MXPA00006239A - Lightweight insulating concrete and method for using same - Google Patents

Abstract

A lightweight insulating concrete composition includes a cementitious forming material and a lightweight aggregate combination of expanded vermiculite and expanded perlite, the weight ratio of one to the other not exceeding about 2:1. Preferably, the composition is about 4 parts by weight cementitious forming material and about 1 part by weight lightweight aggregate. The cementitious forming material may be a hydraulic binder and accelerator combination, and may be Portland cement, plaster of Paris, and terra alba, in a weight ratio of about 5:4:1, or calcium aluminate cement, and plaster of Paris, in a weight ratio of about 11:5. The composition may further include an air entraining admixture in an amount between about 0.5 and about 2.0 percent of the total weight of the mixture, where neutralized vinsol resin and alpha olefin sulfonate are acceptable, and a surfactant in an amount between about 0.3 and about 1.5 percent of the total weight of the mixture, where sulfonated melamine a nd napthalene formaldehyde are acceptable. A method of making the lightweight insulating concrete composition includes blending the cementitious forming material and the combination of lightweight aggregate of expanded vermiculite and expanded perlite, and any admixture or surfactant that may be included. A method of repairing or patching concrete surfaces using the lightweight insulating concrete, includes hydrating the composition, applying the concrete slurry and permitting it to cure for about 2 to about 4 hours until it sets

Description

CONCRETE INSULATING LIGHTWEIGHT AND METHOD FOR USING IT FIELD OF THE INVENTION The present invention relates to lightweight insulating concrete (LWIC) and more particularly to concretes that can be used to patch or otherwise repair lightweight insulating concrete, such as roofing surfaces.

BACKGROUND OF THE INVENTION [0002] Lightweight insulating concrete is known to be used as roofing surface materials, often in combination with a waterproof membrane that covers secured with collapsible base fasteners. The materials of the concrete used for this purpose should be lightweight and of relatively low density, in order to reduce the load of weight applied to the existing structure of the building and help to isolate the building. The lightweight insulating concrete can be used to fill depressions in existing lightweight concrete roof surfaces and thereby correct the water filtration characteristics that are undesirable; repair joints on roof surfaces; or repair other damage to the concrete roof, including fractures and holes left in the surface of the lightweight insulating concrete by removing the fasteners during the replacement of the waterproof membrane. Weight can also be a particular concern if the concrete roofing material is to be placed over an existing layer of concrete as a method of roof repair. Lightweight insulating concrete used to repair patches, fractures, or the like, or when used as a roofing material for concrete, should have several desirable characteristics. It should be relatively lightweight, or low density, compared to structural concrete. It should be resistant to water intrusion from spills on or around the waterproof membrane. It should exhibit little shrinkage of the applied layer in the vertical direction when applied and allowed to harden. It should have the ability to "bevel the edge" at zero thickness, or close to zero to combine the edge of the layer with the existing lightweight insulating concrete layer. In addition, an important feature is the length of time the material will require to set before holding onto the traffic to walk on it and accept and hold base folds or other fasteners. It must be strong enough to effectively retain the fasteners placed on it, although not so strong during application that it prevents the fasteners from being placed. It is known how to repair joints, fractures and depressions filling the desired area. A known material to do so includes gypsum paste reinforced with wood fiber, combinations of Portland cement and lightweight aggregate, and a slurry of Portland cement and water. Combinations of Portland cement and lightweight aggregate can also be used for other repairs, such as for re-roofing by placing a new layer on an existing substrate layer. However, these materials can have many disadvantages. The plaster tends to dry very quickly (in a few minutes) and therefore it is difficult to make the beveled edge. Gypsum mixtures are also resistant to the insertion of fasteners and are prone to softening when exposed to water. They also exhibit significant shrinkage in the vertical direction. Portland cement and light weight aggregate mixtures have a very long setting time, and typically no re-roofing processes can be performed through waterproof membrane placement for at least 24 to 72 hours. This creates a significant disadvantage because, particularly if the building is already occupied, there is no waterproof roofing material applied to the roof during this period of time, which can result in damage in the event of rain. Another disadvantage of Portland cement / aggregate mixes is that the edges can not be reliably reduced to zero thickness, or close to zero, because the resulting surface is rough and the adhesion to existing lightweight insulating concrete is erratic and unpredictable. Portland cement mud and water also have a long setting time, and thus have the same disadvantages as Portland cement / aggregate mixes. These sludges also exhibit excessive shrinkage due to curing and drying, and erratic and unpredictable adhesion resistance with the lightweight insulating concrete substrate to which they are applied. The shrinkage exhibited by Portland cement slurries and gypsum is undesirable because it can result in the material coming off the structures projecting vertically from the concrete roof surface, and it may also be undesirable to affect the slope conditions. for runoff created by the original application of the material. Several formulations of lightweight insulating concrete are known. U.S. Patent No. 4,293,341 to Dudley et al., Discloses a lightweight insulating concrete containing lightweight aggregate, Portland cement, an entraining agent, a dispersing agent and preferably an inert densified particulate material. . Dudley et al. Shows the use of either vermiculite, or less desirably, perlite, but does not disclose any particular combination thereof. U.S. Patent No. 4,293,341 to Dudley et al. Is incorporated herein in its entirety for any purpose. Dudley et al. Also describe the use of air trapping agents and polyelectrolyte sulfonate dispersing agents to improve the characteristics of concrete. Dudley et al. Do not describe specific setting times, or initial compressive strengths of the finished concrete. U.S. Patent No. 3,795,653 to Aignesberger et al. Discloses lightweight concrete containing lightweight filler particles that are coated with melamine formaldehyde condensation product containing sulfonic acid groups and thereafter mixed with cement . Aignesberger et al. Disclose that expanded clay, polystyrene, perlite, vermiculite, pumice, slag, or the like can be used together or in combination as filler particles, but does not disclose any specific combination or proportions. U.S. Patent No. 3,989,534 to Plunguian et al. Describes a cellular composition useful for fire resistance, noise-proof insulation and thermal insulation that is formed from (1) a mineral cement, such as cement plaster, Portland cement, calcium aluminate cement or magnesium cement, (2) a film former, such as guar or bentonite gum, (3) a mixture of ionic and nonionic surfactants, and (4) a lightweight aggregate such as perlite, vermiculite, or hollow silicate spheres, and (5) air substantially in excess of that used in air entrapment in cement. Plunguian et al. Do not describe combinations of perlite and vermiculite. Apart from the low weight insulating concrete, U.S. Patent Nos. 5,542,538 and 5,718,758 to Breslauer describe an ultra-light mortar premixed for use with clay and concrete mosaics using the ASTM C-332 aggregate such as vermiculite or perlite in Place of sand, with a cement mortar made of Portland cement, lime, air-entraining agents and water repellent agents. Breslauer does not describe combinations of perlite and vermiculite. U.S. Patent Nos. 5,542,538 and 5,718,758 to Breslauer are incorporated herein in their entirety for any purpose. Breslauer does not describe specific setting times, nor initial compression resistances of the finished concrete. The Patent of the United States of North America number 4, 159, 302 for Greve et al. Describes a material for a fire door core comprising expanded perlite by 50-70 weight percent, and as a minor ingredient, an organic binder to achieve the desired bending and compression strength, set gypsum and setting hydraulic cement, which may include undilated vermiculite, clay, and fibrous reinforcements. The material is compression molded and terminated in a protective door core. U.S. Patent Nos. 3,372,040 and 3,502,490 to Ware disclose fire and heat resistant cementitious gypsum compositions that include a naturally occurring phosphate rock containing p2 5 'Y from 0 to 50 percent by weight of exfoliated perlite or vermiculite or mixtures thereof. What it does not describe are combinations or specific proportions of perlite with vermillon, nor does Ware describe the strength or density of the material, nor setting times. None of the formulations of the prior art have all the characteristics desired by the roofing industry for a light weight insulating concrete having light weight, high strength, relatively short setting times, water resistance, low shrinkage and the ability to decrease The edges.

