WATER-SOLUBLE AIR-CONTROLLING AGENTS FOR CEMENTITIOUS COMPOSITIONS

Abstract: Water-soluble air-controlling agents can be admixed with dispersant for cementitious compositions to provide an admixture for cementitious compositions that is stable over time. The water-soluble air-controlling agents are compatible with water based polycarboxylate polymer dispersants. Suitable water-soluble air-controlling agents include alkoxylated polymers. A cementitious composition is provided that includes cement, water, a dispersant for cementitious compositions, and a water-soluble air-controlling agent. A method is provided for making a cementitious composition that includes mixing cement, water, a dispersant for cementitious compositions, and a water-soluble air-controlling agent.

Description: WATER-SOLUBLE AIR-CONTROLLING AGENTS FOR CEMENTITIOUS COMPOSITIONS FIELD OF THE INVENTION The present invention is directed to air-controlling agents that are used in conjunction with a dispersant for cementitious compositions to control air content in cementitious compositions. Particularly, the present invention is directed to water- soluble air-controlling agents used in conjunction with a dispersant for cementitious compositions. BACKGROUND OF THE INVENTION Hydraulic cements, such as Portland cement, are used to form structural formations. Hydraulic cements can be mixed with fine aggregate and water to form mortars, or with coarse aggregate to form concretes. When working with hydraulic cements, it is desired to increase the slump and flow properties of the initially-formed hydraulic cement composition to aid in placement of the composition and to extend the period of flowability in order to provide working time to finish the placement of the structure. Admixtures which increase the slump and workability can be added to hydraulic cement. Additionally, there can also be added admixtures which also reduce the amount of water required to produce flowable cementitious compositions. The reduced water content increases the strength of the resulting hydraulic cement formation. One admixture for increasing the flowability and reducing the water content is a polycarboxylate dispersant. Polycarboxylate dispersants are polymers with a carbon backbone with pendant side chains, wherein at least a portion of the side chains are attached to the backbone through a carboxyl group or an ether group. Polycarboxylate dispersants are very effective at dispersing and reducing the water content in hydraulic cements. One drawback of polycarboxylate dispersants is that they have a tendency to entrain air in the cementitious composition during mixing. While some entrained air may be desired for particular applications, such as providing freeze-thaw durability to the cementitious composition, an excess of entrained air is detrimental to the compressive strength of the resulting hydraulic formation. In addition, some insoluble defoamers, or contamination, can cause unpredictable air contents over time. Generally in the construction industry, non-air-entrained cementitious compositions having an air content of less than 3% is desired, with an air content of less than 2% being preferred. Air-entraining admixtures are sometimes used deliberately to provide air contents of 5-8% which improves the freeze-thaw durability of the cementitious mixture. When this is the case, it is desirable to be able to adjust the air content by changing the air entrainer dosage and to have the resulting air remain stable over time. To overcome the excess entraining of air in cementitious compositions, defoamers have been added to the cementitious mix to reduce the air content to a desired level. Defoamers typically have been included with the polycarboxylate admixture. However, the defoamers used in the prior art have been non-water-soluble compositions. The problem with non-water-soluble defoamers is that they give an inadequate long term storage stability to the admixture. The polycarboxylate dispersant is generally a water-soluble dispersant. When a non-water-soluble defoamer is used in conjunction with a water-soluble dispersant, the mixture separates over time. This requires that the mixture be mixed prior to use. Commercial defoamers typically contain a mixture of materials. The major part is an oil or organic liquid (up to 95 parts by weight), small particulate (up to 15 parts by weight), and a surfactant (up to 5 parts by weight). Another technique used in the prior art has been the grafting of the defoamer on to the dispersant molecule. What is needed in the industry is an air-controlling agent that can produce controllable air contents in non-air-entrained and air-entrained cementitious compositions in the presence of a dispersant for cementitious compositions. It is therefore an object of the invention to provide a water-soluble air- controlling agent in the presence of a dispersant for cementitious compositions that produces controllable air contents in non-air-entrained and air-entrained cementitious compositions. It is another object of the invention to provide an admixture containing a water- soluble air-controlling agent and a dispersant for cementitious compositions that is stable over time. SUMMARY OF THE INVENTION Water-soluble air-controlling agents can be mixed with a dispersant for cementitious