Lime-free admixture compositions for hydraulic cements and methods thereof

Abstract

Lime-free admixture compositions comprising a combination of ingredients are disclosed. The ingredients of the lime-free admixture compositions comprise a combination of emulsifiers, toughening resins/plasticizers, adhesive resins, pumping aids for providing lubrication, rheology controllers, water retention agents, water repellants/overcoat finishes, accelerators, liquid adsorbents/water reducers and air entraining agents. The lime-free admixture compositions are total replacements for lime. The ingredients of the lime-free admixture compositions have specific purposes that lead to optimized properties when used in combination with a binder comprising hydraulic cement. The lime-free admixture compositions are non-corrosive, making them safe to use by workers and they have rheological properties that make them suitable for use in various applications including concrete, mortars, grouts and stuccos. The ingredients comprising lime-free admixture compositions are biodegradable and therefore environmentally friendly.

1 . A lime-free admixture composition for hydraulic cement comprising, in combination: about 0.15 pounds to about 0.3 pounds of a plurality of emulsifiers per 1600 pounds of hydraulic cement, about 0.25 pounds to about 1.25 pounds of a plurality of toughening resins per 1600 pounds of hydraulic cement emulsified by said plurality of emulsifiers and about 0.1 pounds to about 1.6 pounds of a plurality of accelerators per 1600 pounds of hydraulic cement for hardening a mixture comprising hydraulic cement, a plurality of aggregates, water and the lime-free admixture composition.  
     
     
         2 . The lime-free admixture composition for hydraulic cement according to  claim 1  further comprising about 0.15 pounds to about 3.2 pounds of a plurality of air entraining agents per 1600 pounds of hydraulic cement for providing microencapsulated air particles in the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition.  
     
     
         3 . The lime-free admixture composition for hydraulic cement according to  claim 1  further comprising about 2 pounds to about 4 pounds of a plurality of overcoat resins per 1600 pounds of hydraulic cement for providing a coating on an outer surface of a hardened product formed from the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition.  
     
     
         4 . The lime-free admixture composition for hydraulic cement according to  claim 1  further comprising about 0.25 pounds to about 1.25 pounds of a plurality of adhesive resins per 1600 pounds of hydraulic cement for enhancing adhesion of the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition to a plurality of substrates.  
     
     
         5 . The lime-free admixture composition for hydraulic cement according to  claim 1  further comprising less than about 4 pounds of a plurality of adsorbents per 1600 pounds of hydraulic cement for providing a dry lime-free admixture composition when the lime-free admixture comprises liquid ingredients.  
     
     
         6 . The lime-free admixture composition for hydraulic cement according to  claim 1  further comprising less than about 4.5 pounds of a plurality of water retention agents per 1600 pounds of hydraulic cement for reducing the amount of water that is added to the mixture comprising hydraulic cement, the plurality of aggregates and the lime-free admixture composition and less than about 1.5 pounds of a plurality of pumping aids per 1600 pounds of hydraulic cement for providing rheological control of the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition.  
     
     
         7 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein said plurality of emulsifiers is selected from the group of surfactants consisting of anionic, cationic, amphoteric and non-ionic.  
     
     
         8 . The lime-free admixture composition for hydraulic cement according to  claim 7  wherein said anionic surfactants is selected from the group consisting of a linear alkyl benzene sulfonate salt of an alkali metal cation, a linear alkyl benzene sulfonate salt of a non-metal cation, an alpha olefin sulfonate salt of an alkali metal cation and an alpha olefin sulfonate salt of a non-metal cation.  
     
     
         9 . The lime-free admixture composition for hydraulic cement according to  claim 8  wherein said alkali metal cation is selected from the group consisting of lithium, sodium, potassium, magnesium and calcium, and said non-metal cation is selected from the group consisting of ammonium, alkyl ammonium, aryl ammonium, pyridine, pyrrole, piperidine, derivatives of alkyl ammonium, derivatives of aryl ammonium, pyridine, derivatives of pyrrole and derivatives of piperidine.  
     
     
         10 . The lime-free admixture composition for hydraulic cement according to  claim 7  wherein said non-ionic surfactant comprises a mixture of alkyl aryl polyethoxylates, compounded silicone and linear alcohol.  
     
     
         11 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein said plurality of toughening resins is selected from the group consisting of isoprene polymer rubbers, isoprene copolymer rubbers, styrene/butadiene/styrene copolymer rubbers and nitrile copolymer rubbers.  
     
     
         12 . The lime-free admixture composition for hydraulic cement according to  claim 11  wherein said plurality of toughening resins is in crumb form.  
     
     
         13 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein said plurality of toughening resins comprises water redispersible polymers.  
     
     
         14 . The lime-free admixture composition for hydraulic cement according to  claim 13  wherein said water redispersible polymers is selected from the group consisting of vinyl acetate/vinyl versatate copolymers, ethyl vinyl acetate copolymers, polyvinyl acetate polymers and polyvinyl acetate copolymers.  
     
     
         15 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein said plurality of accelerators is a thiosulfate salt of a cation selected from the group consisting of lithium, sodium, potassium, barium, calcium and ammonium.  
     
     
         16 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein said plurality of accelerators comprises a free radical initiator selected from the group consisting of peroxides, azo compounds and hydroperoxides.  
     
     
         17 . The lime-free admixture composition for hydraulic cement according to  claim 16  wherein said free radical initiator is selected from the group consisting of dicumyl peroxide and benzoyl peroxide.  
     
     
         18 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein said plurality of accelerators comprises a combination of ingredients comprising aliphatic polycarboxylates, alkylaryl polyoxyethylene ethanol, butyl and isopropyl alcohol, NEODOL® 91-6 and phenyltrimethyl siloxane.  
     
