USOO7144454B2

(12) United States Patent (10) Patent No.: US 7,144.454 B2

Shoshany et al. (45) Date of Patent: Dec. 5, 2006
(54) EFFLORESCENCE CONTROL WITH WAX (56) References Cited
(75) Inventors: Haggai Shoshany, Kfar Tavor (IL); U.S. PATENT DOCUMENTS
Amnon Shoshani, Tel Aviv (IL) 5,695,553 A * 12/1997 Claret et al. ................ 106,778
5,736,600 A * 4/1998 Karkare et al. ... ... 524/400
(73) Assignee: H.A. Industrial Technologies Ltd., Tel 5,743,949 A * 4/1998 Kainz ............... ... 106,271
Aviv (IL) 6,537.366 B1* 3/2003 Supplee, Sr. ... ... 106,712
2002/0022688 A1* 2/2002 Tysak et al. ...... ... 524,558
ck
(*) Notice: Subject to any disclaimer, the term of this 2004/O122144 A1 6/2004 Karkare et al. ............. 524,284
patent is extended or adjusted under 35 OTHER PUBLICATIONS
U.S.C. 154(b) by 0 days. Resume and publications of Prof. Moris S. Elsen, no date.
(21) Appl. No.: 11/103,498
y x- - - 9
Resume of James R. Eckert, no date.
* cited by examiner
(22) Filed: Apr. 12, 2005
Primary Examiner Elizabeth D. Wood
(65) Prior Publication Data (74) Attorney, Agent, or Firm Dekel Patent Ltd.; David
Klein
US 2006/0225623 A1 Oct. 12, 2006
(57) ABSTRACT
(51) Int. Cl.
COSL 9/06 (2006.01) A method for making a concrete shaped product more
C04B I4/00 (2006.01) resistant to efflorescence, including forming a mixture of a
(52) U.S. Cl. ...................... 106/270; 106/724; 106/802: wax blend with a concrete mix into a shaped product, the
106/822: 106/272 wax blend including a weight ratio of 50.01% to 99.99% of
(58) Field of Classification Search ................ 106/272, a main wax and 0.01% to 49.99% of a secondary wax.
106/724, 802, 822, 270
See application file for complete search history. 7 Claims, No Drawings
 US 7,144,454 B2
1. 2
EFFLORESCIENCE CONTROL WITH WAX vegetable and animal fats, emulsions based on white grease,
silicone compounds, siliconates, and siloxanes, waxes, wax
FIELD OF THE INVENTION emulsions, soaps and fatty acids, vegetable oils and emul
sions, petroleum residues, including mineral oil, paraffin,
The present invention relates generally to efflorescence, 5 and bitumens, various poZZolanics, including fly ash, blast
and particularly to using wax compositions and mixtures to furnace slag, diatomaceous earth, inert fillers, including talc,
control, reduce and eliminate efflorescence in concrete bentonite, and siliceous powders, and a mixture thereof. The
shaped products. particulated polymer is selected from the group consisting of
styrene-based polymers and copolymers, acrylic-based
BACKGROUND OF THE INVENTION 10 polymers and copolymers, polyvinyl acetates, polyepoxides,
polyurethanes, butadiene rubbers, and a mixture thereof.
Efflorescence is a calcium or alkaline salt which forms as
a blotchy, powdery or crystalline deposit on the surface of SUMMARY OF THE INVENTION
masonry and concrete products. It is due to moisture enter
ing through the masonry, combining with the calcium 15 The present invention seeks to provide wax compositions
hydroxide in the cement, and bringing the hydroxide to the and mixtures to control, reduce and eliminate efflorescence
Surface in a solution which forms crystals when it combines in concrete shaped products, as is described in detail further
with the carbon dioxide in the air. It is usually white but hereinbelow. Wax may be mixed with the raw materials of
efflorescence may be yellow, green or brown. the concrete shaped product, resulting in a concrete shaped
Efflorescence is generally caused by Salt-bearing com product with advanced hydrophobic properties (that is,
pounds entering the masonry material. Although new, fresh water repelling or resisting, the terms being used inter
bricks do not generally contain significant amounts of changeably) that may solve the abovementioned problems of
soluble salts, mortar and concrete do have relatively high efflorescence.
