CEMENTIFEROUS COMPOSITIONS

Abstract: This invention provides cementiferous compositions having improved flow characteristics which are given by the incorporation of certain hydroxy estercopolymers. The copolymers include those of acrylic or methacrylic acid with a hydroxyalkyl acrylate or methacrylate and are used preferably in the range 0.01% to 2.5% w/w on the cement in the cementiferous composition. This invention also provides novel additive compositions for use in the cementiferous compositions which, in addition to the copolymer, also contain an anti-foaming agent.

Description: CEMENTIFEROUS COMPOSITIONS This invention relates to cementiferous compositions and to additives for use in such compositions, which improve the physical characteristics such as the flow and workability of such compositions. The cementiferous compositions with which this invention is concerned include concretes which comprises cement, coarse and fine aggregates and water; cement pastes which comprise cement and water, and mortars which comprise cement, sand and water; lime, sand and water, or mixtures containing both lime and cement. The invention is also applicable to high-pressure, steam-cured concretes comprising cement, aggregate and water; lime or limestone and siliceous materials such as silica flour and water. The additives with which this invention is concerned are sometimes referred to as plasticisers for concrete. Their purpose is to improve the flow characteristics of the cementiferous compositions containing them so that they may be pumped or effectively poured to fill all the spaces in a mould or other structure and yet not have their strength characteristics weakened by the inclusion of excessive amounts of air which, in certain circumstances, would be undesirable. In addition, these additives can be used to design cementiferous compositions with a reduced water content. This permits the production of concretes having higher compressive strength when cured and also adequate flow properties for certain applications. Various additives for use in cementiferous compositions have been previously proposed, including for example, lignosulphonates and sodium naphthalene sulphonate formaldehyde condensates. Details of such materials are set out in "Chemical Admixtures for Concrete" by M R Rixom, published by E and F N Spon Limited, London, and by the Halstead Press, a division of John Wiley and Sons Incorporated of New York, USA, where, at page 34, various known additives are considered. Various polymeric materials have been evaluated as plasticiser additives for cementiferous compositions and it has been found that certain copolymers and their soluble salts comprising polymerisable carboxylic acids and the hydroxy alkyl esters of such acids have particular merit in this application. This invention provides a cementiferous composition comprising, as a plasticiser additive, a copolymer, or soluble salt thereof, comprising from 50 to 95 mole % of an ethylenically polymerisable carboxylic acid and from 5 to 50 mole % of a hydroxy alkyl ester of an ethylenically polymerisable carboxylic acid. The additives may conveniently contain an anti-foaming agent, alternatively known as an air detraining agent. Suitable agents include tributyl phosphate, dibutyl phthalate, various water-insoluble alcohols and silicone derivatives. In accordance with a further aspect of this invention, there is provided a plasticiser additive composition comprising an aqueous solution of a copolymer or soluble salt thereof, comprising from 50 to 95 mole % of an ethylenically polymerisable carboxylic acid and from 5 to 50 mole % of a hydroxy alkyl ester of an ethylenically polymerisable