compositions to provide an admixture for cementitious compositions that is stable over time. The water-soluble air-controlling agents are compatible with water- based dispersants for cementitious compositions. The resulting compatible admixture has long-term storage stability so that the admixture does not need to be mixed prior to use at the work site. The water-soluble air-controlling agent in the presence of a dispersant for cementitious compositions provides controllable air contents in non-air- entrained and air-entrained cementitious compositions. The present invention provides an admixture for cementitious compositions comprising a water-soluble air-controlling agent and a dispersant for cementitious compositions. The present invention also provides a cementitious composition comprising cement, water, a water-soluble air-controlling agent, and a dispersant for cementitious compositions. The present invention also provides a method of making a cementitious composition comprising mixing cement, water, a water-soluble air-controlling agent, and a dispersant for cementitious compositions. DETAILED DESCRIPTION OF THE INVENTION The term "air-controlling agent" (ACA) refers to any material that functions to regulate the air content in cementitious compositions in a predictable manner. The term "dispersant for cementitious compositions" throughout this specification includes polycarboxylate dispersants and oligomeric dispersants. The term "polycarboxylate dispersant" throughout this specification refers to polymers with a carbon backbone with pendant side chains, wherein at least a portion of the side chains are attached to the backbone through a carboxyl group or an ether group. The term dispersant is also meant to include those chemicals which also function as a plasticizer, water reducer, fluidizer, antiflocculating agent, or superplasticizer for cementitious compositions. A number of different polycarboxylate dispersants are useful in the working of this invention. Examples of suitable dispersants may be found in United States Patents 5,158,996, 5,494,516, 5,612,396, 5,162,402, 5,660,626, 6,063,184, 5,668,195 and 5,798,425, and European Patent Application 0 753 488. A preferred example of a polycarboxylate dispersant is a polymer comprising units derived from at least a substituted carboxylic acid monomer, and optionally including at least one of an unsaturated hydrocarbon, an N-polyoxyalkylene maleimide, and a condensation product of an unsubstituted carboxylic acid monomer and an alkoxypolyoxyalkylene primary amine-substituted carboxylic acid monomer. The polycarboxylate dispersant preferably has the general structure shown below: where: D = a component selected from the group consisting of the structure dl, the structure d2, and mixtures thereof; X = H, CH 3 , C to C 6 alkyl, phenyl, substituted phenyl such as p-methyl phenyl, sulfonated phenyl; Y = H, -COOM; R — H, CH 3 ; Z = H, -SO 3 M, -PO 3 M, -COOM, -OR 3 , -COOR 3 , -CH 2 OR 3 , -CONHR 3 , -CONHC(CH 3 ) 2 CH 2 SO 3 M, -COO(CHR 4 ) n OH where n=2-6; Ri, R , R 3 , R 5 are each independently -(CH CHRO) m R random copolymer of oxyethylene units and oxypropylene units where m=10 to 500 and wherein the amount of oxyethylene in the random copolymer is from 60% to 100% and the amount of oxypropylene in the random copolymer is from 0% to 40%; R 4 = H, methyl, C -C 6 alkyl, C 6 -Cιo aryl; M = H, alkali metal, alkaline earth metal, ammonia, amine, substituted amine such as triethanolamine, methyl, C -C 6 alkyl; a = 0 to 0.8, preferably 0 to 0.6, and most preferably 0 to 0.5; b = 0.2 to 1.0, preferably 0.3 to 1.0, and most preferably 0.4 to 1.0; c = 0 to 0.5, preferably 0 to 0.3, and most preferably 0 to 0.1 ; d = 0 to 0.5, preferably 0 to 0.3, and most preferably 0 to 0.1 ; and wherein a, b, c, and d represent the mole fraction of each unit and the sum of a, b, c, and d is 1.0. Representative monomers for the "a" component include, but are not limited to, styrene, ethylene, propylene, or sulfonated styrene. Representative monomers for the "b" component include, but are not limited to, acrylic acid, methacrylic acid, alkyl esters of acrylic acid, alkyl esters of methacrylic acid, alkoxypolyoxyalkylene esters of acrylic acid, aryloxypolyoxyalklyene esters of acrylic acid, alkoxypolyoxyalkylene esters of methacrylic acid, aryloxypolyoxyalkylene esters of methacrylic acid, maleic acid, maleic anhydride, vinyl sulfonic acid, methoxypolyoxyalkylene vinyl ether, methoxypolyoxyalkylene allyl ether, alkoxypolyoxyalkylene vinyl ether, aryloxypolyoxyalkylene vinyl ether, alkoxypolyoxyalkylene allyl ether, or aryloxypoloxyalkylene allyl ether. Components "c" and "d" can be formed from a post-reaction from the grafting of the side chains on to the polymer backbone such as a polyacrylate maleic anhydride copolymer. If the temperature is high enough, the imide components "c" and "d" are formed. Component "c" is formed from a single monomer which is a component "b" with Y being COOH and Z being CONHR 3 . A condensation reaction occurs wherein water condenses and the ring closes to form component "c". Component "d" is formed by a condensation of two monomers such as acrylic acid (component "b" with Y being COOH and Z being H) and an acrylic acid derivatized with an alkoxypolyoxyalkylene primary amine, that is, a