A HYDRAULIC COMPOSITION FOR THE CONSTRUCTION OF PAVEMENTS

Abstract

A hydraulic composition for the construction of pavements, and in particular for the repair of pavements, includes a hydraulic binder including a cement, 0.18% to 0.35% of a superplasticiser, where the percentage is expressed by dry weight compared to the cement, and where the superplasticiser includes a branched polymer including at least one pendant chain, with a terminal function of the phosphonate or phosphate type, and 0.25% to 2% of a setting accelerator, where the percentage is expressed by dry weight compared to the cement, where the setting accelerator includes a calcium salt, where the hydraulic composition has a Water/Cement ratio higher than 0.38 and strictly less than 0.45.

Claims

1-9. (canceled)

10- A hydraulic composition for the construction of pavements comprising: a hydraulic binder comprising a cement, 0.18% to 0.35% of a superplasticiser, the percentage being expressed by dry weight compared to the cement, and said superplasticiser comprising a branched polymer including at least one pendant chain, with a terminal function of the phosphonate or phosphate type, and 0.25% to 2% of a setting accelerator, the percentage being expressed by dry weight compared to the cement, said setting accelerator comprising a calcium salt, said hydraulic composition having a Water/Cement ratio higher than 0.38 and strictly less than 0.45.

11- The hydraulic composition according to claim 10, wherein the number of pendant chains is less than or equal to three.

12- The hydraulic composition according to claim 10, wherein the calcium salt comprises a calcium nitrite, a calcium nitrate or their blends.

13- The hydraulic composition according to claim 10, wherein the cement comprises a Portland cement of the CEM I type according to Cement standard NF EN 197-1.

14- The hydraulic composition according to claim 13, wherein the Portland cement of CEM I type is in resistance category 42.5 N, 42.5 R, 52.5 N or 52.5 R according to Cement standard NF EN 197-1.

15- The hydraulic composition according to claim 10, wherein the cement includes at least one mineral addition.

16- The hydraulic composition according to claim 10, comprising 0.001% to 0.1% of an air-entraining agent, the percentage being expressed by dry weight relative to the cement.

17- The hydraulic composition according to claim 10, comprising 0.001% to 0.06% of an air-entraining agent, the percentage being expressed by dry weight relative to the cement.

18- The hydraulic composition according to claim 16, wherein the air-entraining agent comprises a sulphonic fatty acid, a carboxylic fatty acid, or their blends.

19- A method for construction of pavements comprising utilizing a hydraulic composition according to claim 10, wherein the hydraulic composition is of ready-mixed type, and has a S1, S2 or S3 consistency according to Cement standard NF EN 197-1.

20- The method for construction of pavements according to claim 19, wherein the construction of pavements is repair.

Description

EXAMPLES

[0117] In the following various examples the percentages are expressed as mass percentages.

[0118] The term “D/d”, as defined in standard NF EN 12620+A1, is stipulated in the various tables for the sands and chips used.

Example 1

Selection of Superplasticiser and Definition of the Components of the Hydraulic Composition

[0119] Consistency tests on a hydraulic composition were undertaken at 20° C. with five different superplasticisers, namely: [0120] superplasticiser 1, sold under the name Optima 203, comprising polymers from the chemical family of polyalkoxylated polycarboxylates (PCP), [0121] superplasticiser 2, sold under the name Advaflow 450, comprising polymers from the chemical family of PCPs, [0122] superplasticiser 3, sold under the trademark Omega 135, comprising for the most part polymers from the chemical family of PCPs, [0123] superplasticiser 4, sold under the trademark Optima 100, belonging to the chemical family of phosphonates. This superplasticiser is a branched polymer comprising at least one pendant chain having a terminal function of the phosphonate or phosphate type.

[0124] The hydraulic composition used to test each of these four superplasticisers included cements from the Le Teil cement works, a mineral addition with a limestone filler of surface specific area 0.8 m.sup.2 per gram, from the Saint Beat quarry, granulates from the La Patte and Brefauchet quarries, and one of the four superplasticisers subject to testing.