     
         19 . The lime-free admixture composition for hydraulic cement according to  claim 2  wherein said plurality of air entraining agents comprises a combination of ingredients comprising aliphatic polycarboxylates, alkylaryl polyoxyethylene ethanol, butyl and isopropyl alcohol, NEODOL® 91-6 and phenyltrimethyl siloxane.  
     
     
         20 . The lime-free admixture composition for hydraulic cement according to  claim 3  wherein said plurality of overcoat resins comprises a combination of latex polyvinyl acetate polymers and copolymers.  
     
     
         21 . The lime-free admixture composition for hydraulic cement according to claim. 4 wherein said plurality of adhesive resins for enhancing adhesion is selected from the group consisting of isoprene polymer rubbers, isoprene copolymer rubbers, styrene-butadiene-styrene copolymer rubbers, nitrile copolymer rubbers, vinyl acetate/vinyl versatate copolymers, ethyl vinyl acetate copolymers, polyvinyl acetate polymers and polyvinyl acetate copolymers.  
     
     
         22 . The lime-free admixture composition for hydraulic cement according to  claim 5  wherein said plurality of adsorbents providing a dry lime-free admixture composition is selected from the group consisting of Perlite, calcium carbonate and diatomaceous earth.  
     
     
         23 . The lime-free admixture composition for hydraulic cement according to  claim 6  wherein said plurality of water retention agents is selected from the group consisting of isoprene polymer rubbers, isoprene copolymer rubbers, styrene-butadiene copolymer rubbers, polyvinyl acetate/vinyl versatate copolymers, polyethylene oxide polymers, hydroxylpropyl methyl cellulose polymers, hydroxylethyl methyl cellulose polymers, polyethylene glycol polymers, polyethylene glycol copolymers, polyacrylamide polymers, polyacrylamide copolymers, xanthan gums and guar gums, and said plurality of pumping aids is selected from the group consisting of polyethylene oxide polymers, hydroxylpropyl methyl cellulose polymers, hydroxyl ethyl methyl cellulose polymers, polyethylene glycol polymers, polyethylene glycol copolymers, polyacrylamide polymers, polyacrylamide copolymers, xanthan gums, guar gums, Perlite, calcium carbonate and diatomaceous earth.  
     
     
         24 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein a combination of the lime-free admixture composition, hydraulic cement, a plurality of aggregates and water comprises a masonry composition selected from the group consisting of a concrete composition, a mortar composition, a stucco composition and a grout composition.  
     
     
         25 . The lime-free admixture composition for hydraulic cement according to  claim 1  wherein a combination of the lime-free admixture composition, hydraulic cement, a plurality of aggregates and water provides a stucco composition for applying the stucco composition directly to non-wire mesh wrapped expanded polystyrene substrates.  
     
     
         26 . A lime-free admixture composition for hydraulic cement comprising, in combination: a plurality of emulsifiers, a plurality of toughening resins emulsified by said plurality of emulsifiers and a plurality of accelerators for hardening a mixture comprising hydraulic cement, a plurality of aggregates, water and the lime-free admixture composition.  
     
     
         27 . The lime-free admixture composition for hydraulic cement according to  claim 26  further comprising a plurality of overcoat resins for providing a coating on an outer surface of a hardened product formed from the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition.  
     
     
         28 . A method for using lime-free admixture compositions to make masonry compositions comprising the steps of: providing a plurality of emulsifiers, a plurality of toughening resins emulsified by said plurality of emulsifiers and a plurality of accelerators for hardening a mixture comprising hydraulic cement, a plurality of aggregates, water and the lime-free admixture composition.  
     
     
         29 . The method for using lime-free admixture compositions to make masonry compositions according to  claim 28  further comprising the steps of: 
 providing a plurality of air entraining agents;    providing a plurality of overcoat resins to coat an outer surface of a hardened product formed from the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition;    providing a plurality of adhesive resins for enhancing adhesion of the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition to a plurality of substrates;    providing a plurality of adsorbents for providing a dry lime-free admixture composition when the lime-free admixture comprises liquid ingredients;    providing a plurality of water retention agents for reducing the amount of water that is added to the mixture comprising hydraulic cement, the plurality of aggregates and the lime-free admixture composition; and    providing a plurality of pumping aids for controlling the rheology of the mixture comprising hydraulic cement, the plurality of aggregates, water and the lime-free admixture composition.    
     
     
         30 . The method for using lime-free admixture compositions to make masonry compositions according to  claim 28  further comprising the steps of: 
 adding a first quantity of water into a mixer;    blending a quantity of hydraulic cement with the water in the mixer;    blending a quantity of the lime-free admixture composition into the water and hydraulic cement in the mixer;    blending a first quantity of a plurality of aggregates into the water, hydraulic cement and the lime-free admixture composition in the mixer;    blending a second quantity of water to the mixer;    blending a second plurality of aggregates to the mixer;    and mixing the mixture comprising water, the hydraulic cement, the admixture composition and the plurality of aggregates in the mixer for a period of time of less than about 4 hours.    
     
     
         31 . The method for using lime-free admixture compositions to make masonry compositions according to  claim 30  wherein the first quantity of water comprises about 7% to about 8% of the mixture; the quantity of hydraulic cement comprises about 20% to about 23% of the mixture; the quantity of lime-free admixture composition comprises about 0.1% of the mixture; the quantity of the first plurality of aggregates comprises about 30% to about 34% of the mixture; the second quantity of water comprises less than about 2% of the mixture; and the second quantity of the plurality of aggregates comprises about 34% to about 41% of the mixture.