soluble salt contents. Ground waters that are naturally salt
bearing can also seep into the masonry, as well as other 25 DETAILED DESCRIPTION OF EMBODIMENTS
Sources of water, such as rain, lawn sprinklers, leaky pipes
and others. The amount of efflorescence that occurs is The term “concrete shaped product encompasses con
related, interalia, to the amount of water in the bricks, and crete products, such as but not limited to, bricks, blocks,
their drying time. The more water in the bricks, and the tiles, columns, pillars, cinder blocks, pavers, interlocking
longer it is there, the more chance salts will have to dissolve 30 bricks, blocks and tiles (also referred to as interlocking
in it and be brought to the surface as the bricks dry out. concrete pavers or pavement stones) which may be molded
In the prior art, attempts to control efflorescence include or otherwise formed into a desired shape. Forming and
waterproof coatings applied to the Surface of the masonry curing the concrete shaped product may be done at room
units. The application of Such coatings is not always effec (ambient) or near room temperature (even including arctic
tive and is costly in terms of labor, coating materials and 35 conditions), but may also be done at elevated temperatures
time. One of the most common methods is to simply "give (e.g., autoclave curing).
up' and brush off the efflorescence deposits with a stiff dry As is well known in the art, concrete is basically a mixture
bristle brush after the wall has dried out. of two components, aggregates and paste. The aggregate
U.S. Pat. No. 6,537.366 to Supplee, Sr. describes a component normally includes sand and gravel, pebbles or
composition for coloring concrete, which includes a hydro 40 crushed Stone. The paste component normally includes
phobic efflorescence control agent, such as a stearate-con cementing materials, such as but not limited to, Portland
taining compound. Supplee, Sr. states that although Stearate cement with or without Supplementary cementing materials,
containing compounds (e.g., calcium Stearate, Zinc Stearate, water, and air. Accordingly, the term "concrete mix' (or
aluminum Stearate, among other Suitable compounds of “concrete mixture') refers to the mixture of the aggregates
Stearic acid, salts and derivatives thereof, and mixtures 45 and paste.
thereof) may be used to minimize or eliminate efflorescence, In accordance with an embodiment of the present inven
they are also known to adversely affect the durability of tion, the concrete shaped product may be made resistant to
concrete. Concrete durability is a function of the totality of efflorescence by adding a wax blend to the concrete mix. The
the polymerization of the cementitious materials in a mix. wax blend may be in the form of an emulsion, Suspension,
Because efflorescence control agents hinder polymerization, 50 Solution, or Small Solid particles (e.g., flakes, powder, pel
use of efflorescence control agents yield a weaker polymer lets, etc.) or any combination thereof.
structure and hence a less durable concrete. A "wax solution' is a homogenous liquid of miscible
Supplee, Sr. describes a concrete admixture composition materials in which wax is dissolved in a main solvent. The
that includes about 0.1% by weight to about 85% by weight wax is in its molecular or ion form.
of a hydrophobic efflorescence control agent; about 0.5% by 55 A “wax emulsion' is a stable dispersion of immiscible
weight to about 75% by weight of a particulated polymer, materials. It is noted that wax in water emulsions of above
the particulated polymer having particle sizes of about 50 micron size particles necessitate emulsifiers to maintain
angstroms to about 7,000 angstroms; and about 0.001% by stability. The emulsifiers prevent the wax particles from
weight to about 80% by weight of a colorant in an aqueous adhering to or merging with themselves. Water soluble
dispersion of the total weight of the composition. The 60 polymer compounds. Such as but not limited to polyvinyl
composition also includes a property enhancing additive alcohol, may be added to the water phase, for the purpose of
selected from the group consisting of plasticizers, Surfac controlling the Viscosity of the emulsion and improving the
tants, rheology modifiers, biological control agents, and a adhesion between the wax and other particles.
mixture thereof. A“wax Suspension' is a buoyant dispersion of immiscible
The efflorescence control agent may be one of the stear 65 materials. It is noted that wax in water Suspensions neces
ate-containing compounds mentioned above, or may be sitate constant agitation without which the wax particles will
selected from the group consisting of tall oil fatty acids, rapidly merge to form a continuous wax phase floating on
 US 7,144,454 B2
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the water. Water soluble polymer compounds, such as but The weight ratio of the wax blend to the total concrete
not limited to polyvinyl alcohol, may be added to the water weight is 0.1% to 10%, preferably 0.5% to 7%, and more
phase, for the purpose of controlling the Viscosity of the preferably 1% to 5%.
