Modifier for concrete and cement formulations and methods of preparing the same

Abstract

Disclosed are wax emulsion modifiers for concrete and cement formulations and methods for preparing the same. The modifiers are applicable to roller compacted concrete (RCC), used for manufacturing of industrial floor slabs, dams and roads. This invention also relates to conventional Portland cement concrete mix designs or other applied concrete mixes for formed structural shapes and transport road mix designs, providing a more rapid dehydration of the aqueous phase, without sacrificing strength, yet providing a higher density that remains workable at the point of application. The modifier of the invention may be utilized for either the initial soil/cement base or for the final/finished placement.

1 . A composition with an initial compressive strength of at least 2400 psi comprising:
 (a) a paraffin hydrocarbon wax,   (b) a saponifiable wax   (c) a saponifier,   (d) a dispersant, and   (e) cement.   
     
     
         2 . The composition of  claim 1 , wherein:
 (a) the paraffin hydrocarbon wax has a melting point between about 50° C. to about 70° C., and   (b) the saponifiable wax is a Montan wax having a melting point in the range of between about 70° C. to about 100° C., an acid number greater than 25, and a saponification number of greater than 85.   
     
     
         3 . The composition of  claim 1 , wherein the saponifier is ammonia hydroxide or an alkali metal hydroxide. 
     
     
         4 . The composition of  claim 2 , wherein the Montan wax is present in an amount of about 0.01 to about 20 parts, by weight, per 100 parts of the paraffin hydrocarbon wax. 
     
     
         5 . The composition of  claim 1 , wherein the dispersant is polynaphthalenesulfonic acid present in an amount of about 0.1 to about 5 wt % based upon the weight of the emulsion. 
     
     
         6 . The composition of  claim 1 , comprising:
 (a) about 20 to about 60 wt % of the paraffin hydrocarbon wax, based upon the weight of the emulsion;   (b) about 0.01 to about 20 parts, by weight, of the saponifiable wax, per 100 parts of the paraffin wax;   (c) about 0.1 to about 5 wt % of the saponifier, based upon the weight of the emulsion;   (d) about 0.1 to about 5 wt % of the dispersant, based upon the weight of the emulsion; and   (e) water.   
     
     
         7 . The composition of  claim 1 , wherein the paraffin hydrocarbon wax, the saponifiable wax, the saponifier, and the dispersant are provided in the form of an emulsion and is present in an amount of about 1 to about 25 gallons per cubic yard of the cement. 
     
     
         8 . The composition of  claim 1 , wherein the composition is a roller compacted concrete. 
     
     
         9 . The composition of  claim 1 , wherein the cement comprises a mixture of Portland cement and class 1 fly ash. 
     
     
         10 . An emulsion for providing a cementitious composition with an initial compressive strength of at least 2400 psi, consisting essentially of:
 (a) a paraffin hydrocarbon wax,   (b) a saponifiable wax,   (c) a saponifier,   (d) a dispersant, and   (e) water.   
     
     
         11 . The emulsion of  claim 10 , wherein:
 (a) the paraffin hydrocarbon wax has a melting point between about 50° C. to about 70° C., and   (b) the saponifiable wax is a Montan wax having a melting point in the range of between about 70° C. to about 100° C., an acid number greater than 25, and a saponification number of greater than 85.   
     
     
         12 . The emulsion of  claim 10 , wherein the saponifier is ammonia hydroxide or an alkali metal hydroxide. 
     
     
         13 . The emulsion of  claim 10 , wherein the Montan wax is present in an amount of about 0.01 to about 20 parts, by weight, per 100 parts of the paraffin hydrocarbon wax. 
     
     
         14 . The emulsion of  claim 10 , wherein the dispersant is polynaphthalenesulfonic acid present in an amount of about 0.1 to about 5 wt % based upon the weight of the emulsion. 
     
     
         15 . The emulsion of  claim 10 , wherein the aqueous emulsion consists essentially of:
 (a) about 38.68 wt % of Paraffin Wax,   (b) about 1 wt % on Montan Wax,   (c) about 1 wt % of polynapthalenesulfonic acid dispersant,   (d) about 0.25 wt % of 45% aqueous potassium hydroxide, and   (e) about 59.07 wt % water.   
     
     
         16 . A method for providing a cementitious composition, comprising:
 preparing an aqueous emulsion, for providing a cementitious composition with an initial compressive strength of at least 2400 psi, the method comprising combining water, a paraffin hydrocarbon wax, a saponifiable wax and a saponifier, heating the combination to a temperature of between about 185° F. (85° C.) to about 205° F. (96.1° C.);   homogenizing the mixture; and   blending the aqueous emulsion with at least cement.   
     
     
         17 . The method of  claim 16 , wherein the paraffin wax is present in an amount of about 20 to about 60 wt %, based upon the weight of the emulsion, and the saponifiable wax is present in an amount of about 0.01 to about 20 parts, by weight, per 100 parts of the paraffin wax. 
     
     
         18 . The method of  claim 16 , wherein:
 (a) the paraffin hydrocarbon wax has a melting point between about 50° C. to about 70° C.,   
       and
 (b) the saponifiable wax comprises a Montan wax having a melting point in the range of between about 70° C. to about 100° C., an acid number greater than 25, and a saponification number of greater than 85. 
 
     
     
         19 . The method of  claim 16 , wherein the saponifier comprises ammonia hydroxide or an alkali metal hydroxide. 
     
     
         20 . The method of  claim 16 , wherein the dispersant comprises polynaphthalenesulfonic acid in an amount of about 0.1 to about 5 wt % based upon the weight of the emulsion.