Method for curing concrete articles

• US 5,089,198 A
• Filed: 02/17/1989
• Issued: 02/18/1992
• Est. Priority Date: 02/17/1989
• Status: Expired due to Term

• Current Assignee: CAM Sales Incorporated
• Original Assignee: CAM Sales Incorporated
• Inventors: Leach, deceased, Christopher B.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): AFTERGUT, KAREN K
• Application Number:
  US07/312,118
• Time in Patent Office: 1,096 Days
• Field of Search: 264/82, 264/DIG. 43, 264/DIG. 59, 264/228, 264/86, 264/333, 264/71, 264/345, 264/234, 34/26, 34/30
• US Class Current: 264/82
• CPC Class Codes: B28B 11/245 Curing concrete articles B28B11/242 takes precedence
• CPC Class Codes: Y10S 264/43 Processes of curing clay and concrete materials

Abstract

A process for fast and uniform hydration of uncured concrete products includes supplying pressurized and superheated water to a manifold supporting a plurality of small diameter orifice nozzles housed inside a curing room which also houses the products during curing. The superheated water is ejected by the nozzles in very fine particulate form, creating a mist or suspension of water particles that surrounds the products and creates the desired high humidity, moderately high temperature environment for promoting hydration. The water preferably is softened before it is pressurized and supplied to the nozzles. Under favorable conditions, the hydration reaction supplies sufficient heat to maintain a desired temperature within the curing room. The water is heated before it is supplied to the nozzles after pressurization.

Claims

1. A process for promoting the hydration of articles of concrete, including the steps of:

confining uncured concrete articles within a curing enclosure;

providing water and raising the pressure of the water to a selected pressure of from 200 to 400 pounds per square inch;

supplying the pressurized water to a plurality of nozzles inside of the curing enclosure, the nozzles producing a water spray of particles having diameters in the range of about 20 to 40 microns, the water spray producing a mist that surrounds the concrete articles in the enclosure;

maintaining the temperature inside of the curing enclosure within a range of from 80°

F. to 130°

F., while supplying a sufficient amount of pressurized water through the nozzles to maintain a saturated atmosphere substantially throughout the interior of the enclosure, for a predetermined period of time, the temperature inside of the enclosure being maintained by superheating the water to the temperature from about 275°

F. to about 300°

F. after raising the pressure of the water and before supplying the water to the nozzles, without converting the water to steam, the superheating being discontinued when not necessary to maintain the temperature inside the enclosure in the specified range.

2. The process of claim 1 including the further step of softening the water prior to raising the pressure of the water.

3. A process for humidifying an atmosphere in an enclosure wherein concrete products are cured during the humidification of the enclosure, comprising pressurizing water to a pressure of from 200 to 400 pounds per square inch, spraying the pressurized water into the enclosure through a plurality of nozzles that release the pressure on the water, thereby producing a fine water spray comprising water particles within the range of from about 20 to about 40 microns in diameter, the particles being sufficiently small that they create a mist that tends to float in the atmosphere in the enclosure, the pressurized water being heated after pressurization and before it is sprayed through the nozzles to the extent necessary to increase the temperature in the enclosure to a temperature where hydration occurs, and the concrete products are cured while avoiding baking or crusting of the concrete products, the water being superheated at the necessary temperature such that the water is maintained in its liquid state until it is sprayed into the enclosure through the nozzles for humidifying the enclosure and curing the concrete products therein.

4. A process according to claim 3, wherein the temperature in the enclosure is maintained in a range of about 80°

F. to 130+ F.

5. A process for curing concrete products in an enclosure comprising the steps of:

supplying pressurized water in its liquid state to the enclosure having uncured concrete articles therein, the pressurized water being at a predetermined elevated pressure;

spraying the pressurized water into the enclosure through one or more nozzles that produce a fine spray of the pressurized water which surrounds the uncured articles in the enclosure, the orifice size of the nozzles and the pressure of the water being such as to produce the fine spray in the enclosure comprising water particles having diameters in the range of from about 20 microns to about 40 microns; and

obtaining and maintaining a temperature in the enclosure of about 80°

F. to 130°

F. by superheating the pressurized water to at least 275°

F. before spraying it into the enclosure, the temperature of the supernated water and the elevated pressure being such that the water is maintained in a liquid state until the water is sprayed into the enclosure, the elevated pressure on the water being released when it is sprayed into the enclosure, the water thus humidifying and heating the enclosure having the uncured concrete articles therein, and the superheating of the pressurized water being discontinued when it becomes unnecessary to maintain the temperature of about 80°