component "b" with Y being H and Z being CONHR 3 . A condensation reaction occurs wherein water condenses and the ring closes to form component "dl" or "d2". Component "d2" is formed by a head-to-head reaction of the two monomers. Component "dl " is formed by a head-to-tail reaction of the two monomers. Component "b" can also be maleic anhydride when Y and Z are selected to be -COOH in the anhydride form. The term "oligomeric dispersant" throughout this specification refers to an oligomer that is a reaction product of a component A, optionally component B, and component C; wherein each component A is independently a nonpolymeric, functional moiety that adsorbs on to a cementitious particle, and contains at least one residue derived from a first component selected from the group consisting of phosphates, phosphonates, phosphinates, hypophosphites, sulfates, sulfonates, sulfinates, alkyl trialkoxy silanes, alkyl triacyloxy silanes, alkyl triaryloxy silanes, borates, boronates, boroxines, phosphoramides, amines, amides, quaternary ammonium groups, carboxylic acids, carboxylic acid esters, alcohols, carbohydrates, phosphate esters of sugars, borate esters of sugars, sulfate esters of sugars, salts of any of the preceding moieties, and mixtures thereof; wherein component B is an optional moiety, where if present, each component B is independently a nonpolymeric moiety that is disposed between the component A moiety and the component C moiety, and is derived from a second component selected from the group consisting of linear saturated hydrocarbons, linear unsaturated hydrocarbons, saturated branched hydrocarbons, unsaturated branched hydrocarbons, aryl, phosphoester, nitrogen- containing compounds, and mixtures thereof; and wherein component C is at least one moiety that is a linear or branched water-soluble, nonionic polymer substantially non-adsorbing to cement particles, and is selected from the group consisting of poly(oxyalkylene glycol), poly(oxyalkylene amine), poly(oxyalkylene diamine), monoalkoxy poly(oxyalkylene amine), monoaryloxy poly(oxyalkylene amine), monoalkoxy poly(oxyalkylene glycol), monoaryloxy poly(oxyalkylene glycol) poly(vinyl pyrrolidones), poly(methyl vinyl ethers), poly(ethylene imines), poly(acrylamides), polyoxazoles, and mixtures thereof. Another preferred class of polycarboxylate polymers capable of functioning as a polymer dispersant, comprises a functionalized polyimide or polyamide main chain polymer on to which are grafted at least a proportion of oligomeric or polymeric hydrophilic side chains. The grafted side chains may include linking amides, esters, and thioesters. This polymer dispersant having a hydrophilic side chain substituted backbone has the general formula: wherein X is at least one of hydrogen, an alkali earth metal ion, an alkaline earth metal ion, ammonium ion, and amine; R is at least one of Cj to C 6 alkyl(ene) ether and mixtures thereof and Ci to C 6 alkyl(ene) imine and mixtures thereof; Q is at least one of oxygen, nitrogen, and sulfur; p is a number from 1 to 300 resulting in at least one of a linear side chain and branched side chain; Ri is at least one of hydrogen, Ci to C 20 hydrocarbon, and functionalized hydrocarbon containing at least one of -OH, -COOH, a derivative of -COOH, sulfonic acid, a derivative of sulfonic acid, amine, and epoxy; Y is a hydrophobic hydrocarbon or polyalkylene oxide moiety; m, m', m", n, n' and n" are each independently 0 or an integer between 1 and 20; Z is a moiety containing at least one of i) at least one amine and one acid group, ii) two functional groups capable of being incorporated into the backbone selected from the group consisting of dianhydrides, dialdehydes, and di-acid chlorides, and iii) a succinimide residue; and wherein a, b, c and d reflect the mole fraction of each unit wherein the sum of a, b, c and d equal one, wherein a, b, c and d are each greater than or equal to zero and less than one, and at least two of a, b, c and d are greater than zero. More particularly, Y is at least one of a hydrophobic polyalkylene glycol block polymer and a hydrophobic polyalkylene glycol random polymer; and Z is at least one of an imide, a succinimide residue, a natural amino acid, a derived amino acid, H N(CH 2 ) k COOH, a derivative of H N(CH 2 ) k COOH, aminobenzoic acid, a derivative of aminobenzoic acid, H N(CH ) k SO 3 H, a derivative of H N(CH ) k SO 3 H, sulfanilic acid, and a derivative of sulfanilic acid where k is an integer between 1 and 20. Most preferably R \ is a Ci to C alkyl; and m, m', m", n, n' and n" are each independently an integer between 0 and 2. In a preferred embodiment, the grafted polymer dispersant has the general formula: wherein a, b, c, d and g reflect the mole fraction of each unit wherein the sum of a, b, c, d and g equal one, wherein a, b, c, d, and g are each a decimal of value greater than or equal to zero and less than one, and at least two of a, b, c, and d are greater than zero; X 3 is at least one of i) a moiety which will neutralize the negative charge on the carboxyl (COO " ) ion, and ii) a hydrophobic hydrocarbon or polyalkylene oxide moiety, which if present, replaces no more than 20 mole% of X 3 . By way of example but not limitation, the neutralizing moiety can be an ammonium ion, ions of sodium, potassium, lithium, calcium, and