NAILABLE CONCRETE FORMWORKS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application No. 63/549,011, filed Feb. 2, 2024, which is incorporated by reference herein in its entirety.

BACKGROUND

Concrete poured in the field must be contained by a temporary structure. This structure is commonly referred to as formwork. Concrete slabs are typically poured using formwork consisting of formboards, which are sections of lumber, either dimensional lumber, such as 2×4, 2×6, etc., or plywood. These formboards contain the wet concrete during the pour. Formworks for concrete are a continual issue for contractors for numerous reasons. The cheapest material to use as formwork is wood. However, wood warps after use, and most contractors discard it after a single use. If the warping isn't enough to cause wood to be discarded, it often sticks to poured concrete and must be forcibly removed using hand tools. Wood is also porous and can dry out concrete too quickly during the curing process. Other materials, such as steel and aluminum, can be used as reusable alternatives; however, these have downsides as well. Steel is more expensive and must be reused many times to be economically feasible. However, steel formwork can only be reused when the formwork is required to be the same shape each pour. This is unrealistic for most concrete pours in the field, save for a few floor systems that require extensive engineering. Aluminum can be used, but suffers from many of the same issues as steel. Aluminum is less dense, but also more prone to damage during handling.

Accordingly, there is a need for improved formworks that can decrease costs and improve the quality of the finished concrete slabs. These needs and others are at least partially satisfied by the present disclosure.

SUMMARY

Disclosed herein is a precast concrete board which can be used as formwork directly. This allows for a cast-in-place formwork composed of concrete, which allows for a slab to be poured such that the formboards need not be removed after curing the concrete. This can increase construction speeds and reduce costs as wood formboards are often destroyed during their removal or warp beyond use after a few uses.

In an aspect, provided is concrete slab precursor comprising: at least partially enclosed structure formed by one or more nailable formworks comprising a first concrete composition; wherein the at least partially enclosed structure comprises a defined area configured to receive a second concrete composition; wherein the first concrete composition is a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material; and wherein the second concrete composition is the same as or different from the first concrete composition.

In another aspect, provided is a concrete slab formed by: providing any of the disclosed concrete slab precursors; and filling the defined area with the second concrete composition; wherein the one or more nailable formworks are incorporated into the concrete slab and are not removed.

In another aspect, provided is a method of assembling a construction, the method comprising: providing any of the disclosed concrete slabs; nailing a construction element into at least one of the one or more nailable formworks.

In another aspect, provided is a construction comprising any of the disclosed concrete slabs.

In another aspect, provided is a construction formed by any of the disclosed methods.

Other systems, methods, features, and/or advantages will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and/or advantages be included within this description and be protected by the accompanying claims.

BRIEF DESCRIPTION OF DRA WINGS

FIG. 1 shows a diagram of an example of a concrete formwork 100 having width 102 and at least one dimension 106 disclosed herein. Wire 104 protrudes from the cast concrete, which can be poured such that this wire can connect into the newly poured concrete.

FIG. 2 shows a diagram of a slab 204 that can be poured using the concrete formworks 200 connected together as shown in 202 shown in FIG. 1.

FIG. 3A shows an example floor plan.

FIG. 3B shows the placement of nailable concrete formwork in the floorplan of FIG. 3A. This significantly reduces the screeding board length needed (reducing high/low spots in the slab) while introducing expansion joints, reference elevation points, reference wall layout points, etc. If necessary, sections can be poured on different days, depending on the footing design at the exterior.

FIG. 3C shows that after pouring concrete to make a continuous slab (top) 302, the concrete can be anchored together by the wire inside 304 studwall components 306 can be nailed directly to the concrete at the locations of the nailable concrete formwork (bottom).

FIGS. 4A-4D depict wire for a reinforcement cage tied using a pair of pliers. FIG. 4A shows wire is pressed together to begin bending. FIG. 4B shows pliers bend the wire underneath one of the looping wires. FIG. 4C shows the wire after looping around and making a hook. FIG. 4D shows that this hook can then be bent around, securing the wire loop to itself.

FIGS. 5A-5D depict various images of the manufactured, reinforced cage with the additional loop sticking out of the top. The loop can be reshaped into a U while the cast section remains a circle or square, as the U-shape can help the new slab secure to the existing concrete formwork.

FIGS. 6A-6D depict a concrete formwork being cast in various stages. FIG. 6A shows the reinforcement cages set in the formwork. FIG. 6B shows that the concrete is poured very stiff to increase the roughness at the point of contact between the concrete formwork and the new slab. FIG. 6C shows the concrete after curing for 16 hours. FIG. 6D shows a close-up of the cured concrete after 16 hours.

FIGS. 7A-7D depict the extrusion of a concrete formwork. FIG. 7A shows an extrusion prototype with concrete formworks forming on the outlet. FIG. 7B shows concrete formworks that have had damaged ends removed. FIGS. 7C-7D show two example concrete formworks cast by the machine at two different angles. This machine can be reconfigured to allow for continuous driving of the form, a significantly larger hopper, and reinforcement wire can be included in future formwork designs. Additionally, reinforcement wire can be added to the formworks after casting by hand or another automated process.

FIGS. 8A-8D depict the process of preparing the concrete formwork of FIGS. 6A-6D for pouring. FIG. 8A shows the formwork after setting with the correct tamping and slope for the pour. FIG. 8B shows the wire reinforcement can be tied together at the edges, if necessary. FIG. 8C shows the slab's reinforcement mesh is secured along one side of the formwork. FIG. 8D shows the securing method for the reinforcement. This helps the reinforcement to be suspended above the dirt at the edges of the slab. Rebar chairs and other reinforcement supports can be used in larger pours, if necessary.

FIGS. 9A-9D depict a time progression of the concrete slab prepared in FIGS. 8A-8D being poured.

FIGS. 10A-10D depict the installation of a short wall section to the nailable concrete slab prepared in FIGS. 9A-9D. Note that the concrete slab itself is still wet. Due to how this process works, items can be fixed to the nailable formwork prior to the slab curing. FIG. 10A shows nailable concrete boards are cut using a saw with an abrasive cutting blade. FIG. 10B shows the boards are nailed directly into the nailable concrete formboards using a pneumatic nailer. FIG. 10C shows the slab after installation of 3 columns and the top and bottom boards. FIG. 10D shows a close-up of the installation.

FIGS. 11A-11C depict the concrete slab of FIGS. 10A-10D during and after curing. FIG. 11A shows the concrete slab after a single day of curing with no cracks visible. FIG. 11B shows the concrete slab after two days of curing with no cracks visible. FIG. 11C shows close-ups of the slab after 4 days of curing showing no cracks.

FIGS. 12A-12N depict the construction of a concrete slab. FIG. 12A shows stakes driven into the ground to denote the edges of a slab. FIG. 12B shows the ground cleared. FIG. 12C shows the ground tampered. FIG. 12D shows a footing trench dug and the lower section of concrete formwork being installed on the ground. FIG. 12E shows the foundation continuing to be installed. FIG. 12F shows the upper section of the concrete formwork being installed on the foundation. FIG. 12G shows more of the upper section installed. FIG. 12H shows the nailable concrete formwork fully installed. FIG. 12I shows a corner inside the nailable concrete formwork.

FIG. 12J shows a lap splice shown in the concrete formwork. FIG. 12K shows the slab ready to be poured. FIG. 12L shows the concrete slab mid-pour. FIG. 12M shows the concrete after pouring and bull floating half the concrete. FIG. 12N shows the concrete slab the day after construction.

FIG. 13A shows a diagram that is representative of a single foundation design.

FIG. 13B shows that the rebar is sitting on top of the screws. This is the configuration used for the slab pour in FIGS. 12A-12N.

The components in the drawings are not necessarily to scale relative to each other. Like reference, numerals designate corresponding parts throughout the several views.

