Cementitious structure treatment

Abstract

Various embodiments disclosed herein provide methods for treating a cementitious material to inhibit the following conditions or reactions from deteriorating a structure composed of the cementitious material, including, but not limited to, alkali-silica reaction gel (ASR), alkali-aggregate reaction (AAR), and mitigating silica from reaction on coarse and fine aggregates within concrete mixes. Methods for treating cementitious material include cleaning and washing the cementitious material, allowing the cementitious material to dry, and thereafter applying one or more aqueous based mitigators to the cementitious material to penetrate a surface of the cementitious material to thereby force a C-S-H conversion reaction and, in instances, mitigate a plurality of impurities of the cementitious material, thereby inhibiting deterioration thereof, reactive and unreactive silica and in addition to aqueous sprayable forms, an admixture method in production of the cementitious structure and an aggregate pre-wash implementation of the foregoing embodiments.

Description

UTILITY PATENT APPLICATION Docket Number: 003068-1A-PCT Cementitious Structure Treatment Inventors: Jeffrey A. Benintendi Jacques Winston QuimpoAttorney Docket No.: 003068 - 1 A - P C T Cementitious Structure Treatment FIELD

[0001] The present invention relates to cementitious structure surface efflorescence reduction, alkali-silica reaction reduction, alkali-aggregate reaction mitigation, and calcium hydroxide conversion. BACKGROUND

[0002] Cementitious material, such as concrete, is used as a building material in a very wide range of applications, including in the construction of buildings, bridges, pipes, paving materials and the like, wherein the manufacture of each has at least some of the disadvantages associated with previously known materials and processes. An object of the invention, therefore, is to provide cementitious material, and a method of manufacture thereof, in which at least some of the disadvantages associated with previously known materials and the associated methods of manufacture are overcome or are of reduced impact. The cementitious material in concrete typically consists of Cal Portland cement, air and water, sand and gravel, as well as potentially many other additives to promote a cohesive bond and improved surface and tensile strength within a cementitious surface.

[0003] Efflorescence, Alkali-Silica Reaction (Gel), Alkali-Aggregate Reaction, Silica on Aggregate, Calcium Hydroxide in cement and the need to hydrate green concrete are common problem(s) that occurs in cementitious materials such as concrete, block, stucco, and masonry. Each of these occurrences have unique characteristics that are harmful to the integrity of each form of a cementitious structure(s) and currently have no effective resolution in a finished topical form, or in admixture during production. There is a need to resolve each of these conditions, preferably using a unique form of chemistry and reactions to mitigate these environments.Attorney Docket No.: 003068 - 1 A - P C T

[0004] Primary efflorescence occurs during the curing process of cementitious materials. As water evaporates from the surface, salt, hydrogen and alkali levels increase and a capillary action occurs, concurrent with hydrostatic pressure and or lime leaching. When hydrogen is present with the combining factors causing a primary efflorescence reaction, a sedimentary trailing material, minerals, organic materials and crystal deposits are leached out onto the surface causing a scaling buildup that many mistakenly refer to as “efflorescence” but is the scaling affects resulting from internal primary efflorescence. Secondary efflorescence occurs when natural and unnatural elements enter the surface and begin to promote a secondary efflorescence reaction. The reaction causes water to enter into the pores and capillaries of a cementitious structure, interacting with the existing primary efflorescence occurrences and causes increased leaching, similar to the Primary Efflorescence reaction. However, these deposits are powderier and chalkier in appearance, and much easier to remove if not scaled or fused to the surface. Removing Primary or Secondary Efflorescence leaching from the surface is important but does not mitigate future reactions.

[0005] Conventional compositions have been developed to etch, clean, and remove scaling, and even sealing off or binding surfaces in attempt to treat and or prevent future scale that might be incorrectly diagnosed as efflorescence, or even the leaching trails of primary or secondary efflorescence, or to reduce efflorescence from further leaching by slowing water intrusion into the material, or sealing the surface altogether. However, these compositions only provide temporary visual relief, as the efflorescence reaction(s) remain productive and active within the material and can cause scale to reappear indefinitely. Furthermore, conventional compositions cause damage to the surfaces, require neutralizing and cleaning, which activate unreactive particulates, which perpetually increase the velocity and volume of reaction, and in some cases, result in applying permanent coatings that are blocking evaporation and escape paths forAttorney Docket No.: 003068 - 1 A - P C T moisture. These treatments lead to enhancing environments such as alkali-silica reaction (Gel) and alkali-aggregate reaction, and thus mitigating reactive and unreactive calcium hydroxide residue between the aggregate (silica) and cement (alkali) creating fissuring and cracking throughout a structure known as “concrete cancer” or alkali- silica reaction (Gel). There is a need to mitigate the efflorescence environment, so the scaling and negative effects of the occurrences allows the structure to perform properly without further damage.