BRIEF COMPENDIUM OF THE INVENTION The object of the present invention is to provide an improved lightweight insulating concrete composition that can be used for patching, repairing joints and fractures, covering surfaces, or filling depressions, or correcting slope conditions for runoff. Another object is to provide methods for using compositions for patching, filling, repairing joints and fractures, coating surfaces, filling depressions, or correcting slope conditions for runoff. Accordingly, the invention comprises a cement-forming material and a combination of lightweight aggregate, preferably comprising a combination of expanded perlite and expanded vermiculite in which the weight ratio of one component to the other does not exceed about 2: 1 In a particularly preferred embodiment, the weight ratio of one component against the other does not exceed about 4: 3. Preferred embodiments of the combination include those in which the weight ratio of perlite to vermiculite is about 10: 9, or about 4: 3. Another embodiment of the composition comprises about 4 parts by weight of cement-forming material and about one part by weight of lightweight aggregate. The cement-forming material may comprise a combination of a hydraulic binder and an accelerator, two preferred compositions of which are: Portland cement, Paris plaster and terra alba, present in weight ratios of approximately 5: 4: 1, (en say, the proportion of the weight of Portland cement to that of plaster of Paris is approximately 5: 4, and the proportion of Paris plaster to terra alba is approximately 4: 1, and calcium aluminate cement, and Paris plaster, present in a weight ratio of about 11: 5 The composition can further comprise a mixture that traps air and a surfactant, the mixture is present in an amount of about 0.5 to 2.2 percent of the total weight of the mixture, and the surfactant present in an amount of between 0.3 to about 1.5 percent of the total weight of the mixture.The surfactant may be present in an amount of from 0.53 to about 0.55 percent of the weight t otal, where both the sulfonated melamine and the formaldehyde naphthalene are acceptable as a surfactant. The mixture may be present in an amount of from about 0.72 to about 0.74 percent of the total weight, wherein neutralized vinsol resin and alpha olefin sulfonate are acceptable as the mixture. The present invention exhibits improved cure times and resistance achieved in reduced times. The reduced time for healing, however, is not so short as to allow the light weight insulating concrete to set before it is necessarily raked or cut in order to adapt the surface to the desired slope, shape or texture. The composition is compatible with other light weight insulating concrete material, allows sufficient adhesion to it, and the edges can be reduced to zero, or near zero thickness without subsequent delamination or flaking. The material does not exhibit the curing and drying shrinkages shown by other materials when used for this application. In addition, the material develops sufficient strength in approximately two to four hours to withstand the traffic of walking on and supporting the roofing process, including the insertion of fasteners, without damage. The composition of the invention shows in particular a faster initial rate of reinforcement development to retain the inserted fasteners, including base fold fasteners, however not such a large force development rate that it is difficult to locate or rake the material to obtain the appropriate thickness, depth or slope. The material also develops an improved overall compression strength compared to lightweight insulating concrete. further, the composition has a significantly high degree of homogeneity that allows the material to be easily plastered or spread with the trowel to a zero or near zero thickness, while at the same time allowing it to remain glued to the substrate material. This ability subsequently discourages the delamination or flaking of the substrate, and does not depend on the detailed, special surface preparation of the substrate. The combination in the proportions described above of the two different lightweight aggregates, and the perlite and vermiculite each having their unique structure and properties, is believed to result in the novel properties described below.