Suspension and improving the adhesion between the wax Although the invention encompasses wax in any form as
and other particles. stated above, it may be advantageous to add the wax as a
"Mixing encompasses adding, coating, dissolving, pour Suspension instead of an emulsion to the concrete mixture.
ing, or any other action to make the wax substance part of Emulsions have to be stored at the site where the concrete
the concrete mixture which is eventually turned into a shaped product is produced, and have a limited shelf life.
finished concrete shaped product.
As is known in the art, certain shaped products, such as 10 The manufacture of emulsions uses relatively a lot of energy
interlocking concrete pavers or cinder blocks, may be made and is relatively costly. In contrast, the raw materials for
with a base mix and a face mix, that is, two mixes are applied making the Suspension may be much cheaper and much
during the stone manufacture. The base mix is used to fill a more stable. The wax suspension may be manufactured at
mold to create the paver. Afterwards, the face mix is used to the site where the concrete shaped product is produced, and
completely fill the mold prior to manufacture. The face mix 15 introduced on-line to the shaped product mixture, thereby
(also referred to as hard facing) is a thin layer of fine providing significant savings in energy, storage, manpower,
aggregate and cement to the top Surface of the concrete etc. Due to its online production, the wax Suspension is not
paver. The layer is often colored and is used to provide a sensitive to storage and/or storage conditions, such as but
more intense appearance, greater abrasion resistance, or not limited to, excessive mechanical shear, pumping, exces
provide a base for a textured finish. This enables the cost sively low or high ambient temperature, storage agitation,
effective use of very special colors in manufacturing the crust formation, particles agglomeration, and the like.
paver. The invention may be better understood by referring to
It has been surprisingly found that when the concrete the following non-limiting example:
shaped product is manufactured using a base mix and a face Standard mixtures of pavers were made from crushed
mix, the concrete shaped product may be made resistant to 25
basalt rock, sand, Portland cement and water. A Suspension
efflorescence by adding a wax blend (or just a wax without of wax blend was added in various quantities to the face mix
a wax blend) Substantially just to the face mix alone. only. The base mix was not treated. The wax blend included
The wax blend may include a weight ratio of 50.01% to paraffin wax of congealing point 57–60° C. and montan wax
99.99% of a main wax, and 0.01% to 49.99% of a secondary of congealing point 75–85° C. The water phase of the
wax. Preferable ratios are 75% to 98% of the main wax and 30
2% to 25% of the secondary wax. More preferable ratios are suspension included fully hydrolyzed polyvinyl alcohol
85%–95% of the main wax and 5-15% of the secondary (PVA).
Wax. The pavers were cured in an ambient temperature 100%
In accordance with an embodiment of the present inven humidity chamber for 12 hours and in ambient temperature
tion, the main wax may include a soft macro-crystalline wax 35 outdoor storage for 28 days.
(preferably, but not limited to, a soft paraffin wax) with a The pavers were tested for compressive strength, abra
congealing point in the range of about 10-45° C., a hard Sion, water drop absorption and efflorescence.
macro-crystalline wax (preferably, but not limited to, a Wax blend addition rates and test results of these pavers
paraffin wax) with a congealing point in the range of about are shown in Table 1.
