US 12,441,658 B2Granted

Non-hydration strength in cementitious compositions

AssigneeGCP Applied Technologies Inc.

InventorsByong-Wa Chung, Nathan A. Tregger, Elise Berodier, Elizabeth Burns, Ernie Rocha, Ezgi Wilson, Mark F. Roberts

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Abstract

Described are compositions and methods for controlled strength development in a hydratable cementitious material, and more particularly to the use of polymerizable monomer components, which are initiated and activated by a redox pair which are mixed in controlled fashion, for enhancing non-hydration strength within the matrix of the plastic hydratable cementitious material before setting of the cementitious material begins. Exemplary applications include minimizing pressures on formwork for high fluid ready-mix applications, enhancing support and bonding properties for integrated concrete slab work and other sequential applications, or facilitating speedy 3D printing applications, among other unique possibilities.

Claims20

Dependent claims

A method for achieving non-hydration strength in a cementitious composition, comprising:

(A) providing a settable composition comprising a hydratable cementitious binder, a plurality of aggregates, and water in an amount effective to establish a hydrating cementitious matrix;
(B) providing a polymerizable component system comprising (i) an ethylenic monomer having at least one hydrophilic group, (ii) at least one cross-linker monomer;
and (iii) a first component of a two-component reduction-oxidation (“redox”) system, to establish a cross-linking system within the hydrating cementitious matrix;
(C) mixing together the settable composition, the polymerizable component system, and a second component of the redox system such that the first and second components of the redox system become mixed together to activate cross-linking of the polymerizable component system within the hydrating cementitious matrix of the settable composition;
and
(D) flowing the mixture from step (C) through a nozzle, into a concrete formwork or mold, or along a chute and into a concrete formwork or mold, whereby the polymerizable component system undergoes polymerization within the hydrating settable cementitious matrix, wherein
the mixing of the settable composition of step (A) and the polymerizable component system of step (B) is accomplished using a batch mixer or continuous mixer, and the second component of the redox system of step (C) is introduced into the settable composition after the mixing of the settable composition with the polymerizable component system, the method increases the non-hydration strength before setting of the cementitious composition begins;
and
the ethylenic monomer having at least one hydrophilic group is 2-acrylamido-2-methylpropane sulfonic acid (“AMPS”) monomer, and the cross-linker monomer is N,N′-methylene bis(acrylamide) (“bis-AAm”), and the weight ratio of AMPS:bis-AAm is from 5:95 to 99.9:0.1.

6 more elements

A method for achieving non-hydration strength in a cementitious composition, the method comprising the steps of:

(A) providing a settable composition comprising a hydratable cementitious binder, a plurality of aggregates, and water in an amount effective to establish a hydrating cementitious matrix;
(B) providing a polymerizable component system comprising (i) an ethylenic monomer having at least one hydrophilic group, (ii) at least one cross-linker monomer;
and (iii) a first component of a two-component reduction-oxidation (“redox”) system, to establish a cross-linking system within the hydrating cementitious matrix;
(C) mixing together the settable composition, polymerizable component system, and a second component of the redox system, such that the first and second components of the redox system become mixed together to activate cross-linking of the polymerizable component system within the hydrating cementitious matrix of the settable composition;
and
(D) flowing the mixture from step (C) through a hose and a nozzle whose position and movement, along with emission through the nozzle of the mixed settable composition and polymerizable component system are controlled by a processor, whereby
the polymerizable component system undergoes polymerization within the hydrating settable cementitious matrix;
extruding through the nozzle a first layer comprising the settable composition and component system undergoing polymerization;
and
extruding through the nozzle a second layer of settable composition and component system undergoing polymerization onto the first layer to build a three-dimensional structure, wherein the method increases the non-hydration strength before setting of the cementitious composition begins.

7 more elements

A method for achieving non-hydration strength in a cementitious composition, comprising:

(A) providing a settable composition comprising a hydratable cementitious binder, a plurality of aggregates, and water in an amount effective to establish a hydrating cementitious matrix;
(B) providing a polymerizable component system comprising (i) an ethylenic monomer having at least one hydrophilic group, (ii) at least one cross-linker monomer;
and (iii) a first component of a two-component reduction-oxidation (“redox”) system, to establish a cross-linking system within the hydrating cementitious matrix;
(C) mixing together the settable composition, the polymerizable component system, and a second component of the redox system such that the first and second components of the redox system become mixed together to activate cross-linking of the polymerizable component system within the hydrating cementitious matrix of the settable composition;
and
(D) flowing the mixture from step (C) through a nozzle, into a concrete formwork or mold, whereby the polymerizable component system undergoes polymerization within the hydrating settable cementitious matrix, wherein
the mixing of the settable composition of step (A) and the polymerizable component system of step (B) is accomplished using a batch mixer or continuous mixer, and the second component of the redox system of step (C) is introduced into the settable composition after the mixing of the settable composition with the polymerizable component system, the method increases the non-hydration strength before setting of the cementitious composition begins;
and
in step D, the settable composition mixed with the polymerizable component system having first and second components of the redox system is extruded onto previously extruded settable composition using a 3D printer device.

6 more elements

A method for achieving non-hydration strength in a cementitious composition, comprising:

(A) providing a settable composition comprising a hydratable cementitious binder, a plurality of aggregates, and water in an amount effective to establish a hydrating cementitious matrix;
(B) providing a polymerizable component system comprising (i) an ethylenic monomer having at least one hydrophilic group, (ii) at least one cross-linker monomer;
and (iii) a first component of a two-component reduction-oxidation (“redox”) system, to establish a cross-linking system within the hydrating cementitious matrix;
(C) mixing together the settable composition, the polymerizable component system, and a second component of the redox system such that the first and second components of the redox system become mixed together to activate cross-linking of the polymerizable component system within the hydrating cementitious matrix of the settable composition;
and
(D) flowing the mixture from step (C) through a nozzle, into a concrete formwork or mold, or along a chute and into a concrete formwork or mold, whereby the polymerizable component system undergoes polymerization within the hydrating settable cementitious matrix, wherein
the mixing of the settable composition of step (A) and the polymerizable component system of step (B) is accomplished using a batch mixer or continuous mixer, and the second component of the redox system of step (C) is introduced into the settable composition after the mixing of the settable composition with the polymerizable component system, the method increases the non-hydration strength before setting of the cementitious composition begins;
and
in step (D), the mixture of the settable composition and polymerizable component system, along with the mixed first and second redox pair, are flowed into a concrete formwork to form a first layer of an integrated concrete slab system;
and, while the first layer is still in a plastic state, casting onto the first layer a second layer comprising concrete comprising fibers chosen from polymer, metal, or both, to achieve an integrated concrete slab structure.

7 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/270,565Filed 29 Aug 2019 · us provisional application
Priority: 29 Aug 2018
Published: US 2021/0355031 A118 Nov 2021
Granted: 14 Oct 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification22 codes

C04B 28/02
Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic…
C04B 28/04
Containing hydraulic cements other than calcium sulfates: portland cements
B28C 5/4258
Discharging; Concrete conveyor means, chutes or spouts therefor: using pumps or transporting screws
B28C 7/128
Supply means, e.g. nozzles: nozzles; Valves; Valve-actuating means