Process for preparing fast-setting aggregate compositions and products of low porosity produced therewith

Claim 2

A PROCESS FOR PRODUCING A FAST-SETTING CONCRETE STRUCTURE, HAVING A POROSITY OF NOT MORE THAN ABOUT 5 PERCENT, WHICH IS CAPABLE OF LOAD-BEARING USE WITHIN A FEW HOURS AFTER MIXING AND WHICH IS PRODUCED AND INTENDED TO BE USE IN A SITUATION OF ORDINARY AMBIENT ATMOSPHERIC TEMPERATURE OF NOT MORE THAN ABOUT 150*F, COMPRISING A. ESTABLISHING A MIXTURE OF I. AN AGGREGATE CONTAING AT LEAST ABOUT 10 PERCENT BY WEIGHT OF MAGNESIA AND II. AMMONIUM PHOSPHATE IN AQUEOUS SOLUTION IN AN AMOUNT EQUAL TO BETWEEN ABOUT 3 AND ABOUT 10 PARTS BY WEIGHT OF P205 PER 100 PARTS BY WEIGHT OF SAID AGGREGATE, THE COMPOSITION OF SAID PHOSPHATES IN PERCENT BY WEIGHT BEING NOT MORE THAN ABOUT 40 PERCENT ORTHOPHOSPHATE AND AT LEAST ABOUT 60 PERCENT PHOSPHATES SELECTED FROM THE CLASS CONSISTING OF PYROPHOSPHATE AND POLYPHOSPHATES WHEREOF AT LEAST ABOUT 2 PERCENT ARE POLYPHOSPHATES; B. APPLYING SAID MIXTURE, PROMPTLY AFTER ESTABLISHMENT THEREOF, INTO A FORM DEFINING A SHAPED OPEN SPACE TO CONSTITUTED SAID STRUCTURE; AND C. ALLOWING SAID APPLIED MIXTURE TO SET IN SAID DEEFINED OPEN SPACE AT A TEMPERATURE IN THEE RANGE FROM ABOVE THE FREEZING POINT OF SAID SOLUTION TO ABOUT 150*F TO PRODUCE A HARD, STRONG STRUCTURE WITHIN SAID FEW HOURS, ALL OF THE STEPS (A) AND (B) ANDOF SAID SETTING EFFECTED WHILE SAID MIXTURE IS MAINTAINED IN A SITUATION OF AMBIENT AOMSPHERIC TEMPERATURE OF NOT MORE THAN ABOUT 150*F AND SAID APPLIED MIX AND SET STRUCTURE BEING MAINTAINED IN SAID SITUAION FOR AT LEAST SEVEN DAYS AFTER STEP (B) TO DEVELOP HYDRAULIC STRENGTH AND SAID SET STRUCTURE BEING SUITABLE FOR CONTINUOUS LOAD-BEARING USE IN SAID SITUATION.

Claim 3

A process for producing a fast-setting concrete structure, having a porosity of not more than about 5 percent, which is capable of load-bearing use within a few hours after mixing and which is produced and intended to be used in a situation of ordinary ambient atmospheric temperature of not more than about 150*F, comprising a. establishing a mixture of i. an aggregate containing at least about 10 percent by weight of magnesia and ii. ammonium phosphates in aqueous solution in an amount equal to between about 3 and about 10 parts by weight of P2O5 per 100 parts by weight of said aggregate, the composition of said phosphates in percent by weight being not more than about 40 percent orthophosphate and at least about 60 percent phosphates selected from the class consisting of pyrophosphate and polyphosphates whereof at least about 2 percent are polyphosphates; b. applying said mixture, promptly after establishment thereof, into a form defining a shaped open space to constitute said structure; and c. allowing said applied mixture to set in said defined open space at a temperature in the range from above the freezing point of said solution to about 150*F to produce a hard, strong structure within said few hours, all of the steps (a) and (b) and of said setting being effected while said mixture is maintained in a situation of ambient atmospheric temperature of not more than about 150*F and said applied mix and set structure being maintained in said situation for at least seven days after step (b) to develop hydraulic strength and said set structure being suitable for continuous load-bearing use in said situation.

