MANUFACTURING PROCESS AND COMPOSITION OF CONCRETE ADDITIVE

Abstract

The current invention comprises the MANUFACTURING PROCESS AND COMPOSITION OF CONCRETE ADDITIVE with the purpose of adding hydrophobic and waterproofing properties to concrete, as well as improving its mechanical properties. The process involves two phases of component mixing/heating, and the additive composition comprises mortar, cement, calcium carbonate, active microsilica, calcium stearate, and graphite.

Claims

1. A CONCRETE ADDITIVE COMPOSITION comprising calcium carbonate, a pore blocker, a hydrophobic compound, and characterized by comprising in its composition: a) AC mortar, b) Portland cement, and c) a separately produced formulation that is composed of Portland cement, hydrophobic compound and graphite.

2. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the mortar is 30% to 50% of the composition, in mass, of the additive.

3. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that Portland cement is 22% to 28% of the composition, in mass, of the additive.

4. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the calcium carbonate is 15% to 25% of the composition, by mass, of the additive.

5. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the pore blocker is 2% to 9% of the composition, by mass, of the additive.

6. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the hydrophobic compound is 3% to 7% of the composition, by mass, of the additive.

7. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the separately produced formulation is 0.5% to 1.5% of the composition, by mass, of the additive.

8. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the separately produced formulation is composed of 30% to 60% Portland cement, 20% to 50% hydrophobic compound and 3% to 10% graphite.

9. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the pore blocker is one or more of the following components: active microsilica, talc, pozzolans, graphite, graphene oxide, aluminosilicates such as bentonite, silicates, granulated blast furnace slag, calcined clays, fly ash, metakaolinite, calcite, aragonite, solid greases, and acrylic emulsions.

10. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the pore blocker is the active microsilica.

11. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the hydrophobic compound is one or more of the following components: unsaturated fatty acids and their salts, with chains from C10 to C24, which may be stearic acid, magnesium stearate, sodium stearate, calcium stearate, potassium stearate, fumaryl stearate, zinc stearate, aluminum stearate, salts of transition metals, and hydrophobic compounds such as: silane, siloxanes, silicone, or a mixture thereof.

12. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the hydrophobic compound is calcium stearate.

13. The CONCRETE ADDITIVE COMPOSITION according to claim 1, characterized by the fact that the concrete additive further comprises: superplasticizer compound and/or defoaming compound and/or graphene.

14. The CONCRETE ADDITIVE COMPOSITION according to claim 13, characterized by the fact that the superplasticizer is 3% to 30% of the composition, in mass, of the additive.

15. The CONCRETE ADDITIVE COMPOSITION according to claim 13, characterized by the fact that the defoamers are 1% to 10% of the composition, in mass, of the additive.

16. The CONCRETE ADDITIVE COMPOSITION according to claim 13, characterized by the fact that the graphene is 0.2% to 1% of the composition, by mass, of the additive.

17. The CONCRETE ADDITIVE COMPOSITION according to claim 13, characterized by the fact that the superplasticizer compound is one or more of the following components: lignosulfonate, naphthalene formaldehyde sulfonate, melamine formaldehyde sulfonate, polycarboxylate esters.

18. The CONCRETE ADDITIVE COMPOSITION according to claim 13, characterized by the fact that the superplasticizer compound is one or more of the following components: mineral oil, silicone oil, vegetable oil, polyethylene glycol, polypropylene glycol, and polymethyl methacrylate.

19. A METHOD OF MANUFACTURING CONCRETE ADDITIVE, characterized by the fact that a) the formulation composed of: Portland cement, hydrophobic compound and graphite is produced separately, where the mixture of these components is heated from 70? C. to 150? C., homogenized properly in a grinder, and b) after the previously produced formulation, a second mixture is made while heating, at a temperature of 70? C. to 170?, the composition that comprises: Portland cement, AC mortar, calcium carbonate, pore blocker, hydrophobic compound, and the previously produced formulation, generating the final product.

20. The METHOD OF MANUFACTURING CONCRETE ADDITIVE, according to claim 19, characterized by the fact that the previously produced formulation is mixed and heated for a period of 2 to 5 minutes.

21. The METHOD OF MANUFACTURING CONCRETE ADDITIVE, according to claim 19, characterized by the fact that the second mixture is mixed and heated for a period of 20 to 30 minutes.

22. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the mortar is 30% to 50% of the composition, by mass, of the additive.

23. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the Portland cement is 22% to 28% of the composition, by mass, of the additive.

24. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the calcium carbonate is 15% to 25% of the composition, by mass, of the additive.

25. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the pore blocker is 2% to 9% of the composition, by mass, of the additive.

26. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the hydrophobic compound is 3% to 7% of the composition, by mass, of the additive.

27. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the separately produced formulation is 0.5% to 1.5% of the additive composition by weight.

28. The METHOD OF MAKING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the separately produced formulation is composed of 30% to 60% Portland cement, 20% to 50% hydrophobic compound, and 3% to 10% graphite.

29. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the pore blocker is one or more of the following components: active microsilica, talc, pozzolans, graphite, graphene oxide, aluminosilicates such as bentonite, silicates, granulated blast furnace slag, calcined clays, fly ash, metakaolinite, calcite, aragonite, solid greases and acrylic emulsions.

30. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that pore blocker is the active microsilica.

31. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the hydrophobic compound is one or more of the following components: unsaturated fatty acids and their salts, with chains from C10 to C24, which may be stearic acid, magnesium stearate, sodium stearate, calcium stearate, potassium stearate, fumaryl stearate, zinc stearate, aluminum stearate, salts of transition metals, and hydrophobic compounds such as: silane, siloxanes, silicone, or a mixture thereof.

32. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the hydrophobic compound is calcium stearate.

33. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 19, characterized by the fact that the concrete additive further comprises: superplasticizer compound and/or defoaming compound, and/or graphene.

34. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 33, characterized by the fact that the superplasticizer is 3% to 30% of the composition, by mass, of the additive.

35. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 33, characterized by the fact that the defoamers are 1% to 10% of the composition, by mass, of the additive.

36. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 33, characterized by the fact that the graphene is 0.2% to 1% of the composition, by mass, of the additive.

37. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 33, characterized by the fact that the superplasticizer compound is one or more of the following components: lignosulfonate, naphthalene formaldehyde sulfonate, melamine formaldehyde sulfonate, polycarboxylate esters.

38. The METHOD OF MANUFACTURING CONCRETE ADDITIVE according to claim 33, characterized by the fact that the superplasticizer compound is one or more of the following components: mineral oil, silicone oil, vegetable oil, polyethylene glycol, polypropylene glycol, and polymethyl acrylate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The FIG. 1 shows the additive dosage for each specific use of the additive.

[0023] The FIG. 2 exemplifies the equipment used in the final mix for the production of the concrete additive.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0024] The current patent proposes a PROCESS FOR THE MANUFACTURING AND COMPOSITION OF CONCRETE ADDITIVE comprising in its composition (in mass): 30% to 50% AC mortar, 22% to 28% Portland cement, 15% to 25% calcium carbonate, 2% to 9% a pore blocker, preferably active microsilica, 3% to 7% a hydrophobic compound, preferably calcium stearate and 0.5% to 1.5% a formulation produced separately before mixing the other products.

[0025] The formulation mentioned above is composed (in mass) of 30% to 60% Portland cement, preferably 50%, 20% to 50% hydrophobic compound (calcium stearate), preferably 45% and 3% to 10% graphite, preferably 5%, which pass through an equipment of preferably 1,500 watts of power that, by electrofusion, heats and mixes, at a temperature of 70? C. to 150? C., preferably 140? C., for a period of 2 to 5 minutes, preferably 3 minutes. After this step, the mixture is transferred to a particle grinder to homogenize it properly, leaving nothing solid (the heating above may solidify some parts of the mixture). The mixture is properly weighed from 0.5% to 1.5%, preferably 1%, this formulation is placed in the secondary mixer, for a second mixing and heating, culminating in the final product. For convenience, we will call this formulation formulation A.

[0026] With the previously produced formulation A, all components (formulation A, Portland cement, AC mortar, calcium carbonate, pore blocker and hydrophobic compound) are mixed together while being heated at a temperature of 70? C. to 170? C. (preferably 120? C.) for 20 to 30 minutes. After this time, the final mixture is sent to a resting silo, where it is subsequently bagged.

[0027] Any change in the time and temperature ranges of the manufacturing method will cause gradual loss of results in the final product, and it is always recommended to use the preferred temperature and time indicated. As a more extreme example, if the heating temperature of the mixture is exceeded, the components may burn and, as a consequence, the hydrophobic, waterproofing, and strength results of the concrete additive may be lost.

