • Concrete production may take place e.g. in a central facility or on the construction site where it is intended to be used.
  • the mixed concrete for example when produced in a central facility, may be kept in hoppers and from there dispensed into concrete mixer trucks for being hauled to the location where its is intended to be casted into formwork.
  • Coatings can be used to protect concrete castings from damage and extend its useful life by e.g. sealing the casting against penetration of substances such as chemicals.
  • a typical coated concrete casting may be obtained by first producing a pre-prepared concrete casting that is left to cure and solidify in order to serve as a substrate. After curing, several layers of coatings may then be applied over the substrate.
  • Such coated concrete casting may have some disadvantages. The coating applied to the casting may peel off in time due to e.g. mechanical stress heat, UV radiation, chemical corrosion, inherent weakness of molecules forming the coating, or simply due to errors in the application of the coating on the substrate casting.
  • US5695811 for example describes a method for bonding a hydrating cement-based overlay onto a cement-based substrate.
  • An integral bond is created between the overlay and the substrate by maximizing capillary suction through properly preparing the substrate and designing the overlay.
  • the integral bond has an interface strength at least substantially similar to the substrate strength.
  • the substrate is prepared to optimize the capillary suction by cleaning and optimal water saturation.
  • EP2189427 describes use of foamed polystyrene and cement for mortar buildings.
  • the mortar contains the foamed polystyrene and e.g. a part of the cement in the form of a ground material including granules.
  • pressed foam concrete that has been allowed to stand and which contains polystyrene foam is ground into granules and to that cement is added together with water.
  • US2012053266 relates to a polymeric-additive for cement such as Portland Cement that improves its compression and tensile strength.
  • the additive is stable at sub-freezing temperatures prior to use and relatively low in cost and easily mixed with the cement prior to utilization.
  • the additive may be controlled such that the cement may be applied by both gunning and casting techniques.
  • a monolithic concrete casting comprising an outer coating integrally formed with the casting.
  • the outer coating may be formed within the casting and preferably not as a separate layer or coat coated and/or added to a casting during or after curing stages of the casting.
  • the coating comprises an additive.
  • the additive may be mostly in the coating and/or dispersed in the casting to also be present in the coating.
  • the additive is a resin-additive and/or a polymeric- additive and/or an acrylic-additive and/or a chemical-additive and/or a mineral- additive.
  • the additive may comprise in an embodiment a specific gravity less than about 1.0 and/or a suitable viscosity possibly a low viscosity close to about water viscosity or less, in order to assist in migration of the additive, preferably upward migration, in the casing during its formation and preferably before curing or substantial curing of the casting.
  • the additive may combine with at least free calcium, and/or bleeding (e.g. excessive) iron oxide and/or bleeding (i.e. excessive) liquids (e.g. water) coming out of (or dispersed in) the concrete to chemically join them into a monolith coat in the concrete casting.
  • the migration may form the coating and/or assist to form a coating providing various embodiments of the casting of the invention with at last one of: improved leak-proof (Gas/Water), improved abrasion resistance, improved chemical resistance (to e.g. gasoline, mineral oil, solvents, acids), improved fork lift-truck resistant, improved tire-mark proof, improved dust proof, improved total UV resistance, improved Crack resistance, improved compressive strength, alleviation from plastic cracking, increased density, increased impermeability and durability, lower internal chemical reaction potential.
  • improved leak-proof Gas/Water
  • improved abrasion resistance to e.g. gasoline, mineral oil, solvents, acids
  • improved fork lift-truck resistant to e.g. gasoline, mineral oil, solvents, acids
  • improved fork lift-truck resistant to e.g. gasoline, mineral oil, solvents, acids
  • improved fork lift-truck resistant to e.g. gasoline, mineral oil, solvents, acids
  • improved fork lift-truck resistant to e.g. gasoline, mineral oil, solvents, acids
  • the additive may preferably be of a chemical and/or a Fatty/Oleic Acid type, and/or a DM additive/admixture, preferably a DM concrete additive/admixture.
  • a DM additive/admixture preferably a DM concrete additive/admixture.
  • Such preference in some embodiments may be due to low weight ratio of such additive relative to cement weight in the casting resulting e.g. in lower production costs.
  • Other possibly advantages may be faster curing time.
  • a method of producing a monolithic concrete casting comprising the steps of: providing a concrete mixture comprising mixing an additive, cement and liquid, preferably water, adding the concrete mixture to a formwork, applying smoothing to the concrete mixture in the formwork, wherein at least after curing, the concrete mixture in the formwork forms a concrete casting comprising a coating at an outer side of the concrete casting and integral with the concrete casting.
