US20060000172A1 - Lightweight concrete composite blocks - Google Patents
Lightweight concrete composite blocks Download PDFInfo
- Publication number
- US20060000172A1 US20060000172A1 US11/209,151 US20915105A US2006000172A1 US 20060000172 A1 US20060000172 A1 US 20060000172A1 US 20915105 A US20915105 A US 20915105A US 2006000172 A1 US2006000172 A1 US 2006000172A1
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- United States
- Prior art keywords
- lightweight concrete
- concrete composite
- cement
- composite block
- polystyrene
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/04—Walls having neither cavities between, nor in, the solid elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0081—Embedding aggregates to obtain particular properties
- B28B23/0087—Lightweight aggregates for making lightweight articles
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B16/04—Macromolecular compounds
- C04B16/08—Macromolecular compounds porous, e.g. expanded polystyrene beads or microballoons
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- the present invention relates to lightweight concrete and, more particularly, but not by way of limitation, to unitary lightweight concrete composite blocks.
- Landscape timbers have been the primary materials used in the construction of such walls, enclosed areas, and raised gardens or flower beds. While landscape timbers have functioned adequately, there are certain disadvantages in their use. Landscape timbers are chemically treated to make them resistant to rot and decay. Unfortunately, the chemicals employed to treat the landscape timbers, in particular arsenic and creosote, are toxic and thus harmful to the environment. Consequently, pollution occurs not only at production facilities but also at points of use since landscape timbers leach the treatment chemicals into the surrounding environment.
- a lightweight concrete composite block includes polystyrene, cement, water, and glass mixed to formulate a lightweight concrete composite, which is then cured into the lightweight concrete composite block.
- the polystyrene may be recycled polystyrene ground into particles having a diameter of less than of an inch.
- the polystyrene comprises between 75% and 95% by total volume of the cement.
- the glass may be recycled glass ground into particles having a diameter of less than 1 ⁇ 4 of an inch.
- the glass comprises between 40% and 45% by total weight of the cement.
- the water comprises between 40% and 50% by total weight of the cement.
- the lightweight concrete composite block may also include fly ash substituted for cement up to 20% by total weight of the cement.
- the lightweight concrete composite block may further include a calcium chloride accelerator mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement.
- the lightweight concrete composite block may still further include a hardening agent mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement.
- a method of manufacturing lightweight concrete composite blocks includes mixing polystyrene, cement, water, and glass to formulate a lightweight concrete composite and curing the lightweight concrete composite into lightweight concrete composite blocks.
- the polystyrene is ground into particles having a diameter of less than of an inch prior to mixing the polystyrene with the cement, water, and glass to formulate the lightweight concrete composite.
- the polystyrene comprises between 75% and 95% by total volume of the cement.
- the glass is ground into particles having a diameter of less than 1 ⁇ 4 of an inch prior to mixing the glass with the polystyrene, cement, and water to formulate the lightweight concrete composite.
- the glass comprises between 40% and 45% by total weight of the cement.
- the water comprises between 40% and 50% by total weight of the cement.
- the lightweight concrete composite block may also include fly ash substituted for cement up to 20% by total weight of the cement.
- the lightweight concrete composite block may further include a calcium chloride accelerator mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement.
- the lightweight concrete composite block may still further include a hardening agent mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement.
- a method of installing lightweight concrete composite blocks to build a retaining structure includes the use of lightweight concrete composite blocks comprising polystyrene, cement, water, and glass mixed to formulate a lightweight concrete composite, which is then cured into the lightweight concrete composite blocks.
- a first lightweight concrete composite block is cut to a desired length and placed at a desired location.
- a second lightweight concrete composite block is cut to a desired length, placed on the first lightweight concrete composite block, and then secured with the first lightweight concrete composite block.
- a third lightweight concrete composite block is cut to a desired length, placed adjacent the first lightweight concrete composite block, and secured with the first lightweight concrete composite block.
- a fourth lightweight concrete composite block is cut to a desired length, placed on the third lightweight concrete composite block and adjacent the second lightweight concrete composite block, and secured with the second and third lightweight concrete composite blocks.
- FIG. 1 is a perspective view illustrating a unitary lightweight concrete block according to a preferred embodiment.
- FIG. 2 is a perspective view illustrating the use of unitary lightweight concrete blocks according to a preferred embodiment for building a retaining structure.
