Insulated Concrete Slab Curing System
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Solution Overview
Problem
Concrete curing for slabs on grade, such as airport runways and highways, is hindered by exposure to ambient temperature fluctuations, leading to slow curing, reduced strength, and increased likelihood of cracking and curling, especially in cold weather, due to inadequate insulation and heat loss during the hydration process.
Innovation Solution
A system utilizing a first layer of insulating material on the ground and a second layer on top and sides of the concrete slab to retain heat and moisture, allowing for accelerated curing and improved strength development by maintaining a consistent temperature and reducing moisture loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional forms or molds are used without insulation, then the concrete is exposed to ambient temperatures allowing for simpler construction, but the heat of hydration is lost to the environment resulting in slow curing and reduced strength
Solution Approach 1:
The patent introduces an insulating blanket as an intermediary layer between the concrete and the ambient environment. This blanket traps the heat of hydration within the concrete, preventing heat loss to the surroundings and maintaining elevated temperatures that accelerate curing and improve strength development.
Solution Approach 2:
The patent changes the thermal parameter of the curing environment by introducing insulation. This modifies the temperature profile within the concrete, maintaining higher temperatures for extended periods to accelerate the hydration process and improve curing efficiency.
2Strength
If larger amounts of portland cement are used to compensate for strength losses, then the concrete achieves required strength, but the likelihood of shrinkage, cracking, and curling increases
Solution Approach 1:
The patent enables the concrete to serve itself by retaining its own heat of hydration through insulation. This self-generated heat accelerates curing and strength development naturally, eliminating the need to add excess cement to compensate for cold-weather curing deficiencies, thereby avoiding associated shrinkage and cracking problems.
3Ease of manufacture
If the concrete is exposed to ambient temperature fluctuations, then the construction process is simpler, but the curing process becomes slow and the ultimate strength is difficult to control or predict
Solution Approach 1:
The patent changes the thermal parameters of the curing environment by introducing insulation, creating a more stable and controlled temperature profile. This allows for predictable strength development while maintaining construction simplicity, as the insulation passively manages temperature without requiring active control systems.
4Reliability
If insulated blankets are used to prevent freezing in winter, then the concrete is protected from freezing, but the heat produced within the concrete form is lost to the ground or air through conventional forms relatively quickly
Solution Approach 1:
The patent introduces an insulating blanket as an intermediary thermal barrier between the concrete and the external environment. This blanket not only prevents freezing by blocking cold temperatures but also retains the heat of hydration, reducing heat loss to the ground and air while maintaining reliable freeze protection.
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
This approach results in faster concrete maturity, increased compressive and flexural strength, reduced shrinkage, and enhanced durability, enabling the use of reduced portland cement amounts while achieving equivalent or superior strength to conventional methods.
Implementation Method 1
A system utilizing a first layer of insulating material on the ground and a second layer on top and sides of the concrete slab to retain heat and moisture
Implementation Method 2
The curing of plastic concrete requires two elements, water and heat, to fully hydrate the cementitious material. The curing of plastic concrete is an exothermic process. This heat is produced by the hydration of the portland cement
Implementation Method 3
A system utilizing a first layer of insulating material on the ground and a second layer on top and sides of the concrete slab to retain heat and moisture
Data Source
AI summary
The invention comprises a method of forming a slab on grade. The method comprises placing a first layer of insulating material horizontally on the ground and placing plastic concrete for a slab on grade on the first layer of insulating material. The plastic concrete is then formed into a desired shape having a top and sides. A second layer of insulating material is placed on the top of the plastic concrete and the first and second layers of insulating material are left in place until the concrete is at least partially cured. The second layer of insulating material is then removed. The product made by the method is also disclosed. A slab on grade is also disclosed.