  • the method also comprises a step of applying vibration to the concrete mixture in the formwork, preferably prior to the applying of smoothing.
  • vibration may assist in movement of substances in the casting preferably substances forming the coating.
  • the smoothing forms a venturi effect at the outer side of the concrete casting urging at least some substances in the concrete mixture to be sucked to move towards the outer side.
  • the substances are the additive and additional substances possibly those forming a skin in normal concrete casting.
  • the moving of additive and substances may possibly be while same being combined preferably chemically combined, and possibly the movement may be via capillary channels in the casting resulting in blocking of at least some of said channels.
  • FIG. 1 schematically shows an additive in accordance with an embodiment of the invention added to a concrete mixture in a mixer truck;
  • FIG. 2 schematically shows a concrete mixture containing an embodiment of an additive of the invention being deposited onto a formwork, as part of a possible step in the forming of an embodiment of a concrete casting;
  • FIG. 3 schematically shows a possible step in the forming of an embodiment of a concrete casting, including vibrating the casting seen in Fig. 2 using a concrete vibrator;
  • FIG. 4 schematically shows a cross sectional view of a portion of the casting of Fig. 3;
  • FIG. 5 schematically shows a possible step in the forming of an embodiment of a concrete casting, including smoothing the upper surface of the portion of the casting seen in Fig. 4 with a mechanical trowel.
  • FIG. 1 showing an action of pouring an additive 10 in accordance with an embodiment of the invention from a source 8, such as a container, into a concrete mixture located within a mixer truck 12, in accordance with one possible form of producing a concrete casting of the present invention.
  • a source 8 such as a container
  • a mixer truck 12 in accordance with one possible form of producing a concrete casting of the present invention.
  • embodiments of the production method of the present invention may not be limited to steps including use of a mixer struck, and mixing of e.g. liquid (e.g. water), coarse granular material and cement may be performed on- site (e.g. construction site) or in any other commonly known method and/or means.
  • liquid e.g. water
  • coarse granular material and cement may be performed on- site (e.g. construction site) or in any other commonly known method and/or means.
  • the additive may be added to the concrete mixture at various stages including stages other than the one seen in this figure.
  • the adding of the additive may be to a mixture liquid (e.g. water) e.g. prior to it's adding to the concrete mixture; and/or to substances/additives added to the concrete mixture such as abrasion resistance substances; and/or coloring pigments (e.g. Iron Oxide pigment Fe 2 O 3 ); (etc.).
  • the additive may be a resin-additive and/or a polymeric-additive and/or an acrylic-additive and/or a chemical-additive and/or a mineral- additive; and preferably with a specific gravity lower than 1.0 (where reference substance is water).
  • the additive in various embodiments may also be a 99% active agent.
  • the additive may be: a resin such as a Hydroxyl- terminated polybutadiene (HTPB), and/or a chemical and/or a Fatty/Oleic Acid, and/or a Water-Borne Acrylic Epoxy, and/or a DM concrete additive/admixture, and/or any other DM additive/admixture, (etc.).
  • HTPB Hydroxyl- terminated polybutadiene
  • a chemical and/or a Fatty/Oleic Acid and/or a Water-Borne Acrylic Epoxy
  • DM concrete additive/admixture and/or any other DM additive/admixture, (etc.).
  • additives may be: the Poly-bd trademark of Cray Valley Hydrocarbon Specialty Chemicals (HSC), the TEOS or HYDRO PLAST or HydroPhob B-WE (DM) or HydroPlast AW trademarks of BETRA Beton- und Baustoffvonstechnik GmbH, the PITT-GLAZE trademark of PPG Industries Inc., PURCOLOR 6000 of SCHOMBURG ICS GmbH, (etc.).
  • Such additives may be defined as: mass-hydrophobic-agent and plasticizer, as having isomeric octyltriethoxysilanes with n-octyltriethoxysilane as main component, as mass-hydrophobic admixture on the basis of highly-reactive silanes and synergetic additives.
  • the additive of preferred embodiments of the invention may be (or include) one or more of the following: of a type not requiring assistance (i.e. not requiring a catalyst such as nitrogen or high temperature) in its curing (such as e.g. a Fatty/Oleic Acid type additive); have a low viscosity close to about water viscosity or less and preferably lower than about 0.99 [mPa- s] at 25°c, more preferably lower that about 0.91 [mPa- s] at 25 °c; of a type combinable with substances normally forming a skin in normal castings such as free-calcium and oxide iron and liquid preferably water and more preferably bleeding water (i.e. excessive water in the concrete).
