FORMULATION BASED ON HYDRAULIC CEMENT ADDED WITH AMORPHOUS GLASSES AND MICRO-SPHERES FOR PRODUCTS OF REPAIR, MAINTENANCE OR REHABILITATION OF CONCRETE STRUCTURES

Abstract

The present invention refers to a base formulation which serves to form a final product intended for the repair, maintenance or rehabilitation of concrete structures. Primarily, the base formulation contains cement in a percentage of 35% to 45% by weight of the final product. The base formulation also possesses amorphous glass in a proportion of 20% to 30% by weight of the final product, in ground from common glass, recycled glass or soda-lime glass. Finally, the base formulation may further possess solid quartz microspheres in a proportion of 10% to 20% by weight of the final product. This provides the final product with many desirable properties, such as high mechanical strength; high chemical resistance; easier application; easier ability to polish; prevents cold seals, leaving the final product thermally and dimensionally stable, among other desirable properties. The final products may include concrete correctors, waterproofing agents, coatings, among others.

Claims

1. A base formulation that serves to form a final product aimed at the repair, maintenance or rehabilitation of concrete structures, the base formulation comprising: cement in a percentage of 35% to 45% by weight of the final product; amorphous glasses in a percentage of 20% to 30% by weight of the final product, and solid microspheres in a percentage of 10% to 20% by weight of the final product.

2. The base formulation according to the claim 1, wherein the amorphous glass is ground from common glass, recycled glass or soda-lime glass.

3. The base formulation according to claim 1, wherein the solid microspheres are quartz.

4. The base formulation according to claim 1, wherein the final product contains additives from 1% to 5% by weight.

5. The base formulation according to claim 1, wherein the final product may include polymeric fibers in proportions less than 1% by weight.

6. The base formulation according to claim 1, wherein the size range of the amorphous glass is less than 180 microns.

7. The base formulation according to claim 6, wherein the size of the amorphous glass is distributed such that the particles of 180 microns comprise 2.56%, particles of 150 microns comprise 3.98%, particles of 125 microns comprise 9.66%, particles of 90 microns comprise 15.63%, particles of 63 microns comprise 11.08%, particles of 45 microns comprise 4.93%, and particles smaller than 45 microns comprise 52.19%.

8. The base formulation according to claim 1, wherein the size range of solid microspheres is less than 600 microns.

9. The base formulation according to claim 8, wherein the final product is a concrete corrector or a waterproofing agent.

10. The base formulation according to claim 8, wherein the size of solid microspheres is distributed such that the particles of 600 microns comprise 20.00%, particles of 300 microns comprise 4.38%, particles of 180 microns Comprise 5.78%, particles of 125 microns comprise 30.73%, particles of 105 microns comprise 10.93%, particles of 90 microns comprise 9.93%, particles of 75 microns comprise 5.97%, particles of 63 microns comprise 6.04%, particles of 53 microns comprise 2.36%, particles of 45 microns comprise 1.92%, and particles smaller than 45 microns comprise 1.98%

11. The base formulation according to claim 1, wherein the size range of solid microspheres is less than 180 microns.

12. The base formulation according to claim 11, wherein the end product is a coating.

13. The base formulation according to claim 12, wherein the coating may form layers less than 1 mm thick.

14. The base formulation according to claim 11, wherein the size of solid microspheres is distributed such that the particles of 180 microns comprise 6.88%, particles of 125 microns comprise 40.98%, particles of 105 microns Comprise 14.57%, particles of 90 microns comprise 13.24%, particles of 75 microns comprise 7.95%, particles of 63 microns comprise 8.05%, particles of 53 microns comprise 3.14%, particles of 45 microns comprise 2.56% and particles smaller than 45 microns comprise 2.63%

15. The base formulation according to claim 1, wherein the fibers in the final product achieve the function of binding the elements and increasing the flexural strength.

16. The base formulation according to claim 1, wherein the cement may comprise fast-curing cement.

17. The base formulation according to claim 1, wherein a variation between final products is due to the combination of different additives.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] To provide a better understanding of the tester device of the invention, the following drawings are appended:

[0021] FIG. 1 corresponds to a graphical representation of the structure of a formulation based on hydraulic cement mixed with prior-art amorphous glasses.

[0022] FIG. 2 corresponds to a graphical representation of the structure of a prior-art hydraulic cement-based formulation with microspheres.

[0023] FIG. 3 corresponds to a graphical representation of the structure of a formulation based on hydraulic cement added with amorphous glasses and microspheres in accordance with the present invention.

[0024] FIG. 4 corresponds to a graphical representation of the structure of the final product formed with the formulation based on hydraulic cement, mixed with amorphous glasses and microspheres in accordance with the present invention.

DETAILED DESCRIPTION

[0025] The present invention will be described herein in accordance with a preferred embodiment and supported by the accompanying figures. FIGS. 1 and 2 are graphical representations of the structure of a hydraulic cement-based formulation combined with either amorphous glasses or crystals and with microspheres, respectively. In the representation of FIG. 1, it is observed that the glass is amorphous and if it moves, there will be a great resistance to such movement due to its irregular shape. Meanwhile, in FIG. 2, the presence of the spheres facilitates the interstitial movement of the cement-based mixtures. Also, it is known that microspheres, when hollow, can provide density reduction, thermal insulation and sound insulation properties. FIG. 3 demonstrates that the presence of solid spheres facilitates the movement of the glass and makes application much simpler, requiring less effort.