[0125] The quantity of components used for each of the four tested hydraulic compositions is summarised in table 1 below; unless otherwise specified the values are expressed in kilograms per cubic metre of hydraulic composition:

TABLE-US-00001 TABLE 1 Formulations of the different tested hydraulic compositions Hydraulic composition C1 C2 C3 C4 Cement Le Teil CEM I 416.7 416.7 416.7 416.7 52.5 R Filler Saint Béat 52.91 52.91 52.91 52.91 Sand 0/4 La Patte 766.9 766.9 766.9 766.9 Chips 4/6 La Patte 187.1 187.1 187.1 187.1 6/10 La Patte 187.8 187.8 187.8 187.8 11/22 Brefauchet 661.6 661.6 661.6 661.6 Super- superplasticiser 1 4.68 plasticisers superplasticiser 2 5.03 superplasticiser 3 4.38 superplasticiser 4 3.24 Effective water 175 175 175 175 W/C ratio 0.42 0.42 0.42 0.42 Volume of paste (L/m3) 328 328 328 328 Superplasticiser (% dry/L) 0.22% 0.30% 0.22% 0.21%

[0126] The percentage given on the last line of table 1 indicates the proportion by dry weight of superplasticiser used in the hydraulic composition.

[0127] These tests were undertaken using the following procedure; [0128] introduction of sand and chips into the mixer, [0129] start-up of the mixer, [0130] introduction within 30 seconds of pre-wetting water, equivalent to 5% of the mass of granulate; this quantity of water was then subtracted from the quantity of mixing water, [0131] mixing for 30 seconds, [0132] rest for 4 minutes, [0133] with the mixer stopped, introduction of cement and if applicable filler within 1 minute, [0134] mixing for 1 minute, [0135] introduction within 30 seconds of the mixing water comprising the additive, whilst continuing to mix, [0136] mixing for 2 minutes, and [0137] stoppage of the mixer.

[0138] The mixer used is of Pemat brand, model ZK500HE. It comprises an eccentric moving blade which rotates at 60 rpm in a tank which itself also rotates in the same direction at 40 rpm. The differential speed between the eccentric moving blade and the tank creates the shearing. The shearing is amplified by a stationary blade attached to the edge of the tank, and directs the product on to the eccentric moving blade.

[0139] The slump measurements were then made according to standard NF EN 12350-02 of April 2012. The press used is of brand 3R and model Quantris.

[0140] The results of these tests are shown in table 2 below, where the values are expressed in cm:

TABLE-US-00002 TABLE 2 Results of slump tests with several superplasticisers Hydraulic composition C1 C2 C3 C4 Slump (cm) after 5 min. 23 14 22.5 12 after 30 min. 13 9.5 20 11 after 60 min. 7 9.5 10 after 90 min. 3 4 7 8 after 120 7 8 min.

[0141] These results enabled it to be ascertained that hydraulic compositions C1, C2 or C3 have a poor rheology maintenance. This poor rheology maintenance did not enable a consistency compatible with use on a pavement to be guaranteed.

[0142] Only hydraulic composition C4, which uses superplasticiser 4 sold by the company Chryso under the trade name Chryso® Fluid Optima 100, had a slump value after 90 min. and even after 120 min. which was very close to the initial consistency after 5 min., which gave the hydraulic composition a consistency compatible with the consistency goals sought for use on a pavement.

[0143] This superplasticiser is sold in liquid form. The data sheet supplied by the manufacturer stipulates that the quantity of dry extract for this superplasticiser is equal to 31%±1.5%, Several other hydraulic composition formulations were made from this superplasticiser.

Example 2

Control Batch Formulations

[0144] The purpose of the tests of example 2 was firstly to define a range of values for the proportion of superplasticiser in the hydraulic composition, but also to define a range of values for the calcium salt type setting accelerator and for the Water/Cement ratio.

[0145] The produced hydraulic compositions use different cements and fillers and different granulates.