DETAILED DESCRIPTION OF THE INVENTION The composition of the light weight insulating concrete of the present invention can be described with reference to the relative weight of the components of the composition. In one embodiment, the composition comprises (1) a cementitious formation material, preferably approximately 4 parts by weight, and (2) a lightweight aggregate component, preferably approximately one part by weight relative to the cementitious formation material, wherein the aggregate component preferably comprises expanded perlite and expanded vermiculite in which the weight ratio of one component of the aggregate to the other does not exceed about 2: 1. Preferably the weight ratio of one component of the aggregate to the other does not exceed about 4: 3. Preferred embodiments of the combination include those in which the weight ratio of perlite to vermiculite is about 10: 9, or about 4: 3. . In still another embodiment, these embodiments may further include from about 0.5 to about 2.0 percent by weight of air entraining mixture and from about 0.3 to about 1.5 percent by weight of surfactant. More preferably, the mixture is present in an amount between about 0.72 to about 0.74 percent of the total weight, wherein the mixture is selected from the group of neutralized vinsol resin and alpha olefin sulfonate, and a surfactant is present in an amount between about 0.53 to about 0.55 percent of the total weight, wherein the surfactant is either sulfonated melamine or naphthalene formaldehyde. Another embodiment is one in which the material that forms cement is a combination of hydraulic binder and accelerator. In another embodiment, the cement-forming material includes Portland cement, Paris plaster, and terra alba, in weight ratios of approximately 5: 4: 1, or calcium aluminate cement and Paris plaster, in a weight ratio of approximately 11: 5. One embodiment of the composition comprises (1) a material forming cement and (2) a lightweight aggregate comprising components of expanded perlite and expanded vermiculite, wherein (3) each of the components of expanded perlite and expanded vermiculite comprises at least about one third of the weight of the lightweight aggregate. This combination is preferably from about 30 to about 33 parts by weight of cement-forming material and from about 7 to about 8 parts by weight of lightweight aggregate, including both perlite and vermiculite, and wherein both the perlite and vermiculite are at least about 3 parts by weight from about 7 to about 8 parts. In another embodiment the perlite and vermiculite are in the lightweight aggregate, and when the composition is used to form a lightweight insulating concrete, in the lightweight insulating concrete - in a ratio ranging from about 3: 4 to about 4: 3 in weight. Still other embodiments include those in which there is a weight ratio of perlite against vermiculite of about 10: 9, or about 4: 3. Another embodiment of this composition has a cement forming material formed of approximately equal parts by weight of cement and accelerator, more preferably where the cement is Portland cement, and the accelerator includes Paris plaster and alba terra at a ratio of 4: 1. in weigh. In still another embodiment, the formulation has a cement-forming material that includes about 22 parts of cement by weight, and about 10 parts of accelerator by weight, more preferably one in which the cement is a calcium aluminate cement, and the Accelerator includes plaster of Paris. In yet another embodiment, these embodiments may also include from about 0.5 to about 2.0 weight percent of air trapping mixture and from about 0.3 to about 1.5 weight percent surfactant. More preferably, the mixture is present in an amount from about 0.72 to about 0.74 percent of the total weight, wherein the mixture is selected from the group of neutralized vinsol resin and alpha-olefin sulfonate, and a surfactant is present in an amount of about 0.53 to about 0.55 percent of the total weight, wherein the surfactant is either sulfonated melamine or naphthalene formaldehyde. Another embodiment of the composition comprises (1) a cement-forming material and (2) a light-weight aggregate comprising at least two of the following component materials: expanded perlite and expanded vermiculite, sintered volatile ash, and expanded shale, and ( 3) wherein the concrete formed from the composition has a density after setting and drying to the furnace that is less than about 480 g / pr. A preferable embodiment is one in which each of the selected component materials comprises at least about one third by weight of the lightweight aggregate. Preferably, the expanded pearlite and the expanded vermiculite are the selected materials. Two additional embodiments are ones in which the proportion of expanded perlite and dilated vermiculite components by weight is about 4: 3 or about 10: 9. Yet another embodiment is one in which about four parts by weight is the material that forms cement and about one part by weight of the lightweight aggregate. In another embodiment, the material forming cement comprises Portland cement, Paris plaster, and terra alba, and the proportions by weight of Portland cement, Paris plaster, and térra alba are approximately 5: 4: 1. In yet another embodiment, the material forming cement comprises calcium aluminate cement and Paris plaster, and the weight ratio of calcium aluminate cement and Paris plaster is approximately 11: 5. One embodiment of the composition comprises (1) from about 75 to about 82 weight percent of the cement binder composition, wherein the cement binder comprises from about 30 to about 65 weight percent of the cement composition, and (2) from about 20 to about 55 percent by weight of the accelerator composition, and from about 10 to about 23 percent by weight of the lightweight aggregate composition, of which from about 5 to about 15 percent by weight. Weight percent of the composition is expanded perlite and from about 5 to about 10 weight percent of the composition is dilated vermiculite. The weight percentage of the composition of, for example, the cement, refers to the percentage by weight of the cement in the composition described, instead of a percentage of the cement binder. Preferably, the composition comprises from about 17.4 to about 19.8 weight percent lightweight aggregate. In another embodiment, each of the perlite and vermiculite comprises at least about 7.6 weight percent of the composition. In another embodiment, the perlite and vermiculite are in a ratio of from about 3: 4 to about 4: 3 by weight. Still other preferable embodiments are those in which the ratio of perlite to vermiculite is about 10: 9 or about 4: 3 by weight. The cement binder in these embodiments preferably comprises cement and accelerator. In one embodiment, the cement comprises from about 50 to about 65 weight percent of the calcium aluminate cement composition, and the accelerator comprises from about 20 to about 30 weight percent of the Paris gypsum composition, preferably about 55 weight percent of the calcium aluminate cement composition and about 25 weight percent of the Paris gypsum composition.