the like. X is a hydrophilic side chain having the structure: R 2 CH R 5 — O (R 3 ) e (R 4 ) f CH 3 wherein R 2 is H, a Cj to C 4 linear or branched alkyl, such as methyl, ethyl, propyl, or butyl, or phenyl; R 5 is a Ci to C linear or branched alkyl, such as methylene, an alkylene, or phenylene; R 3 is a residue derived from ethylene oxide, and R 3 is present randomly or in block form; e is 1 to 300, preferably 11 to 300; R 4 is a residue derived from propylene oxide, and R t is present randomly or in block form; f is 0 to 180, preferably with a mole ratio of R 3 :R t of 100:0 to 40:60. Z is an imide group such as, but not limited to, a succinimide moiety. It is noted that the higher the proportion of propylene oxide present in the side chain, the less hydrophilic the side chain will be. The a and c units of the preferred grafted polymer dispersant each represent an α-linkage and the b and d units each represent a β-linkage of the reacted unit of the reactant N-succinimide polymer. While it is possible to have 100% α or β, preferably the proportion of α to β linkage is 1 : 100 to 100: 1. The grafted polymer dispersant may contain an imide located at the point of attachment of the side chain with the polymer, or located in the backbone of the polymer. The grafted polymer dispersant has a weight-average molecular weight of 1,000 to 1,000,000. More preferably, the grafted polymer dispersant has a molecular weight average of 2,000 to 100,000. Most preferably, the grafted polymer dispersant has a molecular weight average of 3,000 to 50,000. The units comprising the polymer may be present randomly or in block form. The polymer backbone is substantially linear, but could have slight branching, such as every 10 th residue. As used herein, the term "cement" refers to any hydraulic cement. Hydraulic cements are materials which set when mixed with water. Suitable examples of hydraulic cements include, but are not limited to, portland cement, masonry cement, alumina cement, refractory cement, magnesia cement, calcium sulfoaluminate cement, and mixtures thereof. "Pastes" are defined as mixtures composed of a hydraulic cement binder, either alone or in combination with pozzolans such as fly ash, silica fume, or blast furnace slag, and water. "Mortars" are defined as pastes that additionally include fine aggregate. Concretes additionally include coarse aggregate. A water-soluble air-controlling agent can be combined with a dispersant for cementitious compositions to form an admixture for cementitious compositions. This admixture is stable over time in that there is little or no phase separation between the dispersant and air-controlling agent. The amount of water-soluble air-controlling agent that is present in the admixture ranges from 0.25 weight% to 40 weight% based on the weight of the dispersant for cementitious compositions. Preferably, the amount of water-soluble air- controlling agent that is present in the admixture ranges from 1 weight% to 20 weight% based on the weight of the dispersant for cementitious compositions. Examples of the water-soluble air-controlling agent include, but are not limited to, compounds of alkoxylated R, where R could be: a hydrocarbon, sorbitan, polypropylene oxide, fatty acid, fatty alcohol, or C 8 -C 2 alkyl amine. The hydrocarbon preferably contains from 1 to 22 carbons, and the fatty acid and fatty alcohol preferably contain from 8 to 22 carbon atoms. Preferred alkoxylates are molecules containing ethylene oxide and/or propylene oxide. Most preferred alkoxylates are molecules containing ethylene oxide. The water-soluble air-controlling agents can be used in combination with other water-soluble air-controlling agents. Specific examples of these types of water-soluble air-controlling agents include, but are not limited to those set forth below. Block copolymers of ethylene oxide (EO) and propylene oxide (PO), such as PLURONIC® products available from BASF, are examples of water-soluble air- controlling agents. Standard PLURONIC® products are EO-PO-EO based copolymers. PLURONIC® products with an R in the product name are PO-EO-PO based. The basic structures are given below: CH, HO-4-CH 2 CH 2 θ44-CH 2 CHO >-H-<CH 2 CH 2 0- PLURONIC PLURONIC R The SURFYNOL® 400 series of products are acetylenic diols. The basic structure of SURFYNOL® 400 series products is given by the following structure: TERGITOL® NP, from Union Carbide Company, is a polymer of ethylene oxide and nonylphenol (ethoxylated nonylphenol) and is represented by the following structure: JEFFOX® chemicals, from Huntsman Chemical Company, are mono alkyl polyoxyalkylenes. Preferred is a 50/50 ethylene oxide/propylene oxide random polymer with a mono-butyl terminal group [Bu-O-(PO) x (EO) x -H]. One measure of a product's emulsification characteristics is the hydrophile lipophile balance (HLB). As the HLB increases, there are more hydrophilic groups in the surfactant and the more the surfactant is water-soluble. Generally, an HLB of 3-6 indicates a water-in-oil emulsifier, an HLB of 7-9 indicates a wetting agent, an HLB of 8-18 indicates an oil-in-water emulsifier, an HLB of 13-15 indicates a detergent, and an HLB of 15-22 indicates a solubilizer. The following references provide more information about HLB: The Atlas HLB System, 4 th printing, Wilmington, Delaware, Atlas Chemical Industries, 1963; "Emulsions", Ullmans's Encyclopedia of Industrial Chemistry. 