carboxylic acid, and an effective amount of an anti-foaming agent. Preferably, the amount of anti foaming agent in the composition is in the range 0.1% to 2.0% by weight of the copolymer or salt thereof. Suitable acids include acrylic, methacrylic, crotonic, maleic, fumaric, itaconic, citraconic, and/or aconitic acids and like ethylenically unsaturated acids. The preferred acids are acrylic, methacrylic, and maleic acid, with acrylic or methacrylic acids being most preferred. Suitable esters include the hydroxy ethyl, hydroxy propyl, and like esters of the above acids. The preferred are those having up to C8 hydroxy alkyl groups, most preferably hydroxy propyl acrylate. Preferred copolymers include copolymers of acrylic acid and hydroxy ethyl acrylate or methacrylate and of acrylic or methacrylic acid and hydroxypropyl acrylate or methacrylate. The most preferred copolymer is that of acrylic or methacrylic acid and hydroxy propyl methacrylate. Preferably the mole percentage of the acrylic acid in the copolymer is in the range 60 to 85 mole %. Absolute molecular weight of the copolymers of this invention have not been determined. However, apparent molecular weights as calculated relative to polyethylene glycol standards have been determined, using gel permeation chromatography. The apparent molecular weight of the copolymer may be varied over a wide range, the preferred range being 1000 to 15000, more preferably 1000-9000. Precise molecular weights have not been determined for all the copolymers used but in some cases viscosity determinations have been carried out. The preferred viscosity is less than 30 cps as a 15% by weight aqueous solution in 1 molar NaCl. The amount of hydroxy alkyl acrylate copolymer or soluble salt thereof used in the cementiferous compositions is preferably in-the range 0.018 to 2.58 by weight on the cement in the cementiferous composition. Suitable copolymers may be made by the copolymerisation of the hydroxy alkyl acrylate or methacrylate with the acrylic acid or other appropriate comonoErs, using methods known in polymerisation technology. The resultant copolymer may be neutralised with a suitable base such as sodium hydroxide or other soluble base and diluted with water to the required concentration for use in the cementiferous compositions and plasticiser additives provided by this invention. Examples Materials and Methods (a) Mix Design Ordinary Portland Cement ex Blue Circle 350 kg/m3 20 mm Croxden Gravel 780 kg/m3 10 mm Croxden Gravel 330 kg/m3 Zone 3 Almington Pit Sand 740 kg/m3 % Fines = 40 Aggregate/cement = 5.3 Aggregates were washed, dried for 24 hours on a steam bed and allowed to cool for a further 24 hours. (b) Mixing Procedure The aggregate is placed in the mixer, approximately half the mixing water added and mixed for 30 seconds. After standing for 1 minute the mixer is re-started and the cement added over 30 seconds. The remaining water (containing the additive) is added and mixed for a further 3 minutes. (c) Slump Test, Plastic Density, Compressive Strength To British Standard BS 1881. Results Three copolymer additives (A, B and C) of the invention were prepared as described above and compared with known additives (D and E). Visc (cps) 15% solids Mw Mn 1M NaCl (i) 75 mole % acrylic) Admixture 8800 4300 5.5 acid ) A 25 mole% hydroxy propyl acrylate) (ii) 67 mole % acrylic) Admixture 8500 4700 5.3 acid ) 3 33 mole % hydroxy) propyl acrylate) (iii) 80 mole % acrylic) Admixture 9000 4500 5.7 acid c 20 mole % hydroxy) propyl acrylate) (iv) Calcium ligno- ) Admixture sulphonate ) D 42% solution (v) Polymerised ) Admixture sodium ) E naphthalene sulphonate 30% solution Admixtures A, B and C contained 0.25% by