In another embodiment, the cement comprises from about 30 to about 55 weight percent Portland cement, and the accelerator comprises from about 20 to about 40 weight percent of the Paris plaster composition, and from about 4 to about 20. percent by weight of terra alba. The material forming cement in another embodiment comprises about 40 weight percent cement, and about 40 weight percent accelerator, the cement preferably being Portland cement, and preferably including the gypsum accelerator from Paris and terra alba in a proportion of weight percentages of approximately 4: 1. Preferably, the cement-forming material is about 40 weight percent of the composition, Portland cement, about 32 weight percent of the Paris gypsum composition, and about 8 weight percent of the alba ground composition. The expression of the amounts of these materials as percentages by weight refers for this purpose to the percentages by weight of the components described, and do not have other added material, for example inert material such as sand. In another embodiment, the composition comprises (1) from about 75 to about 82 weight percent cement binder, including cement and accelerators, (2) from about 10 to about 23 weight percent lightweight aggregate, ( 3) from about 0.5 to about 2.0 weight percent of air trapping mixture, and (4) from about 0.3 to about 1.5 weight percent surfactant. In a preferred embodiment, the cement binder includes from about 30 to about 65 weight percent (of the composition) of cement, and from about 20 to about 55 weight percent (of the composition) of accelerator, and the aggregate light weight includes from about 5 to about 15 weight percent (of the composition) of expanded vermiculite aggregate, from about 5 to about 10 weight percent (of the composition) of expanded perlite aggregate. In another embodiment, the lightweight aggregate comprises from about 17.4 to about 19.8 of the total composition, wherein each of the expanded perlite and the expanded vermiculite comprises at least about 7.6 weight percent of the composition. In another embodiment, perlite and vermiculite are present in the lightweight aggregate in a range of from about 3: 4 to about 4: 3 in weight ratio, more preferably about 10: 9, or about 4: 3. In another embodiment, the cement comprises from about 50 to about 65 weight percent of the calcium aluminate cement composition, and the accelerator comprises from about 20 to about 30 weight percent of the Paris gypsum composition. Preferably, the cement comprises about 55 weight percent of the calcium aluminate cement composition and the accelerator comprises about 25 weight percent of the Paris gypsum composition. In another embodiment, the cement comprises from about 30 to about 50 weight percent of the Portland cement composition, and the accelerator comprises from about 20 to about 40 weight percent Paris plaster, and from about 4 to about 20 weight percent. percent by weight of the composition of terra alba. Preferably, the cement comprises about 40 weight percent Portland cement, and the accelerator comprises about 32 weight percent of the Paris gypsum composition, and about 8 weight percent of the ground composition. The composition in another embodiment, may comprise from about 0.5 to about 2.0 weight percent of the mixture trapping air, and from about 0.3 to about 1.5 weight percent surfactant. Even more preferably, the mixture is an amount between about 0.72 to about 0.74 percent of the total weight, and is either neutralized vinsol resin or alpha olefin sulfonate, and the surfactant is in an amount between about 0.53 to about 0.55 percent. by weight of the total weight, and it is either sulfonated melamine and naphthalene formaldehyde. In still another embodiment, the composition (1) comprises about 80 weight percent cement binder, including any accelerator, (2) from about 7.8 to about 9.1 weight percent of expanded vermiculite aggregate, (3) from about 9.6 to about 10.7 weight percent aggregate of expanded perlite, (4) from about 0.68 to about 0.78 weight percent of air entraining mixture, and (5) from about 0.50 to about 0.60 weight percent of surfactant. More preferably, this embodiment comprises about 80 weight percent cement binder composition, including any accelerator, about 7.9 weight percent expanded vermiculite aggregate, from about 10.5 to about 10.6 weight percent aggregate of expanded perlite. , from about 0.72 to about 0.74 weight percent of air trapping mixture, and from about 0.53 to about 0.55 weight percent surfactant. In another embodiment, the composition comprises (1) about 4 parts by weight of cement-forming material, which comprises a combination of hydraulic binder and accelerator that is either (i) a first combination that includes Portland cement, Paris plaster and terra alba in weight proportions of approximately 5: 4: 1, or (ii) a second combination that includes calcium aluminate cement and Paris plaster in a weight ratio of approximately 11: 5; (2) about one part by weight of a lightweight aggregate, which comprises a fraction of expanded perlite and a fraction of expanded vermiculite, and the proportion by weight of the fractions does not exceed about 2: 1; (3) a mixture that traps air in an amount of between about 0.5 and about 2.0 percent of the total weight, which is either neutralized vinsol resin or alpha olefin sulfonate; and (4) a surfactant in an amount between about 0.3 and about 1.5 percent of the total weight, which is either a sulfonated melamine and naphthalene formaldehyde. Preferably, the weight ratio of the fractions does not exceed about 4: 3. In a preferred embodiment of the composition, the mixture is from about 0.72 to about 0.74 percent of the total weight. In another preferred embodiment, the surfactant is from about 0.53 to about 0.55 percent of the total weight. To the above embodiments, sufficient water is added to hydrate the cementitious binder and to make the wet mixture pumpable and also workable after placement. The specific amount of water used to hydrate the cement / binder composition falls in a range of from about 80 to about 120 weight percent, and preferably is about 90 weight percent. Excess water is undesirable because it leads to the segregation of specific components of the overall composition. Insufficient water is also undesirable because it could result in insufficient hydration of the cement and the binder components of the composition resulting in lower strength. A material that forms cement is used to bond together aggregate materials, including both expanded perlite and expanded vermiculite. The cement-forming material used in this invention preferably includes a hydraulic binder and some form of an accelerator to reduce the setting time. A first formulation generally comprises a calcium aluminate cement combined with Paris plaster. A second formulation generally comprises Portland cement, Paris plaster, and another accelerator, preferably terra alba. The calcium aluminate cement used is a hydraulic cement manufactured by grinding "slag" composed mainly of bauxite (aluminum oxide) and lime (calcium carbonate). Calcium aluminate cements are useful for their high temperature resistance and flexibility in "cure" or hydration time. The calcium aluminate cements may have a bulk density of about 1.16 to 1.37 grams / cm 3. A calcium aluminate cement which is found convenient for use in the invention is calcium aluminate cement LUMNITE MG5 available from Heidelberger Calcium Alumins, Inc., 7660 Imperial Way, Allentown, Pennsylvania 18195-1040. The Portland cement used is a hydraulic cement produced by grinding "slag" consisting essentially of calcium silicates with smaller amounts of calcium sulfate intermixed with them. ASTM C150 types I, II or III are suitable grades of Portland cement. Portland cement used in this mode was not mixed with lime, hydrated lime, or lime putty. Acceptable Portland cements are commonly available from manufacturers such as Holnam Inc., 6211 Ann Arbor Rd., PO Box, 122 Dundee, Michigan 48131 and Ash Grove Cement West Inc., 320 Union Pacific Way, Elko, Nevada 89801-4622. Plaster of Paris refers to any of a group of cements with gypsum, essentially semi-hydrated calcium sulfate, CaS04 •% H20, semi-hydrated calcium sulfate powder. It is also a hydraulic binder. When mixed with water, it reacts and becomes dihydrated calcium sulfate, a solid cemented matrix. In the present invention, Paris plaster also acts as an accelerator for Portland cements or calcium aluminate. The acceleration mechanism is not clearly understood. It probably has to do with providing a source of soluble sulfate which contributes to the formation of initial resistance constituents (calcium and aluminum hydrous basic sulfate) of Portland cement. As well, the plaster of Paris is believed to suffer its own setting and will actually be a high initial resistance contributor (as a minor constituent binder). An acceptable Paris plaster used in the present invention is the SUNFLOWER brand plaster cast manufactured by Georgia-Pacific Corp., 133 Peachtree St., Atlanta, Georgia 30348 and also the STRUCTO brand manufactured by United States Gypsum Co., 125 So. Franklin St. , Chicago, Illinois 60606-4678. Materials such as PYROFILL plaster concrete, also from United States Gypsum, which contains small amounts of wood chips, can be expected to provide acceptable results. Terra alba is finely powdered gypsum, calcium sulfate dihydrate, that is, CaS? 4-2H20. It is not a hydraulic binder, because it has no capacity for additional hydration when exposed to water. It functions as a soluble sulphate source in the present composition, as an accelerator for the plaster component of Paris. The sources of Térra Alba include both Georgia-Pacific Corp. and United States Gypsum Co., above. Other materials capable of acting as accelerators include lithium carbonate, calcium chloride, and compounds based on calcium nitrate and calcium thiocyanate. The lightweight aggregate used in the present invention includes both expanded perlite and expanded vermiculite. The main consideration in selecting acceptable light weight aggregates includes the desired final density and resilience. Those skilled in the art will recognize that other acceptable lightweight aggregates can satisfy these considerations. Other light weight aggregates such as sintered light ash, or expanded shale that can be replaced by either perlite or vermiculite at approximately equal weights of those components. Substituting either vermiculite or perlite can result in a slightly higher overall density, and increased resistance in lightweight insulation concrete, which may be acceptable in some applications, although it does not offer all the advantages of the modalities that have both dilated perlite such as dilated vermiculite, such as low density, manipulability and reduced setting times.