- a unitary lightweight concrete composite block 10 is rectangular with a horizontal axis greater than a vertical axis to facilitate stacking thereof for the building of retaining structures in the form of walls, enclosed areas, raised gardens, flower beds, and the like. While the preferred embodiment of the block 10 is rectangular to facilitate easier stacking thereof, those of ordinary skill in the art will recognize many alternative shapes, including but not limited to square, circular, triangular, polygonal, L-shaped, and the like.
- the lightweight concrete composite utilized to form the blocks 10 includes polystyrene, which is typically recycled; cement, which is typically Portland; water; and glass, which is typically recycled, ground glass.
- the cement is stored in a hopper prior to delivery from the hopper into a mixer using suitable and well-known means such as an auger, conveyor belt, pneumatic blower, and the like.
- the water is stored in a tank prior to delivery from the tank into the mixer using suitable and well-known means such as a pump, gravity feed, and the like.
- the polystyrene is loaded into a grinder, which is of a type well known to those of ordinary skill in the art, and ground into particles having a diameter of less than of an inch.
- the polystyrene particles are stored in a hopper prior to delivery from the hopper into the mixer using suitable and well-known means such as an auger, conveyor belt, pneumatic blower, and the like.
- suitable and well-known means such as an auger, conveyor belt, pneumatic blower, and the like.
- the glass is loaded into a grinder, which is of a type well known to those of ordinary skill in the art, and ground into particles having a diameter of less than 1 ⁇ 4 of an inch.
- the glass particles are stored in a hopper prior to delivery from the hopper into the mixer using suitable and well-known means such as an auger, conveyor belt, and the like.
- Lightweight concrete composite utilized in manufacturing blocks 10 is formulated by delivering the cement, water, polystyrene particles, and glass particles into the mixer.
- Cement is delivered into the mixer in a desired amount.
- Water is delivered into the mixer in an amount between 40% and 50% by total weight of the cement.
- Polystyrene particles are delivered into the mixer in an amount between 75% and 95% by total volume of the cement.
- Glass particles are delivered into the mixer in an amount between 40% and 45% by total weight of the cement.
- the mixer which is of a type well known to those of ordinary skill in the art, combines the cement, water, polystyrene particles, and glass particles, thus forming a lightweight concrete composite.
- the mixer delivers the lightweight concrete composite into forms via a screed assembly such as that disclosed in U.S. patent application Ser. No. 10/374,886, the disclosure of which is herein incorporated by reference.
- the forms are identical to the forms disclosed in U.S. patent application Ser. No. 10/374,886, except the cap is unnecessary and thus eliminated and the bottom assemblies are segmented to provide individual molds that produce multiple blocks 10 .
- the mixer delivers the lightweight concrete composite into the screed assembly, which, in turn, delivers the lightweight concrete composite into a form.
- a curing oven such as that disclosed in U.S. patent application Ser. No. 10/374,886, cures the lightweight concrete composite within the form.
- a block removal station such as that disclosed in U.S. patent application Ser. No. 10/374,886, removes the cured lightweight concrete composite blocks 10 from the form.
- a conveying system such as that disclosed in U.S. patent application Ser. No. 10/374,886, routes forms in a continuous loop simultaneously through the screed assembly, curing oven, and block removal station, thereby creating a time efficient process.
- the lightweight concrete composite utilized to form the blocks 10 includes at least polystyrene, cement, water and glass; however, the cost of formulating the lightweight concrete composite may be reduced through the substitution of fly ash for a portion of the cement.
- fly ash may be substituted for cement up to 20% by total weight of the cement. Consequently, fly ash may be added to any formulation up to 20% by total weight of the cement.
- the lightweight concrete composite may be necessary to include in the lightweight concrete composite other additives that improve the performance characteristics thereof.
- One such additive is a calcium chloride accelerator that accelerates curing of the lightweight concrete composite.
- Another additive is a hardening agent that enhances hardening of the lightweight concrete composite.
- the calcium chloride accelerator and the hardening agent are each added to the lightweight concrete composite in an amount equal to 2% of total weight of the cement.
- any uneven ground must first be leveled. If necessary a small trench may be dug to receive a bottom layer of the blocks 10 . Leveling ground or digging a trench is unnecessary if the blocks 10 will reside on a level surface such as a concrete patio.