[0146] The cements used are from the Lafarge Le Teil cement works in the case of the cement of type OEM I 52.5 R, from the Lafarge Le Havre cement works in the case of the cement of type CEM I 52.5 N, and from the Lafarge Kujawy cement works in Poland in the case of the cement of type CEM I 42.5 R.

[0147] The technical characteristics of each of these cements are summarised in table 3 below:

TABLE-US-00003 TABLE 3 Technical characteristics of the cements used Cement 1 Cement 2 Cement 3 CEM I CEM I CEM I 52.5 N CE 52.5 R CE 42.5 R CP2 NF CP2 NF Kujawy Cement works: Le Havre Le Teil Poland Mineralogical Alite mono 63.10 62.40 59.30 composition Belite 15.10 17.20 14.80 (% by mass) Ferrite 9.00 7.50 10.40 Cubic 6.60 4.30 3.10 aluminate Ortho 0.80 0.10 2.20 aluminate Lime CaO 0.40 0.50 0.30 Portlandite 0.40 0.00 2.00 Ca(OH)2 Periclase 0.50 0.00 0.20 Quartz 0.00 0.20 0.20 Calcite 0.90 3.20 4.20 Additives (% by Gypsum 1.90 1.10 0.30 mass) Semi-hydrate 1.10 0.80 3.00 Anhydrite 0.20 2.60 0.00 Free CaO (% by mass) 0.85 0.52 2.14 Soluble alkalines (% Soluble K2O 0.32 0.14 0.44 by mass) Soluble Na2O 0.08 0.11 0.08 Chemical SiO2 20.14 20.42 19.17 composition Al2O3 5.19 4.40 4.82 of the clinker Fe2O3 2.78 2.42 3.17 (% by mass) CaO 65.06 65.50 63.39 MgO 1.21 0.92 1.24 K2O 0.36 0.15 0.57 Na2O 0.16 0.17 0.23 SO3 3.01 3.55 3.11 TiO2 0.23 0.20 0.30 Mn2O3 0.09 0.05 0.08 P2O5 0.20 0.07 0.12 Cr2O3 Value < Value < 0.01 detection detection limit limit ZrO2 0.02 0.02 0.01 SrO 0.04 0.16 0.02 PAF 1.27 1.93 3.33 Total 99.76 99.97 99.57 BLAINE surface specific area - 3,570 4,000 3,480 Physical (cm2/g) Granulo-laser curve D10 μm 2.26 2.22 3.20 cement model D50 μm 17.34 12.18 15.79 (% by mass) D90 μm 57.37 33.75 44.17 D(4.3) μm 24.49 15.41 20.18

[0148] The limestone fillers, when used, are from the Lafarge Saint Beat quarry, or alternatively are sold by the company Saint-Hilaire under the Filafluid® brand.

[0149] The granulates used in the hydraulic compositions, for their part, are from the Lafarge La Patte, La Petite Craz or Yssingeaux quarries.

[0150] The granulates used in the compositions according to the invention include sand(s) and chip(s) defined according to standard NF EN 12620-A1 of June 2008.

[0151] Each granulate is characterised by two figures: the first corresponds to the “d” as defined in standard NF P 18-545 of September 2011 and the second corresponds to “D” as defined in standard NF P 18-545 of September 2011.

[0152] The setting accelerator used is sold by the company Sika® under the trade name Set 02.

[0153] The air-entraining agent used is sold by the company BASF® under the trade name MasterAir 104 or by the company Chryso® under the trade name Chryso®Air G100.

[0154] Several control batch formulations (T1 to T5) were produced from all or part of these various components using a protocol similar to the one used above for the selection of the superplasticiser.

[0155] Since the proportion of air initially contained in the hydraulic composition is not known in advance, the quantity of components of the hydraulic composition was initially determined for a theoretical air proportion equal to 2%.

[0156] A measurement of the proportion of air using an aerometer is made at T=60 min., and then the quantities of components of the hydraulic composition were readjusted by calculation according to the real value for the proportion of air which was measured.