The aggregate of expanded vermiculite used in the present invention is a mica form, magnesium aluminum-lamellar iron hydrate silicate. The water molecules between the layers present are not part of the mineral structure. When subjected to high temperature, the water vaporizes and dilates or exfoliates the mineral layers. The result is a low density inorganic material that has several uses as a low-density aggregate for cement and agricultural co-operation. One function of the aggregate in the invention is to reduce the density of the cement mixture to a level compatible with the lightweight insulation concrete. Other functions are to retain moisture, to improve the homogeneity of the composition, and improve the "manageability" of the composition. In addition, it works to improve the ability of the composition to form thin layers that resist delamination of its underlying substrate. In addition, the lower deficiency of the expanded vermiculite allows the concrete composition to have a lower thermal conductivity, and causes a roofing of the material having improved insulation properties to be formed. Dilated vermiculite is generally characterized mainly by a particle size distribution and loose bulk density. The vermiculite aggregate found acceptable for use in this invention is characterized by ASTM C332 as Group I (fine). This dilated vermiculite is available as ZONOLITE brand of W.R. Grace & Company, Grace Construction Products, Whittemore Avenue 62, Cambridge, Massachusetts 02140 and MICRON brand of Strong-Lite Products, Pine Bluff, Arkansas 71611. The pearlite used in the present invention is a dilated volcanic glass. It has uses similar to vermiculite, including as a low density aggregate. The perlite acceptable for this composition is of a very fine grade that works mainly as an additive that increases the wet material's extension capacity, in addition to reducing the density and pee of the composition. The increased exibility capacity contributes to the ability to chamfer the product haeta zero or near zero thickness at the edge of the layer. These particles typically pass 90 percent through a 100 mesh screen and have a loose pore density of approximately 128.2-192.3 kg / pr. In addition, the lower density of the expanded perlite allows the concrete composition to have a lower thermal conductivity, and causes a partially formed roofing of the material having improved insulating properties. The expanded pearlite is available as a ZONOLITE brand of W.R. Grace & Company, earlier, and in Strog-Lite, earlier. Light and interbedded ash is a product formed using light ash, a material defined by ASTM C618 as "finely divided residue that results from the combustion of earth or powdered coal". The light ash classes C and F consist of SÍO2, I2O3 and Fe2Ü3; Class C in a minimum amount of 50 percent and class F in a minimum amount of 70 percent. Claee C is typically the result of burning sub-bituminous coal, while class F is typically the result of burning bituminous coal. The light ash is heated to sufficient temperatures to intersperse some of the particles together, resulting in larger particles of low density. The expanded bedding is a material obtained by heating it to high temperatures to allow it to increase its volume, giving as a result a material that has a reduced deneity. A dilated shale which may be suitable for use in the present invention is one which is based on ASTM C 332 (Group II). It is added that trapping air are alkyl tolerant surfactants used to maintain relatively low densities, via the incorporation of discrete stable air cells that do not coalesce with each other. They also create lodoe of homogeneous setting that do not eegregan. By acting to trap air in the mix during the mixing or pumped process, the effective density of the concrete composition is decreased. To a large extent, a percentage of weight of the aggregate that traps air has the negative effect of trapping too much air, which can result in the concrete having too low density. Conversely, insufficient trapped air is the result of a lower percentage of aggregate trapping air, a very dense composition and increased weight can result. Commercially available air trapping additives include, neutralized vinsol resin, from Hercules Food and Functional, 1313 North Market Street FL 2, Wilmington, Delaware 19801, and ZCA air trapping agent, alpha-olefin sulfonate brand BIO-TERGE AS90, from Stepan Company, 22 West Frontage Road, Northfield, IL 60093, and WITCONATE-A03 brand trapping agent available from Whitco Chemical, One American Lane, Greenwich, Connecticut 06831. Other acceptable mixtures may be known to those skilled in the art. , and may include non-ionic condensates of octylphenol and ethylene oxides. Water reducers and superplasticizers are surfactants that improve the "wettability" of solid materials in cement compositions, causing the composition to be more fluid with less mixing water, increasing strength and finish. Common water reducers based on mixtures of lignosulfonate reduce the water requirement from 6 to 10 percent in usable dosages. One problem is that higher grades of lignosulfonate materials have the adverse effect of delayed setting, ie they increase the time for the concrete to set. Euperplasticizers exhibit a more pronounced effect than ordinary water reducers, and are capable of reducing water demand by up to 30 percent without adverse material impact on concrete or cement chemistry, or forge time. Two common families of superplasticizers are based on sulfonated melamine and naphthalene formaldehyde. Two acceptable superplasticizers for use in the present invention are naphthalene formaldehyde brand DAXAD 19, manufactured by W.R. Grace &; Company, Grace Construction Products, Whittemore Avenue 62, Cambridge, MA 02140, and MELMENT FIO brand sulfonated melamine, manufactured by SKW Chemicals Inc., 1509 Johnson Ferry Road # 150, Marietta, GA 30062. Other acceptable water reductants and superplasticizers can be known to the person skilled in the art.

EXAMPLE 1 Place 17.01 kilogram of LUMNITE calcium aluminate cement, and 7.85 kilograms of SUNFLOWER Paris cast molding gypsum in a rotating drum mixer whose size is suitable for the amount of material to be produced, in this case approximately a total of 30.85 kilograms, and that is able to efficiently mix dry mixes. The example of such an equipment includes an 85-liter mixer, RED LION model FLX-3 by Monarch Industriee Limited, 889 Erin St. , Winnipeg 10, Manitoba Canada. Add to the mixer 2.45 kilograms of dilated vermiculite ASTM C332, Group I (fine), and 3.27 kilograms of expanded perlite, whose particles typically 90 percent pass through a 100 mesh screen and have a loose pore density of approximately 128.2-192.3 kg / pr. The order in which the agglutinant, aggregate and accelerant are introduced into the mixing device is not known to be important. An acceptable procedure is to add cement, gypsum and aggregates at the same time. In addition, it is also acceptable for the invention to add alternating portions in a fraction. The mixer is rotated briefly after each mixing step. These dry materials are mixed until there is no visible segregation of the diethyl compounds, usually about two minutes. A dense inert material, such as sand, may be added if desired; However, doing this usually does not benefit as it increases the weight of the concrete without adding a significant resistance. As soon as the most important components are well mixed, add 163.3 grams of MELMENT FIO brand sulfonated melamine and 226.9 grams of ZCA BIO-TERGE AS-90 brand trapping agent, and mix for 2-3 minutes until the dispersions are well dispersed. minor ingredients. The mixture still appears dry. In order to use this premixed composition, it is mixed with water, typically at the site where it is to be applied. Wet sludge is convenient for mixing either by hand or by machine, depending on the amount to be applied. For hand mixing, in a convenient container, for example, a 19-liter plastic dish, place approximately 8.1 liters of water (or approximately 8.2 kilograms, approximately 90 percent of the weight of the premix composition), measured using a container Graduated or weighed the water to be added with a platform spring balance. Preferably the water is drinking water that is clean and does not have harmful amounts of organic and acidic, alkaline materials. Add approximately 9.1 kilograms of the premix composition to the water. Stir the water and the premix composition with a paddle mixer imputed by a manual motor for 1-3 minutes and allow the material to achieve a homogeneous creamy consistency that satisfies the subsequent flow criteria. For machine mixing, there are many stationary rotary drum mixing devices available that are convenient. Choosing a mixer will depend mainly on the amount of desired material that you are going to mix each time. For the mixture described above, it is found that a SC-90 model mixer is acceptable by Whiteman Conspray, 255 Woodford Ave., Elyria, Ohio 44035. Place in the mixture approximately 27. 55 liters of water (or approximately 27.8 kilogram) (about 90 percent of the weight of the premix composition), measured using a graduated container or by peeping the water to be added with a platform spring balance. Preferably the water is potable water that is clean and does not have harmful amounts of organic, acidic and alkaline materials. Add approximately 30.8 kilograms of the premix composition to the water, and run the mixer until the material reaches a homogeneous creamy consistency that meets the flow criteria mentioned below. There is also a small to intermediate sized yee pump (rotor / eetator type) that can be used to transport the material. Again, selecting the specific piece of pumping equipment will depend on how much material is needed in a given period of time. If a pump is used, it must match the mixer in terms of mixing and pumping volumes over time. Based on known uses, it is believed that acceptable mixers include SEAL MASTER II by Strong Manufacturing Co., Inc., P.O. Box 8068, Pine Bluff, Arkansas 71611, and the SUN 110 tray mixer by SCN Marketing, P.O. Box 6274, Daytona Beach, Florida 32122. Place the wet mud in the pump hopper, and operate the pump to transport the wet mud to the top of the roof as needed.

