Coated-fine-aggregate, concrete composition and method

• US 10,618,843 B2
• Filed: 04/17/2019
• Issued: 04/14/2020
• Est. Priority Date: 07/01/2014
• Status: Active Grant

• Current Assignee: AquaSmart Enterprises, LLC
• Original Assignee: AquaSmart Enterprises, LLC
• Inventors: Hendrickson, Calder
• Primary Examiner(s): Chin, Hui H
• Application Number:
  US16/386,686
• Publication Number:
  US 20190308907A1
• Time in Patent Office: 363 Days
• Field of Search: 264122
• 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

lightweight aggregate, the lightweight aggregate selected from the group consisting of;

an organic material that tends to absorb water, and a highly porous solid material that has sufficient capillary action to absorb and store water, wherein the lightweight aggregate further comprises a shell around the lightweight aggregate.

2. The composition of claim 1, further comprising:

coated fine aggregate, comprising a portion of the fine aggregate and having the granules individually powder coated with a super-absorbent polymer powder.

3. The composition of claim 1, wherein the lightweight aggregate constitutes about one tenth of the composition by weight.

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

5. The composition of claim 3, wherein the coated fine aggregate constitutes less than about one tenth of the fine aggregate.

6. The composition of claim 2, wherein the super-absorbent polymer powder is bound by a binder to the granules individually.

7. The composition of claim 2, wherein the coated fine aggregate further comprises a second layer individually powder coated after the super-absorbent polymer powder and the second layer is a powder selected from the group consisting of:

a lignosulfate, a nitrite salt, a natural wood resin, a poly-acrlyamide, and a second super-absorbent polymer.

8. 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

coated fine aggregate, comprising a portion of the fine aggregate and having the granules individually powder coated with a super-absorbent polymer powder.

9. The composition of claim 8, wherein the coated fine aggregate constitutes less than about one tenth of the fine aggregate.

10. The composition of claim 9, further comprising a shell around the coated fine aggregate.

11. The composition of claim 8, wherein the super-absorbent polymer powder is bound by a binder to the granules individually.

12. The composition of claim 8, wherein the coated fine aggregate further comprises a second layer individually powder coated after the super-absorbent polymer powder and the second layer is a powder selected from the group consisting of:

a lignosulfate, a nitrite salt, a natural wood resin, a poly-acrlyamide, and a second super-absorbent polymer.

13. A method for 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 a first powder having particles, dry, discrete, and comminuted to a size smaller than the fine aggregate; and

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

14. The method according to claim 13, wherein the first powder is selected from the group consisting of:

an accelerator, a corrosion inhibitor, a shrinkage reducer, a superplasticizer, a water reducer, a retarder, an alkali silica reactivity inhibitor, a biopolymer, a viscosity modifier, an air entrainment compound, a waterproofing agent, a polyacrylamide, and a super-absorbent polymer.

15. The method according to claim 13, further comprising:

washing the fine aggregate after selecting the fine aggregate; and

sieving the fine aggregate after washing the fine aggregate.

16. The method according to claim 15, further comprising:

coating the fine aggregate with a shell.

17. The method according to claim 15, further comprising:

curing the fine aggregate after coating the fine aggregate.

18. The method according to claim 15, further comprising:

selecting a second powder having particles, dry, discrete, and comminuted to a size smaller than the fine aggregate, wherein the second powder is different from the first powder and selected from the group consisting of;

an accelerator, a corrosion inhibitor, a shrinkage reducer, a superplasticizer, a water reducer, a retarder, an alkali silica reactivity inhibitor, a biopolymer, a viscosity modifier, an air entrainment compound, a waterproofing agent, a polyacrylamide, and a super-absorbent polymer; and

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