5 th ed 1987; Fox, C, "Rationale for the Selection of Emulsifying Agents", Cosmetics & Toiletries 101.11 (1986), 25-44; Graciaa, A., J. Lachaise, and G. Marion, "A Study of the Required Hydrophile-Lipophile Balance for Emulsification", Langmuir 5 (1989):1215-1318; and Griffin, W.C. "Emulsions", Kirk Othmer Encyclopedia of Chemical Technology, 3 rd ed 1979. Generally, materials with an HLB of up to 4 have strong defoaming properties. As the HLB value increases, the defoaming capabilities decrease and foaming capabilities increase. In the present invention, the air-controlling agents generally have an HLB value ranging from 5 to 22. The admixture of the present invention can be used in combination with any other admixture or additive for cement. Other cement admixtures and additives include, but are not limited to, set retarders, set accelerators, air-entraining or air-detraining agents, corrosion inhibitors, any other dispersants for cement, pigments, wetting agents, water-soluble polymers, strength-enhancing agents, rheology-modifying agents, water repellents, and any other admixture or additive that does not adversely affect the properties of the admixture of the present invention. A method of controlling air in a cementitious composition is also provided which comprises mixing cement, water, a water-soluble air-controlling agent, and a dispersant for cementitious compositions. The amount of water added to the cementitious composition is calculated based on a desired water to cement (W/C) ratio. The water to cement ratio typically ranges from 0.2 to 0.7 with the water and cement being measured by weight. The air-controlling agent can be added to a cementitious composition separately or it can be included with an admixture which is added to the cementitious composition, such as with the dispersant for cementitious compositions. SPECIFIC EMBODIMENTS OF THE INVENTION Samples of cementitious compositions were prepared using a polycarboxylate dispersant, comprising a polymeric carboxylate backbone with polyether side chains, and tested as detailed below. The following tests were used: Slump (ASTM C143), Air content (ASTM C231), Set time (ASTM C403), % Flow (ASTM C-230). Aggregates met the specifications of ASTM C33. The term W/C refers to the water to cement ratio in a cementitious mixture. The term S/A refers to the sand to aggregate ratio by volume. Air-entraining agents used in the following examples were MB AE® 90 or MB VR® from Master Builders, Inc., Cleveland, Ohio. Typical properties of the air-controlling agents (ACA) used in the examples below are : Air-controlling agent HLB Water Solubility Polyoxyalkylene - PLURONIC® L-61 3 insoluble Polyoxyalkylene - PLURONIC® L-31 5 soluble > 10% Polyoxyalkylene - PLURONIC® 17R2 6 soluble > 10% Polyoxyalkylene -PLURONIC® L-43 12 soluble > 10% Ethoxylated acetylenic diol -SURFYNOL® 420 4 insoluble Ethoxylated acetylenic diol -SURFYNOL® 440 8 slightly soluble <1% Ethoxylated acetylenic diol -SURFYNOL® 465 13 soluble >1% Alkyl aryl alkoxylate - TERGITOL® NP-6 10.9 soluble Mono alkyl poly oxyethylene (MW 1400) N/A soluble > 10% Mono alkyl polyoxyethylene (MW 2400) N/A soluble > 10% Example 1 Different ACAs ranging in HLB from 1 to 19, listed below in Table 1, were tested in combination with a polycarboxylate dispersant. The reference dispersant was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 grams per hundred grams of cement. The amount of ACA was based on the active amount of dispersant added and was 1% for all mixtures. The mortar mix contained 540g of Medusa Type I cement, 1455 grams of sand, and 190 grams of water. The W/C ratio was 0.35. The results are listed below in Table 1. TABLE 1 The results shown in Table 1 demonstrate that materials with HLB values as high as 19 reduce air contents in cementitious mixtures containing polycarboxylate dispersants, and that materials with HLB values >5, which are beyond the range generally expected for defoamers, unexpectedly reduce air content in non-air entrained mixtures to acceptable levels. In addition, air contents do not significantly change with mix time and this produces predictable performance in practice. Example 2 Different polyoxyalkylenes ranging in HLB from 1 to 14, listed below in Table 2, were tested in combination with a polycarboxylate dispersant and an air-entraining agent, MB VR®. The reference dispersant was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 grams per hundred grams of cement. The amount of polyoxyalkylene was based on the active amount of dispersant added and was 1% for all mixtures. The air entrainer amount was present at about 62.5 grams per 100 kg cement. The mortar mix design contained 540g of Medusa Type I cement, 1455 grams of sand, and 190 grams of water. The W/C ratio was 0.35. The results are listed below in Table 2. TABLE 2 Mix 2-1 shows high and stable air contents over time due to the polycarboxylate dispersant. Mix 2-2 shows that the combination of polycarboxylate dispersant and air entrainer produces even higher air contents that are stable over time. Mix 2-3 demonstrates unstable air contents over time in the presence of an air entrainer and an insoluble, low HLB defoaming agent. The other mix results demonstrate