[0006] Accordingly, what is needed is an improved composition that is effective and efficient in eliminating both primary and secondary efflorescence occurrences from deep inside a cementitious material; that facilitates restored balance of pH and alkalinity, lowered salt content, decreased hydrogen and pressure, addressing reactive limes, converting calcium hydroxide into calcium silicate hydrate and through a sodium silicate densifier creating a sub-surface membrane, promoting bonding of paint and other sealers to the cementitious material. There is a further need for providing such treatment of cementitious material and structures that do not contain hazardous compounds, do not emit odors, and is both easy to use and environmentally safe. There is a still further need for reducing alkali-silica reaction, alkali-aggregate reaction, and converting calcium hydroxide into a beneficial calcium silicate hydrate to densify and reduce non-intentional passages within cementitious structures. SUMMARY

[0007] Various embodiments of the subject technology provide methods and apparatus for treating a cementitious material to mitigate primary and secondary efflorescence thereof. The methods and apparatus for treating the cementitious material may comprise reducing and removing scale derived from primary and secondary efflorescence, cleaning and washing the surface of the cementitious material, allowing the cementitious material to dry, and thereafter applying an aqueous-based mitigatingAttorney Docket No.: 003068 - 1 A - P C T composition to the cementitious material to penetrate deep into the cementitious material and providing the following four (4) benefits to the internal makeup of the structure: (i) As the material enters the surface of the structure, the secondary and residual primary efflorescence scale is neutralized; (ii) As the technology enters the capillaries, the function of the proprietary nano technology blend allows the alkalinity, imbalanced pH, lime contents, calcium hydroxide, hydrogen, salt content, and other impurities to be neutralized. The calcium hydroxide (Ca(OH)₂ is converted to calcium silicate hydrate (C-S-H (Ca2SiO4)); (iii) The hydrostatic pressure within the capillaries that are expressing sediment towards the surface is reduced, and or eliminated altogether; and (iv)The alkali-silica reaction gel (ASR), a viscous gel of sodium silicate (Na2SiO3· n H2O, also noted Na2H2SiO4· n H2O, or N-S-H (sodium silicate hydrate), as well as alkali-aggregate reaction (AAR) is reduced through the silica reduction and calcium hydroxide to calcium silicate hydrate C-S-H conversion process and reduces further fissuring, spalling and cracking throughout the structure and surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Non-limiting and non-exhaustive aspects are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified.

[0009] FIG. 1 shows a flowchart illustrating an exemplary process for treating a cementitious material in accordance with an embodiment of the present technology; and

[0010] FIG. 2 shows a flowchart illustrating an alternative exemplary process for treating a cementitious material in accordance with an embodiment of the present technology, wherein the cementitious material is treated in production phase as anAttorney Docket No.: 003068 - 1 A - P C T admixture, and as an aqueous application in accordance with an embodiment of the present technology.

[0011] Implementations will become more apparent from the detailed description set forth below when taken in conjunction with the drawings. DETAILED DESCRIPTION

[0012] The present technology may be described in terms of functional compounds, particles, compositions, aqueous mixtures, mixtures, admixtures, solutions, and the like, collectively the “components”. Such functional components may be realized by any number of components configured to perform the specified functions and achieve the various results in numerous product(s). For example, the present technology may employ various acid, aqueous-based solutions, bonding agents, buffering agents, nano- sized particles, oxidizing agents, salts, mixtures, and the like, which may carry out a variety of functions. In addition, the present technology may be practiced in conjunction with any number of cementitious materials, and the improved mitigator composition described herein is merely one exemplary application for the technology.

[0013] In various implementations disclosed herein, “cementitious material” means “concrete,” “masonry,” “grout,” “tile,” “man-made stone,” “natural stone,” “precast material,” “brick,” “block,” “paver,” “stucco,” “coarse and fine aggregate,” “sand,” “Cal Portland cement,” and the like. In still other implementations disclosed herein, “cementitious material” means at least one of Portland cement, ground granulated blast furnace slag, fly ash, silica fume, and limestone fines. In still other disclosed implementations, “cementitious material” may include at least one of Portland cement, air and water, ground granulated blast furnace slag, fly ash, silica fume, coarse and fine aggregate (gravel and sand), and limestone fines.

[0014] According to each implementation disclosed herein, a cementitious material may be treated with an improved composition for mitigating “primary” andAttorney Docket No.: 003068 - 1 A - P C T “secondary” efflorescence (the “mitigating composition”). The mitigator composition may comprise an aqueous solution and a nano-sized particle mixture. The mitigator composition may also comprise a buffering agent, a nitrilotriacetic salt, a sodium silicate densifying mixture, sodium metasilicate densifying mixture (20%-70%), other pozzolanic combinations, and ionizing and non-ionizing surfactants and types of solvents. The sodium metasilicate densifying mixture will be from about twenty percent (20%) to about seventy percent (70%), will preferably be from about twenty percent (20%) to about percent (70%), and will most preferably be less than about thirty percent (30%).

[0015] The buffering agent may comprise a weak halogen such as hydrochloric acid, ammonium hydroxide, muriatic acid and the like. In one embodiment, the mitigator composition may contain between about 1.2% and about 5% by weight of the buffering agent. The mitigator composition may contain between about 1.2% and about 5% by weight of the buffering agent, will preferably be from about 1.2 percent (1.2%) to about percent (5%), and will most preferably be less than about three percent (3%). Some other buffering agents may be utilized, as long as the mitigator composition is basic, generally with a pH of between 10 and 10.5 and beyond.

