Granted Patent B2

US 12,312,272 · App. 18/165,059 · Granted May 27, 2025

Inventor: Randall L. Byrd (Austin, TX)

Assignee: SEBASTOS TECHNOLOGIES, INC.

C04B28/04C04B14/24C04B18/027C04B28/02C04B2103/44C04B2103/58C04B2111/00103C04B2111/40Y02W30/91

Abstract

Claims (27)

1. A hydraulically settable lightweight concrete composition, said composition comprising:

one or more cementitious materials, where the cementitious material comprises one or more natural pozzolans;

water; and

an aggregate mix composed of individual particles that are substantially volumetrically stable and non-absorbent;

said aggregate mix comprising at least a first LWA;

said first LWA comprising hollow glass microspheres; and

a shrinkage reducer and an expansive agent; and

said composition having a plastic density of below about 50 lb./cu.ft.

2. The hydraulically settable lightweight concrete composition of claim 1 , wherein the natural pozzolans are class N natural pozzolans.

3. The hydraulically settable lightweight concrete composition of claim 1 , wherein the cementitious material further comprises one or more of fly ash, silica fume, and calcium carbonate.

4. The hydraulically settable lightweight concrete composition of claim 1 , wherein the cementitious material further comprises calcium carbonate.

5. The hydraulically settable lightweight concrete composition of claim 1 , wherein each of said one or more cementitious materials, water, and aggregate mix has a volume; and wherein a ratio of the volume of the first LWA to a sum of the said volumes is at least about 40%.

6. A method of preparing a hydraulically settable lightweight concrete composition, comprising the steps of:

mixing one or more cementitious materials, a first LWA, and optionally a second LWA, wherein both the first LWA and the second LWA are substantially volumetrically stable and non-absorbent,

said providing an aggregate mix step comprising at least the steps of providing a first and a second LWA;

said first LWA comprising hollow glass microspheres;

said second LWA comprising polymer beads;

said polymer beads being solid and having a median size of greater than about 150 μm,

wherein the cementitious material comprises one or more natural pozzolans.

7. The method of claim 6 , wherein the natural pozzolans are class N natural pozzolans.

8. The method of claim 6 , wherein the cementitious material further comprises one or more of fly ash, silica fume, and calcium carbonate.

9. The method of claim 6 , wherein the cementitious material further comprises calcium carbonate.

10. The method of claim 4 , wherein the amounts of the one or more cementitious materials, first LWA, and second LWA are effective to achieve a target density, after curing of the lightweight concrete composition, of not more than about 125 lb./cu.ft.

11. The method of claim 4 , further comprising:

adding water,

wherein the amounts of water, one or more cementitious materials, the first LWA, and second LWA are effective to achieve a target plastic density in said composition of not more than about 135 Ib./cu.ft.; and wherein the composition is self-compacting.

12. The method of claim 4 , wherein the mixing step further includes mixing a shrinkage reducer and an expansive agent.

Assignments (1)

Continuity (9)

References Cited (123)