Face Concrete Composition to Prevent Efflorescence and Delamination
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Solution Overview
Problem
Concrete elements containing cement as a binder face issues with whitish spots and color fading over time due to lime efflorescence and pigment coating, and they have lower adhesive tensile strength, leading to delamination and increased production time.
Innovation Solution
A concrete element comprising a core and face layer made with a mixture of latent hydraulic and/or pozzolanic binders, specific granular material fractions, and an alkaline hardener, which maintains decorative properties and enhances adhesive tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cement is used as a binder in concrete elements, then the concrete elements gain strength and durability, but they develop whitish spots and experience color fading due to lime efflorescence and pigment coating
Solution Approach 1:
The invention extracts and removes cement from the binder composition, replacing it with a combination of latent hydraulic binder and pozzolanic binder. This extraction eliminates the source of calcium hydroxide that causes lime efflorescence and pigment coating, thereby preventing surface staining and color fading while maintaining durability through the alternative binder system
Solution Approach 2:
The invention uses a composite binder system combining latent hydraulic binder and pozzolanic binder in specific proportions. This composite material provides the necessary strength and durability while avoiding the harmful side effects of cement-based binders, as the combined chemical properties of the two binders create a more stable and aesthetically durable concrete element
2Object-affected harmful factors
If latent hydraulic binder and pozzolanic binder are used instead of cement, then the CO2 footprint is reduced and surface staining is minimized, but the adhesive tensile strength decreases making the face concrete layer prone to delamination
Solution Approach 1:
The invention optimizes the proportions of latent hydraulic binder and pozzolanic binder within specific ranges (60-90 wt.% and 10-40 wt.% respectively) to achieve the desired balance between aesthetic durability and mechanical strength. By precisely controlling these compositional parameters, the adhesive tensile strength is enhanced sufficiently to prevent delamination while maintaining the benefits of reduced surface staining and lower CO2 footprint
Solution Approach 2:
The composite binder system leverages the complementary strengths of latent hydraulic binder and pozzolanic binder. The latent hydraulic binder provides early strength development and binding capability, while the pozzolanic binder contributes to long-term durability and surface stability. Together, they create a synergistic effect that achieves both aesthetic durability and adequate adhesive strength
3Strength
If cement is used as a binder, then the adhesive tensile strength is sufficient to prevent delamination, but the production cycle time increases due to slower hardening
Solution Approach 1:
The invention modifies the binder composition parameters by eliminating cement and using optimized ratios of latent hydraulic binder and pozzolanic binder. This parameter change accelerates the hardening process compared to traditional cement-based binders, reducing the production cycle time while maintaining sufficient adhesive tensile strength through the enhanced chemical reactivity and binding mechanisms of the alternative binder system
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in concrete elements with minimal surface staining and color fading, high adhesive tensile strength, and reduced CO2 footprint, enabling efficient production and improved durability.
Implementation Method 1
a face concrete layer, the face concrete layer being obtained by compacting and hardening a mixture containing a latent hydraulic binder and/or a pozzolanic binder, water, a granular material and an alkaline hardener
Implementation Method 2
with the granular material having, at a screen hole width of 2 mm, a through fraction from 35.5 wt. % to 99.5 wt. % and, at a screen hole width of 0.25 mm, a through fraction from 2.5 wt. % to 33.5 wt. %
Data Source
AI summary
What is shown and described is a concrete element including a core concrete layer and a face concrete layer, the face concrete layer being obtained by compacting and hardening a mixture containing a latent hydraulic binder and/or a pozzolanic binder, water, a granular material and an alkaline hardener, with the granular material having, at a screen hole width of 2 mm, a through fraction from 35.5 wt. % to 99.5 wt. % and, at a screen hole width of 0.25 mm, a through fraction from 2.5 wt. % to 33.5 wt. %, each based on the total weight of the granular material.