HIGHLY WORKABLE CONCRETE COMPOSITIONS HAVING MINIMAL BLEEDING AND SEGREGATION

• US 20090158960A1
• Filed: 10/08/2008
• Published: 06/25/2009
• Est. Priority Date: 12/20/2007
• Status: Abandoned Application

• Current Assignee: iCrete LLC
• Original Assignee: iCrete LLC
• Inventors: Andersen, Per Just, Hodson, Simon K.
• Application Number:
  US12/247,308
• Publication Number:
  US 20090158960A1
• Time in Patent Office: Days
• US Class Current: 106/15.50
• CPC Class Codes: C04B 14/04 Silica-rich materials; Silicates
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 2103/0053 Water-soluble polymers
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2103/61 Corrosion inhibitors
• CPC Class Codes: C04B 2103/65 Water proofers or repellants
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 2103/69 Fungicides
• CPC Class Codes: C04B 24/12 Nitrogen containing compounds organic derivatives of hydrazine hydrazine C04B22/00
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates

Abstract

Concrete compositions have a fine-to-coarse aggregate ratio optimized for increased workability with minimal segregation and bleeding. The concrete compositions include at least water, cement, coarse aggregate, and fine aggregate and have a slump of at least 1 inch and a 28-day compressive strength of at least about 1500 psi. Workability is improved by minimizing the viscosity as a function of the aggregate content, while minimizing segregation and bleeding. To improve workability, the concrete compositions include between 45% and 65% fine aggregate and between 35% and 55% coarse aggregate as a function of total aggregate volume. For relatively low strength concrete (1500-4500 psi), the fine aggregate is 55-65% of the total aggregate volume. For medium strength concrete (4500-8000 psi), the fine aggregate is 50-60% of the total aggregate volume. For high strength concrete (>8000 psi), the fine aggregate is 45-55% of the total aggregate volume. Overall workability can be maintained or improved even if slump is decreased.

Claims

1. A fresh concrete composition having high workability with relatively reduced segregation or bleeding, comprising:

hydraulic cement;

water;

fine aggregate having a volume in a first range between about 45% to about 65% of total aggregate volume; and

coarse aggregate having a volume in a second range between about 35% to about 55% of the total aggregate volume,

the concrete composition having a slump of at least 1 inch and a 28-day compressive strength after curing of at least 1500 psi,

the concrete composition having lower viscosity and greater cohesiveness compared to a concrete composition having a volume of fine aggregate immediately less than the first range and a volume of coarse aggregate immediately greater than the second range.

2. A fresh concrete composition as in claim 1, wherein the fine aggregate has a volume in a range of about 48.5% to about 61.5% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 38.5% to about 51.5% of the total aggregate volume.

3. A fresh concrete composition as in claim 1, wherein the fine aggregate has a volume between 50% to 60% of the total aggregate volume, and wherein the coarse aggregate has a volume between 40% to 50% of the total aggregate volume.

4. A fresh concrete composition as in claim 1, wherein the 28-day compressive strength after curing is in a range from 1500 psi to 4500 psi, wherein the fine aggregate has a volume in a range of about 55% to about 65% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 35% to about 45% of the total aggregate volume.

5. A fresh concrete composition as in claim 4, wherein the fine aggregate has a volume in a range of about 57.0% to about 64.0% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 36.0% to about 43.0% of the total aggregate volume.

6. A fresh concrete composition as in claim 4, wherein the fine aggregate has a volume in a range of about 58.0% to about 61.5% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 36.5% to about 42.0% of the total aggregate volume.

7. A fresh concrete composition as in claim 1, wherein the 28-day compressive strength after curing is in a range from 4500 psi to 8000 psi, wherein the fine aggregate has a volume in a range between 50% to 60% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range between 40% to 50% of the total aggregate volume.

8. A fresh concrete composition as in claim 7, wherein the fine aggregate has a volume in a range of about 51.0% to about 59.0% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 41.0% to about 49.0% of the total aggregate volume.

9. A fresh concrete composition as in claim 7, wherein the fine aggregate has a volume in a range of about 51.5% to about 58.5% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 41.5% to about 48.5% of the total aggregate volume.

10. A fresh concrete composition as in claim 1, wherein the 28-day compressive strength after curing is greater than 8000 psi, wherein the fine aggregate has a volume in a range of about 45% to about 55% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 45% to about 55% of the total aggregate volume.

11. A fresh concrete composition as in claim 10, wherein the fine aggregate has a volume in a range of about 46.0% to about 53.0% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 47.0% to about 54.0% of the total aggregate volume.

12. A fresh concrete composition as in claim 10, wherein the fine aggregate has a volume in a range of about 46.5% to about 52.0% of the total aggregate volume, and wherein the coarse aggregate has a volume in a range of about 48.0% to about 53.5% of the total aggregate volume.

13. A fresh concrete composition as in claim 1, wherein the slump is in a range of about 2 to about 12, as measured using a 12 inch slump cone according to ASTM C143.

14. A fresh concrete composition as in claim 1, wherein the slump is in a range of about 2 to about 8, as measured using a 12 inch slump cone according to ASTM C143.

15. A fresh concrete composition as in claim 1, wherein the fine aggregate consists essentially of sand, wherein the coarse aggregate consists essentially of rock, and wherein the fresh cementation composition contains less than about 10% entrained air.