[0157] The control batch formulations are shown in table 4 below:

TABLE-US-00004 TABLE 4 Control batch formulations Control batches T1 T2 T3 T4 T5 Temperature: 20° C. 10° C. 10° C. 20° C. 20° C. Cement Le Teil CEM I 448.7 352.4 389.1 382.6 400.4 52.5 R Filler Saint Béat 21.6 6.9 7.7 Sand1 0/4 La Patte 743.2 Sand2 0/4 R Petite 825.8 791.2 887.8 804.7 Craz Chip1 4/6 La Patte 181.3 Chip2 6/10 La Patte 182.0 Chip3 10/20 La Patte 707.2 Chip4 Yssingeaux 4/6 Chip5 Yssingeaux 214.2 205.2 230.3 208.8 6/10 Chip6 Yssingeaux 823.7 789.1 885.5 802.6 10/14 Fluidifier Optima 100 1.20 4.03 4.17 4.16 3.65 Setting Set 02 10.58 35.67 28.13 5.43 28.39 accelerator Air-entraining MasterAir 104 1.93 0.09 0.10 0.09 0.10 agent Weff 188.4 144.5 147.9 136.1 152.2 W/C 0.420 0.410 0.380 0.356 0.380 Superplasticiser 0.07% 0.31% 0.29% 0.31% 0.25% Setting accelerator 0.84% 3.37% 2.43% 0.50% 2.43%

[0158] Effective water W.sub.eff is the water required to hydrate a hydraulic binder, and the fluidity of a hydraulic composition in the fresh state.

[0159] The effective water and its calculation method are discussed in standard EN 206-1/CN of December 2012, page 17, paragraph 3.1.30.

[0160] From this table 4, it could be observed that: [0161] the hydraulic composition according to control batch formulation T1 used a proportion of superplasticiser by dry weight compared to the cement which was equal to 0.07%, while the proportion of setting accelerator by dry weight compared to the cement was equal to 0.84% and the W/C ratio was equal to 0.42, [0162] the hydraulic composition according to control formulation T2 used a proportion of setting accelerator by dry weight compared to the cement equal to 3.37%, while the proportion of superplasticiser by dry weight compared to the cement was equal to 0.31% and the W/C ratio was equal to 0.41, [0163] the hydraulic composition according to control formulation T3 used a proportion of setting accelerator by dry weight compared to the cement which was equal to 2.43%, while the proportion of superplasticiser by dry weight compared to the cement was equal to 0.29% and the W/C ratio was equal to 0.38, [0164] the hydraulic composition according to control formulation T4 used a W/C ratio of 0.356, while the proportion of superplasticiser by dry weight compared to the cement was equal to 0.31% and the proportion of setting accelerator by dry weight compared to the cement was equal to 0.50%, and [0165] the hydraulic composition according to control formulation T5 used a proportion of setting accelerator by dry weight compared to the cement which was equal to 2.43%, while the proportion of superplasticiser by dry weight compared to the cement was equal to 0.25% and the W/C ratio was equal to 0.38.

[0166] Table 5 below shows the results of the slump tests obtained for control batch formulations T1 to T5 of table 4:

TABLE-US-00005 TABLE 5 Results for control batches 1 to 5 Control batches T1 T2 T3 T4 T5 Slump after 5 min. (cm) 5.3 7.3 3.6 5.7 (cm) after 30 min. 3 5.9 5.3 2.7 5.2 after 60 min. 2.8 5.05 6.4 4.8 after 90 min. 4.2 6.9 4 after 120 min. 6.8 Average compression 15.9 23.8 35.6 resistance after 24 hours, MPa

[0167] The compression resistance values were obtained according to the test method described in standard NF EN 12390-3 of April 2012.

[0168] Table 5 showed that for the hydraulic composition according to control batch formulation T1 for which the proportion of superplasticiser compared to the cement was less than the lower limit of the claimed range, and for which the proportion of setting accelerator and the W/C ratio were within the claimed ranges, was not sufficiently fluid and was different from a consistency of the S1 or S2 type sought.

[0169] Similarly, the hydraulic composition according to control batch formulation T2 for which the proportion of setting accelerator by dry weight compared to the cement was higher than the upper limit of the claimed range, while the proportion of superplasticiser and the W/C ratio were within the claimed ranges, had workability which was too short, and compression resistance which was too low, making it different from the sought performance.

