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.

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 for producing a mineral foam includes: (i) independently preparing a cement slurry and an aqueous foam, the cement slurry being prepared by mixing water E and cement C, the cement C including a soluble equivalent quantity x of Na.sub.2O, x being expressed by weight for 100 parts cement, the slurry having a ratio x/(E/C) less than or equal to 1.75, E/C being expressed by weight, and the particles of cement C having a size distribution such that the particle size distribution ratio d.sub.max(h/2)/d.sub.min(h/2) is between 5 and 25; (ii) bringing the cement slurry into contact with the aqueous foam in order to obtain a foamed cement slurry; and (iii) shaping the foamed cement slurry obtained in step (ii) and allowing setting to take place.

A method for producing a mineral foam includes: (i) independently preparing a cement slurry and an aqueous foam, the cement slurry being prepared by mixing water E and cement C, the cement C including a soluble equivalent quantity x of Na.sub.2O, x being expressed by weight for 100 parts cement, the slurry having a ratio x/(E/C) less than or equal to 1.75, E/C being expressed by weight, and the particles of cement C having a size distribution such that the particle size distribution ratio d.sub.max(h/2)/d.sub.min(h/2) is between 5 and 25; (ii) bringing the cement slurry into contact with the aqueous foam in order to obtain a foamed cement slurry; and (iii) shaping the foamed cement slurry obtained in step (ii) and allowing setting to take place.

The manufacture of a thermal insulating product whereby a foam is produced from a mixture of mineral particles, the product is shaped, and the foam is dried. Specifically, the foam is produced from a crystallized calcic part and a crystallized magnesian part, and a composite aggregate of the crystals of the calcic and magnesian part is formed. The calcic part is chosen from calcite and/or aragonite, and the magnesian part is made of hydromagnesite.

The manufacture of a thermal insulating product whereby a foam is produced from a mixture of mineral particles, the product is shaped, and the foam is dried. Specifically, the foam is produced from a crystallized calcic part and a crystallized magnesian part, and a composite aggregate of the crystals of the calcic and magnesian part is formed. The calcic part is chosen from calcite and/or aragonite, and the magnesian part is made of hydromagnesite.