weight of composition of tributyl phosphate (TBP). These materials were evaluated as plasticisers in concrete using the same design as earlier described and having a water/cement (W/C) ratio = 0.60. Admixture dosage used was 140 am3/50 kg cement as 40% active solutions of their sodium salts. Results are summarised in Table I. Table I Plastic Compressive Strength Density Slump (N/mm3) Admixture (kg/m') (mm) 1 day 7 day Nil 2330 30 10.0 37.8 D 2330 70 9.4 37.5 A 2330 160 8.8 37.0 B 2330 120 8.3 37.5 C 2310 160 7.5 These results show that the copolymer additives of this invention are more efficient plasticisers than D, admixture A being more efficient than B and equivalent to C. All the admixtures show some retardation on 1 day compressive strength. Admixture A gave slightly more retardation than D with C, showing significantly more retardation than A at 1 day. All 7 day compressive strength results were similar. A similar set of experiments were carried out at two different W/C ratios, ie 0.64 and 0.56. Results are shown in Tables II and III respectively. Table II Dose Plastic Compressive Strength cm /SOkg Density Slump (N /mmg ) Admixture Cement W/C tkgtm3) (mm) 1 day 7 day Nil Nil 0.64 2315 55 9.0 34.5 D 140 0.64 2315 170 7.1 32.8 A 140 0.64 2315 210 6.8 33.5 Table III Dose Plastic Compressive Strength cm3/5Okg Density Slump - (Nlmm:) Admixture Cement W/C (kg/m3) (mum) 1 day 7 day Nil - 0.64 2330 55 9.0 34.5 D 140 0.56 - 10 A 140 0.56 2350 60 12.4 43.3 E 500 0.56 2350 80 - 42.7 It can be seen that D is ineffective at a W/C of 0.56 whereas admixture A still gives a slump similar to the control with a water reduction of 12.5%. E required dosage of 500 cm3/50 kg cement to give a similar water reduction. Compressive strengths are significantly higher than control at 1 and 7 days. Further work was done to determine the effect of changes in the molecular weight and molar ratio of the components of the copolymer. Details of the copolymer are set out in Table IV and the effects on concrete are shown in Table V. Table IV Acrylic Acid (Na salt)-Hydroxyl Propyl Acrylate Copolymers Copolymer Vise(Cps) 15% Copolymer (moles) Sample Solids 25% in in 1M NaCl AA HPA No w/w t water (cps) 3 1 (361/11 40.0 7.5 37 5.0 (361/8 41.0 7.5 42 5.9 (361/12 40.0 7.5 50 6.6 2.5 1 (361/16 46.8 7.1 38 5.1 (361/15 45.5 7.3 43 5.4 (361/25 44.3 7.5 55 6.9 2 1 (361/18 44.4 7.4 38 5.9 (361/19 42.6 7.6 42 6.8 (361/26 38.0 7.6 58 7.7 AA = Acrylic acid HPA = Hydroxy propyl acrylate. These copolymers were evaluated in a 350 kg/m3 OPC concrete mix design. Mix Design OPC ex Blue Circle 350 kg/m3 20 mm Croxden Gravel 780 kg/m3 10 mm Croxden Gravel 330 kg/m3 Zone 3 Almington Pit Sand 740 kg/m3 % Fines = 40 Aggregate/cement = 5.3 Water/cement = 0.6 The copolymers were dosed at 0.28% bwc as 30% aqueous solutions (+0.25% by weight of the composition tributyl phosphate as air entraining suppressant) and the results are detailed below: : Table V Molecular weight Compressive Strength Sample Mole as function of Slump lump No % AA viscosity (mm) 1 day 7 day 28 day EMI11.1 <tb> 361/11 <SEP> 75 <SEP> ) <SEP> 110 <SEP> 8.6 <SEP> 31.4 <SEP> 39.6 <tb> 361/8 <SEP> 75 <SEP> ) <SEP> Increasing <SEP> 90 <SEP> 8.8 <SEP> 31.4 <SEP> 40.4 <SEP> <tb> 361/12 <SEP> 75 <SEP> ) <SEP> 80 <SEP> 8.3 <SEP> 30.9 <SEP> 40.8 <SEP> <tb> 361/16 <SEP> 71.4) <SEP> 110 <SEP> 8.5 <SEP> 31.9 <SEP> 41.3 <tb> 361/15 <SEP> 71.4) <SEP> Increasing <SEP> 95 <SEP> 8.8 <SEP> 31.7 <SEP> 38.6 <tb> 361/25 <SEP> 71.4) <SEP> Z <SEP> <SEP> 90 <SEP> 8.6 <SEP> 31.5 <SEP> 39.0 <tb> 361/18 <SEP> 67 <SEP> ) <SEP> 105 <SEP> <RTI ID=11.9> 8.4 <SEP> 30.6 <SEP> 38.0 <tb> 361/19 <SEP> 67 <SEP> ) <SEP> Increasing <SEP> 105 <SEP> 8.1 <SEP> 31.2 <SEP> 37.0 <tb> 361/26 <SEP> 67 <SEP> ) <SEP> 95 <SEP> 7.4 <SEP> 29.5 <SEP> 37.8 <tb> Nil Nil - 20 9.8 30.4 40.0 AA = Acrylic acid. These results suggest that all the copolymers show some retardation of 1 day compressive strength, being most significant with the 67 mole % AA (2/1) polymers. 