Cellular concrete having normal compressive strength
First Claim
1. A method of sequentially using surfactants for producing pre-pour air-filled bubbles during mixing of fresh concrete and of including a selected amount of aluminum in said matrix for producing post-pour hydrogen-filled bubbles, whereby said post-pour bubbles replace a portion of said pre-pour bubbles which are destroyed during casting of said fresh concrete to form cellular concrete.
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Abstract
A method for producing hardened cellular concrete having normal compressive strength by producing tiny, unconnected, pre-pour, air-filled bubbles during mixing of cement, cementitious substitutes, sand, coarse aggregates, water, fiber, a surfactant, aluminum flakes or powder, calcium formate, and magnesium silico fluoride and then producing additional tiny, unconnected, post-pour, hydrogen-filled bubbles to replace those air-filled bubbles which are destroyed while pouring the fresh concrete during the casting operation. Only as much matrix is added to the coarse aggregate as is needed to engulf the aggregates while enabling the aggregate particles to be in contact.
45 Citations
23 Claims
- 1. A method of sequentially using surfactants for producing pre-pour air-filled bubbles during mixing of fresh concrete and of including a selected amount of aluminum in said matrix for producing post-pour hydrogen-filled bubbles, whereby said post-pour bubbles replace a portion of said pre-pour bubbles which are destroyed during casting of said fresh concrete to form cellular concrete.
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19. A method for ascertaining the exact amount of a preferred matrix to be added to a mixture of aggregates, thereby ascertaining the optimum value of the volume ratio of cementitious matrix to said aggregates, whereby said aggregates will be in contiguous contact with the interstices between said aggregrates filled with and surround by said matrix, according to the following steps:
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a) provide a container of predetermined volume;
b) fill said container to the top thereof with desired amounts of aggregates;
c) gently compact said aggregates and add sufficient additional aggregates to coincide with the top of said container;
d) fill said container to overflowing with water, wait for said aggregates to be saturated with said water, if the water level falls below the plane coinciding to the opening at the top of the container, then add additional water to overflow said container;
e) remove said water from said mold and measure its volume;
f) add said volume of said matrix to said aggregates in said container, thereby forming fresh concrete; and
g) subject said fresh concrete in said container to vibration in order to remove voids and then, if necessary, add additional matrix so that said container is exactly filled to the top of said container. - View Dependent Claims (20, 21)
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22. A method of making a fiber reinforced lightweight high strength cellular concrete casting having a cured weight of under ninety pounds per cubic foot, which comprises the steps of:
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(1) entraining air in a concrete slurry in the presence of a surfactant to form an aerated concrete slurry having a cementitious cellular structure;
(2) casting the aerated concrete of step 1 in admixture with an in situ hydrogen-gas generating composition present in an amount such that hydrogen gas evolution during casting substantially maintains the cementitious cellular structure of the aerated concrete slurry produced in step 1 during the step of casting.
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23. A fiber reinforced lightweight high strength cellular concrete casting having a cured weight of under ninety pounds per cubic foot, made by the process of:
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(1) entraining air in a concrete slurry in the presence of a surfactant to form an aerated concrete slurry having a cementitious cellular structure;
(2) casting the aerated concrete of step 1 in an admixture with an in situ hydrogen-gas generating composition present in an amount such that hydrogen gas evolution during casting substantially maintains the cementitious cellular structure of the aerated concrete slurry produced in step 1 during the step of casting.
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Specification