- the blocks 10 are lightweight and thus easily carried.
- the blocks 10 are further easily cut with a saw and in particular a chain saw. Consequently, the blocks 10 may be cut if necessary to a desired size and laid end to end to form a first layer.
- the ends the blocks 10 further may be secured together using any suitable adhesive or fastener.
- Additional blocks 10 may be cut if necessary to the desired size and laid end to end on top of the first layer to form a second layer. Not only may the ends of the additional blocks 10 be secured together using any suitable adhesive or fastener, but also the additional blocks 10 forming the second layer may be secured to the blocks 10 forming the first layer using any suitable adhesive or fastener. Still further layers of blocks 10 may be stacked and secured as described above until the desired height for the retaining structure is reached. The ends of the blocks 10 may be cut at any angle so that retaining structures with different shapes may be constructed. Illustratively, three, four, five, and more sided retaining structures may be built depending upon the angle of the cut along an end of a block 10 .
- the blocks 10 are accordingly extremely advantageous for building retaining structures in the form of a walls, enclosed areas, raised gardens, flower beds, and the like because they are lightweight, easily cut and stacked, and more importantly do not introduce harmful chemicals into the environment.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Architecture (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
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- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
A lightweight concrete composite is utilized to form blocks. The lightweight concrete composite includes polystyrene, cement, water, and glass. The blocks are advantageous for building retaining structures in the form of walls, enclosed areas, raised gardens, flower beds, and the like because the blocks are lightweight, easily cut and stacked, and more importantly do not introduce harmful chemicals into the environment.
Description
- This application is a continuation-in-part of application Ser. No. 10/374,886, filed Feb. 26, 2003, which was a continuation-in-part of U.S. Pat. No. 6,827,570 B2, issued Dec. 7, 2004.
- This present application claims all available benefit, under 35 U.S.C. § 119(e), of U.S. provisional patent application Ser. No. 60/605,102, filed Aug. 27, 2004. By this reference, the full disclosure of U.S. provisional patent application Ser. No. 60/605,102 is incorporated herein as though now set forth in its entirety.
- 1. Field of the Invention
- The present invention relates to lightweight concrete and, more particularly, but not by way of limitation, to unitary lightweight concrete composite blocks.
- 2. Description of the Related Art
- Landscaping as well as gardening often requires the building of retaining structures in the form of walls, enclosed areas, and raised gardens or flower beds. Heretofore, landscape timbers have been the primary materials used in the construction of such walls, enclosed areas, and raised gardens or flower beds. While landscape timbers have functioned adequately, there are certain disadvantages in their use. Landscape timbers are chemically treated to make them resistant to rot and decay. Unfortunately, the chemicals employed to treat the landscape timbers, in particular arsenic and creosote, are toxic and thus harmful to the environment. Consequently, pollution occurs not only at production facilities but also at points of use since landscape timbers leach the treatment chemicals into the surrounding environment. Furthermore, landscape timbers ultimately rot and decay necessitating replacement in addition to more fully delivering the treatment chemicals into the environment. Accordingly, a block suitable for use in constructing walls, enclosed areas, and raised gardens or flower beds that is not chemically treated as well as resistant to rot and decay would be a significant improvement over current landscape timbers.
- In accordance with the present invention, a lightweight concrete composite block includes polystyrene, cement, water, and glass mixed to formulate a lightweight concrete composite, which is then cured into the lightweight concrete composite block. The polystyrene may be recycled polystyrene ground into particles having a diameter of less than of an inch. The polystyrene comprises between 75% and 95% by total volume of the cement. The glass may be recycled glass ground into particles having a diameter of less than ¼ of an inch. The glass comprises between 40% and 45% by total weight of the cement. The water comprises between 40% and 50% by total weight of the cement. The lightweight concrete composite block may also include fly ash substituted for cement up to 20% by total weight of the cement. The lightweight concrete composite block may further include a calcium chloride accelerator mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement. The lightweight concrete composite block may still further include a hardening agent mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement.
