Low density cellular concrete with accelerators for rapid hardening
OwnerClinton D. Dattelinventor
Life of this patent
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Abstract
Compositions and methods are provided for creating a low density cellular concrete that has a viscosity which rapidly increases after adding an accelerator, while maintaining substantially the same density. The initial components include a cement, water, a surfactant to create a foam, and an accelerator such as sodium carbonate. The accelerator serves to rapidly increase the viscosity of the mixture, thereby entrapping the foam or air within the matrix of the mixture before air can escape. An additional embodiment includes using a byproduct such as fly ash in the composition to further reduce costs and make an environmentally friendly product.
Claims20
A cellular concrete composition, comprising in total % by weight:
- a) 15-68 lime cement;
- b) 20-42 water;
- c) 0.1-1.0 non-ionic surfactant foaming agent;
- d) 0.01-10 sodium carbonate as an accelerator;
- and
- e) 12-65 fly ash;
- wherein said composition has a compressive strength of at least 32 psi after a cure period of about 12 hours at a temperature of about 70-72 degrees Fahrenheit.
A rapid set concrete composition comprising in total % by weight:
- a) a Portland cement in the amount of 50 to 68;
- b) a water in the amount of 30 to 41;
- c) a non-ionic surfactant in the amount of 0.2 to 0.4;
- d) a sodium carbonate accelerator in the amount of 0.3 to,6.0;
- and
- e) a fly ash in the amount of 12 to 19.5.
A rapid set concrete which maintains a substantially constant viscosity during hardening, comprising in % total by weight:
- a) a Portland cement in the amount of 12-68;
- b) a type f fly ash in the amount of 12-50;
- c) a water in the amount of 30-45;
- d) a non-ionic surfactant in the amount of 0.01.-0.33;
- and,
- e) a sodium carbonate accelerator in the amount of 0.05-6;
- wherein said concrete has a density of less than about 55 pounds per cubic foot after curing.
A method for making a cellular concrete with a density of less than about 60 pounds per cubic foot, comprising the steps of:
- a) mixing 12-68 total % by weight of a lime cement with 12-50 total % by weight of a fly ash with 20-34 total % by weight of water to create a liquid cement mixture;
- b) mixing 0.01-0.33 total % by weight of a non-ionic surfactant with 7-11 total % by weight of water to create a foam;
- c) mixing said liquid cement mixture with said foam to create a low density liquid concrete;
- and,
- d) mixing 0.05-6 total % by weight of dry sodium carbonate accelerator with said low density liquid concrete to increase the viscosity of said low density liquid concrete.
A method of making a rapid-set low density cellular concrete with a density of less than about 55 pounds per cubic foot, comprising the steps of:
- a) mixing a cement in the amount of 12-75 total % by weight, with a fly ash in the amount of 12-75 total % by weight, and a sodium carbonate or sodium bicarbonate accelerator in the amount of 0.3-3.5 % by weight of said cement used, to create a dry cellular concrete mixture;
- b) mixing a non-ionic surfactant in the amount of 0.1-0.5 total % by weight, with water in the amount of 1-12 total % by weight, to create a foam;
- and
- c) mixing said dry cellular concrete mixture with additional water in the amount of 15-50 total % by weight with said foam to create a low density liquid concrete that rapidly sets to become said rapid-set low density cellular concrete.
Dependencies are inferred from the claim text.