[0170] Similarly, the hydraulic composition according to control batch formulation T3 for which the proportion of setting accelerator by dry weight compared to the cement was higher than the upper limit of the claimed range, while the proportion of superplasticiser and the W/C ratio were within the claimed ranges, was over-fluidified and was different from a sought consistency of type S1 or S2.

[0171] Similarly, the hydraulic composition according to control batch formulation T4 for which the W/C ratio was less than lower limit of the claimed range, while the proportion of superplasticiser by dry weight compared to the cement and the proportion of setting accelerator by dry weight compared to the cement were within the claimed ranges, had poor rheology maintenance, which made this hydraulic composition difficult to handle.

[0172] Similarly, the hydraulic composition according to control batch formulation T5 for which the proportion of setting accelerator by dry weight compared to the cement was higher than the upper limit of the claimed range, while the proportion of superplasticiser and the W/C ratio were within the claimed ranges, had poor rheology maintenance after 90 minutes.

Example 3

Batch Formulations according to the Invention

[0173] Several batch formulations of hydraulic compositions according to the invention (F1 to F18) were produced at a temperature of 20° C. from all or part of the various components presented above, using a procedure similar to that which had been used above to select the superplasticiser.

[0174] These batch formulations according to the invention are shown in tables 6A and 6B below:

TABLE-US-00006 TABLE 6A Hydraulic composition formulations according to the invention Batch formulations F1 F2 F3 F4 F5 F6 F7 F8 F9 Cement 1 Le Teil 442.7 441.8 414.1 406.7 342.3 346.0 342.9 352.9 350.3 CEM I 52.5 R Filler 1 Saint Béat 21.3 21.3 34.5 18.0 18.2 6.8 7.0 6.9 Filler 2 Filafluid 35.1 Sand1 0/4 La 876.3 928.0 Patte Sand2 Yssingeaux 230.0 0/4 Sable3 0/4 R 542.8 740.3 802.2 810.9 803.6 827.1 821.0 Petite Craz Chip1 4/6 La 154.6 145.2 Patte Chip2 6/10 La 155.2 145.7 Patte Chip3 10/20 La 603.1 566.4 Patte Chip4 Yssingeaux 98.1 4/6 Chip5 Yssingeaux 97.8 192.1 208.1 210.4 208.5 214.6 213.0 6/10 Chip6 Yssingeaux 751.9 738.4 800.2 808.8 801.5 825.0 818.9 10/14 Fluidifier1 Optima 100 2.85 3.00 3.15 2.94 3.03 3.07 3.68 3.79 3.38 Setting Set 02 18.42 18.38 19.11 16.27 13.29 7.23 4.96 5.10 20.26 accelerator Air-entraining MasterAir 1.90 4.43 0.98 0.96 0.70 0.44 0.42 0.09 0.09 agent 1 104 Weff 185.9 185.5 173.9 170.8 143.8 145.3 140.6 144.7 143.6 W/C 0.420 0.420 0.420 0.420 0.420 0.420 0.410 0.410 0.410 % 0.18% 0.19% 0.20% 0.19% 0.24% 0.24% 0.30% 0.30% 0.26% Superplasticiser % Setting 1.48% 1.48% 1.47% 1.28% 1.28% 0.69% 0.50% 0.50% 1.96% accelerator