- In accordance with the present invention a method of manufacturing lightweight concrete composite blocks includes mixing polystyrene, cement, water, and glass to formulate a lightweight concrete composite and curing the lightweight concrete composite into lightweight concrete composite blocks. The polystyrene is ground into particles having a diameter of less than of an inch prior to mixing the polystyrene with the cement, water, and glass to formulate the lightweight concrete composite. The polystyrene comprises between 75% and 95% by total volume of the cement. The glass is ground into particles having a diameter of less than ¼ of an inch prior to mixing the glass with the polystyrene, cement, and water to formulate the lightweight concrete composite. The glass comprises between 40% and 45% by total weight of the cement. The water comprises between 40% and 50% by total weight of the cement. The lightweight concrete composite block may also include fly ash substituted for cement up to 20% by total weight of the cement. The lightweight concrete composite block may further include a calcium chloride accelerator mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement. The lightweight concrete composite block may still further include a hardening agent mixed with the polystyrene, cement, water, and glass in an amount equal to 2% of total weight of the cement.
- In accordance with the present invention, a method of installing lightweight concrete composite blocks to build a retaining structure includes the use of lightweight concrete composite blocks comprising polystyrene, cement, water, and glass mixed to formulate a lightweight concrete composite, which is then cured into the lightweight concrete composite blocks. A first lightweight concrete composite block is cut to a desired length and placed at a desired location. A second lightweight concrete composite block is cut to a desired length, placed on the first lightweight concrete composite block, and then secured with the first lightweight concrete composite block. A third lightweight concrete composite block is cut to a desired length, placed adjacent the first lightweight concrete composite block, and secured with the first lightweight concrete composite block. A fourth lightweight concrete composite block is cut to a desired length, placed on the third lightweight concrete composite block and adjacent the second lightweight concrete composite block, and secured with the second and third lightweight concrete composite blocks.
- It is therefore an object of the present invention to provide lightweight concrete composite blocks comprised of polystyrene, cement, water, and glass.
- It is another object of the present invention to provide lightweight concrete composite blocks that do not introduce harmful chemicals into the environment.
- It is a further object of the present invention to provide a method of manufacturing lightweight concrete composite blocks comprised of polystyrene, cement, water, and glass.
- It is still a further object of the present invention to provide lightweight concrete composite blocks suitable for the building of retaining structures.
- Still other objects, features, and advantages of the present invention will become evident to those of ordinary skill in the art in light of the following.
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FIG. 1 is a perspective view illustrating a unitary lightweight concrete block according to a preferred embodiment. -
FIG. 2 is a perspective view illustrating the use of unitary lightweight concrete blocks according to a preferred embodiment for building a retaining structure. - As illustrated in
FIGS. 1 and 2 , a unitary lightweightconcrete composite block 10 is rectangular with a horizontal axis greater than a vertical axis to facilitate stacking thereof for the building of retaining structures in the form of walls, enclosed areas, raised gardens, flower beds, and the like. While the preferred embodiment of theblock 10 is rectangular to facilitate easier stacking thereof, those of ordinary skill in the art will recognize many alternative shapes, including but not limited to square, circular, triangular, polygonal, L-shaped, and the like. - The lightweight concrete composite utilized to form the
blocks 10 includes polystyrene, which is typically recycled; cement, which is typically Portland; water; and glass, which is typically recycled, ground glass. The cement is stored in a hopper prior to delivery from the hopper into a mixer using suitable and well-known means such as an auger, conveyor belt, pneumatic blower, and the like. Likewise, the water is stored in a tank prior to delivery from the tank into the mixer using suitable and well-known means such as a pump, gravity feed, and the like. The polystyrene is loaded into a grinder, which is of a type well known to those of ordinary skill in the art, and ground into particles having a diameter of less than of an inch. After grinding, the polystyrene particles are stored in a hopper prior to delivery from the hopper into the mixer using suitable and well-known means such as an auger, conveyor belt, pneumatic blower, and the like. Likewise, the glass is loaded into a grinder, which is of a type well known to those of ordinary skill in the art, and ground into particles having a diameter of less than ¼ of an inch. After grinding, the glass particles are stored in a hopper prior to delivery from the hopper into the mixer using suitable and well-known means such as an auger, conveyor belt, and the like. - Lightweight concrete composite utilized in manufacturing blocks 10 is formulated by delivering the cement, water, polystyrene particles, and glass particles into the mixer. Cement is delivered into the mixer in a desired amount. Water is delivered into the mixer in an amount between 40% and 50% by total weight of the cement. Polystyrene particles are delivered into the mixer in an amount between 75% and 95% by total volume of the cement. Glass particles are delivered into the mixer in an amount between 40% and 45% by total weight of the cement. The mixer, which is of a type well known to those of ordinary skill in the art, combines the cement, water, polystyrene particles, and glass particles, thus forming a lightweight concrete composite.