DETAILED DESCRIPTION

It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate aspects, can also be provided in combination with a single aspect. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single aspect, can also be provided separately or in any suitable subcombination. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure.

In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:

Throughout the description and claims of this specification, the word “comprise” and other forms of the word, such as “comprising” and “comprises,” means including but not limited to, and are not intended to exclude, for example, other additives, segments, integers, or steps. Furthermore, it is to be understood that the terms comprise, comprising, and comprises as they relate to various aspects, elements, and features of the disclosed invention also include the more limited aspects of “consisting essentially of” and “consisting of.”

As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “fastener” includes aspects having two or more such fasteners unless the context clearly indicates otherwise.

Ranges can be expressed herein as from “about” one particular value and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It should be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.

Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value recited or falling within the range unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited. Ranges provided herein are understood to be shorthand for all of the values within the range. For example, a range of 1 to 50 is understood to include any number, or combination of numbers, from the group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 or sub-ranges from the group consisting of 10-40, 20-50, 5-35, etc. Similarly, numerical ranges recited herein by endpoints include subranges subsumed within that range (e.g., 1 to 5 includes 1-1.5, 1.5-2, 2-2.75, 2.75-3, 3-3.90, 3.90-4, 4-4.24, 4.24-5, 2-5, 3-5, 1-4, and 2-4).

As used herein, the term “substantially” means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs.

Still further, the term “substantially” can, in some aspects, refer to at least about 80%, at least about 85%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% of the stated property, component, composition, or other condition for which substantially is used to characterize or otherwise quantify an amount.

In other aspects, as used herein, the term “substantially free,” when used in the context of a composition or component of a composition that is substantially absent, is intended to refer to an amount that is then about 1% by weight, e.g., less than about 0.5% by weight, less than about 0.1% by weight, less than about 0.05% by weight, or less than about 0.01% by weight of the stated material, based on the total weight of the composition or based on any other calculations as disclosed.

As used herein, the term “substantially,” in, for example, the context “substantially identical” or “substantially similar,” refers to a method or a system, or a component that is at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% by similar to the method, system, or the component it is compared to.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur and that the description includes instances where said event or circumstance occurs and instances where it does not.

For the terms “for example” and “such as,” and grammatical equivalences thereof, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise.

The term “nailing” or “nailed,” as used herein, refers to driving a nail, screw, peg, or another suitable fastener into or through a material or article. Similarly, the term “nailable,” as used herein, refers to a material or composition which is configured to receive a nail, screw, peg, or other fastener.

As used herein, the term “formwork” refers to a mold or a portion of a mold used for casting concrete. The dimensions, shape, and arrangement of formworks are known in the art and can be selected by a skilled artisan. As an example, a formwork can be rectangular and have a thickness of from about 0.75 inches to about 24 inches, a depth of from about 1 inch to about 20 feet, and a length of from about 1 inch to about 60 feet.

In some aspects, a formwork can have a thickness of from about 0.75 inches to about 24 inches, including exemplary values of about 1 inch, about 1.5 inches, about 2 inches, about 2.5 inches, about 3 inches, about 3.5 inches, about 4 inches, about 4.5 inches, about 5 inches, about 6 inches, about 7 inches, about 8 inches, about 10 inches, about 12 inches, about 14 inches, about 16 inches, about 18 inches, about 20 inches, or about 22 inches. It is considered that the formwork can have a thickness of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a thickness of from about 0.75 inches to about 24 inches, or from about 1 inch to about 22 inches, or from about 1.5 inches to about 20 inches, or from about 2 inches to about 18 inches, or from about 2.5 inches to about 16 inches, or from about 3 inches to about 14 inches, or from about 3.5 inches to about 12 inches, or from about 4 inches to about 10 inches, or from about 4.5 inches to about 8 inches, or from about 5 inches to about 6 inches, or from about 0.75 inches to about 5 inches, or from about 1 inch to about 4.5 inches, or from about 1.5 inches to about 4 inches, or from about 2 inches to about 3.5 inches, or from about 2.5 inches to about 3 inches, or from about 6 inches to about 24 inches, or from about 7 inches to about 22 inches, or from about 8 inches to about 20 inches, or from about 10 inches to about 18 inches, or from about 12 inches to about 16 inches.

In some aspects, a formwork can have a depth of from about 1 inch to about 20 feet, including exemplary values of about 2 inches, about 4 inches, about 6 inches, about 8 inches, about 1 foot, about 1.5 feet, about 2 feet, about 2.5 feet, about 3 feet, about 3.5 feet, about 4 feet, about 4.5 feet, about 5 feet, about 6 feet, about 7 feet, about 8 feet, about 10 feet, about 12 feet, about 14 feet, about 16 feet, or about 18 feet. It is considered that the formwork can have a depth of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a depth of from about 1 inch to about 20 feet, or from about 2 inches to about 18 feet, or from about 4 inches to about 16 feet, or from about 6 inches to about 14 feet, or from about 8 inches to about 12 feet, or from about 1 foot to about 10 feet, or from about 1.5 feet to about 8 feet, or from about 2 feet to about 6 feet, or from about 2.5 feet to about 5 feet, or from about 3.5 feet to about 4.5 feet, or from about 1 inch to about 4 feet, or from about 2 inches to about 3.5 feet, or from about 4 inches to about 3 feet, or from about 6 inches to about 2.5 feet, or from about 8 inches to about 2 feet, or from about 1 foot to about 1.5 feet, or from about 4 feet to about 20 feet, or from about 4.5 feet to about 18 feet, or from about 5 feet to about 16 feet, or from about 6 feet to about 14 feet, or from about 8 feet to about 12 feet.

In some aspects, a formwork can have a length of from about 1 inch to about 60 feet, including exemplary values of about 2 inches, about 4 inches, about 6 inches, about 8 inches, about 1 foot, about 1.5 feet, about 2 feet, about 2.5 feet, about 3 feet, about 3.5 feet, about 4 feet, about 4.5 feet, about 5 feet, about 6 feet, about 7 feet, about 8 feet, about 10 feet, about 12 feet, about 14 feet, about 16 feet, about 18 feet, about 20 feet, about 25 feet, about 30 feet, about 35 feet, about 40 feet, about 45 feet, about 50 feet, or about 55 feet. It is considered that the formwork can have a length of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a length of from about 1 inch to about 60 feet, or from about 2 inches to about 55 feet, or from about 4 inches to about 50 feet, or from about 6 inches to about 45 feet, or from about 8 inches to about 40 feet, or from about 1 foot to about 35 feet, or from about 1.5 feet to about 30 feet, or from about 2 feet to about 25 feet, or from about 2.5 feet to about 20 feet, or from about 3 feet to about 18 feet, or from about 3.5 feet to about 16 feet, or from about 4 feet to about 14 feet, or from about 4.5 feet to about 12 feet, or from about 5 feet to about 10 feet, or from about 6 feet to about 8 feet, or from about 1 inch to about 10 feet, or from about 2 inches to about 8 feet, or from about 4 inches to about 7 feet, or from about 6 inches to about 6 feet, or from about 8 inches to about 5 feet, or from about 1 foot to about 4 feet, or from about 1.5 feet to about 3.5 feet, or from about 2 feet to about 3 feet, or from about 10 feet to about 60 feet, or from about 12 feet to about 55 feet, or from about 14 feet to about 50 feet, or from about 16 feet to about 45 feet, or from about 18 feet to about 40 feet, or from about 20 feet to about 35 feet, or from about 25 feet to about 30 feet.

A formwork can be formed in any predetermined shape that can be used in construction. For example, in some aspects, the formwork can be a solid shape with a square or rectangular cross-section. In other embodiments, the formwork can be partially convex—for example, C-shaped or including a channel—or partially concave—for example, including a ridge. The formwork can, in some aspects, be shaped such that it is configured to receive additional elements such as construction elements or other formworks, for example, by mating. In some such aspects, a first formwork can include a male mating and a second formwork or a first construction element can include a female mating. In other such aspects, a first formwork can include a female mating and a second formwork or a first construction element can include a male mating.

