Coated-fine-aggregate, concrete composition and method

• US 10,266,450 B2
• Filed: 05/16/2018
• Issued: 04/23/2019
• Est. Priority Date: 07/01/2014
• Status: Active Grant

• Current Assignee: AquaSmart Enterprises, LLC
• Original Assignee: AquaSmart Enterprises, LLC
• Inventors: Hendrickson, Calder, Naff, Todd
• Primary Examiner(s): Chin, Hui H
• Application Number:
  US15/981,314
• Publication Number:
  US 20180257988A1
• Time in Patent Office: 342 Days
• Field of Search: 524 4
• CPC Class Codes: B01J 20/262 obtained otherwise than by reactions only involving carbon to carbon unsaturated bonds, e.g. obtained by polycondensation macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds per se C08G
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: B28B 17/02 Conditioning the material prior to shaping for mixtures containing clay or cement B28C
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 16/04 Macromolecular compounds C04B16/02 takes precedence
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 20/1003 Non-compositional aspects of the coating or impregnation
• CPC Class Codes: C04B 20/1022 Non-macromolecular compounds
• CPC Class Codes: C04B 20/1033 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 20/107 Acids or salts thereof
• CPC Class Codes: C04B 2103/0051 Water-absorbing polymers, hydrophilic polymers
• CPC Class Codes: C04B 2103/0068 Ingredients with a function or property not provided for elsewhere in C04B2103/00
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2103/30 Water reducers, plasticisers, air-entrainers, flow improvers
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/58 Shrinkage reducing agents
• CPC Class Codes: C04B 2103/603 Agents for controlling alkali-aggregate reactions
• CPC Class Codes: C04B 2103/61 : Corrosion inhibitors
• CPC Class Codes: C04B 2103/65 : Water proofers or repellants
• CPC Class Codes: C04B 22/085 : containing nitrogen in the anion, e.g. nitrites
• CPC Class Codes: C04B 24/16 : Sulfur-containing compounds
• CPC Class Codes: C04B 24/2652 : Nitrogen containing polymers, e.g. polyacrylamides, polyacrylonitriles
• CPC Class Codes: C04B 24/287 : Polyamides
• CPC Class Codes: C04B 24/34 : Natural resins, e.g. rosin C04B24/243 takes precedence
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 40/0633 : Chemical separation of ingredients, e.g. slowly soluble activator
• CPC Class Codes: E04G 21/02 : Conveying or working-up concrete or similar masses able to be heaped or cast in connection with finishing work E04F; construction and surfacing of floorings made of similar material to roads or pavements E01C; in connection with barrages E02B7/00; in connection with foundations E02D15/00; composition of concrete C04B; working concrete in general, e.g. mixing machines B28C

Abstract

A concrete composition and method include a portion of fine aggregate bearing a coating of a polymer or an admixture, which may be a continuous coating layer or a layer of powdered, discrete particles embedded in a binder. The polymeric coating may be an admixture in powdered form, a super absorbent polymer (insoluble in water, but absorbing water), or another polymer such as the acrylamides, co-polymers thereof, polyacrylamides, or the like (soluble in water). The coating absorbs water, but particles are too small to form significant voids. Water is absorbed into the concrete mix in far greater proportions (e.g. w/c ratio over 0.5) improving workability, doubling workability time, and improving ultimate compressive stress (strength).

Claims

1. A composition comprising:

coarse aggregate comprising rocks of a comparatively larger size;

fine aggregate comprising granules of sand having an average maximum dimension substantially smaller than the coarse aggregate;

cement; and

admixture coated fine aggregate comprising a portion of the fine aggregate having the granules individually powder coated with a powder comprising an admixture.

2. The composition of claim 1, wherein the admixture coated fine aggregate constitutes less than about one tenth of the fine aggregate.

3. The composition of claim 2, wherein the powder is bound by a binder to the granules individually, as a substrate.

4. The composition of claim 1, wherein the admixture coated fine aggregate further comprises a shell.

5. The composition of claim 1, wherein the powder is comprised of at least two admixture powders selected from a lignosulfate, a nitrite salt, a natural wood resin, a polyacrylamide (PAM), and a super absorbent polymer (SAP).

6. The composition of claim 5 further comprising a binder binding the contact portions of the powder to the substrate, wherein the binder is a liquid admixture.

7. The composition of claim 1, constituted from parts proportioned by weight, wherein:

the cement constitutes an amount of from about one and a half to about two and a half parts;

the fine aggregate constitutes from about 3 to about 5 parts;

the coarse aggregate constitutes from about 3 to about 5 parts;

the water constitutes from about 1.25 to about 2 parts.

8. A method of combining constituents, the method comprising:

selecting a coarse aggregate comprising rocks of a comparatively larger size;

selecting a fine aggregate comprising granules of sand substantially smaller than the rocks;

selecting a cement;

selecting an admixture comprising a powder having particles, dry, discrete, and comminuted to a size smaller than the granules; and

coating, by powder coating, a portion of the fine aggregate with the admixture in a manner that maintains the portion as individual granules.

9. The method of claim 8, further comprising:

coating, by powder coating, the portion of the fine aggregate with a second admixture comprising a powder having particles, dry, discrete and comminuted to a size smaller than the granules.

10. The method of claim 8, further comprising:

coating the portion of the fine aggregate with a shell.

11. The method of claim 8, wherein the admixture comprises two admixture component powders selected from the group consisting of accelerators, corrosion inhibitors, shrinkage reducers, superplasticizers, water reducers, retarders, alkali silica reactivity inhibitors, biopolymers, viscosity modifiers, air entrainment compounds, polyacrylamides, and superabsorbent polymers.

12. The method of claim 11, further comprising:

coating the portion of the fine aggregate with a shell, wherein the shell is an admixture.

13. The method of claim 8, further comprising:

washing the fine aggregate after selecting the fine aggregate.

14. A method of providing a coated fine aggregate, the method comprising:

selecting a fine aggregate comprising granules having an average effective diameter effectively equivalent to an average effective diameter of sand;

selecting an admixture comprising a powder having particles, dry, discrete, and comminuted to a size smaller than the granules; and

coating, by powder coating, the fine aggregate with the admixture in a manner that maintains the fine aggregate as individual granules.

15. The method of claim 14, wherein the admixture is selected from the group consisting of accelerators, corrosion inhibitors, shrinkage reducers, superplasticizers, water reducers, retarders, alkali silica reactivity inhibitors, biopolymers, viscosity modifiers, air entrainment compounds, waterproofing agents, polyacrylamides, and superabsorbent polymers.

16. The method of claim 14, further comprising:

washing the fine aggregate after selecting the fine aggregate.

17. The method of claim 14, further comprising:

coating the fine aggregate with a shell, wherein the shell is an admixture.

18. The method of claim 16, further comprising:

coating, by powder coating, the fine aggregate with a second admixture comprising a powder having particles, dry, discrete, and comminuted to a size smaller than the granules in a manner that maintains the fine aggregate as individual granules.

19. The method of claim 14, further comprising:

washing the fine aggregate after selecting the fine aggregate; and

applying a binder to the fine aggregate before coating the fine aggregate with the admixture, wherein the binder is a liquid admixture.

20. The method of claim 14, further comprising:

curing the fine aggregate after coating the fine aggregate with the admixture.