[0016] If utilized, the nitrilotriacetic salt combination may comprise tripotassium nitrilotriacetate and the like. In one embodiment, the mitigator composition may contain between about 2% and to about 10% by weight of the tripotassium nitrilotriacetate, preferably from about two percent (2%) to about percent (10%), and will most preferably be less than about seven percent (7%) by weight of the tripotassium nitrilotriacetate. In an alternative embodiment, instead of tripotassium nitrilotriacetate, the pozzolanic reaction in range of 1%-10% in concert with sodium silicate penetrators and membranes ranging from 20%-70%, isopropyl alcohol ranging 1%-10%, and waterAttorney Docket No.: 003068 - 1 A - P C T in range of 25%+ will reduce the active organics and minerals causing the efflorescence reaction(s).

[0017] The ionizing / non-ionizing surfactants and oxidizing agent(s) may comprise any suitable compound that facilitates the oxidation process. For example, the oxidizing agent may comprise hydrogen hydroxide, hydrogen peroxide, and the like. In one embodiment, the composition may contain between about 1% and about 12% by weight of the hydrogen hydroxide.

[0018] The nano-sized particle mixture may comprise nano-sized particles capable of penetrating the cementitious material deeply and efficiently. In some embodiments, the nano-sized particle mixture may comprise sodium metasilicate and or sodium silicate densifiers with pozzolans and other amorphous micro silica. Embodiment may also contain sodium hydroxide, isopropyl alcohol and other oxidizing agents, and distilled, softened and filtered waters. Specifically, the nano-sized particles may react with various impurities of the cementitious material, such as calcium, mineral salts, silica, calcium hydroxide and reactive and unreactive lime compounds, to mitigate the impurities and consume excessive alkali ions present in the cement matrix, that increase solubility that may react throughout the cementitious material, and silica attached to aggregate, thereby mitigating the causes of deteriorating cementitious material. Additionally, the nano-sized particles may improve the transport properties of the mitigator composition, which may cause the nano-sized particles to react quickly and reduce the diffusion rate and leaching of the alkali ions, which, in turn, effectively and efficiently inhibits efflorescence from leaching out of the surface of the cementitious material.

[0019] The nano-sized particles may be approximately 100,000 times smaller than even the smallest cement particle. The size of the nano-sized particles will be from about 50 nanometers (nm) to about 1,100 nm, will preferably be from about 50 nm toAttorney Docket No.: 003068 - 1 A - P C T about 300 nm, and will most preferably be less than about 60 nm. For example, the nano-sized particles may comprise a grain size of about 70 nm. Accordingly, the nano- sized particles may pass-through cementitious material, such as cement minerals or hollow sand, and become a part of the impurities or minerals it reacts with. Specifically, the nano-sized particle mixture may react in the presence of the oxidizing agent, particularly in the presence of hydrogen when the cementitious material is wet. The nano-sized particle mixture may be unreactive when the cementitious material is dry. Because the treatment disclosed herein may involve repeatedly wetting and drying the cementitious material, applying the nano-sized particle mixture to the cementitious material may improve the ability of the cementitious material to lock out the efflorescence. In one embodiment, the mitigator composition may comprise between about one thousandth of one percent (0.001%) by weight of the nano-sized particle mixture and about ten percent (10%) by weight of the nano-sized particle mixture.

[0020] In some embodiments, the mitigator composition may further comprise a blend of reactive nano silica that may improve the bond between the treated cementitious material and coatings that may be applied thereafter by reducing the occurrence of peeling, cracking and loss of bond caused by capillary moisture or internal chemical reactions. For example, in one embodiment, the blend of reactive nano silica may comprise nano-sized silica particles having a size of about 5 nm with a pH of about 9.5 that permanently bonds with existing chemicals of the cementitious material, offering improved protection and longevity. Additionally, the mitigator composition may further comprise an acrylic bonding agent for improving adhesion between the treated cementitious material and acrylic paint that is applied thereto.

[0021] Modifications may, however, be made to the blend of reactive nano silica without departing from the scope of embodiments disclosed herein. For example, in an alternative embodiment, the mitigator composition may not comprise the blend ofAttorney Docket No.: 003068 - 1 A - P C T reactive nano silica, the acrylic bonding agent, or any other residual film, sealant, or moisture sealing compound. In such an embodiment, the mitigator composition may not have any adhesion or bonding resistance to other compositions like acrylic paint, which, in turn, facilitates the adhesion of products to the cementitious material that are applied thereto post-treatment.

[0022] In operation, and referring to Figure 1, a method for treating a cementitious material (100) may comprise applying a priming efflorescence descaler to break-down, liquify and reduce the surface tension of the scale, and after, an mitigator composition to the cementitious material to penetrate the cementitious material and thereby inhibit the internal efflorescence reactions thereof. Prior to a first application of the mitigator composition, the cementitious material may be primed with the aforementioned topical priming compound to break down the scale, and thereafter, cleaned and washed thoroughly (105) utilizing a pressure washer or other suitable washer to remove existing efflorescence scale deposits, salt trails, leaching, and other debris and contaminants, such as oil, grease, dirt, and soot therefrom. Once the cementitious material is clean, the cementitious material may be allowed to dry thoroughly (110), after which the mitigator composition may be applied thereto (115). The mitigator composition may be applied to the cementitious material utilizing a low-pressure sprayer, such as a “garden” sprayer, a “backpack” sprayer, a “Hudson” sprayer, or an “airless paint” sprayer, or continuous sprayer. As shown at step 120 of FIG. 1, an aqueous spray is applied to penetrate the surface and mitigate the primary and secondary efflorescence occurrences.