During construction, formworks are needed for concrete work. Formwork is often destroyed during removal, and if it isn't destroyed, the warping caused by casting concrete makes it such that most formworks (especially wooden formworks) can only be used once. The disclosed concrete formworks can be used without having to remove said formworks later. These concrete formworks can save costs for contractors, as they would not have to pay for materials that are not incorporated into the slab. The use of a nailable concrete for the concrete formwork can additionally allow for fast installation of components that are to be nailed to the formwork. This would be a faster process for contractors due to time savings from no formwork removal and greater installation speed of components that nail to the concrete.

In an aspect, provided is concrete slab precursor comprising: at least partially enclosed structure formed by one or more nailable formworks comprising a first concrete composition; wherein the at least partially enclosed structure comprises a defined area configured to receive a second concrete composition; wherein the first concrete composition is a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35% based on a total mass of dry material; and wherein the second concrete composition is the same as or different from the first concrete composition.

In some aspects, the one or more nailable formworks further comprises a first concrete reinforcing element. In some aspects, the first concrete reinforcing element is embedded in the one or more nailable formworks such that at least a portion of the first concrete reinforcing element extends outside of a body of the one or more nailable formworks. In some aspects, the first concrete reinforcing element is rebar. In some aspects, the first concrete reinforcing element is reinforcement wire. In some aspects, the first concrete reinforcing element is another suitable mesh, grid, or lath. An example concrete reinforcing element is shown in FIG. 1.

In some aspects, the defined area further comprises a second concrete reinforcing element. In some aspects, the second concrete reinforcing element is disposed along at least a portion of the defined area. In some aspects, the second concrete reinforcing element is disposed such that it covers an entire area of the defined area. In some aspects, the second concrete reinforcing element is rebar. In some aspects, the second concrete reinforcing element is reinforcement wire. In some aspects, the second concrete reinforcing element is another suitable mesh or grid. In some aspects, the first concrete reinforcing element is the same as the second concrete reinforcing element. In some aspects, the first concrete reinforcing element is different from the second concrete reinforcing element. In some aspects, the second concrete reinforcing element comprises a portion of the first concrete reinforcing element that is reconfigured to be disposed along at least a portion of the defined area. In some aspects, the first concrete reinforcing element is configured to support the second concrete reinforcing element. In such aspects, a portion of the first concrete reinforcing element can be connected to the second concrete reinforcing element via tying, interlocking, welding, or another suitable connection. This can provide a convenient securing method to tie the entire slab together and enable precise placement of the second concrete reinforcing element.

In some aspects, the at least partially enclosed structure is formed by two or more nailable formworks. In some aspects, at least one boundary of the at least partially enclosed structure is a preexisting construction element, and wherein the one or more nailable formworks abut the preexisting construction element. An example of an at least partially enclosed structure is shown in FIG. 2. In some aspects, the defined area further comprises an internal nailable formwork partitioning the defined area.

In some aspects, the defined area has a width of from about 1 inch to about 20 feet, including exemplary values of about 2 inches, about 4 inches, about 6 inches, about 8 inches, about 1 foot, about 1.5 feet, about 2 feet, about 2.5 feet, about 3 feet, about 3.5 feet, about 4 feet, about 4.5 feet, about 5 feet, about 6 feet, about 7 feet, about 8 feet, about 10 feet, about 12 feet, about 14 feet, about 16 feet, or about 18 feet. It is considered that the defined area can have a width of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a width of from about 1 inch to about 20 feet, or from about 2 inches to about 18 feet, or from about 4 inches to about 16 feet, or from about 6 inches to about 14 feet, or from about 8 inches to about 12 feet, or from about 1 foot to about 10 feet, or from about 1.5 feet to about 8 feet, or from about 2 feet to about 6 feet, or from about 2.5 feet to about 5 feet, or from about 3.5 feet to about 4.5 feet, or from about 1 inch to about 4 feet, or from about 2 inches to about 3.5 feet, or from about 4 inches to about 3 feet, or from about 6 inches to about 2.5 feet, or from about 8 inches to about 2 feet, or from about 1 foot to about 1.5 feet, or from about 4 feet to about 20 feet, or from about 4.5 feet to about 18 feet, or from about 5 feet to about 16 feet, or from about 6 feet to about 14 feet, or from about 8 feet to about 12 feet.

In some aspects, the defined area can have a length of from about 1 inch to about 60 feet, including exemplary values of about 2 inches, about 4 inches, about 6 inches, about 8 inches, about 1 foot, about 1.5 feet, about 2 feet, about 2.5 feet, about 3 feet, about 3.5 feet, about 4 feet, about 4.5 feet, about 5 feet, about 6 feet, about 7 feet, about 8 feet, about 10 feet, about 12 feet, about 14 feet, about 16 feet, about 18 feet, about 20 feet, about 25 feet, about 30 feet, about 35 feet, about 40 feet, about 45 feet, about 50 feet, or about 55 feet. It is considered that the defined area can have a length of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a length of from about 1 inch to about 60 feet, or from about 2 inches to about 55 feet, or from about 4 inches to about 50 feet, or from about 6 inches to about 45 feet, or from about 8 inches to about 40 feet, or from about 1 foot to about 35 feet, or from about 1.5 feet to about 30 feet, or from about 2 feet to about 25 feet, or from about 2.5 feet to about 20 feet, or from about 3 feet to about 18 feet, or from about 3.5 feet to about 16 feet, or from about 4 feet to about 14 feet, or from about 4.5 feet to about 12 feet, or from about 5 feet to about 10 feet, or from about 6 feet to about 8 feet, or from about 1 inch to about 10 feet, or from about 2 inches to about 8 feet, or from about 4 inches to about 7 feet, or from about 6 inches to about 6 feet, or from about 8 inches to about 5 feet, or from about 1 foot to about 4 feet, or from about 1.5 feet to about 3.5 feet, or from about 2 feet to about 3 feet, or from about 10 feet to about 60 feet, or from about 12 feet to about 55 feet, or from about 14 feet to about 50 feet, or from about 16 feet to about 45 feet, or from about 18 feet to about 40 feet, or from about 20 feet to about 35 feet, or from about 25 feet to about 30 feet.

In some aspects, the defined area can be from about 1,000 square feet to about 50,000 square feet, including exemplary values of about 2,000 square feet, about 4,000 square feet, about 6,000 square feet, about 8,000 square feet, about 10,000 square feet, about 15,000 square feet, about 20,000 square feet, about 25,000 square feet, about 30,000 square feet, about 35,000 square feet, about 40,000 square feet, or about 45,000 square feet. It is considered that the defined area can be any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be from about 1,000 square feet to about 50,000 square feet, or from about 2,000 square feet to about 45,000 square feet, or from about 4,000 square feet to about 40,000 square feet, or from about 6,000 square feet to about 35,000 square feet, or from about 8,000 square feet to about 30,000 square feet, or from about 10,000 square feet to about 25,000 square feet, or from about 15,000 square feet to about 20,000 square feet, or from about 1,000 square feet to about 20,000 square feet, or from about 2,000 square feet to about 15,000 square feet, or from about 4,000 square feet to about 10,000 square feet, or from about 6,000 square feet to about 8,000 square feet, or from about 15,000 square feet to about 50,000 square feet, or from about 20,000 square feet to about 45,000 square feet, or from about 25,000 square feet to about 40,000 square feet, or from about 30,000 square feet to about 35,000 square feet.

