Multiple Crystallization Enhance (MCE) Intermix for Portland Cement Concrete

Abstract

A water-based mixture of multi compounds for adding to fresh concrete to protect the concrete against moisture and moisture-associated problems. A hygroscopic and hydrophilic behavior of its crystallization system within a concrete matrix minimizes moisture transmission through capillaries and connected voids. As a result, the mixture may reduce moisture related problems, such as damage caused by repeated freeze and thaw cycles and chloride ion penetration as from deicing salts, as well as alkali-silica reactions, and other problems.

What is claimed is: 
     
         1 . A method for providing an admixture to be intermixed with uncured concrete for enhancing hydration during curing and reducing water penetration after curing, the method comprising:
 mixing a crystallization enhancer with cement and water to form an uncured concrete mixture having the crystallization enhancer dispersed therein, the crystallization enhancer comprising one or more organic acids, sodium salt of carbonic acid, alkali metal silicate, and silanetriol, methyl-, potassium salt;   allowing the uncured concrete mixture to go through a curing process that cures the uncured concrete mixture to form a cured concrete, wherein the crystallization enhancer increases a number of micro capillaries formed in the cured concrete during the curing process;   wherein the crystallization enhancer converts at least a portion of the calcium hydroxide into CaSiO 3  during cement hydration of the uncured concrete;   wherein the crystallization enhancer reduces water penetration into concrete matrices of the cured concrete by providing enhanced hydrophilic, hygroscopic, and hydrophobic characteristics to the cured concrete;   wherein the enhanced hydrophobic characteristic comprises repelling water at a surface of the cured concrete;   wherein the enhanced hygroscopic characteristic comprises forming hygroscopic crystals within the concrete matrices of the cured concrete; and   wherein the enhanced hydrophilic characteristic comprises forming hydrophilic crystals within the concrete matrices of the cured concrete.   
     
     
         2 . The method of  claim 1 , wherein the crystallization enhancer is a stable containerizable aqueous mixture added to the cement during batching. 
     
     
         3 . The method of  claim 1 , wherein the one or more organic acids includes 2,3-Dihydroxybutanedioic acid. 
     
     
         4 . The method of  claim 1 , wherein the one or more organic acids includes ethanoic acid. 
     
     
         5 . The method of  claim 1 , wherein the crystallization enhancer is an aqueous solution comprising:
 approximately 0.5 to 2% by weight 2,3-Dihydroxybutanedioic acid;   approximately 1 to 2% by weight sodium salt of carbonic acid;   approximately 1% by weight ethanoic acid;   approximately 2 to 7% by weight alkali metal silicate; and   approximately 1 to 3% by weight silanetriol, methyl-, potassium salt.   
     
     
         6 . The method of  claim 1 , wherein the crystallization enhancer further comprises one or more of a surfactant, an anti-foaming agent, and an emulsifier. 
     
     
         7 . The method of  claim 1 , wherein the crystallization enhancer further comprises:
 approximately 5% by weight nonylphenol polyethylene glycol ether;   approximately 0.5% by weight isopropyl alcohol; and   approximately 0.01% by weight alkyl-benzene-sulfonic acid.   
     
     
         8 . The method of  claim 1 , wherein the crystallization enhancer reduces the calcium hydroxide in the cured concrete by promoting pozzolanic reactions that produce CSH by consuming at least some of the calcium hydroxide. 
     
     
         9 . The method of  claim 8 , wherein the produced CSH at least partially fills the micro capillaries and expands with water due to hydrophilic characteristics of the CSH. 
     
     
         10 . An aqueous mixture for mixing with uncured concrete to improve hydration of Portland cement, the aqueous mixture comprising:
 approximately 0.5% by weight ethanoic acid;   approximately 0.75 to 2% by weight 2,3-Dihydroxybutanedioic acid;   approximately 1 to 2% by weight anhydrous sodium salt of carbonic acid;   approximately 2% to 7% by weight alkali metal silicate solids; and   approximately 1% to 3% by weight silanetriol, methyl-, potassium salt.   
     
     
         11 . The aqueous mixture of  claim 10 , wherein the aqueous mixture has a solid content in a range of 12 to 18%. 
     
     
         12 . The aqueous mixture of  claim 10 , wherein the aqueous mixture has a viscosity in a range of 3 to 8 centipoises. 
     
     
         13 . A method for protecting cured concrete, comprising:
 mixing the aqueous mixture of  claim 10  with uncured concrete to form an uncured concrete mixture.   
     
     
         14 . The method of  claim 13  and further comprising:
 allowing the uncured concrete mixture to cure; 
 wherein the aqueous mixture forms a hydrophobic barrier on a surface of the cured concrete; and 
 wherein the aqueous mixture forms hygroscopic and hydrophilic crystals within pores of the cured concrete. 
 
     
     
         15 . The method of  claim 14 , wherein trihydroxy(methyl)silane ions from the aqueous mixture react with carbon dioxide to form the hydrophobic barrier. 
     
     
         16 . The method of  claim 14 , wherein water penetration into concrete matrices of the cured concrete is reduced by the hygroscopic crystals absorbing water and the hydrophilic crystals swelling.