[0023] In an alternative operation also depicted in Figure 1, a method for treating a cementitious material (100) may comprise applying an admixture formulation at step 200 of FIG. 1. Thereafter, at step 205 of FIG. 1, a liquid or powder is applied to the admixture formulation into the concrete mix design in production. After step 205 inAttorney Docket No.: 003068 - 1 A - P C T FIG. 1, step 210 in FIG. 1 applies an aqueous spray to penetrate the surface of new concrete and mitigate any residual primary and secondary efflorescence occurrences.

[0024] After the first application of the mitigator compound, treating the cementitious material may further comprise allowing the cementitious material to dry for a first time period, generally between about one to two hours, after which the mitigator composition may be applied to the cementitious material for a second application as needed, or to remove expressed C-S-H reactivity. The composition may be applied while the cementitious material is damp, but not soaked. Repeated applications of the mitigator composition may or may not be necessary if the efflorescence is “deep and excessive.” For repeated applications of the mitigator composition, the cementitious material may be allowed to dry for a second time period, generally between about two to four hours, between each subsequent application. Once the cementitious material is treated, it may be allowed to dry for a final time. Once treated, the mitigated area cannot be washed, rinsed or cleaned off. The surface after being treated is prepared for sealant, colorants, primer and paints. There is no sealant or protectant requirements following a treatment, as the mitigation is stable following treatment, excluding power washing or any substance-blasting processes or etching chemicals which will remove the mitigation and void efficacy.

[0025] In yet another implementation of the foregoing embodiments, cementitious structure treatment methods are disclosed for the mitigation of alkali-silica reaction (ASR), alkali-aggregate reaction (AAR), and mitigating reactive silica on coarse and fine aggregate in concrete mix design through the conversion of calcium hydroxide to calcium silicate hydrate in both new and existing cementitious structures.

[0026] In the foregoing implementation, calcium oxide (CaO) is the main component of lime found in cement used in concrete, and other cementitious products. When water combines with CaO an exothermic reaction occurs forming Calcium HydroxideAttorney Docket No.: 003068 - 1 A - P C T (Ca(OH)2), also known as hydrated, or slaked lime. Tricalcium silicate (C3S) and dicalcium silicate (C2S) are also compounds that exist within hydrated cement paste. When C3S and C2S combine with water, Calcium Silicate Hydrate (CaH2O4Si - also known as C-S-H) and calcium hydroxide are formed. In production and curing this process promotes densification of the concrete. The residual unreacted calcium hydroxide is soluble, and may leach to the surface through capillaries, fissures and pores within a structure. When calcium ions are leached to the surface, it increases the internal porosity of the structure, creating gaps and negatively impacting compressive and tensile strength of the structure. It could cause damage by creating enlarged unintended pathways leading to primary and secondary efflorescence, alkali-silica reaction (ASR), alkali-aggregate reaction (AAR), and reactive silica on coarse and fine aggregate in cement. An aqueous and admixture mitigator that can convert the calcium hydroxide (Ca(OH)2), to a positive composition of calcium silicate hydrate (C-S-H), will improve densification, strength, longevity, and internal integrity of a structure, further reducing the need for demolition and or post-installation repairs to the surface cracking.

[0027] In operation, and referring to Figure 2, a method for treating a cementitious material at step 100 which includes:

[0028] Part 1: Calcium Hydroxide to Calcium Silicate Hydrate Conversion

[0029] Part 2: Alkali-Silica Reaction Gel (ASR)

[0030] Part 3: Alkali-Aggregate Reaction (AAR); and

[0031] Part 4: Coarse and Fine Aggregate for Silica Reduction

[0032] Step 105 of FIG. 2 includes a cleaning and washing thoroughly of an existing surface by use an aqueous sprayable formulation for Part 1 through Part 4. At step 105 in FIG.2 a pressure washer or other suitable washer can be utilized to remove existing efflorescence scale deposits, salt trails, leaching, and other debris and contaminants, such as oil, grease, dirt, and soot therefrom. At step 110 of FIG 2, a priming agent willAttorney Docket No.: 003068 - 1 A - P C T be applied to remove scale from the primary and secondary efflorescence (if present). Once the cementitious material is clean, the cementitious material may be allowed to dry thoroughly at step 115 of FIG. 2. Thereafter, at step 120, which the mitigator composition may be applied thereto (115). As shown at step 120 of FIG.2, an aqueous spray is applied to penetrate the surface and mitigate the primary and secondary efflorescence occurrences. The mitigator composition may be applied to the cementitious material utilizing a low-pressure sprayer, such as a “garden” sprayer, a “backpack” sprayer, a “Hudson” sprayer, or an “airless paint” sprayer, or continuous sprayer.