- After formulation of the lightweight concrete composite, the mixer delivers the lightweight concrete composite into forms via a screed assembly such as that disclosed in U.S. patent application Ser. No. 10/374,886, the disclosure of which is herein incorporated by reference. The forms are identical to the forms disclosed in U.S. patent application Ser. No. 10/374,886, except the cap is unnecessary and thus eliminated and the bottom assemblies are segmented to provide individual molds that produce
multiple blocks 10. The mixer delivers the lightweight concrete composite into the screed assembly, which, in turn, delivers the lightweight concrete composite into a form. Once the screed assembly completes delivery of the lightweight concrete composite into the form, a curing oven, such as that disclosed in U.S. patent application Ser. No. 10/374,886, cures the lightweight concrete composite within the form. A block removal station, such as that disclosed in U.S. patent application Ser. No. 10/374,886, removes the cured lightweight concrete composite blocks 10 from the form. A conveying system, such as that disclosed in U.S. patent application Ser. No. 10/374,886, routes forms in a continuous loop simultaneously through the screed assembly, curing oven, and block removal station, thereby creating a time efficient process. - The lightweight concrete composite utilized to form the
blocks 10 includes at least polystyrene, cement, water and glass; however, the cost of formulating the lightweight concrete composite may be reduced through the substitution of fly ash for a portion of the cement. In particular, fly ash may be substituted for cement up to 20% by total weight of the cement. Consequently, fly ash may be added to any formulation up to 20% by total weight of the cement. - Furthermore, due to varying atmospheric conditions, in particular, temperature and humidity, it may be necessary to include in the lightweight concrete composite other additives that improve the performance characteristics thereof. One such additive is a calcium chloride accelerator that accelerates curing of the lightweight concrete composite. Another additive is a hardening agent that enhances hardening of the lightweight concrete composite. When used, the calcium chloride accelerator and the hardening agent are each added to the lightweight concrete composite in an amount equal to 2% of total weight of the cement.
- To install the
blocks 10 and thus build a retaining structure in the form of a wall, enclosed area, raised garden, flower bed, and the like, any uneven ground must first be leveled. If necessary a small trench may be dug to receive a bottom layer of theblocks 10. Leveling ground or digging a trench is unnecessary if theblocks 10 will reside on a level surface such as a concrete patio. Theblocks 10 are lightweight and thus easily carried. Theblocks 10 are further easily cut with a saw and in particular a chain saw. Consequently, theblocks 10 may be cut if necessary to a desired size and laid end to end to form a first layer. The ends theblocks 10 further may be secured together using any suitable adhesive or fastener.Additional blocks 10 may be cut if necessary to the desired size and laid end to end on top of the first layer to form a second layer. Not only may the ends of theadditional blocks 10 be secured together using any suitable adhesive or fastener, but also theadditional blocks 10 forming the second layer may be secured to theblocks 10 forming the first layer using any suitable adhesive or fastener. Still further layers ofblocks 10 may be stacked and secured as described above until the desired height for the retaining structure is reached. The ends of theblocks 10 may be cut at any angle so that retaining structures with different shapes may be constructed. Illustratively, three, four, five, and more sided retaining structures may be built depending upon the angle of the cut along an end of ablock 10. Theblocks 10 are accordingly extremely advantageous for building retaining structures in the form of a walls, enclosed areas, raised gardens, flower beds, and the like because they are lightweight, easily cut and stacked, and more importantly do not introduce harmful chemicals into the environment. - Although the present invention has been described in terms of the foregoing embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope, accordingly, is not to be limited in any respect by the foregoing description; rather, it is defined only by the claims that follow.
Claims (33)
1. A lightweight concrete composite block, comprising polystyrene, cement, water, and glass mixed to formulate a lightweight concrete composite, wherein the lightweight concrete composite is cured into the lightweight concrete composite block.
2. The lightweight concrete composite block according to claim 1 , wherein the polystyrene is recycled polystyrene.
3. The lightweight concrete composite block according to claim 1 , wherein the polystyrene is ground into particles having a diameter of less than of an inch.
