Methods and an associated system for processing unhardened concrete are disclosed. With these methods, the porosity of the unhardened concrete is significantly increased to decrease the strength so much that it can be easily broken up for sale or reuse. In at least one embodiment, the method includes adding a large volume of foam to the returned unhardened concrete and then mixing the foam with the returned concrete in the ready-mix concrete truck or other concrete mixing devices at any location including the jobsite, enroute to the concrete plant, or at the concrete plant. Through the mixing of foam with the returned concrete, the hydrated cement and aggregate particles are separated by large volumes of air voids, which significantly increase the porosity and dramatically reduce the strength of the returned concrete. The treated concrete is discharged and allowed to solidify in this weakened state, after which it is easily broken into loose particulate material that can be sold or reused.

Methods and an associated system for processing unhardened concrete are disclosed. With these methods, the porosity of the unhardened concrete is significantly increased to decrease the strength so much that it can be easily broken up for sale or reuse. In at least one embodiment, the method includes adding a large volume of foam to the returned unhardened concrete and then mixing the foam with the returned concrete in the ready-mix concrete truck or other concrete mixing devices at any location including the jobsite, enroute to the concrete plant, or at the concrete plant. Through the mixing of foam with the returned concrete, the hydrated cement and aggregate particles are separated by large volumes of air voids, which significantly increase the porosity and dramatically reduce the strength of the returned concrete. The treated concrete is discharged and allowed to solidify in this weakened state, after which it is easily broken into loose particulate material that can be sold or reused.

An expanded lightweight aggregate has compositional ranges (Wt. % Range) of about: (a) 40 to 60% ground glass or pumice, 40 to 60% water, 3 to 15% sodium silicate, and 0.1 to 5% NaNO.sub.3 for the slurry; and (b) 50 to 85% ground glass or pumice, and 15 to 50% slurry for the granulator.

Methods and an associated system for processing unhardened concrete are disclosed. With these methods, the porosity of the unhardened concrete is significantly increased to decrease the strength so much that it can be easily broken up for sale or reuse. In at least one embodiment, the method includes adding a large volume of foam to the returned unhardened concrete and then mixing the foam with the returned concrete in the ready-mix concrete truck or other concrete mixing devices at any location including the jobsite, enroute to the concrete plant, or at the concrete plant. Through the mixing of foam with the returned concrete, the hydrated cement and aggregate particles are separated by large volumes of air voids, which significantly increase the porosity and dramatically reduce the strength of the returned concrete. The treated concrete is discharged and allowed to solidify in this weakened state, after which it is easily broken into loose particulate material that can be sold or reused.

Methods and an associated system for processing unhardened concrete are disclosed. With these methods, the porosity of the unhardened concrete is significantly increased to decrease the strength so much that it can be easily broken up for sale or reuse. In at least one embodiment, the method includes adding a large volume of foam to the returned unhardened concrete and then mixing the foam with the returned concrete in the ready-mix concrete truck or other concrete mixing devices at any location including the jobsite, enroute to the concrete plant, or at the concrete plant. Through the mixing of foam with the returned concrete, the hydrated cement and aggregate particles are separated by large volumes of air voids, which significantly increase the porosity and dramatically reduce the strength of the returned concrete. The treated concrete is discharged and allowed to solidify in this weakened state, after which it is easily broken into loose particulate material that can be sold or reused.

A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

A method of preparing a reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance that meet or exceed one or more industry standard fire tests.

A method of preparing a reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance that meet or exceed one or more industry standard fire tests.

A method for producing an insulating composite block including a mineral foam, includes: providing a block including at least one cell having walls which are either sufficiently humid or consist of a water-repellent material, and b. filling the cell with a mineral foam that does not substantially include any calcium aluminate.