[0033] In an alternative operation also depicted in Figure 2, a method for treating a cementitious material (100) may comprise applying an admixture formulation at step 200 of FIG. 2. Thereafter, at step 205 of FIG. 2, a liquid or powder is applied to the admixture formulation into the concrete mix design in production. After step 205 in FIG.2, step 210 in FIG.2 applies an aqueous spray to penetrate the surface and thereby convert, mitigate, and resolve as noted above in Parts 1 through 4, respectively, Calcium Hydroxide to Calcium Silica Hydrate Conversion, Alkali-Silica Reaction Gel (ASR), Alkali-Aggregate Reaction (AAR); and Coarse and Fine Aggregate for Silica Reduction.

[0034] In steps 110, 105, and 210 of FIGS.1-2, a descaling priming agent that can be used will be a descaler specific to primary and secondary efflorescence that is designed to liquify and soften hardened scale, that remains on the surface, to be removed with water once the scale softens to a state of removal, and will preferably be composed of a combination of chemistry including 20BE (muriatic acid) 25%, softened or distilled water 49%, urea 25%, citric acid 5%, tetrasodium EDTA 1%, guar polymer 0.1%, and polysorbate 201% and, when used, will liquify the hardened scale and allow it to be removed from the surface, and will most preferably be removed with water usingAttorney Docket No.: 003068 - 1 A - P C T conventional pressure washing or power washing removal methods. The aqueous-based mitigator composition that can be used will be applied to penetrate deep into the surface and allow the formulation to find impurities within the structure and mitigate and reduce those impurities that are resulting in combination. The efflorescence reaction(s) will preferably be sodium silicate 70%, softened or distilled water 30%, silica fume 0.25%, polysorbate 200.3% and will, when in combination, lower salt, lime run, hydrogen and hydrostatic pressure, calcium hydroxide and will convert into C-S-H, balancing alkali and pH, and allowing plugged capillaries to be open and fluid. A result of the foregoing implementation is a remaining sodium silicate membrane situated below the surface.

[0035] This membrane provides a semi-soluble barrier. The semi-soluble barrier provides protection when the structure is dry and also when moisture is present. The semi-soluble barrier carries the mitigating formulation through the capillaries and pores to further reduce the calcium hydroxide and contributing factors aforementioned that result in primary and secondary efflorescence reaction and scale.

[0036] The result of the respective methods illustrated in FIGS. 1-2 for treating a cementitious material will be sodium silicate densification membrane beneath the surface of the cementitious material. The sodium silicate densification membrane will advantageously prevent occurrences of efflorescence on the surface of the cementitious surface that are triggered by moisture. The sodium silicate densification membrane will be composed of a combination of chemicals that are designed to form a sub-surface barrier that is hardened when dry, and semi-soluble when moisture is present. The solubility allows the formulation to flow through the capillaries and pores inside of a cementitious structure and continually mitigate the contributing factors to efflorescence, ASR, AAR, calcium hydroxide and silica attached to coarse and fine aggregate. An aqueous-based mitigator composition will preferably be composed of Sodium Silicate 70%, Softened or Distilled Water 30%, Silica Fume 0.25%,Attorney Docket No.: 003068 - 1 A - P C T Polysorbate 20 0.3% and will most preferably be composed of a remaining sodium silicate densifier that will harden when dry and become semi-soluble with water to continuously resist and help prevent primary and secondary efflorescence reoccurance.

[0037] In a still further implementation of the foregoing embodiments, a cementitious material is treated by a method that includes the steps of: (i) a descaling priming agent for reducing, and (ii) liquifying and removing scale derived from primary and secondary efflorescence. Preferably a topical sprayable descaler will be used that is designed to emulsify, liquify and breakdown scale derived from primary and secondary efflorescence using a proprietary modified acid-based solution. By way of example, and not be way of limitation, the proprietary modified acid-based solution can be composed of 20BE (muriatic acid), softened or distilled water, urea, citric acid, tetrasodium EDTA, guar polymer and polysorbate 20, Unlike many descalers that are created primarily using harsh acidic chemicals, the preferred efflorescence descaler is intended to be a priming agent for an Efflorescence Mitigator to remove existing efflorescence and lime scale from previously compromised cementitious surfaces. The preferred formulation will reduce and / or remove the unattractive appearance of scale from efflorescence, as well as scale from reactive leached lime.

[0038] Referring to Figure 1, step 110, the composition of the efflorescence descaler can include 20 Baume 31% HCl (Muriatic Acid) 25% V / V, Softened or Distilled Water 49% V / V, Urea 25% W / V, Citric Acid 5% W / V, Tetrasodium EDTA 1% W / V, Guar Polymer 0.1% W / V, and Polysorbate 201% V / V. Referring to Figure 1, step 115, in cleaning and washing the cementitious material; the cementitious material is allowing to dry,. and an aqueous-based mitigator composition is applied to the cementitious material to penetrate the cementitious material and force a final reaction and in instances mitigate a plurality of impurities of the cementitious material, thereby mitigating efflorescence thereof and leaving a sodium silicate densification membraneAttorney Docket No.: 003068 - 1 A - P C T beneath the surface that would be reactive with moisture that triggers primary and secondary efflorescence occurrences, to be continuously active in helping to prevent future occurrences. The foregoing formula may be made in admixture form to be utilized during the production phase of producing a cementitious structure. Referring to Figure 1, step 120, the penetrating efflorescence mitigator as disclosed herein is superior to conventional products impacting efflorescence which use strong acids to remove the scale and to close off surfaces with sealers in an attempt to prevent water ingress which could promote the occurrence of primary or secondary efflorescence.