Claim 4

A process for producing a fast-setting concrete structure, having a porosity of not more than about 5 percent, which is capable of load-bearing use within a few hours after mixing and which is produced and intended to be used in a situation of ordinary ambient atmospheric temperature of not more than about 150*F, comprising a. establishing a mixture of i. an aggregate containing at least about 10 percent by weight of magnesia and ii. ammonium phosphates in aqueous solution in an amount equal to between about 3 and about 10 parts by weight of P2O5 per 100 parts by weight of said aggregate, the composition of said phosphates in percent by weight being not more than about 40 percent orthophosphate and at least about 60 percent phosphates selected from the class consisting of pyrophosphate and polyphosphates whereof at least about 2 percent are polyphosphates; b. applying said mixture, promptly after establishment thereof, into a form defining a shaped open space to constitute said structure; and c. allowing said applied mixture to set in said defined open space at a temperature in the range from above the freezing point of said solution to about 150*F to produce a hard, strong structure within said few hours, all of the steps (a) and (b) and of said setting being effected while said mixture is maintained in a situation of ambient atmospheric temperature of not more than about 150*F and said applied mix and set structure being maintained in said situation for at least seven days after step (b) to develop hydraulic strength and said set structure being suitable for continuous load-bearing use in said situation.

Claim 5

A process according to claim 1, wherein said solution contains at least about 8 percent by weight ammoniacal nitrogen and at least about 30 percent by weight P2O5.

Claim 6

A process according to claim 1, wherein said solution contains about 8-12 percent by weight ammoniacal nitrogen and about 30-38 percent by weight P2O5.

Claim 7

A process according to claim 1, wherein said solution comprises about 10 percent by weight ammoniacal nitrogen, about 34 percent by weight P2O5, and about 50 percent by weight water.

Claim 8

A process according to claim 1, wherein the step of establishing said mixture comprises mixing said aggregate in dry state with a pre-established aqueous solution of said phosphates.

Claim 9

A process according to claim 1, wherein said aggregate contains at least about 10 percent magnesia.

Claim 10

A process for repairing a concrete structure having, as a defect, an open space therein, by filling the open space with a fast-setting concrete filler body directly bonded to the concrete structure and having a porosity of not more than about 5 percent, said process comprising a. establishing a mixture of i. an aggregate containing at least about 10 percent by weight of magnesia and ii. ammonium phosphates in aqueous solution in an amount equal to between about 3 and about 10 parts by weight of P2O5 per 100 parts by weight of said aggregate, the composition of said phosphates in percent by weight being not more than about 40 percent orthophosphate and at least about 60 percent phosphates selected from the class consisting of pyrophosphate and polyphosphates whereof at least about 2 percent are polyphosphates; b. applying said mixture, promptly after establishment thereof, into an open space in and defined by a concrete structure and in direct contact with space-defining surface portions of the structure, and c. allowing said applied mixture to set in said defined open space to produce a hard, strong filler body self-bonded to said structure surface portions while d. continuously maintaining the mixture, throughout performance of steps (a), (b) and (c), in a situation of ambient atmospheric temperature of not more than about 150*F.

Claim 11

A process for repairing a concrete structure having, as a defect, an open space therein, by filling the open space with a fast-setting concrete filler body directly bonded to the concrete structure and having a porosity of not more than about 5 percent, said process comprising a. establishing a mixture of i. an aggregate containing at least about 10 percent by weight of magnesia and ii. ammonium phosphates in aqueous solution in an amount equal to between about 3 and about 10 parts by weight of P2O5 per 100 parts by weight of said aggregate, the composition of said phosphates in percent by weight being not more than about 40 percent orthophosphate and at least about 60 percent phosphates selected from the class consisting of pyrophosphate and polyphosphates whereof at least about 2 percent are polyphosphates; b. applying said mixture, promptly after establishment thereof, into an open space in and defined by a concrete structure and in direct contact with space-defining surface portions of the structure, and c. allowing said applied mixture to set in said defined open space to produce a hard, strong filler body self-bonded to said structure surface portions while d. continuously maintaining the mixture, throughout performance of steps (a), (b) and (c), in a situation of ambient atmospheric temperature of not more than about 150*F.

Claim 12

A process according to claim 7, wherein said concrete structure is an outdoor way having a substantially flat upper surface for supporting moving loads and said open space opens upwardly through said surface.

Claim 13

A structure produced by the process of claim 1, having a porosity of not more than about 5 percent.