EXAMPLE II Place 12.47 kilograms of ASH GROVE type I Portland cement, 9.98 kilograms of Paris GP casting gypsum, and 2.49 kilograms of térra alba on a rotating drum mixer whose size is suitable for the volume of material to be used. produce. In this case approximately 30.85 kilograms in total. The mixer in Example I is acceptable. Add to the mixer 2.45 kilogram of dilated vermiculite Group I (fine) ASTM C332, and 3.27 kilograms of expanded perlite, whose particles typically 90 percent pass through a 100 mesh screen and have a loose pore deficiency of approximately 128.2-192.3 kg / m3).

Follow the mixing steps of Example I. The comments about the inert material are applied here. As soon as the major component is scrambled, add 163.3 grams of MELMENT FIO brand sulfonated melamine, and 226.9 grams of ZCA BIO-TERGE AS-90 brand trapping agent. Use the steps described in example I to stir these materials. In order to use this premix composition, use the same procedures described above. The characteristics of the wet sludge formed after adding and mixing the water were verified to determine the quality control by examining its density and its fall. The wet density was verified using the following procedure: weigh a container of known volume, and then fill it with wet mud; ee used a 148-milliliter container. Weigh the filled container, and subtract the tare weight from the container. Calculate mud deficiency based on the net weight of the wet mud and the volume of the container. The wet density in the range of approximately 961.5-1282 kg / m3 is acceptable; ee prefers density in the range of approximately 1041.6-1201.9 kg / m0. The wet density values of numerous formulations are given in Table 1, infra. In order to measure the fall, or consistency, of the wet mud, the following procedure was carried out. Place a cylinder of PVC tube, 10.16 by 5.08 centimeters in a sheet of polyacrylate or glass. Fill the tube with the dry mud. Flip the top evenly and carefully lift the cylinder upwards. Measure the diameter of the resulting circular deposit of material. Diameters of approximately 15.24 to 22.86 centimeters are acceptable. The setting time of the lightweight concrete formed using the present invention is important and must be tested. Setting time is important because workers can not or can not afford to walk on the concrete before its forge, nor can the waterproof membrane fix it, because the concrete is not ready to adequately accept and sustain The fasteners used to secure the membrane. The term "set" in this context means that you can walk on the material and the clamping of the roof membrane can begin. Setting times of approximately 1-4 hours are acceptable; the gain of resistance will continue well beyond this point in time. A composition that will heal to set in about 2 to 4 hours is preferable. When the penetration resistance (PR) reaches 1,724 to 2,414 MPa, the material is considered set. A PR of more than about 2,414 MPa is considered undesirable if it is reached in less than about an hour, because it does not allow for an "open time" during which the fasteners can be inserted and the roof membrane installed for the material to be practically usable. In order to determine the penetration resistance, fill a cup of re-eminent, lightweight polyethylene foam (for example STYROFOAM brand) of 148 milliliters or a plastic tray with a depth of 2.54 centimeters with the material in wet sludge formed by mixing water with the ready-mixed material. Periodically probe the surface of the concrete material to a depth of 6.35 millimeters with a concrete penetrometer equipped with a probe, for example brand SOILTEST model CT 421A, available from ELE International, Inc., Soliteet Products Division, P.O. Box 8004, 86 Albrecht Drive, Lake Bluff, IL 60044-8004. A probe that has a diameter of 6.35 millimeters was found acceptable. Alternatively, the reintercept to penetration can be measured with respect to a "patch" instead of a tray or cup. In this case, the wet mud material is used to fill a defect or hole left in the surface of the lightweight insulating concrete by the removal of a fastener, specifically an NVS brand fastener or a ZONOLITE brand base fold, which has approximately 2.45 by 7.35 by 2.45 to 4.9 centimeters deep. It is noted that higher penetration resistance values are achieved for the same composition when the test on a patch is carried out. It is believed that this results from the porous surrounding concrete absorbing some of the excess water of the composition, increasing the apparent "re-appearance". The penetration resistance measurement test is not intended to directly measure the compressive or shear strength of the concrete. Several compositions were made using the above procedures and tested to determine the re-eminence to penetration achieved, and moisture deficiency, the results of which are found in Table 1, below.

Charola = Horae and minutes in test / PR (in kg / cm2) of material in a tray. Patch = Hours and minutes in test / PR (in kg / cm) of material in patch / hole. The characteristics of the lightweight insulating concrete formed by this composition after setting can be determined in various ways. They were carried out pruebae comparing a particular insulating lightweight of the present invention and specific Gypsum brand PYROFILL used for similar applications, which was composed mainly of plaster of Paris, and other cellulose fiber, about 5 percent, sold by US Gypsum The light weight hot-melt concrete of the present invention in this test comprised concrete formed using the composition of Example 1. The density and the resistance to concrete compression were measured in compliance with ASTM C495-91a. A desirable minimum oven drying density should be approximately 480.75 kg / m3. Lae tests were carried out at intervals of 1.3 and 7 days. A desirable minimum compression ratio should be approximately 2069 MPa within and for a period of one week after the application of the concrete. Haeta some degree, the material will gain additional compression resistance when the healing continues. The compression resistance values are given in Table 2, below.

TABLE 2 Another method to determine the characteristics of the formed concrete is to measure the power of ejaculation of an embedded ember inside the concrete. Two different tests were carried out, in which the material was applied in a single layer of 5.08 centimeters and in two layers, a layer 1.27 centimeters of the concrete on top of a lightweight concrete base of lightweight peje exietente. Insert a fastener (ZONOLITE or NVS brand fasteners are acceptable) into the material within 1-4 hours after the concrete has set. The fastener should be inerted through a suitable pull chair, and inserted at a depth of 4.6 centimeters. Thus, in the two-layer test, the fastener penetrates the existing substrate. Remove the fasteners after successively longer periods (1 and 3 days, and 7, 21 and 28 days for the two-layer test) using an appropriate spring scale or a physical test machine. It has been found that is acceptable machine model STM-10 testing by United Testing Machine, 5802 Engineer Dr, Huntington Beach, California 92649 or Model 1122 by Instron Testing Machine, 21624 Melrose Ave., Southfield, Michigan 48075. A minimum Pulling resistance of approximately a force of 177.9 N per fastener is acceptable; a pull resistance greater in 1 or 3 days is desirable, and the fasteners serve to retain the waterproof membrane that protects lightweight insulating concrete, as well as the structure, from potential water damage. This greater pulling resistance is preferably more than a force of about 444.8 N. These values are given in Table 3, below.