In some aspects, the defined area can be from about 1 square foot to about 1,000 square feet, including exemplary values of about 5 square feet, about 10 square feet, about 15 square feet, about 20 square feet, about 25 square feet, about 30 square feet, about 40 square feet, about 50 square feet, about 60 square feet, about 80 square feet, about 100 square feet, about 150 square feet, about 200 square feet, about 250 square feet, about 300 square feet, about 350 square feet, about 400 square feet, about 450 square feet, about 500 square feet, about 600 square feet, about 700 square feet, about 800 square feet, or about 900 square feet. It is considered that the defined area can be any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be from about 1 square foot to about 1,000 square feet, or from about 5 square feet to about 900 square feet, or from about 10 square feet to about 800 square feet, or from about 15 square feet to about 700 square feet, or from about 20 square feet to about 600 square feet, or from about 25 square feet to about 500 square feet, or from about 30 square feet to about 450 square feet, or form about 40 square feet to about 400 square feet, or from about 50 square feet to about 350 square feet, or from about 60 square feet to about 300 square feet, or from about 80 square feet to about 250 square feet, or from about 100 square feet to about 200 square feet, or from about 1 square foot to about 100 square feet, or from about 5 square feet to about 80 square feet, or from about 10 square feet to about 60 square feet, or from about 15 square feet to about 50 square feet, or from about 20 square feet to about 40 square feet, or from about 25 square feet to about 30 square feet, or from about 100 square feet to about 1,000 square feet, or from about 150 square feet to about 900 square feet, or from about 200 square feet to about 800 square feet, or from about 250 square feet to about to about 700 square feet, or from about 300 square feet to about 600 square feet, or from about 350 square feet to about 500 square feet, or from about 400 square feet to about 450 square feet.

In some aspects, the cement can be present in an amount of about 25 wt % to about 70 wt %, including exemplary values of about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, about 34 wt %, about 35 wt %, about 36 wt %, about 37 wt %, about 38 wt %, about 39 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, about 60 wt %, about 61 wt %, about 62 wt %, about 63 wt %, about 64 wt %, about 65 wt %, about 66 wt %, about 67 wt %, about 68 wt %, about 69 wt %, and about 69.9 wt %, based on a total mass of dry material. It is considered that the cement can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from about 25 wt % to about 70 wt %, or from about 30 wt % to about 65 wt %, or from about 35 wt % to about 60 wt %, or from about 40 wt % to about 55 wt %, or from about 45 wt % to about 50 wt %, or from about 25 wt % to about 50 wt %, or from about 30 wt % to about 45 wt %, or from about 35 wt % to about 40 wt %, or from about 45 wt % to about 70 wt %, or from about 50 wt % to about 65 wt %, or from about 55 wt % to about 60 wt %.

In some aspects, the cement can be any known in the art cementitious material suitable for the desired application can be used. In some aspects, the cement can comprise Portland cement, calcium aluminate cement, calcium silicate, magnesium silicate, calcium phosphate cement, calcium aluminate sulfonate cement, fly ash, silica fume, slaked lime, cement kiln dust, limestone fines, ground granulated blast furnace slag, recycled cement mixtures, cement waste, and combinations of thereof. In still further aspects, the cement is Portland cement.

In some aspects, any other known in the art cement can be utilized in this disclosure. For example, the cement can be chosen from Portland cement, Portland cement blends (Portland blast-furnace slag cement, or blast furnace cement, Portland-fly ash cement, Portland pozzolan cement, Portland silica fume cement, masonry cement, expansive cement, white blended cement, and very finely ground types of cement), pozzolan-lime cement, slag-lime cement, supersulfated cement, calcium sulfoaluminate cement, geopolymer cement, polymer cement, Sorel cement (named by the chemist Stanislas Sorel), limestone cement, and hydraulic cement and non-hydraulic cement.

In some aspects, the rubber can be present in an amount of about 10 wt % to about 60 wt %, including exemplary values of about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, and about 55 wt % on a total mass of dry material. While in still further aspects, the rubber is present in an amount of about 15 wt % to about 35 wt %, including exemplary values of about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, and about 34 wt % on a total mass of dry material. It is considered that the rubber can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from about 10 wt % to about 60 wt %, or from about 15 wt % to about 55 wt %, or from about 20 wt % to about 50 wt %, or from about 25 wt % to about 45 wt %, or from about 30 wt % to about 40 wt %, or from about 10 wt % to about 35 wt %, or from about 15 wt % to about 30 wt %, or from about 20 wt % to about 25 wt %, or from about 35 wt % to about 60 wt %, or from about 40 wt % to about 55 wt %, or from about 45 wt % to about 50 wt %.

Yet in still further aspects, the rubber can be present in an amount of about 20 wt % to about 140 wt % based on the weight of the cement, including exemplary values of about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 100 wt %, about 110 wt %, about 120 wt %, and about 130 wt % based on the weight of the cement. It is considered that the rubber can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from about 20 wt % to about 140 wt %, or from about 30 wt % to about 130 wt %, or from about 40 wt % to about 120 wt %, or from about 50 wt % to about 110 wt %, or from about 60 wt % to about 100 wt %, or from about 70 wt % to about 90 wt %, or from about 20 wt % to about 80 wt %, or from about 20 wt % to about 70 wt %, or from about 30 wt % to about 60 wt %, or from about 40 wt % to about 50 wt %, or from about 80 wt % to about 140 wt %, or from about 90 wt % to about 130 wt %, or from about 100 wt % to about 120 wt %.

It is understood that the rubber can be used as is, or it can be pretreated prior to use in the concrete. Any known in the art methods of pretreatment can be utilized. For example, and without limitations, the rubber can be treated with cement (to increase adherence, for example), treated with acids (sulfuric, hydrochloric, nitric, etc.), and treated with bases (sodium hydroxide, potassium hydroxide, etc.). It is understood that the examples provided herein include pretreated and non-treated rubber.

In some aspects, the concrete composition can comprise fine aggregates in an amount of about 10 wt % to about 35 wt %, including exemplary values of about 11 wt %, about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, and about 34 wt % on a total mass of dry material. It is considered that the fine aggregates can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, they can be present from about 10 wt % to about 35 wt %, or from about 15 wt % to about 30 wt %, or from about 20 wt % to about 25 wt %, or from about 10 wt % to about 25 wt %, or from about 15 wt % to about 20 wt %, or from about 20 wt % to about 35 wt %, or from about 25 wt % to about 30 wt %.

It is understood that cement, rubber, and fine aggregates can be present in any ratio to each other.

In some aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 5:8:15 or 3:4:8 by volume. In other aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 5:18:26 or 1:3:4 by volume. In yet still further aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 1:1.6:3 based on volume or 1:3.6:5.2 based on volume. It is understood that, in some aspects, volumetric ratios can be used. The use of volumetric ratios can be useful when the mixture is prepared in the field during the mixing of the components. In such exemplary and unlimiting aspects, the shovels” or “shovel-fulls” can be used as measurement units.

In some aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 7:11:5 by weight. In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 20:68:25 by weight. In yet still further aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 1.4:2.2:1 based on weight or mass or 1:3.4:1.25 based on weight or mass.

In some aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 3:14:12 or 7:8:1 by volume. In yet still further aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 2:11:28 or 7:6:28 by volume. In yet still further aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 7:10:12 by volume.

In some aspects, the disclosed herein cement compositions are substantially free of coarse aggregates. It is understood that common cement compositions comprise aggregates that are fine aggregates having a diameter of less than about 9.5 mm and coarse aggregates having a diameter of about 9.5 mm to about 40 mm. The aggregates, in general, can comprise natural sand, silica sand, crushed stone, recycled foundry sand, bottom ash, slag, gravel, recycled concrete, glass, limestone, granite, and the like, and any combination thereof.

In some aspects, the fine aggregates present in the disclosed composition comprise any known aggregates having a size smaller than about 9.5 mm, smaller than about 9 mm, smaller than about 8.5 mm, smaller than about 8 mm, smaller than about 7.5 mm, smaller than about 7 mm, smaller than about 6.5 mm, smaller than about 6 mm, smaller than about 5.5 mm, smaller than about 5 mm, smaller than about 4.5 mm, smaller than about 4 mm, smaller than about 3.5 mm, smaller than about 3 mm, smaller than about 2.5 mm, smaller than about 2 mm, smaller than about 1.5 mm, smaller than about 1 mm, or smaller than about 0.5 mm.