7 and 28 day compressive strengths are very similar to control concrete except perhaps with the 67 mole % AA polymers which are somewhat lower. Plasticising action is shown to be related to the molecular weight/viscosity of the polymers and tends to increase as molecular weight/viscosity decreases. The super-plasticising properties of the additives provided by this invention were compared with admixture E. The additive of the invention was a sodium salt of a 2.5/1 AA/HPA copolymer and comprised: 75 parts of a 40% solids copolymer solution 25 parts of water, and 0.25 parts tributyl phosphate (TBP) All parts by weight and referred to as EP 82/27. Super-plasticising Properties Flowing Concrete Super-plasticised concrete mixes were produced using admixture E and EP 82/27 at a range of dosage levels. Workability was measured using the flow table method (DIN 1048). Flow 'A' refers to the spread before tamping and flow 'B' to the spread after the prescribed number of tamps. Mix Design OPC ex Blue Circle 350 kg/m3 20 mm Croxden Gravel 780 kg/m3 10 mm Croxden Gravel 330 kg/mg Zone 3 Almington Sand 740 kg/m3 % Fines = 40 Aggregate/cement = 5.3 Water/cement = 0.66 Results are shown in Table VI. Table VI Admixture Dose Flow Flow Compressive Strength % by wt Slump 'A' 'B' (N/mm2) Admixture OPC (mm) (elm) (cm) 1 day 7 day 28 day Nil - 50 20 - 9.4 31.3 38.0 Admix E 0.3 - 21,23 47,47 8.1 29.7 38.5 Admix E 0.5 - 25,25 51,51 9.5 32.0 39.5 Admix E 0.74 - 26,27 55,56 8.3 32.0 39.0 Admix E 1.0 - 40,40 63,61 9.5 32.0 37.3 EP 82/27 0.1 - 22,22 50,50 8.6 31.3 38.0 EP 82/27 0.2 - 26,26 53,52 9.8 32.0 38.5 EP 82/27 0.3 - 27,28 56,55 7.7 31.5 37.5 EP 82/27 0.4 - 35,33 62,58 7.4 31.5 37.0 EP 82/27 is shown to produce highly workable concrete at much lower dosages than admixture E. The flow properties obtained by using admixture E at typical super-plasticiser dosage rates (0.6-1%) can be achieved by EP 82/27 at rates of addition in the range 0.2-0.4%. High Range Water Reduction Admixture E and EP 82/27 were used to produce high range water reductions (constant workability) in the following mix design. Mix Design OPC ex Blue Circle 350 kg/m3 20 mm Croxden Gravel 780 kg/m3 10 mm Croxden Gravel 330 kg/m3 Zone 3 Almington Pit Sand 740 kg/m3 8 Fines = 40 Aggregate/cement = 5.3 Results shown in Table VII. Table VII Admixture Dose % Compressive Strength by wit Slump % Water (N/mm2) Admixture OPC W/C (mm) Reduction 1 day 7 day 28 day Nil - 0.66 60 - 8.2 27.3 38.5 Admix E 0.3 0.61 55 7.4 9.1 32.7 42.0 Admix E 0.5 0.59 50 10.9 11.0 32.6 43.0 Admix E 1.0 0.55 60 15.7 12.9 39.0 45.0 Admix E 1.5 0.53 50 19.6 15.6 44.4 46.8 Admix E 2.5 0.51 45 22.8 15.0 44.0 53.0 EP 82/27 0.1 0.59 50 10.0 10.0 33.1 44.0 EP 82/27 0.2 0.59 55 10.9 10.2 36.3 46.0 EP 82/27 0.5 0.55 55 15.7 11.1 39.8 49.8 EP 82/27 0.8 0.53 60 19.6 11.1 44.0 51.0 EP 82/27 1.5 0.51 55 22.8 9.2 45.0 56.8 Compared with admixture E, EP 82/27 is shown to perform very efficiently as a water reducing agent, producing similar increases in compressive strength at much lower doses. Evaluation of Range of Hydroxy Monomers Abbreviations used: AA = Acrylic acid MAA = Methacrylic acid HPA = Hydroxy propyl acrylate HPMA = Hydroxy propyl methacrylate HEMA = Hydroxy ethyl methacrylate HEA = Hydroxy ethyl acrylate TBP = Tri-n-butyl phosphate Copolymers were prepared as 30% w/w active solutions as sodium salts in water (+0.25% TBP). Visc (cps) 15% 1M aqueous