[0028] To understand the manufacturing process of the concrete additive better, FIG. 2 shows an example of machinery that can be used in the manufacture of the additive. The raw material is poured into the feed screw (1), where it is transported via the worm screw (2) to the heating mixer (3), where mixing and heating occurs as mentioned above. After this step, the mixture is transported by the endless screw (4) to the silo (5) where the final mixture is stored to be bagged by the bagging machine (6).

[0029] Although the additive shows the improvements reported above when manufactured following the ranges stipulated above, the optimal results are achieved with the following composition: [0030] 43% mortar AC; [0031] 27% cement CP2; [0032] 20% calcium carbonate [0033] 5% active microsilica [0034] 4% calcium stearate; [0035] 1% formula (A);

[0036] Not only can the dosage ranges of the mixture components be changed, but also the components themselves can be replaced by similar ones. However, the components described above were the ones that showed the best results.

[0037] Following this line of thought, the mortar can be chosen among the classifications AC1, AC2 and AC3, depending on the type of application. Taking as an example, the AC1 classification is usually used for laying ceramic tiles and floors, while AC2 is chosen when the use is for outdoor environments and, finally, AC3 is the most adherent of the three and is commonly used for laying linings in hot water pools or saunas.

[0038] All types of Portland cement can be used. However, the best results were achieved with the type CP2. Depending on the type of application, Portland cement CP2 can be replaced by, for example, types CP1 (common), CP3 (blast furnace), CP4 (pozzolanic), CP V-ARI (high early strength), etc.

[0039] Calcium carbonate, also known as calcite, is a chemically inert, inorganic mineral extracted from mines and refined in various granulometric ranges according to the desired application. It has the function of helping in waterproofing and has encapsulated water-repellent characteristics.

[0040] Calcium stearate is the hydrophobic and waterproofing compound that can be replaced by: unsaturated fatty acids and their salts, with chains from C10 to C24, which can be stearic acid, magnesium stearate, sodium stearate, potassium stearate, fumaryl stearate, zinc stearate, aluminum stearate, and salts of transition metals. The following can also be used as hydrophobic compounds: silane, siloxanes, silicone, or a mixture of these.

[0041] Regarding the physical property, the calcium stearate or substitute material should have the average particle size (D50), when in the solid state, should be 100 nm to 50 ?m, more preferably in the nanometer scale of 400 nm to 2000 nm.

[0042] The active microsilica is responsible for blocking concrete pores, since microsilica particles are 50 to 100 times smaller than cement grains and, depending on the degree of dispersion, fill up to 100% of the voids between them, making the concrete denser and thus ensuring lower permeability, excellent thixotropy, and strength by ensuring improved void filling, which significantly improves concrete resistance.

[0043] Microsilica can be replaced by: talc, pozzolans, graphite, graphene oxide, aluminosilicates such as bentonite, silicates, granulated blast furnace slag, calcined clays, fly ash, metakaolinite, calcite, aragonite, solid greases, and acrylic emulsions.

[0044] The pore blocker (the microsilica or its substitutes), should be thinly divided; the average particle size (D50) should be 500 nm to 100 ?m.

[0045] In addition to the components described above, the current invention also discloses other concretizations where superplasticizer components are added, from 3% to 30% by mass and/or defoamers from 1% to 10% by mass and/or 0.2% to 1% by mass of graphene. The addition of these components is done at the time of mixing all the components, participating in the mixing and heating step along with the other components.

[0046] The superplasticizer can be one of the following (or a mixture of them): lignosulfonate, naphthalene formaldehyde sulfonate, melamine formaldehyde sulfonate, polycarboxylate esters.

[0047] The anti-foam can be one of the following components (or a mixture of them): mineral oil, silicone oil, vegetable oil, polyethylene glycol, polypropylene glycol, and polymethylacrylate.

[0048] Finally, the graphene is responsible for the improvement in the flexural resistance of the concrete, which can be more than 20% higher than concrete without the additive, depending on the dosage of additive used in the concrete.

[0049] As an example of complementary composition, we can cite: [0050] 42% AC mortar; [0051] 27% cement CP2; [0052] 20% calcium carbonate [0053] 5% active microsilica [0054] 4% calcium stearate; [0055] 1% formula A; [0056] 1% graphene.

[0057] The application of the concrete additive is done in the concrete mixer, and first the concrete without additive must be homogenized. After this homogenization, add the additive and homogenize for another 10 minutes, and then it is ready for the final application.

[0058] The recommended dosage of water repellent and waterproofing additive varies according to its application. Some of the most common applications are found in the spreadsheet in FIG. 2.