In still further aspects, the fine aggregates present in the disclosed composition can have a size greater than 0 mm to about 9.5 mm, including exemplary values of about 0.5 mm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, and about 9 mm. It is considered that the fine aggregates have a size of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, they can have a size greater than 0 mm to about 9.5 mm, or from about 1 mm to about 8.5 mm, or from about 2 mm to about 7.5 mm, or from about 3 mm to about 6.5 mm, or from about 4 mm to about 5.5 mm, or from 0 mm to about 5 mm, or from about 1 mm to about 4 mm, or from about 2 mm to about 3 mm, or from about 5 mm to about 9.5 mm, or from about 6 mm to about 8.5 mm, or from about 7 mm to about 7.5 mm.

In some aspects, the fine aggregates present in the disclosed herein compositions are sand. Again it is understood that sand can be natural sand, silica sand, recycled foundry sand, and the like.

In some aspects disclosed herein, the cement composition is substantially free of coarse aggregates a size larger than about 9 mm, larger than about 9.5 mm, larger than about 10 mm, larger than about 10.5 mm, larger than about 11 mm, larger than about 11.5 mm, larger than about 12 mm, larger than about 12.5 mm, larger than about 13 mm, larger than about 13.5 mm, larger than about 14 mm, larger than about 14.5 mm, larger than about 15 mm, larger than about 15.5 mm, larger than about 16 mm, larger than about 16.5 mm, larger than about 17 mm, larger than about 17.5 mm, larger than about 18 mm, larger than about 18.5 mm, larger than about 19 mm, larger than about 19.5, larger than about 20 mm, larger than about 20.5 mm, larger than about 21 mm, larger than about 21.5 mm, larger than about 22 mm, larger than about 22.5 mm, larger than about 23 mm, larger than about 23.5 mm, larger than about 24 mm, larger than about 24.5 mm, larger than about 25 mm, larger than about 25.5 mm, larger than about 26 mm, larger than about 26.5 mm, larger than about 27 mm, larger than about 27.5 mm, larger than about 28 mm, larger than about 28.5 mm, larger than about 29 mm, larger than about 29.5 mm, larger than about 30 mm, larger than about 30.5 mm, larger than about 31 mm, larger than about 31.5 mm, larger than about 32 mm, larger than about 32.5 mm, larger than about 33 mm, larger than about 33.5 mm, larger than about 34 mm, larger than about 34.5 mm, larger than about 35 mm, larger than about 35.5 mm, larger than about 36 mm, larger than about 36.5 mm, larger than about 37 mm, larger than about 37.5 mm, larger than about 38 mm, larger than about 38.5 mm, larger than about 39 mm, or larger than about 39.5 mm.

In some aspects, the concrete composition described herein is substantially free of coarse aggregates having a size of about 9.5 mm to about 40 mm, including exemplary values of about 10 mm, about 12 mm, about 15 mm, about 17 mm, about 20 mm, about 22 mm, about 25 mm, about 27 mm, about 30 mm, about 32 mm, about 35 mm, and about 37 mm. It is considered that the coarse aggregates have a size of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a size from about 9.5 mm to about 40 mm, or from about 10 mm to about 35 mm, or from about 15 mm to about 30 mm, or from about 20 mm to about 25 mm, or from about 9.5 mm to about 25 mm, or from about 10 mm to about 20 mm, or from about 20 mm to about 40 mm, or from about 25 mm to about 35 mm.

In some aspects, the coarse aggregates disclosed herein can comprise gravel, crushed rock, crushed limestone, crushed recycled concrete, crushed granite, and the like. In further aspects, the disclosed herein compositions are substantially free of rock aggregates.

In some aspects, the rubber present in the concrete composition can be virgin. Yet, in other aspects, the rubber can be recycled. It is understood that the term “virgin” refers to rubbers as produced. In still further aspects, recycled rubber can be post-consumer recycled rubber or post-manufacturing recycled rubber. It is understood that post-manufacturing recycled rubber includes waste rubber, unused rubber, discarded good rubbers, unused rubber that does not pass quality control inspection, and the like.

In some aspects, recycled rubber can comprise recycled tires, tire buffing, recycled conveyor belts, rubber clothing, rubber gloves, rubber mats, rubber flooring, rubber seals, rubber gaskets, rubber hoses, or any combination thereof.

In some aspects, the recycled rubber that is used in the concrete compositions disclosed herein does not have to be cleaned or purified. In such aspects, recycled rubber can comprise at least some amount of recycled material that is not rubber. For example, and without limitations, if the recycled rubber is recycled tires or conveyor belts, such rubber can contain recycled metals, nails, staples, other polymers, fabrics, and the like.

In some aspects, the rubber present in the compositions disclosed herein has a particle size no greater than about 0.5 inches, no greater than about 0.45 inches, no greater than about 0.4 inches, no greater than about 0.35 inches, no greater than about 0.3 inches, no greater than about 0.25 inches, no greater than about 0.2 inches, no greater than about 0.15 inches, no greater than about 0.1 inches, or no greater than about 0.05 inches. In yet still further aspects, the rubber present in the compositions disclosed herein can have a particle size in microns or in millimeters. In some aspects, the rubber present in the compositions disclosed herein has a particle size no smaller than about 0.00001 inches, no smaller than about 0.0001 inches, no smaller than about 0.001 inches, no smaller than about 0.01 inches, no smaller than about 0.1 inches, no smaller than about 0.15 inches, no smaller than about 0.2 inches, no smaller than about 0.25 inches, no smaller than about 0.3 inches, no smaller than about 0.35 inches, no smaller than about 0.4 inches, or no smaller than about 0.45 inches.

In some aspects, the aggregates present in the composition need to be a smaller diameter than the diameter of the nails, screws, or other fasteners intended for use. Without wishing to be bound by any theory, it is assumed that a small enough piece of aggregate may allow for nail deflection without detrimental effects.

In some aspects, the rubber can have a particle size of about 0.05 inches to about 0.45 inches, including exemplary values of about 0.1 inches, about 0.15 inches, about 0.2 inches, about 0.25 inches, about 0.3 inches, about 0.35 inches, about 0.4 inches, and about 0.45 inches. In yet other aspects, the rubber can have a particle size up to about 1 inch, including exemplary values of about 0.1 inches, about 0.15 inches, about 0.2 inches, about 0.25 inches, about 0.3 inches, about 0.35 inches, about 0.4 inches, about 0.45 inches, about 0.5 inches, about 0.55 inches, about 0.6 inches, about 0.65 inches, about 0.7 inches, about 0.75 inches, about 0.8 inches, about 0.85 inches, about 0.9 inches, and about 0.95 inches. It is considered that the rubber has a particle size of any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can have a particle size from about 0.05 inches to about 0.45 inches, or from about 0.1 inches to about 0.4 inches, or from about 0.15 inches to about 0.35 inches, or from about 0.2 inches to about 0.3 inches, or from about 0.05 inches to about 0.25 inches, or from about 0.1 inches to about 0.2 inches, or from about 0.25 inches to about 0.4 inches, or from about 0.3 inches to about 0.35 inches.

In some aspects, the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber, ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof. In yet still further aspects, the rubber can be substituted by an elastomer such as thermoplastic elastomers, proteins resilin, elastin, elastolefin, poly(dichlorophosphazene), and the like, and any combination thereof.