NaCl F 2.5/1 molar MAA/HPA 7.4 G 2.5/1 molar AAtEEMA 5.1 H 2.5/1 molar AA/HPMA 5.4 J 2.5/1 molar AA/HEk 3.4 The copolymers were evaluated in concrete in comparison with EP 82/27 (viscosity 5.1 cps) (2.5/1 molar AA/HPA). Mix Design OPC 3.5 kg 20 mm Croxden Gravel 7.8 kg 10 mm Croxden Gravel 3.3 kg Zone 3 Almington Pit Sand 7.0 kg Water/cement = 0.61 Admixtures were dosed at 0.4% bwc in order to produce flowing concrete. Workability of the concrete was measured using 'Flow Table' according to DIN 1048. Flow A refers to spread before tamping and Flow B to the spread after tamping. Table VIII Compressive Strength Slump Flow A Flow B (N/mm2) Admixture (mm) (cm) (cm) 7 day 28 day Nil 90 23 40 33.2 44.8 EP 82/27 - 31 60 34.5 44.0 F - 32 61 32.5 44.3 G - 35 61 34.5 45.2 H - 39 64 32.8 - 44.3 J - 32 60 33.0 45.5 Using the same mix design, admixtures G and H were re-evaluated in comparison with both EP 82/27 and admixture E in order to determine 1 day compressive strengths and 'set' times. Table IX Compressive Admixture Strength Dose Slump Flow A Flow B (N/mm2) Admixture % bwc (mm) (cm) (cm) 1 day Nil - 90 23 40 9.5 EP 82/27 0.4 - 43 63 8.1 G 0.4 - 43 66 8.8 H 0.3 - 44 67 8.4 H 0.4 - 49 68 8.2 Admix E 1.0 - 48 66 8.5 Penetration tests were conducted using a Proctor Needle (according to ASTM No C-403-80) were carried out and the results are summarised below: Table X Admixture Extension of Set over Control Dose (hours) Admixture % bwc Initial Final EP 82/27 0.4 2.2 2.2 G 0.4 1.4 1.6 H 0.3 1.0 1.3 H 0.4 2.7 2.5 Admix E 1.0 2.7 2.5 The plasticising performance of a range of hydroxy acrylates/methacrylates demonstrates that the AA/HPMA copolymer is preferred. The use of methacrylic acid instead of acrylic acid in EP 82/27 gives similar results. In concretes of similar initial high workability set retardation is in the following order (2.5/1 copolymers with AA). Admixture E > HPA > HEMA > HPMA (retards most) (retards least) Various copolymers were made to demonstrate the effect of varying the AA/HPMA ratio of the general type of admixture H. Visc (cps) 15% solids in 1M aqueous NaCl K 2/1 molar (67 mole % AA) AA/HPMA 5.3 L 2.5/1 " (71 mole % AA) AA/HPMA 5.1 M 3.0/i n (75 mole % AA) AA/HPMA 6.4 N 5.0/1 n (83 mole % AA) AA/HPMA 5.2 P 1/0 " (100 mole % AA) AA/- 6.6 Each copolymer was made up into the following additive composition: 30% Copolymer as Na salt 69.75% Water 0.25% TBP Mix Design OPC 350 kg/m3 20 mm Croxden Gravel 780 kg/m3 10 mm Croxden Gravel 330 kg/m3 Zone 3 Almington Pit Sand 700 kg/m3 Water 200 kg/m3 Water/cement = 0.57 % Fines = 38.7 Aggregate/cement = 5.2 Admixture dose = 0.4% bwc. Table XI Compressive Strength Slump (N/mm2) Admixture (mm) Flow A Flow B 1 day 7 day Nil 60 20 * 11.2 38.0 K 32 56 9.5 37.0 L 30 56 9.6 38.0 M 28 53 8.8 35.5 N 24 50 8.6 38.3 P 20 44 8.0 34.7 * No cohesion Results show mole% AA in copolymer significantly affects performance as a plasticiser and to some extent early compressive strength development and support the preferred 60 to 85 mole % acrylic acid content. Comparisons were made with two other commercially-available plasticisers. They were: Composition B - a calcium lignosulphonate 43% w/w solution Composition C - a polysaccharide-based water reducing agent Mix Design OPC ex Blue Circle 350 kg/m3 20 mm Croxden Gravel 780 kg/m3 10 mm Croxden Gravel 330 kg/m3 Zone 1 Almington Pit Sand 70 kg/m3 Zone 2 Almington Pit Sand 670 kg/m3 Aggregate/cement = 5.3 % Fines = 40 Table XII Admixture Plastic Compressive Strength Dose Density Slump (N/mm; ;) Admixture % bwc W/C St!L (mm) 1 day 7 day 28 day Nil Nil 0.67 2360 45 3.1 31.8 40.2 EP 82/27 0.05 0.67 2360 85 3.1 31.7 39.3 EP 82/27 0.1 0.67 2360 160 2.8 31.0 39.6 EP 82/27 0.2 0.67 2360 195 3.1 31.3 40.0 Comp B 0.2 0.67 2360 140 3.1 32.4 41.2 Comp B 0.3 0.67 2360 150 2.3 30.7 39.1 Comp B 0.4 0.67 2360 180 2.3 31.2 41.0 Comp C 0.2 0.67 2360 175 3.3 33.1 40.5 Comp C 0.3 0.67 2360 190 2.7 33.6 41.2 Comp C 0.4 0.67 2360 220 1.0 33.9 43.0 At the dosage levels used here EP 82/27 shows no retardation of 1 day compressive strength. Increased dosages of composition B and composition C to obtain higher workability result in retardation of early strength. 