that with higher HLB air-controlling agents, stable and predictable air contents can be achieved with the combination of polycarboxylate dispersant and air entraining agent. Examples 3, 4, and 5 contain the results for air-controlling agents in non-air- entrained concrete. Concrete mixture proportions for the examples shown in Table 3 contained 658 lb./yd 3 cement content using a Type I portland cement, a sand: aggregate ratio (S/A) of 0.429 using limestone coarse aggregate, sand, and sufficient water to obtain a slump of 6" to 8" (15.24-20.32 cm). Concrete mixture proportions for the examples shown in Tables 4 and 5 contained a 600 lb./yd (356 kg/m ) cement content using a Type I portland cement, a S/A of 0.433 using limestone coarse aggregate, sand, and sufficient water to obtain a slump of 6" to 8" (15.24-20.32 cm). Examples 6 and 7 contain the results for air-controlling agents in purposefully air-entrained concrete. Concrete mixture proportions contained a 600 lb./yd (356 kg/m 3 ) cement content using a Type I portland cement, a S/A ratio of 0.440 using limestone coarse aggregate, sand, and sufficient water to obtain a slump of 6" to 8" (15.24-20.32 cm). Example 3 Air-controlling agents were tested at different levels in combination with a polycarboxylate dispersant. The reference dispersant was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.29 lbs. per hundred weight of cement. The types of air-controlling agent tested were polyoxyalkylenes ranging in HLB from 1 to 12, PLURONIC® L-101, PLURONIC® L-61, PLURONIC® 17R2, and PLURONIC® L-43 from BASF, and a soluble alkyl aryl alkoxylate, TERGITOL® NP-6 from Union Carbide Company. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and the other air-controlling agents were added with the sand, except 3-6 and 3-7, which were added with the water. The results are listed below in Table 3. TABLE 3 The results in Table 3 show that the polyoxyalkylene and alkyl aryl alkoxylate type air-controlling agents can effectively lower the air content of a concrete mixture containing a polycarboxylate dispersant. Similar to the results found in Example 1, the soluble air-controlling agents having an HLB>5 were equally and unexpectedly as effective at lowering the air as traditional defoamers having an HLB<4. Example 4 Air-controlling agents were tested at different levels in combination with a polycarboxylate dispersant. The reference dispersant was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 kg per 100 kg cement. The types of air-controlling agent tested were polyoxyalkylenes ranging in HLB from 5 to 12 (PLURONIC® L-31, PLURONIC® 17R2, and PLURONIC® L-43 from BASF) and mono alkoxyalkoxylates (JEFFOX® WL-5000 and JEFFOX® WL- 660 from Huntsman Chemical Co). Two insoluble defoamers, a polyoxyalkylene, PLURONIC® L-61 (HLB=3), and SURFYNOL® DF-75, (a non-silicone proprietary mixture) from Air Products and Chemicals, Inc., were included for comparison. The amount of air-controlling agent stated was based on the active amount of dispersant added, and the dispersant and air-controlling agent were added together with the water. The composition test results are listed below in Table 4. TABLE 4 Example 4 shows a comparison of air-controlling agents and insoluble defoamers in non-air-entrained cementitious mixtures. Unexpectedly, the soluble air- controlling agent/polycarboxylate admixtures (4-3, 4-4, 4-7, 4-8, 4-9, 4-10, 4-11) performed as effectively as the known insoluble defoamer/dispersant combination. However, the soluble air-controlling agent/polycarboxylate dispersant admixtures are more stable over time as compared to the insoluble defoamer mixtures. Example 5 Air-controlling agents were tested at different levels in combination with a polycarboxylate dispersant. The reference dispersant was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 lbs. per hundred weight of cement. The type of air-controlling agent tested was an ethoxylated acetylenic diol, SURFYNOL® 465, compared to insoluble defoamers SURFYNOL® 420, and SURFYNOL® 440, from Air Products and Chemicals, Inc. The dispersant and air-controlling agent or defoamer were added together with the water. The amount of air-controlling agent or defoamer was based on the active amount of dispersant added. The SURFYNOL® 440 and 465 were stirred into the dispersant. The SURFYNOL® 420 was dispersed into the dispersant using a high shear propeller mixer operating at 1300 rpm for 2 minutes. The test results are listed below in Table 5. TABLE 5 Example 5 shows a comparison of acetylenic diol air-controlling agents with various degrees of solubility. The insoluble defoamer and soluble air-controlling agents performed similarly. Unexpectedly, the soluble air-controlling agent/polycarboxylate admixtures (5-7 and 5-8) performed as effectively as the known insoluble defoamer/dispersant combination. However, the soluble air-controlling agent/polycarboxylate dispersant admixtures are more stable over time as compared to the insoluble defoamer mixtures. The results in Tables 3, 4, and 5 demonstrate that any number of soluble polyoxyalkylenes, mono alkyl polyoxyalkylenes, or alkyl aryl alkoxylates may be used to control air contents of non-air-entrained concrete mixtures containing a polycarboxylate dispersant. Examples 6-1 through 6-6 Cement mixes were prepared that