Table 3 Damage to the surface of the concrete roof often eurge removal or partial removal of a waterproof membrane, and removal of the fold coneecuente BAEE and other fasteners and devices existing substrate. The present inventive composition can be used for patching or otherwise repairing the concrete roof surface in the following manner. It is also believed that some of the different different formulations that have longer setting times could be used for re-roofing applications, although currently this would be prohibitive in cost. In order to patch a damaged surface, a quantity of material is prepared as described above, appropriate to the volume of fractures, depressions, holes or other damaged areas. Typically, 18.9 liters of wet mud will fill approximately 75 holes left by the removal of the drills. He Area to be repaired or refilled is cleaned of reetoe eueltoe and strange material. The interior is moistened but not so much to allow liquid water to accumulate at the bottom of them. A trowel is used to place a quantity of concrete mud in the hole to create a patch. It is preferred that about 5 to 10 percent more than the volume needed to fill the hole is placed in order to ensure that there is a sufficient amount to fill the hole without leaving air pockets. Optionally, a rod or wire of a smaller diameter than the hole can be inserted and moved around in it, to ensure that the hole is filled, and that there are no air pockets. The trowel is used to scrape the mud material that is on the surface of the existing substrate to form a flat surface of the patch. A trowel is used to chamfer the mud to a zero or near zero thickness at its edges, thereby forming a continuous transition from the patch to the stratum. Then the patch is allowed to heal. The setting should occur between 2 to 4 hours after the mud is applied to create the patch. A similar method can be used to repair areas such as those that form depressions within the exogenous substrate and allow the accumulation of water in the concrete, or more typically, on the waterproof membrane that lies on top. To repair these depressions, before installing a new waterproof membrane, the above steps can be repeated, except that the concrete slurry can be poured into the depression in an adequate amount to cause it to be level with the surrounding concrete. Any holes in the depression of the fastener removal should be addressed before this step using the above procedure. A metal teacher of a length appropriate to the size of the depression is used to level the mud with the surrounding concrete. Alternatively, another tool can be used, such as a 2 by 4 board. Then, the edges of the patch are terminated by beveling as above. Then the patch is allowed to heal. Must set within 2 to 4 hours of application, although this time may be affected by factors such as humidity, temperature, wind and sun. A conventional waterproof membrane can be applied over the patch or repair, after it has set, and fasteners can be placed in the newly applied lightweight insulating concrete. Pressure compression or molding of concrete mud is not necessary. Any of the modalities described above may be used to carry out these methods. The additional scope of this invention will be apparent after the reversal of the detailed description of the preferred embodiments. However, it should be understood that these descriptions do not limit the scope of the invention and are given as an example only, and that various changes and modifications that are completely within the scope of the present invention will be apparent to those skilled in the art.

Claims (45)

