GRAPHENE REINFORCED CONCRETE

Abstract

A reinforced concrete material is described comprising a cementitious material (22) in which graphene is substantially uniformly distributed. A method of production of concrete is also described comprising the steps of forming a substantially uniform suspension (20) of graphene with water, and mixing the suspension (20) with a cementitious material (22) to form a concrete material (28).

Claims

1. A reinforced concrete material comprising a cementitious material in which graphene is substantially uniformly distributed.

2. A material according to claim 1, wherein the graphene is in the form of flakes.

3. A material according to claim 2, wherein the flakes are of lateral dimensions of less than 5 μm.

4. A material according to claim 3, wherein the flakes are of lateral dimensions in the range of 1-3 μm.

5. A material according to claim 4, wherein the flakes are of lateral dimensions in the range of 1.5-2.5 μm.

6. A material according to claim 5, wherein the flakes have a lateral dimension in the region of 2 μm.

7. A material according to claim 1, wherein the graphene is dispersed or suspended within water prior to the formation of the concrete material.

8. A material according to claim 7, wherein the concentration of graphene within the water is in the range of 0.2-2.5 g/L.

9. A material according to claim 8, wherein the concentration of graphene within the water is in the range of 0.3-1.5 g/L.

10. A material according to claim 9, wherein the concentration of graphene within the water is in the range of 0.6-0.8 g/L.

11. A material according to claim 10, wherein the concentration of graphene within the water is in the region of 0.7 g/L.

12. A material according to claim 1, further comprising at least one of a plasticizer or superplasticizers, a water reducing agent, an early age strength improvement agent, a retarding admixture and a corrosion inhibiting material.

13. A material according to claim 1, wherein the cementitious material comprises at least one of Portland cement, ground granulated blast furnace slag, fly ash, silica fume and limestone fines.

14. A method of production of concrete comprising the steps of forming a substantially uniform suspension of graphene with water, and mixing the suspension with a cementitious material to form a concrete material.

15. A method according to claim 14, wherein the graphene is in the form of flakes.

16. A method according to claim 15, wherein the flakes are of lateral dimensions of less than 5 μm.

17. A method according to claim 14, wherein the concentration of graphene within the water is in the range of 0.2-2.5 g/L.

18. A method according to claim 14, wherein the suspension of graphene with water is formed by mixing preformed graphene flakes with water to form a uniform suspension.

19. A method according to claim 14, wherein the suspension is formed by mixing graphite powder or graphene powder with water and using a high shear mixer to exfoliate the graphite or graphene powder.

20. A method according to claim 18, wherein a surfactant presents within the suspension.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:

[0018] FIG. 1 is a diagrammatic representation of steps in a method of manufacture of concrete in accordance with an embodiment of the invention;

[0019] FIG. 2 is a graph illustrating the impact upon compressive strength of concrete formed with graphene flakes of a range of sizes and in a range of suspension concentrations;

[0020] FIG. 3 is a graph illustrating the impact upon compressive strength of concrete fowled with graphene flakes of a range of sizes and in a range of suspension concentrations; and

[0021] FIG. 4 is a graph illustrating the impact upon compressive strength of concrete formed with graphene flakes of a range of sizes and in a range of suspension concentrations.

DESCRIPTION OF THE EMBODIMENT(S)

[0022] In describing the embodiment of the present invention, reference will be made herein to FIGS. 1-4 of the drawings in which like numerals refer to like features of the invention.

[0023] Referring to FIG. 1, steps in a method for use in the manufacture of graphene reinforced concrete are illustrated. The method comprises the steps of adding graphite powder or graphene powder 10, water 12 and a surfactant in the form of sodium cholate 14 to a vessel 16, and using a high shear mixing device 18 to mix the graphite or graphene powder 10, water 12 and sodium cholate 14. The presence of the surfactant results in the formation of a substantially uniform suspension of the graphite or graphene powder 10 within the water. The high shear mixing device 18 rotates at high speed, for example at a speed in the region of 5000-8000 rpm, the mixing device 18 generating sufficiently high shear forces within the water 12 that the movement of the water 12 is able to cause exfoliation of the powder 10 to form graphene flakes. By way of example, the graphene flakes may be of few layers form, having ten or fewer layers. The mixing device 18 is operated for a period of time in the region of 2 hours to achieve exfoliation of substantially all of the powder 10. Any relatively heavy remaining powder material 10 may be removed by decanting the graphene/water suspension. The presence of the surfactant further serves to result in the graphene forming a substantially uniform suspension 20 with the water, avoiding significant aggregation of the graphene flakes formed in this manner.

[0024] After formation of the graphene/water suspension 20, the suspension 20 is mixed with a cementitious material 22 such as Portland cement, sand 24 and aggregate or gravel 26 to form concrete 28. The mixing of the suspension 20 with the cementitious material 22, and 24 and gravel 26 is similar to the usual concrete manufacturing process with the exception that the suspension 20 is used in substitution for the water that is usually added to the cementitious material, sand and gravel, and the relative proportions of the materials used in the formation of the concrete is substantially the same as is conventional.