varied the amount of an insoluble polyoxyalkylene defoamer (HLB=3), PLURONIC® L-61, and the amount and type of an air entraining agent. The air-entraining agents were proprietary mixtures MB VR® or MB AE® 90 from Master Builders, Inc. The ACA levels were percentages based on the active weight of dispersant. The air entrainer amounts are listed as ml per 100 kg cement. All samples contained a dispersant, which comprised a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 kg per 100 kg cement. The amount of defoamer was based on the active amount of dispersant added. The dispersant and defoamer were added together with the water, and the air-entraining agent was added with the sand. The test results are listed below in Table 6. Examples 6-1 to 6-6 show the performance of a defoamer that demonstrates desired performance characteristics in air-entrained concrete; however, it is insoluble. The mixtures had typical dosages of air-entraining agents, which were stable over time. Examples 6-7 to 6-12 Concrete mixes were prepared that varied the amount of soluble polyoxyalkylene (HLB^) air-controlling agent, PLURONIC® L-31, the amount of air entraining agent, MB AE® 90, and the amount of dispersant. The air entrainer amount is listed as ml per 100 kg cement. The dispersant was a polymeric carboxylate backbone with polyether side chains. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and air-controlling agent were added together with the water and the air-entraining agent was added with the sand, except for Mix 6-12, which had the air entrainer added first, then the dispersant and air- controlling agent added two minutes later. The test results are listed below in Table 6. Examples 6-13 to 6-17 Concrete mixes were prepared with the same air-controlling agent as in examples 6-7 to 6-12 and a lower dosage of air entraining agent, MB AE® 90, and a varied amount of dispersant. A second air entrainer, MB VR®, was included for comparison. The air entrainer amounts are listed as ml per 100 kg cement. The dispersant was a polymeric carboxylate backbone with polyether side chains. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and air-controlling agent were added together with the water and the air entraining agent was added with the sand. The test results are listed below in Table 6. Examples 6-18 to 6-23 Concrete mixes were prepared that varied the amount of soluble polyoxyalkylene air-controlling agent (HLB=12), PLURONIC® L-43, and the amount of an air entraining agent, MB AE® 90. The air entrainer amount is listed as fluid ounces per hundred weight of cement. All samples contained a dispersant, which was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 kg per 100 kg cement. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and air-controlling agent were added together with the water. The air entraining agent was added with the sand. The test results are listed below in Table 6. Examples 6-24 to 6-28 Concrete mixes were prepared that varied the amount of soluble polyoxyalkylene air-controlling agent (HLB=7), PLURONIC® 17R2, and the amount of an air entraining agent, MB AE® 90. The air entrainer amount is listed as ml per 100 kg cement. All samples contained a dispersant, which was a polymeric carboxylate backbone with polyether side chains. The dispersant was added at 0.2 kg per 100 kg cement. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and air-controlling agent were added together with the water and the air entraining agent was added with the sand. The test results are listed below in Table 6. Examples 6-29 to 6-32 Concrete mixes were prepared that varied the amount of soluble polyoxyalkylene air-controlling agent (HLB=15), PLURONIC® L-64, and the amount of air entraining agent, MB AE® 90, and the amount of dispersant. The air entrainer amount is listed as ml per 100 kg cement. The dispersant was a polymeric carboxylate backbone with polyether side chains. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and air-controlling agent were added together with the water and the air entraining agent was added with the sand. The test results are listed below in Table 6. TABLE 6 Table 6 shows the results of water-soluble polyoxyalkylene air-controlling agents (6-7 to 6-32) compared to an insoluble polyoxyalkylene defoamer. Examples 6- 1 to 6-6 pertain to the insoluble polyoxyalkylene reference and show controlled and predictable air contents over time. Examples 6-7 to 6-12 show that a soluble air- controlling agent can provide similarly predictable air contents over time. Examples 6- 13 to 6-17 demonstrate that air contents can be adjusted by changing the dosage of the air entraining agent. Examples 6-18 to 6-23, 6-24 to 6-28, and 6-29 to 6-32 demonstrate that, as the solubility (HLB) increases, similar and predictable air contents can be obtained by increasing the percentage of the air-controlling agent in the polycarboxylate dispersant, adjusting the air-entraining agent dosage, or both. Example 7 Concrete mixes were prepared that varied the amount of one insoluble and one soluble ethoxylated acetylenic diol, SURFYNOL® 440 and SURFYNOL®465, the amount of air entraining agent, MB AE® 90, and the amount of dispersant. The air entrainer amount is listed as ml per 100 kg cement. The dispersant was a polymeric carboxylate backbone with polyether