In some aspects, the concrete composition disclosed herein can comprise water in an amount of about 20 wt % to about 40 wt %, including exemplary values of about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, about 34 wt %, about 35 wt %, about 36 wt %, about 37 wt %, about 38 wt %, and about 39 wt %, based on the water-to-cement-ratio. It is considered that the water can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from about 20 wt % to about 40 wt %, or from about 22 wt % to about 38 wt %, or from about 24 wt % to about 36 wt %, or from about 26 wt % to about 34 wt %, or from about 28 wt % to about 32 wt %, or from about 20 wt % to about 30 wt %, or from about 22 wt % to about 28 wt %, or from about 24 wt % to about 26 wt %, or from about 30 wt % to about 40 wt %, or from about 32 wt % to about 38 wt %, or from about 34 wt % to about 36 wt %.

In some aspects, the concrete composition disclosed herein can comprise one or more fillers, plasticizers, water-reducing agents, pumping agents, air entrainers, set retarders, fire retardants, water repellents, defoamers, antifreeze agents, expanding agents, curing agents, coloring additives, anti-dispersant agents, mold release agents, antimicrobial agents, fire-retardants, antifungal agents, insect- and animal-repellant agents, anti-corrosion additive, adhesive additives, or any combination thereof.

In some aspects, if plasticizers are present, they can be an amount of about 0.25 wt % to about 8 wt %, including exemplary values of about 1 wt %, about 1.5 wt %, about 2 wt %, about 2.5 wt %, about 3 wt %, about 3.5 wt %, about 4 wt %, about 4.5 wt %, about 5 wt %, about 5.5 wt %, about 6 wt %, about 6.5 wt %, about 7 wt %, and about 7.5 wt %, based on the weight of the cement. It is considered that the plasticizers can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, they can be present from about 0.25 wt % to about 8 wt %, or from about 1 wt % to about 7 wt %, or from about 2 wt % to about 6 wt %, or from about 3 wt % to about 5 wt %, or from about 0.25 wt % to about 4 wt %, or from about 1 wt % to about 3 wt %, or from about 4 wt % to about 8 wt %, or from about 5 wt % to about 7 wt %.

In some aspects, the one or more plasticizers comprise lignosulfonates, naphthalene, sulfonated naphthalene formaldehyde (SNF), melamine sulfonate-based superplasticizer, polycarboxylate ether superplasticizer (PCE), just polycarboxylate (PC), polycarboxylate superplasticizer monomer in ether mode (TPEG-HPEG) or any combination thereof.

In some aspects, the filler can be present from greater than 0 wt % to about 70 wt %, including exemplary values of about 0.1 wt %, about 0.5 wt %, about 1 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, and about 69 wt % based on the total concrete composition. It is considered that the filler can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from 0 wt % to about 70 wt %, or from about 5 wt % to about 65 wt %, or from about 10 wt % to about 60 wt %, or from about 20 wt % to about 50 wt %, or from about 30 wt % to about 40 wt %, or from 0 wt % to about 35 wt %, or from about 5 wt % to about 30 wt %, or from about 10 wt % to about 25 wt %, or from about 15 wt % to about 20 wt %, or from about 35 wt % to about 70 wt %, or from about 40 wt % to about 65 wt %, or from about 45 wt % to about 60 wt %, or from about 50 wt % to about 55 wt %.

In some aspects, the filler can be present up to about 300 wt % based on the weight of the cement, including exemplary values of about 1 wt %, 10 wt %, about 20 wt %, about 50 wt %, about 100 wt %, about 120 wt %, about 150 wt %, about 170 wt %, about 200 wt %, about 220 wt %, about 250 wt %, and about 280 wt %. It is considered that the filler can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from about 1 wt % to about 300 wt %, or from about 10 wt % to about 280 wt %, or from about 20 wt % to about 250 wt %, or from about 50 wt % to about 220 wt %, or from about 100 wt % to about 200 wt %, or from about 120 wt % to about 170 wt %, or from about 1 wt % to about 150 wt %, or from about 10 wt % to about 120 wt %, or from about 20 wt % to about 100 wt %, or from about 150 wt % to about 300 wt %, or from about 170 wt % to about 280 wt %, or from about 200 wt % to about 250 wt %.

In some aspects, the filler comprises one or more of calcium carbonate, flyash, pozzolanic ash, calcium carbonate, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, fiberglass glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof.

In some aspects, the cement composition can comprise reinforcing materials, such as, for example, and without limitations fiberglass. It is understood, however, that other reinforcing materials can be utilized. In some aspects, the fiberglass can be present as it, or it can also be reinforced with the polymers, such as for example, polypropylene, nylon, or a combination thereof. In still further aspects, these reinforcing materials can be present in an amount of about 0.1 wt % to about 10 wt %, including exemplary values of about 0.2 wt %, about 0.5 wt %, about 0.7 wt %, about 1 wt %, about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 6 wt %, about 7 wt %, about 8 wt %, and about 9 wt %, based on the weight of the cement present in the composition. It is considered that the fiberglass can be present in any amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be present from about 0.1 wt % to about 10 wt %, or from about 0.5 wt % to about 9 wt %, or from about 1 wt % to about 8 wt %, or from about 2 wt % to about 7 wt %, or from about 3 wt % to about 6 wt %, or from about 4 wt % to about 5 wt %, or from about 0.1 wt % to about 5 wt %, or from about 0.5 wt % to about 4 wt %, or from about 1 wt % to about 3 wt %, or from about 4 wt % to about 10 wt %, or from about 5 wt % to about 9 wt %, or from about 6 wt % to about 8 wt %.

In some aspects, the water-reducing agent can be sodium lignosulfonate or calcium lignosulfonate. Water-reducing agents can also comprise hydroxycarboxylic acids, hydroxylated polymers, and the like.

In some aspects, the air entrainers can comprise wood-derived acid salts, such as vinsol resins and wood rosins, and synthetic resins. It is understood that these compounds are only exemplary, and any known in the art air entrainers suitable for the desired purpose can be utilized.

In some aspects, the cement composition disclosed herein comprises fire-retardants. In such aspects, the fire-retardant can comprise aluminum trihydrate (ATH), chlorinated tris [tris(1,3-dichloro-2-propyl)phosphate, TDCPP, and TDCIPP], pentabromodiphenyl ether (PentaBDE) mixture [DE-71 (technical grade)], tetrabromobisphenol A (TBBPA), tris(2-chloroethyl) phosphate (TCEP), or any combination thereof.

In some aspects, the rubber is virgin and/or recycled and has a particle size no greater than about 0.5 inches. In some aspects, the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof.

In some aspects, the nailable concrete composition is self-leveling or self-consolidating. In some aspects, a slab can be any desired size is consolidating

In some aspects, the nailable concrete composition is formed according to the disclosure of U.S. patent application Ser. No. 18/183,271, which is hereby incorporated by reference in its entirety.

In another aspect, provided is a concrete slab formed by: providing any of the disclosed concrete slab precursors; and filling the defined area with the second concrete composition; wherein the one or more nailable formworks are incorporated into the concrete slab and are not removed.

In some aspects, the second concrete composition comprises the nailable concrete composition.

In some aspects, the at least partially enclosed structure is formed by four or more nailable formworks. In some aspects, the at least partially enclosed structure is formed by at least one nailable formwork and a preexisting construction element. In some aspects, the preexisting construction element comprises a building foundation or another concrete slab.

In some aspects, the concrete slab further comprises a first construction element nailed into the at least one of the one or more nailable formworks. In some aspects, the first construction element comprises a first wall, a first retaining wall, a first beam, or a first column.

In some aspects, the concrete slab further comprises an internal nailable formwork partitioning the defined area. In some aspects, two or more sides of the internal nailable formwork are in contact with the second concrete composition.

In some aspects, the internal nailable formwork functions as a reference elevation for the slab. This allows the slab to be more easily poured level as the distance spanned during screeding is decreased. For example, leveling a concrete slab that is 30 feet by 30 feet would require approximately a 34-foot long board. By compartmentalizing the defined area at the widths of rooms, the distance necessary to screed can be easily reduced to 12 feet, requiring a 16-foot screed board. In some aspects, the concrete slab is substantially level.

