Method, composition and apparatus for controlled concrete

Abstract

A method is provided for use of a concrete composition and an associated apparatus. The method provides for mixing of the concrete material, accelerant powder and, optionally, an associated substance to enable the controlled hardening of the concrete material in a monolithic structure. The apparatus can dispose a slip-plane film to facilitate a relatively continuous process.

1 . A process for installing a concrete composition, the process comprising: 
 admixing (a) a first composition comprising a concrete composition, and (b) a second composition comprising an accelerant powder to form a projectable admixture;    projecting the admixture into a space between a base wall and a moveable form having a surface area in an adjacent position relative to the base;    enabling the admixture to set to form a wall with a free wall surface; and,    moving the form to a different adjacent position;    whereby the above process is repeated to form a monolithic wall section having a surface area larger than the surface area of the form.    
     
     
         2 . The process of  claim 1  wherein the second composition comprises the accelerant effectively in association with one or more of a carrier substance(s) selected from the group consisting of a powder, a liquid and a melt such that the one or more of the components controls the action of the accelerant composition to enable the projectable composition to temporarily flow.  
     
     
         3 . The process of  claim 2  wherein the carrier substance(s) is an organic liquid composition.  
     
     
         4 . The process of  claim 1  wherein the process is performed to provide a variability of thickness less than about ten millimeters.  
     
     
         5 . The process of  claim 2  wherein the carrier is miscible in water.  
     
     
         6 . The process of  claim 1  wherein the concrete composition comprises one or more cement(s) selected from the group consisting of a calcium aluminate cement, a silicate bonded cement, a chlorine-bonded cement, a colloidal silica binder cement, a calcium silicate cement, and a colloidal alumina binder cement.  
     
     
         7 . The process of  claim 1  wherein the accelerant powder is from about 0.05 to about 5 weight percent of the total weight of projectable admixture.  
     
     
         8 . The process of  claim 7  wherein the accelerant powder is from about 0.1 to about 1 weight percent of the total weight of projectable admixture.  
     
     
         9 . The process of  claim 1  wherein the concrete composition is a refractory composition.  
     
     
         10 . The process of  claim 1  wherein the accelerant powder comprises a flocculating agent and a setting agent.  
     
     
         11 . The process of  claim 10  further comprising adjusting the proportion of the flocculating agent and the setting agent to effectively control the action of the accelerant powder to enable the projectable composition to temporarily flow.  
     
     
         12 . The process of  claim 1  further comprising supplying a slip-plane between the concrete composition and the moveable form to enable moving the form to a different adjacent position so that the free wall surface maintains integrity.  
     
     
         13 . The process of  claim 12  wherein the slip-plane comprises one or more material selected from the group consisting of a plastic, a rubber, a metallic foil, a paper and a screen.  
     
     
         14 . The process of  claim 13  wherein the material is a latex or polymer composition.  
     
     
         15 . A moldable composition comprising an admixture of (a) a first composition comprising a concrete composition, and (b) a second composition comprising (i) an accelerant powder and (ii) an organic liquid composition, the organic liquid composition being effectively associated with the accelerant powder so that, when the admixture is made, a reaction between the first composition and the accelerant powder is controlled to enable the moldable composition to temporarily flow.  
     
     
         16 . The composition of  claim 15  wherein the moldable composition is a pumpable composition.  
     
     
         17 . The composition of  claim 15  wherein the moldable composition is a castable composition.  
     
     
         18 . The composition of  claim 15  wherein the accelerant powder comprises one or more compound(s) selected from the group consisting of sodium silicate, sodium aluminate, lithium carbonate, lithium citrate, potassium silicate, potassium aluminate, potassium carbonate, sodium carbonate, and lithium hydroxide.  
     
     
         19 . The composition of  claim 15  wherein the accelerant powder is characterized by having a particle size distribution which is effective to control the rate of the reaction.  
     
     
         20 . The composition of  claim 15  wherein the organic liquid is a glycol.  
     
     
         21 . The composition of  claim 15  wherein the organic liquid is an oil.  
     
     
         22 . The composition of  claim 20  wherein the second composition comprises from about 30 to about 60 weight percent of accelerant powder and from about 40 to about 70 weight percent propylene glycol.  
     
     
         23 . The composition of  claim 15  wherein the moldable composition is moldable from about fifteen seconds to about 5 minutes.  
     
     
         24 . An apparatus comprising: 
 (a) a first application means for applying a moldable concrete composition to a base surface to produce a monolithic mass adhering to the base surface;    (b) a forming means for slip-forming an outer surface on the monolithic mass at a distance from the base surface;    (c) a second application means for applying a protective barrier between the monolithic mass and the forming means effective to maintain the integrity of the outer surface;    (d) a structural means for positioning the first application means relative to the base surface effectively to produce the monolithic mass; and,    (e) a control means for controlling the forming of the monolithic mass by effectively controlling positioning of the structural means so that the monolithic mass maintains integrity and adheres to the base surface.    
     
     
         25 . The apparatus of  claim 24  further comprising a mixing means for admixing a concrete composition and a concrete accelerant composition to produce the moldable concrete composition.  
     
     
         26 . The apparatus of  claim 24  wherein the first application means further comprises a means for admixing pressurized air to provide the moldable concrete composition with sufficient energy to be projected through ambient air to the surface.  
     
     
         27 . The apparatus of  claim 24  where the variability of thickness of the monolithic mass is less than about 10 millimeters.