[0039] Moreover, conventional efflorescence liquifying descaling products, although designed to break down scale from efflorescence, are inferior in that they do not stop the potential efflorescence reactions inside the cementitious surfaces, nor do other such conventional products on the market. In contrast to conventional methods of treating cementitious surfaces, implementations disclosed herein include methods to penetrate the cementitious surface using a nano-delivery system that is designed to reduce and or eliminate the contributing factors to primary and secondary efflorescence reactions. These implementations reduce hydrostatic pressure inside the capillaries, lower salt content, alkali levels, and reactive limes, while converting harmful, residual calcium hydroxide into beneficial calcium silicate hydrate (CSH). Moreover, these implementations include sodium silicate formulations having dynamic abilities to reactivate with moisture, allowing a continual converting of the internal calcium hydroxide salts into CSH which would have otherwise been solubilized by that same moisture, and thereby be leached out as unsightly efflorescence, and / or lime run. As moisture evaporates, the membrane reforms along and below the CSH-densified surface, helping to retain the residual sediment while still allowing vapor from evaporation to pass through to the surface. The composition of the aqueous based efflorescence mitigator will preferably include: Sodium Silicate 70% volume perAttorney Docket No.: 003068 - 1 A - P C T volume (V / V), Softened or Distilled Water 30% V / V, Silica Fume 0.25% weight by volume (W / V), and polysorbate 20 0.3% V / V. The admixture formulation for the efflorescence mitigator to be used during the formation of a cementitious surface in Figure 1, step 105 will preferably include: Sodium Silicate 70% V / V, Softened or Distilled Water 30% V / V, Silica Fume 0.25% W / V, Polysorbate 200.3% V / V, and Fine Fiber Mesh 0.8% KG (1lb per cubic yard)

[0040] In yet another implementation of the foregoing embodiments, includes a method of treating residual unreacted calcium hydroxide (CaO) (H2O) that can create (Ca2+), that may cause damage leaching through pores, capillaries and fissures within concrete. This method includes treating the foregoing problem in production through admixtures, or post production by and or applying an aqueous-based mitigator composition to the cementitious material to penetrate the cementitious material that may convert the calcium hydroxide (Ca(OH)2), to a positive composition of calcium silicate hydrate C-S-H (Ca 2) is converted to calcium silicate hydrate (C-S-H (Ca2SiO4)) within a structure that can improve densification and compressive and tensile strength of the structure, to thereby improve the longevity and integrity of a structure and reduce the need for post-installation repairs to the surface. The sodium silicate densifier blend with nano pozzolanic additive(s) will provide a fluid densification in solution that will continue to mitigate silica and residual calcium hydroxide (CaO) (H2O) create (Ca2+), and promote C-S-H conversion internally reducing capillary expansion, unwanted spatial reactions such as cracking, fissures, spalling and the like thereof.

[0041] The hydrostatic pressure within the capillaries that are expressing unreactive and reactive residual calcium hydroxide and sediment towards the surface is reduced, and or eliminated altogether. The Alkali-Silica Reactive Gel (ASR), a viscous gel of sodium silicate (Na2SiO3 · n H2O, also noted Na2H2SiO4 · n H2O, or N-S-HAttorney Docket No.: 003068 - 1 A - P C T (sodium silicate hydrate), as well as Alkali-Aggregate Reaction (AAR) are mitigated through the C-S-H conversion process and reduces further fissuring, spalling and cracking throughout the surface. The coarse and fine aggregates contributing to ASR and AAR reactions may be washed and sprayed prior to production and or prior to being added to the concrete mix (design), which reduces unreactive and reactive attached silica from the aggregate and reduces the potentiality of these occurrences. The pozzolanic nano technology additive may be used for other implementations disclosed in the present application to reduce and remove the following occurrences, Hydrostatic Pressure, Alkali-Silica Reaction (ASR Gel), Alkali-Aggregate Reaction, Calcium Hydroxide conversion to Calcium Silicate Hydrate and silicates on coarse and fine aggregate used within cementitious mix designs. Along with topical formulation(s), admixture instances of these implementations to be used in the production and formation of cementitious surfaces, as the aforementioned formulation(s) are post formation and topical and penetrating treatments on existing cementitious structures.