side chains and the percentage quantity is based on cement. The amount of air-controlling agent was based on the active amount of dispersant added. The dispersant and air-controlling agent were added together with the water and the air entraining agent was added with the sand. The test results are listed below in Table 7. TABLE 7 Table 7 shows that predictable air contents were obtained with the various levels of dispersant and soluble, ethoxylated acetylenic diol air-controlling agent, which was similar to the insoluble reference of the same chemistry. Example 8 Concrete mixtures were prepared at a ready mix plant to confirm the effectiveness of a water-soluble air-controlling agent in practice under field conditions, such as truck mixing. Mixes 8-1 and 8-3 represent a soluble air-controlling agent (HLB=5), PLURONIC® L-31. Mix 8-2 represents an insoluble defoamer (HLB=3), PLURONIC® L-61. Mix 8-4 represents the non-silicone proprietary mixture as in Example 4-12, SURFYNOL® DF-75. The air-controlling agent and reference defoamers were tested in combination with a polycarboxylate dispersant and an air-entraining agent, MB AE® 90. The reference dispersant was a polymeric carboxylate backbone with polyether side chains. The dispersant amount is listed as %> based on cement. The amount of air-controlling agent was based on the active amount of dispersant added. The air entrainer amount is listed as ml per 100 kg cement. The concrete mix proportions are listed in Table 8 below. For examples 8-1 and 8-2, the dispersant and air-controlling agent or reference defoamer combination was added to a concrete mix having a 2-3.5" (5.1-8.9 cm) slump. Examples 8-3 and 8-4 had the combination added immediately after batching all of the ingredients. TABLE 8 The results shown in Table 8 demonstrate that the water-soluble air-controlling agent is effective under field conditions, and that it provided predictable air contents that were maintained over a 60 minute time frame. A similar air content response was observed for the soluble air-controlling agent and insoluble defoamer when used with a dispersant level of 0.08%. The non-silicone proprietary mixture reference was found to have high and unpredictable air contents over time. Therefore, the present invention provides an admixture containing a polycarboxylate dispersant and a water-soluble air-controlling agent for controlling the amount of air in a predictable manner in cementitious compositions, and which is stable over time. The invention also provides a cementitious composition comprising cement, water, a water-soluble air-controlling agent, and a polycarboxylate dispersant for controlling the amount of air in a predictable manner in the cementitious composition. The present invention also provides a method of making a cementitious composition comprising mixing cement, water, a water-soluble air-controlling agent, and a polycarboxylate dispersant for controlling the amount of air in a predictable manner in cementitious compositions. The present invention also provides a water-soluble air-controlling agent to be used in conjunction with a polycarboxylate dispersant that is as effective at controlling the air content in cementitious compositions. It should be appreciated that the present invention is not limited to the specific embodiments described above, but includes variations, modifications and equivalent embodiments defined by the following claims.

Claims: CLAIMS 1. An admixture for cementitious compositions comprising a water-soluble air- controlling agent and a dispersant for cementitious compositions. 2. The admixture of claim 1, wherein the water-soluble air-controlling agent is at least one of an alkoxylated R, wherein R is at least one of a hydrocarbon, sorbitan, polypropylene oxide, fatty acid, fatty alcohol, or C 8 -C alkyl amine. 3. The admixture of claim 1 further comprising an air entrainer. 4. The admixture of claim 1, wherein the water-soluble air-controlling agent is present in an amount from 0.25%o to 40%> based on the weight of the dispersant for cementitious compositions. 5. A cementitious composition comprising cement, water, a water-soluble air- controlling agent and a dispersant for cementitious compositions. 6. The cementitious composition of claim 5, wherein the water-soluble air- controlling agent is at least one of an alkoxylated R, wherein R is at least one of a hydrocarbon, sorbitan, polypropylene oxide, fatty acid, fatty alcohol, or C 8 -C 2 alkyl amine. 7. A method of making a cementitious composition comprising mixing cement, water, a water-soluble air-controlling agent and a dispersant for cementitious compositions. 8. The method of claim 7, wherein the water-soluble air-controlling agent and the dispersant for cementitious compositions are added as one solution. 9. The method of claim 7, wherein the water-soluble air-controlling agent is added to the cementitious composition by one of i) separately, ii) in combination with the dispersant for cementitious compositions, and iii) in combination with an admixture.

Inventors: BURY JEFFREY R, LUCIANO JOHN, SHENDY SAMY M, VICKERS THOMAS M JR, BURY, JEFFREY, R., LUCIANO, JOHN, SHENDY, SAMY, M., VICKERS, THOMAS, M., JR.
Applicants: MBT HOLDING AG
Application year: 2000
Main classification: C04B24
IPC codes: C04B24, C04B28, C04B40, C04B103