  • the weight of the additive may be determined as being between about 0.2-30% of a weight of the cement in (or to be added to) a concrete mixture.
  • the additive weight may be between about 0.2-20%, more preferably between about 0.2-10%, and even more preferably between about 0.2-2%; of a weight of the cement in (or to be added to) a concrete mixture.
  • Lower additive weight may contribute to reduce costs of a production of various embodiments of a concrete casting and possibly faster curing times.
  • upper ends of the weight percent ranges may be associated to an embodiment of an additive of e.g. a mineral type, and the lower ends of the weight percent ranges may be associated to an embodiment of an additive of e.g. a chemical and/or a Fatty/Oleic Acid type.
  • a weight of a HTPB type additive may be about 5% of a weight of a cement in (or to be added to) a concrete mixture
  • a weight of a Water-Borne Acrylic Epoxy type additive may be between about 0.2- 10% of a weight of a cement in (or to be added to) a concrete mixture
  • a weight of a DM concrete type additive/admixture may be between about 0.2-3% of a weight of a cement in (or to be added to) a concrete mixture.
  • the additive weight may be between about 0.7 kg to about 105 kg for the 0.2-30% weight range, with additive weights closer to the lower end of 0.7 kg being for e.g. chemical and/or Fatty/Oleic Acid type additives and weights closer to the upper end of 105 kg being for e.g. mineral type additives.
  • the additive may be added to the concrete mixture at the factory or at the construction site, possibly mixed together with the concrete mixture for at least about 3 minutes, preferably at least about 5 minutes, more preferably at least about 15 minutes.
  • FIG. 2 shows a concrete mixture 14 including an additive of an embodiment of the invention being poured to a formwork 16 directly or by pump (or the like) to form a concrete casting 18.
  • formwork should be understood in a broad aspect to relate to any e.g. means suitable to receive (or interact with or support) a concrete mixture for forming a concrete casting, such as (but not limited to): a mold and/or structure and/or slab and/or structural system and/or coffor and/or re-usable system and/or timber or plastic system and/or metal/steel grid and/or foundation, (etc.)
  • a possible production step in the formation of the concrete casing 18 includes vibrating (possible compacting) the casting 18 using a concrete vibrator 20 to form a given region 22 in the concrete casting where vibration has been performed.
  • Fig. 3 Attention is now drawn to Fig. 3.
  • substances such as calcium (Calcium hydroxide Ca(OH) 2 ), liquid (e.g. water), the polymeric-additive, (etc.) may rise (float) upwards via e.g. capillary channels in the casting.
  • the wavy arrows in this figure represent such rising.
  • Such rising substances may preferably be promoted in the region 22 due to the vibration of the vibrator 20.
  • the additive preferably has a specific gravity smaller than about 1.0 to assist its surfacing/rising/floating to the upper layer of the concrete casting.
  • the upwardly moving additive while being transported via e.g. the capillary channels in the casting, chemically bonds/combines with the liquid (e.g. bleeding excessive water) and e.g. free calcium in the casting.
  • Basing 24 upon which casting 18 may be formed. Basing 24 may be an infrastructure on which formwork 16 was located/placed such as an earth or soil, a thin layer of concrete (or the like).
  • Fig. 5 showing a possible production step in the formation of the concrete casing 18 according to an embodiment of the invention, which includes smoothing the upper surface of the casting 18 with a mechanical trowel 26.
  • mechanical trowel 26 in addition (or while) smoothing casting 18 further forms a venturi effect assisting in sucking and floating the additive and substances such as liquid (e.g. excessive bleeding water), calcium (and possibly color pigment); upwards in the casting towards the upper layer of the casting, while possibly plugging during the upwards movement (at least part or substantially most) of the capillary channels in the casting.
  • liquid e.g. excessive bleeding water
  • calcium and possibly color pigment
  • the straight arrows in this figure represent venturi assisted rising.
  • the result of such rise of additive and substances forms a, preferably chemically and physically combined, outer coating 28 of casting 18 that may preferably be a hydrophobic coating.
  • Coating 28 forms an integral part of the casting, and in other words monolithic casting 18 includes at its top side a coating 28 acting to protect the casting 18 which may not be susceptive to peeling off. Coating 28 may preferably last as long as the casting thus having an increased durability and fast application.
  • Coated casting 18 thus may in various embodiments have at least one of: improved leak-proof (Gas/Water), improved abrasion resistance, improved chemical resistance (to e.g.
  • Various embodiments of casting 18 of the invention may also be defined as in compliance with at least one of the following standards or definitions: EN 934- 2-2012 and EN 934-2.T.9, EN 206-1, ASTM C-67 Section 7, 9 and 10, ASTM C- 666, ASTM C-23-69..