[0042] Referring now to Figure 2 at step 120, the C-S-H conversion product is uniquely designed to reduce the impact of reactive silica from coarse and fine aggregate that could lead to alkali-aggregate reaction (AAR) and the formation of the destructive alkali-aggregate reaction (ASR) gel by applying an active, protective membrane directly on the aggregate, to thereby form a barrier between alkali and silica. Implementations disclosed herein advantageously reduce and / or impact these reactions after the initial cure of the cementitious form. Conventional uses of low-alkali cement mix and / or low-silica aggregate can also be used in conjunction with implementations disclosed herein. The formulation for the aqueous mitigator for C-S-H conversion, as depicted in Figure 2 at step 120, will preferably include: Sodium Silicate 70% V / V, Softened or Distilled Water 30% V / V, Silica Fume 0.25% W / V, and polysorbate 20 0.3% V / V.Attorney Docket No.: 003068 - 1 A - P C T

[0043] The C-S-H conversion admixture formulation will help ensure the pozzolans are carried throughout the concrete mix. Small adjustments may be needed in the mix design to compensate for the addition of the admix so as to prevent negatively impacting the slump or ratio of the concrete mix. Admix used in conjunction with the aqueous aggregate wash spray will reduce the reaction of the silica from the aggregates with the alkali from the cement matrix, thereby reducing the potential for AAR and ASR. The admixture formulation of the C-S-H conversion product to be used, as shown in Figure 2 at step 205, include: Sodium Silicate 70% V / V, Softened or Distilled Water 30% V / V, Silica Fume 0.25% W / V, Polysorbate 200.3% V / V, and Fine Fiber Mesh 0.8% KG (1lb per cubic yard).

[0044] In yet another implementation of the foregoing embodiments, a method for treating a cementitious material is performed by steps that include: applying to the cementitious material a descaling priming agent for reducing, liquifying and removing scale derived from primary and secondary efflorescence, cleaning and washing the cementitious material; allowing the cementitious material to dry; and applying an aqueous-based mitigator composition to the cementitious material to penetrate the cementitious material and force a final reaction and in instances mitigate a plurality of impurities of the cementitious material, thereby mitigating efflorescence thereof and leaving a sodium silicate densification membrane beneath the surface that would be reactive with moisture and that triggers primary and secondary efflorescence occurrences, to be continuously active in helping to prevent future occurrences. The foregoing implementation may be made in admixture form to be utilized during the production phase of producing a cementitious structure.

[0045] In the foregoing description, the technology has been described with reference to specific embodiments. Various modifications and changes may be made, however, without departing from the scope of the present technology as set forth. The descriptionAttorney Docket No.: 003068 - 1 A - P C T and figure are to be regarded in an illustrative manner, rather than a restrictive one and all such modifications are intended to be included within the scope of the present technology. Accordingly, the scope of the technology should be determined by the generic embodiments described and their legal equivalents rather than by merely the specific examples described above.

[0046] Benefits, other advantages, and solutions to problems have been described above with regard to particular embodiments. Any benefit, advantage, solution to problems or any element that may cause any particular benefit, advantage, or solution to occur or to become more pronounced, however, is not to be construed as a critical, required, or essential feature or component.

[0047] The terms “comprises,” “comprising,” or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and / or modifications of the above-described structures, arrangements, applications, proportions, elements, materials, or components used in the practice of the present technology, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.

[0048] The present technology has been described above with reference to an embodiment. However, changes and modifications may be made to the embodiment without departing from the scope of the present technology. These and other changes or modifications are intended to be included within the scope of the present technology.

Claims

Attorney Docket No.: 003068 - 1 A - P C T CLAIMS What is claimed is:

1. A method of treating a surface of a comprising: applying a descaling priming agent to the surface of the cementitious material to leave a liquid on the surface of the cementitious material; removing the liquid from the surface of the cementitious material; applying an aqueous-based mitigator composition to the surface of the cementitious material; and forming a sodium silicate densification membrane beneath the surface of the cementitious material.

2. The method as defined in Claim 1, wherein the descaling priming agent comprises: 20 Baume 31% HCl (Muriatic Acid) 25% V / V; Softened or Distilled Water 49% V / V; Urea 25% W / V; Citric Acid 5% W / V; Tetrasodium EDTA 1% W / V; Guar Polymer 0.1% W / V; and Polysorbate 201% V; wherein the liquid left on the surface of the cementitious material breaks down and liquifies each of: a hardened scale derived from lime leeching; and primary and secondary efflorescence reactions.

3. The method as defined in Claim 1, wherein the aqueous-based mitigator composition comprises: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V; andAttorney Docket No.: 003068 - 1 A - P C T polysorbate 20 0.3% V / V; wherein the application of the aqueous-based mitigator composition to the surface of the cementitious material: penetrates the aqueous-based mitigator composition into the surface of a cementitious surface; and reduces reactivity causing efflorescence reactions.

4. The method as defined in Claim 3, wherein the aqueous-based mitigator composition includes an efflorescence penetrating mitigator comprising: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V; and polysorbate 20 0.3% V / V; wherein application of the efflorescence penetrating mitigator: reduces hydrostatic pressure in the cementitious material; lowers an alkali level in the cementitious material; balances pH in the cementitious material; lowers salt in the cementitious material; and forms formed beneath the surface of the cementitious material: reactive lime content; and the sodium silicate densification membrane.

5. The method as defined in Claim 1, wherein the sodium silicate densification membrane beneath the surface of the cementitious material comprises: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V’; and polysorbate 20 0.3% V / V; wherein the formation of the sodium silicate densification membrane:Attorney Docket No.: 003068 - 1 A - P C T reduces lime reaction; and increases moisture penetration, when hardened, dry, semi-soluble, and reactive, into capillaries and pores of the cementitious material, whereby the occurrence of a mitigation occurs for at least one of: efflorescence reactions; alkali-silica reactions; alkali-aggregate reactions; and calcium hydroxide conversions to C-S-H.

