Casting method for making a lightweight concrete product

Patent metadata

Field	Value
Publication number	US-10457603-B2
Application number	US-201916276285-A
Country	US
Kind code	B2
Filing date	Feb 14, 2019
Priority date	Mar 30, 2016
Publication date	Oct 29, 2019
Grant date	Oct 29, 2019

Abstract

A structural lightweight concrete composition comprising cement, a fine aggregate such as sand, a natural coarse aggregates, such as limestone, scoria or perlite or mixtures thereof, a synthetic coarse aggregate comprising a polymeric material, such as polypropylene beads, an industrial waste byproduct in the form of fine particles, such as silica fume or heavy oil ash, a superplasticizer, such as a polycarboxylate ether and water demonstrating lower thermal conductivity and sufficient compressive strength. Concrete products made therefrom and methods for producing such products are also provided.

First claim

The invention claimed is:

1. A lightweight concrete product casting method, comprising:
mixing a cement, a fine aggregate, a natural coarse aggregate, spherical polymeric beads and a industrial waste byproduct in the form of fine particles to form a solid cement mixture having the following composition:
the cement;
the fine aggregate;
the natural coarse aggregate which comprises 10-25 wt % expanded perlite based on the weight of the natural coarse aggregate;
the synthetic coarse aggregate which comprises a spherical polymeric material beads;
the industrial waste byproduct which is in the form of fine particles;
wherein the average particle size of the fine aggregate and the industrial waste byproduct is less than or equal to 1 mm and the average particle size of the synthetic coarse aggregate spherical polymeric beads and the natural coarse aggregate is greater than 1 mm;
wherein the weight ratio of water to cement is in the range of 0.33 to 0.8 and is sufficient to affect hydraulic setting of the cement; and
wherein the spherical polymeric beads have a specific gravity of 0.8-0.95;

adding water and a superplasticizer to the cement mixture to affect hydraulic setting while maintaining a slump in the range of 50-100 mm to form a fluid concrete mixture;
casting the fluid concrete mixture in a predetermined shape by placing the fluid concrete mixture in a mold to produce a cast concrete product after setting.

2. The method of claim 1 , wherein the spherical polymeric beads are spherical polypropylene beads pith an average particle size of 4-15 mm.

3. The method of claim 1 , wherein the fine aggregate is sand with an average particle size of less than 700 μm.

4. The method claim 1 , wherein the natural coarse aggregate comprises crushed limestone having an average particle size in the range of 1-20 mm.

5. The method of claim 1 , wherein the industrial waste byproduct is at least one selected from the group consisting of silica fume and heavy oil ash.

6. The method of claim 1 , wherein the superplasticizer is a polycarboxylate ether.

Assignees

• Univ King Fahd Pet & Minerals

Inventors

• Maslehuddin Mohammed
• Al-Dulaijan Salah U
• Ali Mohammed Rizwan
• Nasr Mahmoud

Classifications

• C04B28/006

  containing mineral polymers, e.g. geopolymers of the Davidovits type · CPC title

• C04B28/04 Primary

  Portland cements · CPC title

• C04B28/08

  Slag cements · CPC title

• C04B28/10

  Lime cements or magnesium oxide cements · CPC title

• C04B2111/40

  Porous or lightweight materials · CPC title