Durable concrete and method for producing the same

• US 9,126,864 B2
• Filed: 11/13/2014
• Issued: 09/08/2015
• Est. Priority Date: 05/16/2013
• Status: Active Grant

• Current Assignee: Ashok H. Shah
• Original Assignee: NAVS, LLC
• Inventors: Shah, Ashok H.
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): HIJJI, KARAM Y
• Application Number:
  US14/540,987
• Publication Number:
  US 20150068430A1
• Time in Patent Office: 299 Days
• US Class Current: 1/1
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 14/301 porous or hollow
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 16/0641 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/082 Cenospheres
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0036 Microsized or nanosized
• CPC Class Codes: C04B 20/004 inorganic
• CPC Class Codes: C04B 20/0056 Hollow or porous fibres
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• 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 2111/29 Frost-thaw resistance
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A concrete mix for producing freeze-thaw durable concrete having enhanced strength properties, like compressive strength, abrasion resistance, impact strength, toughness, is disclosed. The novel concrete mix contains deformable solid elements in place of 4-8% entrained air for good durability of concrete under freeze-thaw cycles.

Claims

1. A hardened concrete resistant to cracking in a freeze-thaw environment, comprising the following components:

cement;

aggregates;

optionally admixtures; and

deformable spaces containing physical or chemical remnants of inorganic disintegrated solid elements,

wherein the total volume of said deformable spaces is less than 2%, and the maximum dimension of said deformable spaces is less than about 300 micrometers, and the distance between the deformable spaces is no greater than about 200 micrometers, so as to prevent a pressure build-up in capillary pores of cement gel exceeding 1000 psi upon freezing of water within the capillary pores, said hardened concrete having a density above about 1.5 g/cm³.

2. The hardened concrete of claim 1, wherein said deformable spaces contain physical or chemical remnants of inorganic, hollow, spherical, deformable solid elements.

3. The hardened concrete of claim 2, wherein said inorganic deformable solid elements are made of materials selected from the group of glass, ceramic and silica and combinations thereof.

4. The hardened concrete of claim 2, wherein said spheres have a crush strength of <

1000 psi.

5. The hardened concrete of claim 3, wherein said inorganic deformable solid elements are cenospheres.

6. The hardened concrete of claim 3, wherein said inorganic deformable solid elements are deformed by chemical disintegration over time.

7. The hardened concrete of claim 6, wherein said inorganic deformable solid elements are glass spheres.

8. The hardened concrete of claim 1, which has a density of above about 2 g/cm³.

9. The hardened concrete of claim 1, which has a density of above about 2.5 g/cm³.

10. The hardened concrete of claim 1, which has a density from about 2 g/cm³ to about 2.5 g/cm³.

11. The hardened concrete of claim 1, wherein the total volume of said deformable spaces is less than about 1%.

12. The hardened concrete of claim 1, wherein the total volume of said deformable spaces is less than or equal to about 0.6%.