In some aspects, the internal nailable formwork can further be used for studwall installation to aid in the layout of internal structures, such as internal walls. An example floor plan and example placements of internal nailable formworks in said example floor plan are shown in FIG. 3A and FIG. 3B, respectively. In some aspects, the concrete slab further comprises a second construction element nailed into the internal nailable formwork. In some aspects, the second construction element comprises a second wall, a second retaining wall, a second beam, or a second column. An example of studwall installation is shown in FIG. 3C.

Furthermore, due to room designs, by incorporating nailable concrete formwork at key locations such as interior walls and a few minor additional areas, in some aspects, the internal nailable formwork can serve as an expansion joint or control joint. This could prevent the need to cut control joints in a concrete slab to prevent cracking as the nailable concrete can effectively function as an expansion joint due to the flexibility of the concrete.

In some aspects, the internal nailable formwork can be spaced from an edge of the concrete slab by from about 5 feet to about 15 feet, including exemplary values of about 6 feet, about 7 feet, about 8 feet, about 9 feet, about 10 feet, about 11 feet, about 12 feet, about 13 feet, or about 14 feet. It is considered that the internal nailable formwork can be spaced from another nailable formwork by amount that falls between any of the disclosed herein values or between any values that can be formed by any of the disclosed herein values. For example, it can be spaced from an edge of the concrete slab by from about 5 feet to about 15 feet, or from about 6 feet to about 14 feet, or from about 7 feet to about 13 feet, or from about 8 feet to about 12 feet, or from about 9 feet to about 11 feet, or from about 5 feet to about 10 feet, or from about 6 feet to about 9 feet, or from about 7 feet to about 8 feet, or from about 10 feet to about 15 feet, or from about 11 feet to about 14 feet, or from about 12 feet to about 13 feet. In some aspects, multiple internal nailable formworks may be used as expansion joints or control joints. In some such aspects, the multiple internal nailable formworks may be spaced from one another as described above. In some aspects, the multiple internal nailable formworks are spaced evenly. In other aspects, the multiple internal nailable formworks are spaced at varying intervals.

In another aspect, provided is a method of assembling a construction, the method comprising: providing any of the disclosed concrete slabs; nailing a construction element into at least one of the one or more nailable formworks. In some aspects, the construction element is nailed into the at least one of the one or more nailable formworks while the second concrete composition is still wet. In some aspects, the construction element is nailed into the at least one of the one or more nailable formworks when the second concrete composition is substantially dry.

In another aspect, provided is a construction comprising any of the disclosed concrete slabs. In another aspect, provided is a construction formed by any of the disclosed methods. In some aspects, the construction is a free-standing structure (e.g., a building). In some aspects, the construction is an addition to an existing structure (e.g., a building expansion). In some aspects, the construction is a portion of a free-standing structure (e.g., a building) and/or a portion of an addition to an existing structure (e.g., a building expansion).

EXAMPLES

Example 1: Prototype Slab

Casting Samples: In order to cast samples, reinforcing wires were tied. An example tying technique is shown in FIGS. 4A-4D. Note that these wires were made from a standard 2″×4″ spaced galvanized fence wire (11 ga.). By twisting, as shown in FIGS. 4A-4D, the cage could be tied without requiring additional wire ties. Note that this manual tying technique is only an example. The wire tying may be automated or semi-automated, using a machine or device that can automatically create the wire cages or a portion of the wire cages.

Next, the cages were constructed with an additional loop to allow for the concrete to be installed into the new slab later. This can be seen in FIGS. 5A-5D, where the new loops have already been incorporated. Next, the concrete was poured with the nailable concrete that is covered by U.S. patent application Ser. No. 18/183,271. In this example, the water content of the nailable concrete was kept low to increase the ability of the nailable concrete to secure to concrete later installed into the slab. This is shown in FIGS. 6A-6D.

Additionally, the concrete formworks can be cast using an extrusion method. In this method, a steel form is used as a mold and the nailable concrete is extruded while the molding machine travels along a path. The extrusion is aided by a concrete vibrator. Wire or rebar can be installed into the nailable concrete formwork this way. This requires a stiff nailable concrete but allows for stiffer nailable concrete formworks to be manufactured more quickly. Said stiff nailable concrete can have the same composition as any of the nailable concrete compositions disclosed herein. Additional reinforcement wire can be placed into the concrete formwork after extrusion by hand or another automated process. This is shown in FIGS. 7A-7D.

Installing Samples in Practical Application: Once the concrete has cured sufficiently (this is possible in as little as 16 hours), the concrete formwork can be de-molded from its casting mold. FIG. 8A shows the formwork being set in a location where a new slab is to be poured after leveling off and tamping the dirt underneath. The slab was poured such that it sloped gently away from the building (approximately ¼″ per foot).

FIGS. 8B-8D show various additional steps. FIG. 8B shows that the corners of the reinforcement can be tied together, if necessary, to secure the formwork. Stakes not shown (the prototype slab was too small to be needed stakes, and the wire mesh ties the entire system together) can also be used. Nailable concrete stakes have been tested on separate occasions and do function as intended (i.e., can secure the edges of the formwork to the earth). The nailable concrete stakes can have the same composition as any of the nailable concretes disclosed herein. FIG. 8C shows that the wire mesh for the slab had been tied to one side of the reinforcement. FIG. 8D shows the wire mesh cut and hooked to the formwork reinforcement. This was done on all sides.

Pouring the Prototype Slab: The slab was then poured. The concrete used was Sakrete High-Strength Concrete Mix. The concrete pour in various stages is shown in FIGS. 9A-9D.

Fixing to the Prototype Slab: Once the slab had been poured, additional formworks were nailed to the nailable concrete formwork. 2×4 sections made of the same nailable concrete are shown in FIG. 10A. These boards were nailed to the nailable concrete formboards, as shown in FIGS. 10B-10D.

Curing, Showing No Cracks: Following the pouring of the new slab, it was determined if the two sections of concrete would perform as intended. Concrete with vastly different properties may crack at the interface due to these differences. However, after checking over several days, the concrete did not show any signs of cracking, as shown in FIGS. 11A-11C.

Any of the nailable concretes disclosed herein can additionally be made self-consolidating (i.e., when poured, the concrete can become sufficiently level without much effort, for example using mild vibration). Such a modification would allow accurate dimensions with less work, as the self-consolidating concrete would easily flow into the forms. It has been previously determined that a self-consolidating mix of the nailable concrete composition is possible. However, as mentioned above, the concrete formwork may be extruded without the use of molds.

The slab can additionally include reinforcement wire in two faces, perpendicular to each other, that protrude from the formworks into the poured concrete. This would allow for the tying of the reinforcement wire such that stemwall foundations can be used while providing the use of this concrete. This would be accomplished by creating a foundation, placing concrete masonry units (CMUs) on top of the foundation, and securing a nailable concrete section on top of the tallest CMU, but with a wire that extends into the concrete block and into the slab to be poured. Doing this would allow concrete to fill the CMUs (as intended) while securing the nailable concrete to both the slab and the concrete inside the CMUs and providing a nailable concrete surface at the upper edge of the slab.

The primary advantages that were seen in this system were increased installation speed for bottom plates and other items into the concrete formwork, not having to remove formwork after curing, the ability to nail to the formwork while the slab is wet, and supporting of reinforcement at the edges as well as tying the reinforcement more carefully to the edges of the slab.

Example 2: Shed Slab Pour

To make a more complex example, a shed slab was constructed using the nailable concrete formwork. This formwork allows for a reduction in waste, as the formwork most commonly used in construction is wood, and is discarded due to warping typically after a single use. It also provides a nailable surface for significantly quicker installation of walls after the slab is poured.

Pouring of the slab can be done in sections, using the nailable concrete formwork as expansion joints; doing this would significantly reduce cracking. By subdividing into smaller sections, the width per section to be screed (leveling while the concrete is wet) is minimized. Additional nailable formworks can be used as reference elevations. This is an additional measure to reduce high/low spots within the slab.