[0025] The concrete 28 manufactured in this manner is advantageous compared to concrete manufactured in the conventional manner in that the compressive strength and other characteristics thereof are significantly enhanced. By way of example, tests have shown that the compressive strength may be increased significantly compared to conventional concrete. Furthermore, the flexural strength may be increased significantly, and displacement upon the application of a compressive load may be significantly reduced. The graphene reinforced concrete may have an enhanced heat capacity, and its water permeability may be reduced compared to conventional concrete. The material may have an increased bond strength to steel, and is thought to be suitable for use in the manufacture of precast concrete products.

[0026] It has been found that the high surface energy of the graphene material encourages calcium silicate hydrate (C-S-H) particles to bond thereto, forming nucleation sites which promote the growth of the C-S-H gels along the graphene flakes. It is the presence of these gels that gives rise to many of the physical characteristics of concrete, and so by providing the graphene flakes which serve to promote the formation of the C-S-H gels, the bond strength of the cement in the concrete is enhanced. Furthermore, the enhanced formation of C-S-H nucleation sites results in the formation of a denser network of interlocked cement crystals which not only gives rise to enhanced physical properties but also act as a barrier to the ingress of water leading to reduced water permeability.

[0027] The enhanced physical characteristics have been found to be stable over time.

[0028] The enhanced properties of the graphene reinforced concrete may allow the quantity of concrete required in certain applications to be reduced, leading to savings and increased efficiencies in those applications. The reduced amount of concrete, and hence cement, used in such applications may have significant environmental benefits. The reduced water permeability may allow the use of concrete in certain applications in which, conventionally, concrete would not be suitable for use, for example in some applications in flood prone areas. Also, the reduced water permeability may extend the life span of structures exposed to water, in use, without requiring the application of water-resistant additives or coatings or the like to the structures.

[0029] The graphene/water suspension 20 may be manufactured at a high rate, for example at a rate of 100 L/h or more, and so industrial scale production of graphene reinforced concrete is possible using the method of this embodiment of the invention.

[0030] As shown in FIGS. 2 and 3, the concentration of graphene within the suspension is preferably relatively low, for example in the range of 0.2 to 2.5 g/L. More preferably, it is in the range of 0.3-1.5 g/L, and it is conveniently in the range of 0.6-0.8 g/L, for example in the region of 0.7 g/L. The use of a suspension 20 containing this level of graphene has found to be especially advantageous in that the compressive strength of concrete manufactured therewith is particularly enhanced.

[0031] As shown in FIG. 4, the graphene flakes within the suspension 20 are conveniently of lateral dimensions of less than 5 μm, and more preferably have lateral dimensions in the range of 1-3 μm. More preferably still, the flakes have a lateral dimension in the range of 1.5-2.5 μm, the flakes preferably having a lateral dimension in the region of 2 μm. The use of a suspension 20 including graphene flakes of this size is beneficial in that the compressive strength is, again, particularly enhanced.

[0032] Although the description hereinbefore is of the use of a surfactant functionalized graphene/water suspension in the manufacture of concrete, the invention may alternatively employ graphene produced using other techniques, and is not restricted to the use of shear exfoliated graphene. By way of example, a suspension may be formed by mixing industrial grade graphene flakes produced using other techniques with water. Such graphene flakes typically have a slightly greater number of layers, for example in the region of 10 to 14 layers. Again, a surfactant may be used to avoid aggregation of the graphene flakes, and so assist in the production of a substantially uniform suspension. The suspension produced in this manner may then be used in the manufacture of concrete using the techniques outlined hereinbefore.

[0033] If desired, the concrete material may further include one or more of a range of additives that are commonly used in the manufacture of concrete to enhance the workability and/or other properties thereof. The additives may include, for example, plasticizers or superplasticizers to enhance fluidity and workability, water reducing agents to allow a reduced proportion of water to be used in the material, early age strength improvement agents, retarding admixtures and corrosion inhibiting materials. It will be appreciated that this list is not exhaustive and that other additives may be used, if desired.

[0034] The cementitious material 22 may, as mentioned hereinbefore, comprise Portland cement. However, if desired, it may comprise, alternatively or additionally, a cement replacing material such as ground granulated blast furnace slag, fly ash, silica fume or limestone fines.

[0035] It will he appreciated that the references herein to graphene are not restricted to monolayer graphene materials but also include other forms of material commonly referred to as graphene, such a bi-layer, tri-layer and few layer graphene, and graphene nano platelets and the like, for example as defined in ISO/TS 80004-13.

[0036] While the present invention has been particularly described, in conjunction with one or more specific embodiments, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.