[0026] The present invention consists of a base formulation serving to produce a multitude of products for repair, maintenance or rehabilitation of concrete structures. These products may include concrete correctors, waterproofing, coatings, among others. The variation between one product and another is due to the combination of different additives for the formation of the final product. Therefore, variability between these and other products which utilize the base formulation is within the scope of the present invention.

[0027] Thus, the base formulation consists of a combination of hydraulic cement with amorphous glass or crystals and solid microspheres. In the preferred embodiment, the amorphous glass is crushed or milled from common glass, recycled glass or soda-lime glass. Preferably, the amorphous glass is used in a proportion of 20% to 30% by weight of the final product. Likewise, in the preferred embodiment, the solid microspheres are quartz. Preferably, the solid microspheres make up 10% to 20% by weight of the final product. Preferably, the remainder of the final product has cement from 35% to 45% by weight and additives from 1% to 5% by weight. Additionally, the final product may include polymeric fibers in proportions less than 1% by weight of the final product.

[0028] Now then, the particle size or granulometry of the amorphous glass and the solid microspheres is relevant to the invention, since its size variation produces an important synergistic effect. The variation in the size of the amorphous glasses allows a mechanical resistance, while the size variation of the solid microspheres allows them to settle into the interstitial spaces that form between the hydraulic cement and the amorphous glass, such as illustrated in FIG. 3. Thus, in the preferred embodiment, the range of amorphous glass is less than 180 microns. On the other hand, a first embodiment of the base formulation has a range of solid microspheres less than 600 microns and a second embodiment of the base formulation has a range of solid microspheres less than 180 microns. Thus, the first embodiment is primarily used in concrete corrective and waterproofing products, while the second embodiment is mainly used in the coating product where the final product can form films less than 1 mm thick.

[0029] Moreover, the percentage distribution of grain size or granulometry is relevant, since a predominant size of each component adequately achieves the combined effect. In an exemplary embodiment, the percentage distribution of the particle size of the amorphous glasses is outlined in Table 1 below:

TABLE-US-00001 TABLE 1 Distribution of granulometry of amorphous glass in an exemplary embodiment. Granulometry % of (Microns) distrubution 180 2.56% 150 3.98% 125 9.66% 90 15.63% 63 11.08% 45 4.93% <45 52.19%

[0030] In turn, Table 2 below illustrates the percentage distribution of the granulometry of the solid microspheres for the first embodiment:

TABLE-US-00002 TABLE 2 Distribution of granulometry of solid microspheres in the first embodiment. Granulometry % of (Microns) distrubution 600 20.00% 300 4.38% 180 5.78% 125 30.73% 105 10.93% 90 9.93% 75 5.97% 63 6.04% 53 2.36% 45 1.92% <45 1.98%

[0031] Finally, Table 3 below demonstrates the percentage distribution of the granulometry of the solid microspheres for the second embodiment:

TABLE-US-00003 TABLE 3 Distribution of granulometry of microspheres in the second embodiment. Granulometry % of (Microns) distrubution 180 6.88% 125 40.98% 105 14.57% 90 13.24% 75 7.95% 63 8.05% 53 3.14% 45 2.56% <45 2.63%

[0032] According to FIG. 4, a graphic representation of a finished final product can be observed, which includes in its composition the base formulation. In the representation, different amorphous glasses, microspheres and additives such as fibers can be observed. As already explained above, with the different sizes and distributions in both the amorphous glasses and crystals as well as in the solid quartz microspheres the formulation of the present invention enables the interstitial spaces to be optimally sealed off. In addition, the fibers present in the final product enable the bonding of the elements, increasing flexural strength. The fiber content and characteristics of the fiber that will be used in the different final products will also depend on the use for which it is intended.

[0033] In another final product, the cement may comprise fast-curing cement with a smaller particle size than normal cement. This type of fast-curing cement works very well with the base formulation object of the present invention since instead of using aggregates such as gravel and sands, soda-lime glass and microspheres of different granulometries are used to better seal the spaces, additives and fibers.

[0034] As mentioned above, solutions that exist in the market contain some of the components that are mentioned individually, such as fast-curing cement or fiber; however, none of them use soda-lime glasses or quartz microspheres. These give the present solution unique properties, such as: high mechanical strength, high chemical resistance, ease of application and polishing of the resulting surface, as well as sealing the spaces with microspheres, which is what allows the final product to have a very low water absorption and therefore have a minimum permeability to it. In turn, this technology does not form a cold seal (as long as the proper procedure is used to scarify the surface) of the products with the old surfaces, allowing perfect adhesion between the two and ensuring that the selected product meets the desired characteristics depending on the desired use of the surface. The replacement of the aggregates normally used in the glass building industry is beneficial since it does not cause significant changes in the density of the concrete. This is because the glass has a density of the same order as the commonly used aggregates, depending on their production characteristics. In addition, it has a very low water absorption and does not exhibit crystalline silica since it was processed prior for the preparation of the glasses. Like glass, the quartz microspheres are free of crystalline silica and because they make up a substantial percentage of 10% to 20%, they reduce the risk of contracting any illnesses that may be caused by overexposure or continuous use of this material.

[0035] Based on the foregoing disclosure, certain embodiments and details have been described in order to illustrate the present invention, and it will be apparent to those skilled in the art that variations and modifications may be made without departing from the scope of the present invention.