7 and 28 day compressive strength results are all similar. EP 82/27 is shown to perform as a highly effective low dosage plasticiser. Comparing the dosage levels required to produce concrete with, eg 150 mm slump: EP 82/27 0.09% bwc Composition B 0.25% bwc Composition C 0.16% bwc

Claims: CLAIMS 1. A cementiferous composition comprising as a plasticiser additive, a copolymer or soluble salt thereof comprising from 50 to 95 mole % of an ethylenically polymerisable carboxylic acid and from 5 to 50 mole % of a hydroxy alkyl ester of an ethylenically polymerisable carboxylic acid. 2. A cementiferous composition as claimed in claim 1 in which the acid is selected from methacrylic acid, maleic acid and acrylic acid and the esters selected from hydroxy ethyl, propyl and butyl acrylates and methacrylates. 3. A cementiferous composition as claimed in claim 1 or claim 2 in which the mole percentage of acrylic acid in the copolymer is in the range 60 to 85 mole %. 4. A cementiferous composition as claimed in claim 1, 2 or 3 in which the molecular weight of the copolymer is in the range 1000 to 15000.. 5. A cementiferous composition as claimed in claim 4 in which the molecular weight of the copolymer is in the range 1000-9000. 6 A cementiferous composition as claimed in any one of the preceding claims in which the amount of hydroxy alkyl acrylate copolymer, or soluble salt thereof in the cementiferous composition is in the range 0.01% to 2.5% by weight on the cement in the cementiferous composition. 7. A plasticiser additive composition comprising an aqueous solution of a copolymer, or a soluble salt thereof, comprising 50 to 95 mole % of an ethylenically polymerisable carboxylic acid and from 5 to 50 mole $-of a hydroxy alkyl ester of an ethylenically polymerisable carboxylic acid and an effective amount of an anti-foaming agent. 8. A plasticiser additive composition as claimed in claim 7 in which the acid is maleic acid, methacrylic acid or acrylic acid and the ester is hydroxy ethyl, propyl and butyl acrylate or methacrylates. 9. A plasticiser additive composition as claimed in claim 7 or 8, in which the amount of anti-foaming agent is in the range 0.1 to 2% by weight of the copolymer or salt thereof. 10. A plasticiser additive as claimed in claims 7, 8 or9, in which the anti-foaming agent is selected from tributyl phosphate, di-butyl phthalate, water-insoluble alcohols and silicone derivatives. 11. A plasticiser additive as claimed in any one of the claims 7, 8, 9 or 10, in which the hydroxy alkyl acrylate is hydroxy propyl methacrylate. 12. A plasticiser additive as claimed in any one of the claims 7, 8, 9, 10 or 11, in which the mole percentage of acrylic acid in the copolymer is in the range 60 to 85 mole %. 13. A process for the preparation of a plasticised cementiferous composition comprising adding to a cementiferous material a plasticiser additive as claimed in any one of the claims 7 to 12. 14. -A cementiferous composition comprising a plasticiser additive as claimed in any one of the claims 7 to 12.

Inventors: BRADLEY, GEOFFREY, SZYMANSKI, CHESTER D.
Applicants: NATIONAL STARCH AND CHEMICAL CORPORATION
Application year: 1983
Main classification: C04B24
IPC codes: C04B24