6. The method as defined in Claim 4, wherein the sodium silicate densification membrane beneath the surface of the cementitious material prevents an efflorescence occurrences triggered by moisture.

7. A cementitious material have a surface treated by the method defined in Claim 1.

8. A method of treating a cementitious material comprising: reducing, liquifying, and removing a scale derived from primary and secondary efflorescence from a surface of the cementitious material by applying a descaling priming agent, and leaving a liquid and a solid on the surface of the cementitious material; removing the liquid and the solid from the surface of the cementitious material; allowing the cementitious material to dry; and penetrating the surface of the cementitious material by applying an aqueous-based mitigator composition to leave a sodium silicate densification membrane beneath the surface of the cementitious material.

9. The method as defined in Claim 8, wherein the descaling priming agent comprises: 20 Baume 31% HCl (Muriatic Acid) 25% V / V; Softened or Distilled Water 49% V / V; Urea 25% W / V;Attorney Docket No.: 003068 - 1 A - P C T Citric Acid 5% W / V; Tetrasodium EDTA 1% W / V; Guar Polymer 0.1% W / V; and Polysorbate 201% V; wherein the liquid left on the surface of the cementitious material breaks down and liquifies each of: a hardened scale derived from lime leeching; and primary and secondary efflorescence reactions.

10. The method as defined in Claim 8, wherein the aqueous-based mitigator comprises: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V; and polysorbate 20 0.3% V / V; wherein the application of the aqueous-based mitigator composition to the surface of the cementitious material: penetrates the aqueous-based mitigator composition into the surface of a cementitious surface; and reduces reactivity causing efflorescence reactions.

11. The method as defined in Claim 10, wherein the aqueous-based mitigator composition includes an efflorescence penetrating mitigator comprising: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V; and polysorbate 20 0.3% V / V; wherein the application of the efflorescence penetrating mitigator: reduces hydrostatic pressure in the cementitious material;Attorney Docket No.: 003068 - 1 A - P C T lowers an alkali level in the cementitious material; balances pH in the cementitious material; lowers salt in the cementitious material; and forms formed beneath the surface of the cementitious material: reactive lime content; and the sodium silicate densification membrane.

12. The method as defined in Claim 8, wherein the sodium silicate densification membrane beneath the surface of the cementitious material comprises: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V’; and polysorbate 20 0.3% V / V; wherein the formation of the sodium silicate densification membrane: reduces lime reaction; and increases moisture penetration, when hardened, dry, semi-soluble, and reactive, into capillaries and pores of the cementitious material, whereby there are mitigations of: efflorescence reactions; alkali-silica reactions; alkali-aggregate reactions; and calcium hydroxide conversions to C-S-H; 13. The method as defined in Claim 8, wherein the sodium silicate densification membrane beneath the surface of the cementitious material prevents an efflorescence occurrences triggered by moisture.

14. The method as defined in Claim 8, wherein the cementitious material comprises at least one of Portland cement, ground granulated blast furnace slag, fly ash, silica fume, and limestone fines.Attorney Docket No.: 003068 - 1 A - P C T 15. A cementitious material have a surface treated by the method defined in Claim 8.

16. A method of treating a surface of a cementitious material comprising: applying a descaling priming agent to the surface of the cementitious material to leave a liquid on the surface of the cementitious material; removing the liquid from the surface of the cementitious material; applying an aqueous-based mitigator composition to the surface of the cementitious material; and forming a sodium silicate densification membrane beneath the surface of the cementitious material, wherein: the descaling priming agent comprises: 0 Baume 31% HCl (Muriatic Acid) 25% V / V; Softened or Distilled Water 49% V / V; Urea 25% W / V; Citric Acid 5% W / V; Tetrasodium EDTA 1% W / V; Guar Polymer 0.1% W / V; and Polysorbate 201% V; the aqueous-based mitigator composition comprises: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V; and polysorbate 20 0.3% V / V; and the sodium silicate densification membrane beneath the surface of the cementitious material comprises: Sodium Silicate 70% V / V; Softened or Distilled Water 30% V / V; Silica Fume 0.25% W / V’;Attorney Docket No.: 003068 - 1 A - P C T and polysorbate 20 0.3% V / V; whereby the sodium silicate densification membrane beneath the surface of the cementitious material prevents efflorescence occurrences triggered by moisture.

17. The method as defined in Claim 16, wherein the application of the descaling priming agent to the surface of the cementitious material reduces, liquefies, and removes a scale derived from primary and secondary efflorescence from the surface of the cementitious material.

18. The method as defined in Claim 16, wherein the removing of the liquid from the surface of the cementitious material is performed by at least one of positive heating and evaporation.

19. The method as defined in Claim 16, wherein the cementitious material comprises at least one of Portland cement, ground granulated blast furnace slag, fly ash, silica fume, and limestone fines.

20. A cementitious material have a surface treated by the method defined in Claim 16.

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