FAST-CURING PERVIOUS CONCRETE MIX

• US 20140187680A1
• Filed: 12/19/2013
• Published: 07/03/2014
• Est. Priority Date: 12/21/2012
• Status: Active Grant

• Current Assignee: Hanson Aggregates LLC (HeidelbergCement AG)
• Original Assignee: Hanson Aggregates LLC (HeidelbergCement AG)
• Inventors: Kripavicius, Edward
• Granted Patent: US 9,328,027 B2
• Time in Patent Office: Days
• US Class Current: 524/5
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 16/0625 Polyalkenes, e.g. polyethylene
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/0057 added as redispersable powders
• CPC Class Codes: C04B 2103/0088 Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 2111/00284 Materials permeable to liquids
• CPC Class Codes: C04B 2111/0075 for road construction
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/10 Carbohydrates or derivatives thereof
• CPC Class Codes: C04B 24/18 Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2647 containing polyether side chains
• CPC Class Codes: C04B 24/2664 of ethylenically unsaturated dicarboxylic acid polymers, e.g. maleic anhydride copolymers
• CPC Class Codes: C04B 26/04 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 38/00 Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof treating slag with gases or gas generating material C04B5/06 ; expanded graphite C04B35/536
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A fast-curing pervious concrete mix made by combining: water; a cementitious material comprising portland cement and a supplementary cementitious material; aggregate sized to form a pervious concrete; a water reducer; a quantity of fibers; and a polymeric bonding agent, the mix curing to a compressive strength of at least 2,000 psi within 24 hours of placement. Also, a method of forming a pervious concrete structure by forming the fast-curing pervious concrete mix, placing the mix in a desired formation, and curing the placed mix, and a pervious concrete obtained by placing and curing the fast-curing pervious concrete mix.

Claims

1. A fast-curing pervious concrete mix made by combining:

(a) water;

(b) a cementitious material comprising;

(1) portland cement; and

(2) a supplementary cementitious material;

(c) aggregate sized to form a pervious concrete;

(d) a water reducer;

(e) a quantity of fibers; and

(f) a polymeric bonding agent,

the mix curing to a compressive strength of at least 2,000 psi within 24 hours of placement.

2. The mix of claim 1, having a water to cementitious material ratio of 0.25 to 0.40.

3. The mix of claim 2, having a water to cementitious material ratio of 0.27 to 0.38.

4. The mix of claim 3, having a water to cementitious material ratio of 0.27 to 0.30.

5. The mix of claim 1, wherein the supplementary cementitious material comprises fly ash.

6. The mix of claim 1, wherein the supplementary cementitious material comprises a pozzolan.

7. The mix of claim 6, wherein the pozzolan is pumicite, volcanic ash, pumice, pumice stone, obsidian, scoria, tuff, andesite, diatomite, diatomaceous earth, chert, shale, clay, opal, fly ash, flue dust, slag, or any mixture thereof.

8. The mix of claim 7, wherein the pozzolan comprises fly ash.

9. The mix of claim 1, wherein the aggregate comprises substantially no particles smaller than 0.0625 in.

10. The mix of claim 1, having a weight ratio of aggregate to cementitious material of about 4 to about 4.5.

11. The mix of claim 1, wherein the water reducer comprises a lignosulfate, amine, carbohydrate, carboxylated polyether, hydroxycarboxylic acid salt, carbohydrate, or any mixture thereof.

12. The mix of claim 1, wherein the fibers comprise one or more natural or synthetic fibers.

13. The mix of claim 12, wherein the synthetic fibers comprise one or more polyolefins.

14. The mix of claim 13, wherein the polyolefins comprise polypropylene.

15. The mix of claim 1, wherein the polymeric bonding agent comprises polyvinyl acetate, vinyl acetate/dibutylmaleate copolymer, or any mixture thereof.

16. The mix of claim 1, having a void content of 15% to 35% by volume after placement.

17. The mix of claim 16, having a void content of 20% to 30% by volume after curing.

18. The mix of claim 1, made by combining 400 to 700 lbs/yd³ of the cementitious material, 2000 to 3000 lbs/yd³ of the aggregate, 1 to 20 oz./cwt. of the water reducer, 0.5 to 2.5 lbs/yd³ of the fibers, and 0.5 to 1.5 gal./yd³ of the polymeric bonding agent.

19. The mix of claim 18, made by combining 450 to 650 lbs/yd³ of the cementitious material, 2250 to 2750 lbs/yd³ of the aggregate, 2 to 15 oz./cwt. of the water reducer, 0.75 to 2.25 lbs/yd³ of the fibers, and 0.75 to 1.25 gal./yd³ of the polymeric bonding agent.

20. A pervious concrete obtained by placing and curing the mix of claim 1.

21. A method of producing pervious concrete, comprising the steps of:

a. forming a mix by combining;

(1) water;

(2) a cementitious material comprising;

(a) portland cement; and

(b) a supplementary cementitious material;

(3) aggregate sized to form a pervious concrete;

(4) a water reducer;

(5) a quantity of fibers; and

(6) a polymeric bonding agent;

b. placing the mix in a desired formation; and

c. curing the placed mix to a compressive strength of at least 2000 psi within 24 hours of placement.

22. A fast-curing pervious concrete mix made by combining, per cubic yard of the mix:

(a) 15 to 25 gallons of water;

(b) 400 to 700 pounds of a cementitious material comprising;

(1) 70% to 90% by weight of portland cement; and

(2) 10% to 30% by weight of flyash;

(c) 2000 to 3000 pounds of aggregate sized to form a pervious concrete;

(d) a water reducer, comprising;

(1) 1 to 5 oz./cwt. of a water-reducing admixture comprising a lignosulfonate;

(2) 5 to 10 oz./cwt. of a water-reducing admixture comprising a polyacrylate; and

(3) 1 to 5 oz./cwt. of a water-reducing admixture comprising carbohydrate;

(e) 0.5 to 2.5 pounds of fibers; and

(f) 0.5 to 1.5 gallons of a polymeric bonding agent comprising polyvinyl acetate and vinyl acetate/dibutyl maleate copolymer,

the mix curing to a compressive strength of at least 2,000 psi within 24 hours of placement.