Lightweight concrete composition containing perlite and resin beads

Patent metadata

Field	Value
Publication number	US-2019169070-A1
Application number	US-201916267770-A
Country	US
Kind code	A1
Filing date	Feb 5, 2019
Priority date	Mar 30, 2016
Publication date	Jun 6, 2019
Grant date	—

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

1 . A lightweight concrete composition containing perlite and resin beads, comprising:
cement; a fine aggregate; a natural coarse aggregate comprising 10-25 wt % expanded perlite based on the weight of the natural coarse aggregate; a spherical polymeric beads; an industrial waste byproduct in the form of fine particles; a superplasticizer; and water; 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 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.

2 . The structural lightweight concrete composition of claim 1 , wherein the spherical polymeric beads are spherical polypropylene beads with an average particle size of 4-15 mm.

3 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of the spherical polymeric beads ranging from 2-15% relative to the total weight of the composition.

4 . The structural lightweight concrete composition of claim 1 , wherein the cement is present in the composition at 300-500 kg/m 3 .

5 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of cement ranging from 20-30% relative to the total weight of the composition.

6 . The structural lightweight concrete composition of claim 1 , wherein the fine aggregate is sand with an average particle size of less than 700 μm.

7 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of the fine aggregate ranging from 15-30% relative to the total weight of the composition.

8 . (canceled)

9 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of the natural coarse aggregate ranging from 20-45% relative to the total weight of the composition.

10 . The structural lightweight concrete composition of claim 1 , wherein the natural coarse aggregate comprises crushed limestone having an average particle size in the range of 1-20 mm.

11 . The structural lightweight concrete composition of claim 1 , wherein the industrial waste byproduct is at least one selected from the group consisting of silica fume a ad heavy oil ash.

12 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of the industrial waste byproduct in the form of fine particles ranging from 0.5-10% relative to the total weight of the composition.

13 . The structural lightweight concrete composition of claim 1 , wherein the superplasticizer is a polycarboxylate ether.

14 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of the superplasticizer ranging from 0.1-2M % relative to the total weight of the composition.

15 . The structural lightweight concrete composition of claim 1 , which has a weight percentage of water ranging from 10-20% relative to the total weight of the composition.

16 . The structural lightweight concrete composition of claim 1 , which has a 28-day unit weight in the range of 1600-1900 kg/m 3 after setting.

17 . The structural lightweight concrete composition of claim 1 , which has a compressive strength in the range of 20-26 MPa after setting.

18 . The structural lightweight concrete composition of claim 1 , which has a thermal conductivity in the range of 0.3-0.7 W/(m·K) after setting.

19 - 20 . (canceled)

Assignees

• Univ King Fahd Pet & Minerals

Inventors

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

Classifications

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• C04B2201/32

  for the thermal conductivity, e.g. K-factors · CPC title

• C04B28/10

  Lime cements or magnesium oxide cements · CPC title

• C04B2111/40

  Porous or lightweight materials · CPC title

• C04B28/065

  Calcium aluminosulfate cements, e.g. cements hydrating into ettringite · CPC title