1. CLAIMS 1. A composition of material suitable for forming lightweight insulating concrete, comprising: a material that forms cement; and a lightweight aggregate in combination comprising a component of expanded perlite and a component of expanded vermiculite in which a weight ratio of a first of these components to a second of these components does not exceed about 2: 1.
2. 2. The composition of the material of claim 1, wherein the ratio of the first component against the second component does not exceed about 4: 3.
3. 3. The composition of the material of claim 1, wherein the weight ratio of the expanded perlite component against the expanded vermiculite component is about 4: 3.
4. 4. The composition of the material of claim 1, wherein the weight ratio of the expanded perlite component against the expanded vermiculite component is about 10: 9.
5. 5. The composition of the material of claim 1, wherein about 4 parts by weight are cement-forming material and approximately one part by weight is the aggregate of light pee.
6. 6. The composition of the material of claim 5, which further comprises about 5 parts by weight of water, the composition having a moisture density of about 961.35 to about 1281.8 kg per cubic meter.
7. The composition of the material of claim 1, wherein the cement-forming material is selected from the group consisting of (i) a combination of Portland cement, Paris plaster, and alba terra, and (ii) a combination of calcium aluminate cement, and yeeo from Paris.
8. 8. The composition of the material of claim 1, wherein the cement-forming material comprises Portland cement, Paris plaster, and terra alba, in weight ratios of approximately 5: 4: 1.
9. 9. The composition of the material of claim 1, wherein the cement-forming material comprises calcium aluminate cement and Paris plaster in a ratio of about 11: 5.
10. 10. The composition of the material of claim 1, further comprising a mixture that traps air in an amount between about 0.5 and about 2.0 percent pee of the cementitious material and the lightweight aggregate, and a surfactant in a amount between about 0.3 and about 1.5 percent of the weight of the cement-forming material and the lightweight aggregate.
11. 11. A composition of matter suitable for forming lightweight insulating concrete comprising: a material that forms cement; and a lightweight aggregate, the lightweight aggregate comprising a expanded pearlite component and a dilated vermiculite component, wherein each of the components comprises at least one third of said light weight aggregate by weight.
12. The composition of the material of claim 11, wherein the composition is from about 30 to about 33 parts by weight of cement-forming material, and from about 7 to about 8 parts by weight of light-weight aggregate, and in where each of the components is at least about 3 parts in size from about 7 haeta to about 8 parts.
13. The composition of the material of claim 12, wherein the weight ratio of the perlite component to the vermiculite component is about 4: 3.
14. The composition of the material of claim 12, wherein the weight ratio of the perlite component to the vermiculite component is about 10: 9.
15. 15. The composition of the material of claim 12, wherein the cement-forming material comprises cement and accelerator in about equal parts by weight.
16. 16. The composition of the material of claim 15, wherein the cement is Portland cement and the accelerator comprises parie gypsum and terra alba in a ratio of approximately 4: 1 by weight.
17. 17. The composition of the subject of claim 12, wherein the material forming cement is approximately 22 parts by weight of cement and approximately 10 parts by weight of accelerator.
18. 18. The composition of the material of claim 17, wherein the cement is calcium aluminate cement, and the accelerator comprises plaster of Paris.
19. 19. The composition of the material of claim 11, further comprising a mixture that traps air in an amount between about 0.5 and about 2.0 percent by weight of the material that forms cement and the lightweight aggregate, and a surfactant in a amount between about 0.3 and about 1.5 percent in weight of the material that forms cement and the lightweight aggregate.
20. The composition of the material of claim 19, wherein the mixture is present in an amount of between about 0.72 and about 0.74 percent of the total weight, and the mixture is selected from the group of neutralized vinsol resin and alpha sulfonate. olefin, and wherein the surfactant is present in an amount between about 0.53 and about 0.55 percent of the total pee, and the teneoactive is selected from the group of sulfonated melamine and naphthalene formaldehyde.
21. 21. A composition of matter suitable for forming a lightweight insulating concrete comprising: a material that forms cement; and a light weight aggregate comprising at least two materials selected components of the group that connects in dilated vermiculite, expanded perlite, light and intersized ash and dilated erectile; wherein the concrete formed from the composition has a density after setting and oven drying which is less than about 486.6 kg per cubic meter.
22. 22. The composition of the material of claim 21, wherein each of the selected component materials comprises at least about one third by weight of the lightweight aggregate.
23. 23. The composition of the material of claim 21, wherein about 4 parts by weight is the cementitious material and about one part by weight is the lightweight aggregate.
24. 24. The composition of the material of claim 21, wherein the cement-forming material comprises Portland cement, Parie gypsum, and terra alba, and wherein the weight proportions of Portland cement, parie yeeo, and alba are approximately 5: 4: 1.
25. 25. The composition of the material of claim 21, wherein the cement-forming material comprises calcium aluminate cement and Paris gypsum and the weight ratio of calcium aluminate cement and Parie gypsum of about 11: 5.
26. 26. A composition of matter suitable for forming light-weight foam concrete comprising: from about 75 haeta about 82 weight percent of the cement binder composition, wherein the cement binder comprises from about 30 to about 65 percent by weight of the cement composition and of about 20 haeta about 55 percent by weight of the accelerator composition; and about 10 haeta approximately 23 percent by weight of the lightweight aggregate composition, wherein the lightweight aggregate comprises from about 5 haeta about 15 percent by weight of the expanded perlite composition and from about 5 to about 10 percent by weight. the composition of dilated vermiculite.
27. 27. The composition of the material of claim 26, wherein the lightweight aggregate comprises from about 17.4 haeta about 19.8 percent by weight of the composition.
28. The composition of the material of claim 26, wherein each of the perlite and vermiculite comprises at least about 7.6 percent by weight of the composition.
29. 29. The composition of the subject of claim 26, wherein the cement comprises about 50 haeta about 65 percent by weight of the calcium aluminate cement composition and the accelerator comprises from about 20 to about 30 weight percent. of the plaster composition of Paris.
30. 30. The composition of the material of claim 29, which further comprises from about 0.5 to about 2.0 weight percent air entraining mixture, and from about 0.3 to about 1.5 weight percent surfactant.
31. The composition of the material of claim 26, wherein the cement comprises from about 30 to about 50 percent by weight of the Portland cement composition and the accelerator comprises from about 20 to about 40 percent by weight of the composition. of plaster of Paris and from approximately 4 to approximately 20 percent in peeo of the composition of terra alba.
32. 32. The composition of the material of claim 31, which further comprises from about 0.5 to about 2.0 weight percent air entraining mixture, and from about 0.3 to about 1.5 weight percent surfactant.
33. 33. A composition of matter suitable as a component of lightweight insulating concrete, comprising: about 4 parts in weight of a cement-forming material, wherein the cement-forming material comprises a combination of a hydraulic binder and accelerator selected from the group consisting of (i) a first combination comprising Portland cement, Paris plaster, and terra alba in weight proportions of approximately 5: 4: 1; and (ii) a second combination comprising calcium aluminate cement and Paris plaster in a weight ratio of about 11: 5; about one part by weight of a lightweight aggregate, wherein the lightweight aggregate comprises a fraction of expanded perlite and a dilated vermiculite fraction, wherein a weight ratio of these fractions does not exceed about 2: 1; a mixture that traps air in an amount between about 0.5 and about 2.0 percent of the total weight, where the mixture is selected from the neutralized vinsol and alpha olefin sulfonate reeine group; and a surfactant in an amount between about 0.3 and about 1.5 percent of the total weight, wherein the surfactant is selected from the group of sulfonated melamine and naphthalene formaldehyde.
34. 34. The composition of the material of claim 33, wherein a weight ratio of the fractions has a weight ratio not exceeding about 4: 3.
35. 35. A method for making a composition suitable for forming lightweight insulating concrete, comprising the step of: providing a first component comprising a material forming cement; mixing the first component with a second component comprising a light weight aggregate, the aggregate of light pee comprising a fraction of expanded vermiculite and a fraction of expanded perlite, wherein the first fraction and the second fraction have a proportion by weight that does not exceeds approximately 2: 1.
36. 36. The method of claim 35, wherein the weight ratio of the first fraction and the second fraction does not exceed about 4: 3.
37. 37. The method of claim 35, wherein a ratio of the dilated vermiculite fraction to the expanded perlite fraction is approximately 4: 3.
38. 38. The method of claim 35, wherein the first component and the second component have a ratio in peeo of about 4: 1.
39. 39. The method of claim 35, wherein the cement-forming material comprises Portland cement, yeeo Paris and alba dawn in weight proportions of approximately 5: 4: 1.
40. 40. The method of claim 35, wherein the cement-forming material comprises calcium aluminate cement and Paris plaster in a weight ratio of about 11: 5.
41. 41. The method of claim 35, further comprising the step of mixing in the composition: a mixture that traps air in an amount between about 0.5 and about 2.0 percent by weight of the first and second components; and a teneoactive in an amount between about 0.3 and about 1.5 weight percent of the first and second components.
42. 42. A method for making a composition suitable for forming lightweight insulating concrete, comprising the step of: providing a first component comprising a material forming cement; mixing the first component with a second component comprising a lightweight aggregate, the lightweight aggregate comprising a fraction of expanded perlite and a fraction of expanded vermiculite, wherein each of the fraction comprises when less than one third of the aggregate of light weight in weight.
43. 43. The method of claim 42, wherein the first component is from about 30 to about 33 parts by weight of cement-forming material, the second component is from about 7 to about 8 parts in light weight aggregate, and each of the fractions is at least 3 parts by weight from about 7 to about 8 parts.
44. 44. A method for repairing or patching a concrete surface using the composition of any of claims 1, 11, 21, 26 or 33, comprising the steps of: sufficiently hydrating the composition to create a mud; and apply the mud to the surface to create a patch.
45. 45. The method of claim 44, wherein the patch is cured to set from about 2 hours to about 4 hours after said slurry was applied. SUMMARY A light weight concrete composition includes a cement-forming material and a combination of lightweight aggregate of expanded vermiculite and expanded pearlite, not exceeding the weight ratio of one to the other by about 2: 1. Preferably, the composition is about 4 parts by weight of material forming cement and about 1 part by weight of weight aggregate 10 light. The cementitious material may be a combination of hydraulic binder and accelerator, and may be Portland cement, Paris plaster, and terrazzo, in a weight ratio of approximately 5: 4: 1, or calcium aluminate cement, and plaster of Paris, in a proportion by weight of 15 approximately 11: 5. The composition may further include a mixture that traps air in an amount between about 0.5 and about 2.0 percent of the total weight of the mixture, wherein the neutralized vinsol resin and alpha-olefin eulphonate, and a teneoactive 20 an amount between about 0.3 and about 1.5 percent of the total weight of the mixture, where sulfonated melamine and naphthalene formaldehyde are acceptable. One method of making the lightweight insulating concrete composition includes mixing the cement-forming material and the combination 25 of lightweight aggregate of the expanded vermiculite and the expanded perlite, and any surfactant mixture that may be included. A method for repairing or patching concrete surfaces using light weight insulating concrete includes hydrating the composition, applying the concrete mud and allowing it to cure for about 2 to about 4 hours until it sets. k k k k $ 0