F. to about 130°

F. in the enclosure.

6. A process according to claim 5, wherein the water is pressurized to about 200 to 400 pounds per square inch.

7. A process for curing concrete products in an enclosure while avoiding the baking or crusting of the concrete products therein by maintaining a desired temperature and humidified atmosphere in the enclosure, comprising spraying pressurized water into the enclosure through a plurality of spaced nozzles thereby producing a fine mist which surrounds the concrete products in the enclosure, the nozzle orifice size and water pressure being such as to produce a spray of the fine mist comprising water particles in the range of about 20-40 microns in diameter;

and maintaining a temperature of about 80°

F. to about 130°

F. in the enclosure during the curing of the products by superheating the pressurized water before spraying the water into the enclosure while maintaining the water under a condition of elevated pressure that prevents the water from boiling at the superheated temperature, the superheated water being sprayed into the enclosure to raise the temperature in the enclosure while humidifying the enclosure for the curing of the concrete products therein, and the superheating of the water being discontinued when unnecessary to maintain the desired temperature in the enclosure.

8. A method of curing concrete articles in enclosure while avoiding the baking or crusting of the concrete articles in the enclosure by maintaining a desired temperature in the enclosure while humidifying the enclosure, comprising:

providing a continuous supply of water;

elevating the pressure of the water with a pump;

conveying the pressurized water to one or more nozzles having spray outlets in the enclosure, the orifice size of the nozzles and the pressure on the water being such as to provide a fine spray mist of water particles in the enclosure that surrounds that concrete articles being cured in the enclosure, while providing the necessary humidity and temperature in the enclosure to initiate hydration of the concrete articles therein; and

at least intermittently heating the pressurized water with a flow-through heater positioned between the pump and the nozzles to a temperature at which the pressurized water is superheated, the pressure on the superheated water preventing the water from converting into steam until it is sprayed from the nozzles into the enclosure, the heating being discontinued when it is not needed to maintain the desired temperature in the enclosure required for curing the concrete articles therein.

9. A method of curing concrete articles in an enclosure while avoiding the baking or crusting of the concrete articles by maintaining a desired temperature in the enclosure, comprising:

providing a continuous supply of water from a source to the enclosure having the concrete articles therein;

pressurizing the water to an elevated pressure;

spraying the pressurized water into the enclosure through one or more nozzles in the enclosure, the pressure on the water and the nozzle size being such that the nozzles produce a mist of fine water particles in the enclosure, which mist surrounds the concrete articles and provides the necessary humidity and temperature in the enclosure to initiate hydration of the concrete articles, wherein the water is heated after it has been pressurized but before it is sprayed into the enclosure to a temperature at which the water is superheated, the pressure on the superheated water being sufficient to prevent the water from converting into steam until it is sprayed into the enclosure, the heating being undertaken at least intermittently so as to maintain the temperature in the enclosure at the desired curing temperature while curing the concrete articles in the enclosure.

10. A process according to claim 9, wherein the water is pressurized to at least 200 pounds per square inch.

11. A process according to claim 10, wherein the water is pressurized to 200 to 400 pounds per square inch.

12. A process according to claim 9,. wherein the water is superheated to at least about 275°

F.

13. A process according to claim 9, wherein the pressurized water sprayed into the enclosure comprises water particles in the range of about 20 microns to about 40 microns in diameter.

14. A process according to claim 9 where the temperature in the enclosure in maintained at about 80°

F. to 130°

F. by the superheating of the pressurized water when heat is required to raise the temperature in the enclosure, the superheating being discontinued when the desired temperature is achieved.

15. A process according to claim 14, wherein the temperature is maintained in the enclosure by the superheated water at a temperature of about 110°

F.

16. A process according to claim 9, wherein the water is received from the water supply source, pressurized by a pump, and supplied to the nozzles in the enclosure through pressurizable piping interconnecting the pump and the nozzles, with the nozzles maintaining the pressure on the water in the piping until the water is sprayed from the nozzles into the enclosure, the water being heated by a water heater connected in the piping between the pump and nozzles, the water heater being such that the pressure on the water is maintained as the water passes through the water heater and is superheated.

17. A process according to claim 16, wherein the water is softened in a water softener before the water is provided to the pump where the pressure is elevated.

18. A process according to claim 16, wherein the temperature in the enclosure is maintained by a thermostatic switch that senses the temperature in the enclosure and controls the operation of the water heater in response thereto.