Non-Self-Consolidating Concrete for Complex Shapes
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Solution Overview
Problem
Current ultra-high performance concretes face challenges in producing complex shapes like U or L-shaped parts, requiring separate casting and assembly, which increases manufacturing operations, errors, and reduces robustness, and lack the ability to remain in place on inclined or vertical surfaces without self-compacting.
Innovation Solution
A hydraulic binder composition comprising 20-82% Portland cement with specific particle sizes, 15-56% non-pozzolanic mineral additions, and 4-30% pozzolanic mineral additions, allowing for a mixture with at least 43% hydraulic binder and 30% sand, which can be applied on inclined or vertical surfaces and offers high mechanical resistance and ductility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If ultra-high performance self-compacting concrete is used, then manufacturing complexity is reduced, but the concrete cannot remain in place on inclined or vertical surfaces
Solution Approach 1:
The patent modifies the rheological parameters of the concrete by adjusting the binder composition (Portland cement, non-pozzolanic mineral additions, pozzolanic mineral additions) and particle size distribution (D50 values) to achieve a stress threshold between 20-400 Pa. This allows the concrete to be non-self-compacting yet remain stable on inclined or vertical surfaces without requiring complex manufacturing processes.
2Quantity of substance
If traditional concrete formulations are used, then cement content is high, but CO2 emissions increase
Solution Approach 1:
The patent creates a composite binder system combining Portland cement (20-82% by mass) with non-pozzolanic mineral additions (15-56% by mass) and pozzolanic mineral additions (4-30% by mass). This composite formulation reduces the cement content to below 82% while maintaining ultra-high performance characteristics and reducing CO2 emissions associated with cement production.
Solution Approach 2:
The patent changes the chemical composition parameters of the binder by incorporating specific ratios of mineral additions to cement, transforming the traditional high-cement formulation into a lower-cement, multi-component system that reduces carbon footprint while preserving mechanical performance.
3Adaptability or versatility
If separate casting and assembly is used for complex shapes, then manufacturing flexibility is improved, but the number of operations increases
Solution Approach 1:
The patent enables the production of complex U-shaped or L-shaped concrete parts as single monolithic elements rather than requiring segmentation into separate castings. The non-self-compacting concrete with controlled stress threshold can be placed and retained in complex geometries without self-flow, eliminating the need for assembly operations while maintaining manufacturing flexibility.
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
Enables the production of complex concrete parts in a single step, reduces CO2 emissions by lowering cement usage, and provides high compressive strength and ductility, allowing the binder to remain stable on non-horizontal surfaces.
Implementation Method 1
A hydraulic binder is a material that sets and hardens through hydration.
Data Source
AI summary
The present invention relates to a hydraulic binder containing, in wt%: - 20% to 82% Portland cement, the particles of which have a D50 from 2 μm to 11 μm; - 15% to 56% of a non-pozzolanic mineral additive A1, the particles of which have a D50 from 1 μm to 150 μm, said additive being selected from limestone additives such as calcium carbonate, silica additives such as quartz, silica/limestone mineral additives, calcined shales, zeolites, burnt plant ash, and the mixtures thereof; and - 4% to 30% of a pozzolanic mineral additive A2, the particles of which have a D50 between 1 and 150 μm. The sum of said percentages is between 90% and 100%.