4. The lightweight concrete composite block according to claim 1 , wherein the glass is recycled glass.
5. The lightweight concrete composite block according to claim 1 , wherein the glass is ground into particles having a diameter of less than ¼ of an inch.
6. The lightweight concrete composite block according to claim 1 , wherein the cement is Portland cement.
7. The lightweight concrete composite block according to claim 1 , wherein the water comprises between 40% and 50% by total weight of the cement.
8. The lightweight concrete composite block according to claim 1 , wherein the polystyrene comprises between 75% and 95% by total volume of the cement.
9. The lightweight concrete composite block according to claim 1 , wherein the glass comprises between 40% and 45% by total weight of the cement.
10. The lightweight concrete composite block according to claim 1 , wherein fly ash may be substituted for a portion of the cement.
11. The lightweight concrete composite block according to claim 1 , wherein fly ash may be substituted for cement up to 20% by total weight of the cement.
12. The lightweight concrete composite block according to claim 1 , further comprising a calcium chloride accelerator mixed with the polystyrene, cement, water, and glass to formulate a lightweight concrete composite cured into the lightweight concrete composite block.
13. The lightweight concrete composite block according to claim 12 , wherein the calcium chloride accelerator comprises an amount equal to 2% of total weight of the cement.
14. The lightweight concrete composite block according to claim 1 , further comprising a hardening agent mixed with the polystyrene, cement, water, and glass to formulate a lightweight concrete composite cured into the lightweight concrete composite block.
15. The lightweight concrete composite block according to claim 14 , wherein the hardening agent comprises an amount equal to 2% of total weight of the cement.
16. The lightweight concrete composite block according to claim 1 , wherein the lightweight concrete composite block comprises a horizontal axis greater than a vertical axis to facilitate stacking thereof.
17. A method of manufacturing lightweight concrete composite blocks, comprising:
mixing polystyrene, cement, water, and glass to formulate a lightweight concrete composite; and
curing the lightweight concrete composite into lightweight concrete composite blocks.
18. The method of manufacturing lightweight concrete composite blocks according to claim 17 , further comprising grinding the polystyrene into particles prior to mixing the polystyrene with the cement, water, and glass to formulate the lightweight concrete composite.
19. The method of manufacturing lightweight concrete composite blocks according to claim 18 , wherein the polystyrene is ground into particles having a diameter of less than of an inch.
20. The method of manufacturing lightweight concrete composite blocks according to claim 17 , further comprising grinding the glass into particles prior to mixing the glass with the polystyrene, cement, and water to formulate the lightweight concrete composite.
21. The method of manufacturing lightweight concrete composite blocks according to claim 20 , wherein the glass is ground into particles having a diameter of less than ¼ of an inch.
22. The method of manufacturing lightweight concrete composite blocks according to claim 17 , wherein the water comprises between 40% and 50% by total weight of the cement.
23. The method of manufacturing lightweight concrete composite blocks according to claim 17 , wherein the polystyrene comprises between 75% and 95% by total volume of the cement.
24. The method of manufacturing lightweight concrete composite blocks according to claim 17 , wherein the glass comprises between 40% and 45% by total weight of the cement.
25. The method of manufacturing lightweight concrete composite blocks according to claim 17 , wherein fly ash may be substituted for a portion of the cement.
26. The method of manufacturing lightweight concrete composite blocks according to claim 17 , wherein fly ash may be substituted for cement up to 20% by total weight of the cement.
27. The method of manufacturing lightweight concrete composite blocks according to claim 17 , further comprising a calcium chloride accelerator mixed with the polystyrene, cement, water, and glass to formulate a lightweight concrete composite cured into the lightweight concrete composite blocks.
28. The method of manufacturing lightweight concrete composite blocks according to claim 27 , wherein the calcium chloride accelerator comprises an amount equal to 2% of total weight of the cement.
29. The method of manufacturing lightweight concrete composite blocks according to claim 17 , further comprising a hardening agent mixed with the polystyrene, cement, water, and glass to formulate a lightweight concrete composite cured into the lightweight concrete composite blocks.
30. The method of manufacturing lightweight concrete composite blocks according to claim 29 , wherein the hardening agent comprises an amount equal to 2% of total weight of the cement.