16. A fresh concrete composition as in claim 1, further comprising one or more admixtures selected from the group consisting of air entraining agents, strength enhancing amines, dispersants, viscosity modifiers, set accelerators, set retarders, corrosion inhibitors, pigments, wetting agents, water soluble polymers, rheology modifying agents, water repellents, fibers, permeability reducers, pumping aids, fungicidal admixtures, germicidal admixtures, insecticidal admixtures, finely divided mineral admixtures, alkali reactivity reducer, and bonding admixtures.

17. A fresh concrete composition as in claim 1, further comprising an amount of plasticizer that increases slump and decreases viscosity without causing significant segregation or bleeding of the cementitious composition.

18. A fresh concrete composition having high workability with relatively reduced segregation or bleeding, comprising:

hydraulic cement;

water;

fine aggregate having a volume in a first range of about 55% to about 65% of total aggregate volume; and

coarse aggregate having a volume in a second range of about 35% to about 45% of the total aggregate volume,

the concrete composition having a slump in a range of about 1 inch to about 12 inches, as measured using a 12 inch slump cone according to ASTM C143, and a 28-day compressive strength after curing in a range of about 1500 psi to about 4500 psi,

the concrete composition having lower viscosity and greater cohesiveness compared to a concrete composition having a volume of fine aggregate immediately less than the first range and a volume of coarse aggregate immediately greater than the second range.

19. A fresh concrete composition having high workability with relatively reduced segregation or bleeding, comprising:

hydraulic cement;

water;

fine aggregate having a volume greater than 50% and less than 60% of total aggregate volume; and

coarse aggregate having a volume greater than 40% and less than 50% of the total aggregate volume,

the concrete composition having a slump in a range of about 1 inch to about 12 inches, as measured using a 12 inch slump cone according to ASTM C143, and a 28-day compressive strength after curing in a range of about 4500 psi to about 8000 psi,

the concrete composition having a lower viscosity, segregation and bleeding compared to a concrete composition having a volume of fine aggregate immediately less than 50% of total aggregate volume and a volume of coarse aggregate immediately greater than 50% of total aggregate volume.

20. A fresh concrete composition having high workability with relatively reduced segregation or bleeding, comprising:

hydraulic cement;

water;

fine aggregate having a volume in first a range of about 45% to about 55% of total aggregate volume; and

coarse aggregate having a volume in a second range of about 45% to about 55% of the total aggregate volume,

the concrete composition having a slump in a range of about 1 inch to about 12 inches, as measured using a 12 inch slump cone according to ASTM C143, and a 28-day compressive strength after curing of at least about 8000 psi,

the concrete composition having lower viscosity and greater cohesiveness compared to a concrete composition having a volume of fine aggregate immediately less than the first range and a volume of coarse aggregate immediately greater than the second range.

21. A method for designing a concrete composition having high workability with relatively reduced segregation or bleeding, comprising:

designing a cement paste having a desired water-to-cement ratio for achieving a desired strength greater than about 1500 psi after curing;

selecting relative amounts of fine aggregate and coarse aggregate that minimize segregation and bleeding and result in a desired workability; and

determining a volume of cement paste relative to the overall volume of aggregate that will yield concrete having the desired strength, the desired workability, and a slump in a range about 1 inch to about 12 inches, as measured using a 12 inch slump cone according to ASTM C143.

22. A method as in claim 21, wherein the desired strength is in a range of about 1500 psi to about 4500 psi and wherein the fine-to-coarse aggregate ratio yields a volume of fine aggregate in a range of about 55% to about 65% of the total aggregate volume and a volume of coarse aggregate in a range of about 35% to about 45% of the total aggregate volume.

23. A method as in claim 21, wherein the desired strength is in a range of about 4500 psi to about 8000 psi and wherein the fine-to-coarse aggregate ratio yields a volume of fine aggregate in a range of about 50% to about 60% of the total aggregate volume and a volume of coarse aggregate in a range of about 40% to about 50% of the total aggregate volume.

24. A method as in claim 21, wherein the desired strength is greater than about 8000 psi and wherein the fine-to-coarse aggregate ratio yields a volume of fine aggregate in a range of about 45% to about 55% of the total aggregate volume and a volume of coarse aggregate in a range of about 45% to about 55% of the total aggregate volume.

25. A method as in claim 21, further comprising determining a quantity of plasticizer that will increase slump and decrease viscosity without causing significant bleeding or segregation.

26. A method for manufacturing ready-mix concrete having relatively reduced segregation or bleeding, comprising:

providing a batching plant having a batching system capable of dispensing and mixing together desired amounts of cement, water, fine aggregate and coarse aggregate;

forming a fresh concrete composition by mixing together in the batching system a measured quantity of;

hydraulic cement;

water;

fine aggregate in a range of about 45% to about 65% by volume of total aggregate; and

coarse aggregate in a range of about 35% to about 55% by volume of the total aggregate,

the fresh concrete composition having a slump of at least about 1 inch and a 28-day compressive strength after curing of at least about 1500 psi.

27. A method as in claim 26, further comprising adding a plasticizer to the fresh concrete composition in an amount so as to increase slump and decrease viscosity without causing significant segregation or bleeding.