40–85° C., or a mixture thereof. Other macro-crystalline 40
waxes such as plant/insect waxes (bee wax, carnauba wax, TABLE 1.
candelila wax, bayberry wax, Japan wax, etc.) and synthetic
waxes (wax produced from a Fischer-Tropsch process, poly Reference Sample 1 Sample 2 Sample 3
ethylene wax, polypropylene wax, etc.), or any mixture Density (kg/m. 2310 2292 2308 2325
thereof may be used as the main wax. 45 Wax additive 96) O.O 1.3 2.2 3.1
The secondary wax may include a hard or micro-crystal Compressive
strength MPa)*
53 52 S4 53
line wax with a congealing point higher than 70° C., and Abrasion 4.3 4.9 4.6 4.5
preferably at least 10° C. higher than that of the main wax. Water drop 1 ** ** **
The secondary wax is preferably montan wax with a con absorption time
gealing point in the range of about 70–95° C., more pref 50 seconds
Efflorescence Positive Negative Negative Negative
erably 75-85°C. Other hard micro-crystalline waxes, such appearance test *
as but not limited to, natural waxes (peat wax, castor wax,
jojoba wax, etc.) and synthetic waxes (wax produced from Test according to Israel standard specification 376
a paraffin precipitation process, Fischer-Tropsch process, *Water drops of samples 1, 2, 3 dried out after 3–5 hours without being
absorbed in the brick surface
polyethylene wax, polypropylene wax, etc.) or any mixture 55
***Efflorescence appearance test was conducted the following way: refer
thereof may be used as the secondary wax. ence and test pavers were put in a tub containing tap water up to 10 mm
For example, the main wax may be a macro-crystalline below paver surface. The tab was kept outdoors in a shed for a period of
wax and the secondary wax may be montan wax. As another 7 days. Water level of the tub was adjusted twice a day to compensate for
evaporation. After 7 days the pavers were dried at ambient temperature for
example, the main wax may be a paraffin macro-crystalline 24 hours and inspected visually for efflorescence appearance.
wax and the secondary wax may be a paraffin micro 60
crystalline wax. It is appreciated that various features of the invention
In cases of ambient temperature curing of the concrete which are, for clarity, described in the contexts of separate
shaped product, the congealing point of the wax blend is embodiments, may also be provided in combination in a
preferably 5–15° C. above the ambient temperature. In cases single embodiment. Conversely, various features of the
of autoclave curing of the concrete shaped product, the 65 invention which are, for brevity, described in the context of
congealing point of the wax blend is preferably at least 10° a single embodiment, may also be provided separately or in
C. below the autoclave temperature. any suitable Subcombination.
 US 7,144,454 B2
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What is claimed is: 4. The method according to claim 1, wherein the wax
1. A method for making a concrete shaped product more blend has a congealing point 5–15° C. above ambient
resistant to efflorescence, comprising: temperature.
5. The method according to claim 1, wherein the wax
forming a mixture of a wax blend with a concrete mix, blend has a congealing point at least 10° C. below an
said wax blend comprising about 0.25-2.50% inclusive autoclave temperature.
of a total weight of said mixture, said wax blend having 6. A method for making a concrete shaped product more
a weight ratio of from about 1:1 to 10:1 of a main wax resistant to efflorescence, comprising:
and 0.01 to a secondary wax, said main wax comprising partially filling a mold with a concrete base mix and
paraffin wax and said secondary wax comprising mon 10 placing a concrete face mix over said concrete base
tan wax, and forming said mixture of the wax blend and mix, wherein a wax blend is added substantially just to
the concrete mix into a concrete shaped product, the concrete face mix alone, and curing said concrete
wherein the wax blend makes said concrete shaped base mix and said concrete face mix to form a concrete
product more resistant to efflorescence. shaped product, wherein said wax blend in said con
2. The method according to claim 1, comprising manu 15 crete face mix makes said concrete shaped product
facturing the concrete shaped product using a base mix and more resistant to efflorescence.
a face mix, and adding said wax blend Substantially just to 7. A concrete shaped product comprising a wax blend
the face mix alone. mixed with a concrete mix that has been formed into a
3. The method according to claim 1, wherein said wax shaped product, said wax blend comprising about
blend comprises at least one of: a wax emulsion of said main 0.25-2.50% inclusive of a total weight of said mixture, said
wax and said secondary wax and at least one emulsifier, a wax blend having a weight ratio of about 1:1 to 10:1 of a
wax Suspension that includes said main wax and said main wax and 0.01 to a secondary wax, said main wax
secondary wax Suspended in a fluid, and a wax solution that comprising paraffin wax and said secondary wax comprising
montan WaX.
includes said main wax and said secondary wax dissolved in
a solvent.