  • curing of casting 18 after the above discussed possible production steps may take no more than about 3 days and preferably no more than about 1 day.
  • Possible uses of embodiments of the concrete casting of the present invention may be (but not limited to): industrial facilities, factory floors, airplane hangers, retail facilities, car parks, run-ways, ware-houses, (etc.).
  • each of the verbs, "comprise” “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements or parts of the subject or subjects of the verb.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Paints Or Removers (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

Un produit de coulage de béton monolithique comporte un revêtement extérieur formé d'un seul tenant avec la produit de coulage . Le revêtement comporte un additif constitué d'une résine et/ou d'un type polymère et/ou acrylique et/ou un chimique et/ou minéral. L'additif est ajouté à un mélange formant la produit de coulage de béton.
PCT/IB2015/054314 2014-06-25 2015-06-08 Produit coulage de béton à revêtement et procédé de sa production WO2015198178A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201462016963P 2014-06-25 2014-06-25
US62/016,963 2014-06-25

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WO2015198178A1 true WO2015198178A1 (fr) 2015-12-30
WO2015198178A4 WO2015198178A4 (fr) 2016-02-25

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Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH06128014A (ja) * 1992-10-21 1994-05-10 Kao Corp コンクリート製品の製造方法
JPH07195318A (ja) * 1993-12-28 1995-08-01 Ohbayashi Corp 防食形ｐｃ版の製造方法
JPH08239256A (ja) * 1995-03-02 1996-09-17 Maeda Seikan Kk コンクリートの製造方法
US5662731A (en) * 1992-08-11 1997-09-02 E. Khashoggi Industries Compositions for manufacturing fiber-reinforced, starch-bound articles having a foamed cellular matrix
US5679145A (en) * 1992-08-11 1997-10-21 E. Khashoggi Industries Starch-based compositions having uniformly dispersed fibers used to manufacture high strength articles having a fiber-reinforced, starch-bound cellular matrix
US5683772A (en) * 1992-08-11 1997-11-04 E. Khashoggi Industries Articles having a starch-bound cellular matrix reinforced with uniformly dispersed fibers
US5695811A (en) 1989-10-10 1997-12-09 E. Khashoggi Industries Methods and compositions for bonding a cement-based overlay on a cement-based substrate
JP2000102912A (ja) * 1998-09-30 2000-04-11 Yamax Corp 高流動コンクリート成形品の表面気泡低減方法
EP2189427A1 (fr) 2008-11-19 2010-05-26 3D Termoház System Kft. Béton léger comprenant des agrégats, à base de polystyrène alvéolaire lié par ciment, procédé pour la fabrication du béton léger et des éléments de construction produisent du béton léger
US20120053266A1 (en) 2010-08-31 2012-03-01 Brilliant Coatings, Inc. Polymer additive to strengthen concrete

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5695811A (en) 1989-10-10 1997-12-09 E. Khashoggi Industries Methods and compositions for bonding a cement-based overlay on a cement-based substrate
US5662731A (en) * 1992-08-11 1997-09-02 E. Khashoggi Industries Compositions for manufacturing fiber-reinforced, starch-bound articles having a foamed cellular matrix
US5679145A (en) * 1992-08-11 1997-10-21 E. Khashoggi Industries Starch-based compositions having uniformly dispersed fibers used to manufacture high strength articles having a fiber-reinforced, starch-bound cellular matrix
US5683772A (en) * 1992-08-11 1997-11-04 E. Khashoggi Industries Articles having a starch-bound cellular matrix reinforced with uniformly dispersed fibers
JPH06128014A (ja) * 1992-10-21 1994-05-10 Kao Corp コンクリート製品の製造方法
JPH07195318A (ja) * 1993-12-28 1995-08-01 Ohbayashi Corp 防食形ｐｃ版の製造方法
JPH08239256A (ja) * 1995-03-02 1996-09-17 Maeda Seikan Kk コンクリートの製造方法
JP2000102912A (ja) * 1998-09-30 2000-04-11 Yamax Corp 高流動コンクリート成形品の表面気泡低減方法
EP2189427A1 (fr) 2008-11-19 2010-05-26 3D Termoház System Kft. Béton léger comprenant des agrégats, à base de polystyrène alvéolaire lié par ciment, procédé pour la fabrication du béton léger et des éléments de construction produisent du béton léger
US20120053266A1 (en) 2010-08-31 2012-03-01 Brilliant Coatings, Inc. Polymer additive to strengthen concrete

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