Note that this shed was constructed for experimental purposes and is not intended for use.

Slab Construction: The figures described below show the slab being constructed. The slab's outside dimensions were 14′-6″ by 12′-2″. The walls that are intended to be installed are nailable rubber concrete wall panels, while the roof joists are also nailable rubber concrete. The nailable rubber concrete wall panels and nailable concrete roof joists can have the same composition as any of the nailable concrete compositions disclosed herein.

FIG. 12A shows stakes driven to denote the edges of the slab. FIG. 12B shows the ground cleared. FIG. 12C shows the ground tamped. FIG. 12D shows the footing trench dug and the lower section of concrete formwork being installed. FIG. 12E shows the foundation continues to be installed. FIG. 12F shows the upper section of the concrete formwork being installed. FIG. 12G shows more of the upper section installed. Note the wires that extend into the slab to secure the nailable concrete formwork to the eventual slab. FIG. 12H shows the nailable concrete formwork installed. FIG. 12I shows a corner inside the nailable concrete formwork. The inclusion of rebar, as shown, develops additional strength and stiffness of the section at the exterior edge of the slab. FIG. 12J shows a lap splice shown in the concrete formwork. Note that not all ties have been installed. FIG. 12K shows the slab ready to be poured. FIG. 12L shows the concrete slab mid-pour. FIG. 12M shows concrete after pouring and bull floating half the concrete. FIG. 12N shows the concrete slab the day after construction. The concrete formwork can still be seen on the exterior.

Diagrams: FIG. 13A shows a diagram that is representative of a single foundation design. This system can be redesigned to meet specific customer needs. For example, it may be chosen to use other nailable concrete sections, such as a channel below for reduced weight, a complete section that doesn't require drilling through the top of the 3″ and into the 3.5″, or a section that includes the footing reinforcement of rebar. FIG. 13B shows the physical representation.

The patents, applications, and publications as listed throughout this document are hereby incorporated by reference in their entirety herein.

Example Aspects

Example 1: A concrete slab precursor comprising: at least partially enclosed structure formed by one or more nailable formworks comprising a first concrete composition; wherein the at least partially enclosed structure comprises a defined area configured to receive a second concrete composition; wherein the first concrete composition is a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material; and wherein the second concrete composition is the same as or different from the first concrete composition.

Example 2: The concrete slab precursor of any examples herein, particularly Example 1, wherein the one or more nailable formworks further comprises a first concrete reinforcing element.

Example 3: The concrete slab precursor of any examples herein, particularly Example 2, wherein the first concrete reinforcing element is embedded in the one or more nailable formworks such that at least a portion of the first concrete reinforcing element extends outside of a body of the one or more nailable formworks.

Example 4: The concrete slab precursor of any examples herein, particularly Examples 2 or 3, wherein the first concrete reinforcing element is rebar or reinforcement wire.

Example 5: The concrete slab precursor of any examples herein, particularly Examples 1-4, wherein the defined area further comprises a second concrete reinforcing element.

Example 6: The concrete slab precursor of any examples herein, particularly Example 5, wherein the second concrete reinforcing element is disposed along at least a portion of the defined area.

Example 7: The concrete slab precursor of any examples herein, particularly Examples 5 or 6, wherein the second concrete reinforcing element is disposed such that it covers an entire area of the defined area.

Example 8: The concrete slab precursor of any examples herein, particularly Examples 5-7, wherein the second concrete reinforcing element is rebar or reinforcement wire.

Example 9: The concrete slab precursor of any examples herein, particularly Examples 5-8, wherein the first concrete reinforcing element is configured to support the second concrete reinforcing element.

Example 10: The concrete slab precursor of any examples herein, particularly Examples 1-9, wherein the at least partially enclosed structure is formed by two or more nailable formworks.

Example 11: The concrete slab precursor of any examples herein, particularly Examples 1-10, wherein at least one boundary of the at least partially enclosed structure is a preexisting construction element, and wherein the one or more nailable formworks abut the preexisting construction element.

Example 12: The concrete slab precursor of any examples herein, particularly Examples 1-11, wherein the defined area further comprises an internal nailable formwork partitioning the defined area.

Example 13: The concrete slab precursor of any examples herein, particularly Example 1-12, wherein the rubber is virgin and/or recycled and has a particle size no greater than about 0.5 inches.

Example 14: The concrete slab precursor of any examples herein, particularly Examples 1-13, wherein the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof.

Example 15: The concrete slab precursor of any examples herein, particularly Examples 1-14, wherein the nailable concrete composition further comprises water in an amount of about 20 wt % to about 40 wt % based on the water-to-cement ratio.

Example 16: The concrete slab precursor of any examples herein, particularly Examples 1-15, wherein the nailable concrete composition further comprises one or more fillers, plasticizers, water-reducing agents, pumping agents, air entrainers, set retarders, fire retardants, water repellants, defoamers, antifreeze agents, expanding agents, curing agents, coloring additives, anti-dispersant agents, mold release agents, antimicrobial agents, fire-retardants, antifungal agents, insect- and animal-repellant agents, anti-corrosion additive, adhesive additives, or any combination thereof.

Example 17: A concrete slab formed by: providing the concrete slab precursor of any examples herein, particularly Examples 1-16; and filling the defined area with the second concrete composition; wherein the one or more nailable formworks are incorporated into the concrete slab and are not removed.

Example 18: The concrete slab of any examples herein, particularly Example 17, wherein the second concrete composition comprises the nailable concrete composition.

Example 19: The concrete slab of any examples herein, particularly Examples 17-18, wherein the at least partially enclosed structure is formed by four or more nailable formworks.

Example 20: The concrete slab of any examples herein, particularly Examples 17-18, wherein the at least partially enclosed structure is formed at least one nailable formworks and a preexisting construction element.

Example 21: The concrete slab of any examples herein, particularly Example 20, wherein the preexisting construction element comprises a building foundation or another concrete slab.

Example 22: The concrete slab of any examples herein, particularly Examples 17-21, further comprising a first construction element nailed into the at least one of the one or more nailable formworks.

Example 23: The concrete slab of any examples herein, particularly Example 22, wherein the first construction element comprises a first wall, a first retaining wall, a first beam, or a first column.

Example 24: The concrete slab of any examples herein, particularly Examples 17-23, further comprising an internal nailable formwork partitioning the defined area.

Example 25: The concrete slab of any examples herein, particularly Example 24, wherein two or more sides of the internal nailable formwork are in contact with the second concrete composition.

Example 26: The concrete slab of any examples herein, particularly Examples 24-25, further comprising a second construction element nailed into the internal nailable formwork.

Example 27: The concrete slab of any examples herein, particularly Example 26, wherein the second construction element comprises a second wall, a second retaining wall, a second beam, or a second column.

Example 28: The concrete slab of any examples herein, particularly Examples 24-27, wherein the internal nailable formwork serves as an expansion joint.

Example 29: The concrete slab of any examples herein, particularly Examples 17-28, wherein the concrete slab is substantially level.

Example 30: A method of assembling a construction, the method comprising: providing the concrete slab of any examples herein, particularly Examples 17-29; nailing a construction element into at least one of the one or more nailable formworks.

Example 31: A construction comprising the concrete slab of any examples herein, particularly Examples 17-29.

Example 32: A construction formed by the method of any examples herein, particularly Example 30.

Example 33: The construction of any examples herein, particularly Examples 31 or 32, wherein the construction is a free-standing structure (e.g., a building).

Example 34: The construction of any examples herein, particularly Examples 31 or 32, wherein the construction is an addition to an existing structure (e.g., a building expansion).

Example 35: The construction of any examples herein, particularly Examples 31 or 32, wherein the construction is a portion of a free-standing structure (e.g., a building) and/or a portion of an addition to an existing structure (e.g., a building expansion).