TABLE-US-00007 TABLE 6B Hydraulic composition formulations according to the invention Batch formulations F10 F11 F12 F13 F14 F15 F16 F17 F18 Cement Le Teil 341.4 352.0 356.1 391.2 357.2 399.6 1 CEM I 52.5 R Cement Le Havre 353.0 364.2 2 CEM I 52.5 N Cement Kujawy 412.2 3 CEM I 42.5 R Filler 1 Saint 6.7 Béat Sable3 0/4 R 800.1 816.7 826.2 786.1 840.4 822.9 814.2 803.0 827.3 Petite Craz Chip3 10/20 La 814.0 838.7 Patte Chip5 Yssing- 207.6 211.9 214.3 203.9 218.0 213.5 211.2 eaux 6/10 Chip6 Yssing- 798.1 814.6 824.1 784.1 838.2 820.8 812.1 eaux 10/14 Gravil- 4/10 La 212.9 219.3 lon7 Patte Fluid- Optima 3.66 3.83 4.37 4.11 3.88 2.97 3.58 3.92 3.76 ifier1 100 Setting Set 02 4.94 4.99 2.52 19.41 3.55 15.02 20.66 17.00 17.54 accel- erator Air- Master- 0.09 0.13 0.09 0.19 0.20 entrain- Air ing 104 agent 1 Air- Chryso ® 2.19 0.10 0.10 0.10 entrain- Air ing G100 agent 2 Weff 140.0 144.3 146.0 148.6 136.8 144.7 138.4 151.8 156.6 W/C 0.410 0.410 0.410 0.380 0.383 0.410 0.380 0.380 0.380 Super- 0.30% 0.31% 0.35% 0.29% 0.31% 0.24% 0.27% 0.28% 0.26% plastic- iser Setting 0.50% 0.50% 0.25% 1.71% 0.35% 1.47% 1.96% 1.47% 1.50% accel- erator

[0175] In all these formulations the proportion of superplasticiser and the proportion of setting accelerator by dry weight compared to the cement, and the W/C ratio, are all within the claimed ranges.

[0176] All these formulations include a minimum of 4% of entrapped air and are therefore compliant with standard NF EN 206-1 of December 2012.

[0177] Tables 7A and 7B below show the results of the slump and mechanical resistance tests obtained for the batch formulations according to the invention F1 to F18 of tables 6A and 6B.

TABLE-US-00008 TABLE 7A Results for batch formulations F1 to F8 according to the invention Batch formulations F1 F2 F3 F4 F5 F6 F7 F8 F9 Slump after 5 min. 6.8 7.2 7 7.7 8 6.8 7 (cm) after 30 min. 4.2 4.35 5.2 7 7.3 6 7.9 4.9 5.3 after 60 min. 4.1 4.3 5.1 6.8 7 6 7.6 4.9 5.6 after 90 min. 4.25 4.55 4.7 6 6.3 5.6 7.4 4.8 5.2 after 120 4.6 4 5.2 5 5.2 7.2 4.6 4.5 min. Average after 18 32 34.3 compression hours resistance after 24 37.3 27.9 27.1 25.5 26.1 25.2 29 22.5 (MPa) hours after 7 days 46.8 55.4

TABLE-US-00009 TABLE 7B Results for batch formulations F9 to F17 according to the invention Batch formulations F10 F11 F12 F13 F14 F15 F16 F17 F18 Slump after 5 min. 6.1 6.2 6.5 5.3 6.3 7 5.7 (cm) after 30 min. 5.6 6 4.7 5.3 6.2 5 5.7 after 60 min. 8 6.1 5 7 4.7 5.5 6.5 5 5 after 90 min. 7 6 4.9 5.6 4.2 5 7.2 5.5 4.9 after 120 min. 7 5.6 4.6 3.5 3.8 3 2.4 4.8 Average after 7 hours 9.8 1.4 compression after 12 hours 20 resistance after 16 hours 33 27.2 (MPa) after 18 hours 38.8 22.5 20 after 24 hours 27.3 25.5 34.5 42.6 29.5 22.6 26.5 39.1 28.6 after 7 days 57 after 28 days 69.5 64.6

[0178] Tables 7A and 7B show that all formulations F1 to F18 have a compression resistance of over 20 MPa after 24 hours at 20° C. Formulations F1, F2 and F13 have a compression resistance of over 30 MPa after 18 hours at 20° C. and even after 16 hours in the case of formulation F13.

[0179] Formulation F17 has a compression resistance of 20 MPa after 12 hours at 20° C.

[0180] In addition, these formulations give the hydraulic composition a consistency of type S1, S2 or S3 and a workability of between 10° C. and 30° C. allowing its use on site.