31. A method of installing lightweight concrete composite blocks to build a retaining structure, comprising:
providing lightweight concrete composite blocks, comprising polystyrene, cement, water, and glass mixed to formulate a lightweight concrete composite, wherein the lightweight concrete composite is cured into the lightweight concrete composite blocks;
cutting a first lightweight concrete composite block to a desired length;
placing the first lightweight concrete composite block at a desired location;
cutting a second lightweight concrete composite block to a desired length;
placing the second lightweight concrete composite block on the first lightweight concrete composite block; and
securing the second lightweight concrete composite block with the first lightweight concrete composite block.
32. The method of installing lightweight concrete composite blocks to build a retaining structure according to claim 31 , further comprising:
cutting a third lightweight concrete composite block to a desired length;
placing the third lightweight concrete composite block adjacent the first lightweight concrete composite block; and
securing the third lightweight concrete composite block with the first lightweight concrete composite block.
33. The method of installing lightweight concrete composite blocks to build a retaining structure according to claim 32 , further comprising:
cutting a fourth lightweight concrete composite block to a desired length;
placing the fourth lightweight concrete composite block on the third lightweight concrete composite block and adjacent the second lightweight concrete composite block; and
securing the fourth lightweight concrete composite block with the second and third lightweight concrete composite blocks.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/209,151 US20060000172A1 (en) | 2001-06-22 | 2005-08-22 | Lightweight concrete composite blocks |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/887,369 US6827570B2 (en) | 2000-06-29 | 2001-06-22 | Method and apparatus for manufacture of unitary lightweight concrete composite blocks |
| US10/374,886 US6974317B2 (en) | 2001-06-22 | 2003-02-26 | Lightweight concrete composite blocks |
| US60510204P | 2004-08-27 | 2004-08-27 | |
| US11/209,151 US20060000172A1 (en) | 2001-06-22 | 2005-08-22 | Lightweight concrete composite blocks |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US10/374,886 Continuation-In-Part US6974317B2 (en) | 2001-06-22 | 2003-02-26 | Lightweight concrete composite blocks |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20060000172A1 true US20060000172A1 (en) | 2006-01-05 |
Family
ID=35512474
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US11/209,151 Abandoned US20060000172A1 (en) | 2001-06-22 | 2005-08-22 | Lightweight concrete composite blocks |
Country Status (1)
| Country | Link |
|---|---|
| US (1) | US20060000172A1 (en) |
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| US20060001724A1 (en) * | 2004-07-01 | 2006-01-05 | Canon Kabushiki Kaisha | Sheet feeding/conveying method and sheet feeding/conveying apparatus |
| WO2008019425A1 (en) * | 2006-08-14 | 2008-02-21 | Grant Leslie Shallard As Trustee Of The Shallard Family Trust | Composite structure and method of forming same |
| US20080157430A1 (en) * | 2006-12-29 | 2008-07-03 | Apex Construction Systems, Inc. | Compacting techniques for forming lightweight concrete building blocks |
| US20090173027A1 (en) * | 2006-05-10 | 2009-07-09 | Kerry Bennett | Concrete masonry hollow block |
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| US10087105B2 (en) | 2016-05-24 | 2018-10-02 | 2581776 Ontario Inc. | Lightweight concrete formulations |
| US20180281382A1 (en) * | 2017-03-28 | 2018-10-04 | Canon Kabushiki Kaisha | Printing apparatus and control method |
| CN109653346A (en) * | 2019-02-01 | 2019-04-19 | 马清浩 | A kind of method of construction |
| US10450230B2 (en) | 2017-09-26 | 2019-10-22 | Nano And Advanced Materials Institute Limited | Fire resistant eco concrete blocks containing waste glass |
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| US11873413B2 (en) | 2018-08-03 | 2024-01-16 | National Research Council Of Canada | UV-sinterable molecular ink and processing thereof using broad spectrum UV light |
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| US10544587B2 (en) | 2018-03-14 | 2020-01-28 | King Fahd University Of Petroleum And Minerals | Composite wall panel |
| US11873413B2 (en) | 2018-08-03 | 2024-01-16 | National Research Council Of Canada | UV-sinterable molecular ink and processing thereof using broad spectrum UV light |
| CN109653346A (en) * | 2019-02-01 | 2019-04-19 | 马清浩 | A kind of method of construction |
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