A lightweight structural concrete formulation comprises a wet mix of about 460 kg/m.sup.3 of cementitious material such as ordinary Portland cement of which about 50 percent has been replaced by ground granulated basic furnace slag (GGBFS) and 7 percent by silica fume (SF) in other words the mix introduces between about 178 and 228 kg/m.sup.3 therefore the combination is good to produce secondary reaction products when the cement hydrates which produces secondary calcium silicate hydrate (C-S-H) which makes the structure dense and thereby increases its mechanical durability characteristics of the concrete product. Possible ratios of GGBFS and SF are 30-70 percent and 5-10 percent, respectively. By making the structures dense increases the mechanical and durability characteristics of the concrete product. Other ratios have been made including GGBFS of 30-70 percent and silica fume 5-10 percent, respectively. It can be noted that the silica fume was added to the mixture as a supplementary cementitious material (SCM) not as an aggregate. It should also be noted that the particle sizes of GGBFS ranges between about 20-40 mm and that of silica fume is less than 20 mm.

Quarry fines and/or limestone powder are used to reduce clinker content in concrete, mortar and other cementitious compositions, typically in combination with one or more pozzolanically active SCMs. Quarry fines and/or limestone powder can replace and/or augment a portion of hydraulic cement binder and/or fine aggregate. Quarry fines and/or limestone powder can advantageously replace a portion of cement binder and fine aggregate, acting as an intermediate that fills a particle size void between the largest cement particles and smallest fine aggregate particles. Supplemental lime can advantageously maintain or enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can advantageously address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticers, and SCMs containing aluminates. Such systematic approach to beneficially using quarry fines, limestone powder, SCMs, lime, and sulfate addresses many issues and permits high clinker reduction with similar or increased strength.

A roofing tile composed of concrete material and a method for producing such a roofing tile. The concrete material contains a binder, a gravel, a light-weight aggregate, and added water. The roofing tile has at least one watercourse and a lateral interlocking joint having a covering fold and a water fold. The ratio of water to binder is less than 0.3, the light-weight aggregate is composed of a material that is hydrophobic and/or not hygroscopic, and the roofing tile has a density in the range of 1.6 g/cm.sup.3 to 1.9 g/cm.sup.3 after the hardening. The roofing tile has a thickness of 5 mm to 9 mm, preferably 7 mm to 8 mm, in the highly loaded regions, preferably in the region of the watercourse.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses described, including survival bunkers, composting pits, mine reclamation encapsulation and carbon sequestration facilities, water storage facilities, compressed air storage facilities, carbon sequestration/mineral carbonation facilities and a pumped hydroelectric facility adapted for use with a lock system of a waterway.

The concrete composition includes, in a mixture with water, a hydraulic binder, sand and aggregates, wherein the hydraulic binder includes a Portland cement of high reactivity, and the hydraulic binder is present in an amount of 280-340 kg per cubic meter of concrete, a shrinkage reducing admixture is present in an amount of 0-4 L per cubic meter of concrete, and water is present in an amount of 140-160 L per cubic meter of concrete.

An ultra-light, pourable, self-drying cementitious product with improved density control and ultra-low water demand is provided. Compositions and methods for making the products are provided as well, including compositions and methods with ultra-low water demand.

The present disclosure provides a performance testing method and system for a polycarboxylate superplasticizer in a concrete system. An interface model is constructed based on a calcium silicate hydrate (CSH) gel model and a molecular dynamics model of a polycarboxylate superplasticizer, which can cover complexity of a cement particle interface and variability of the polycarboxylate superplasticizer, and can also establish a link between a microstructure of the polycarboxylate superplasticizer and a macroscopic fluidity of a cement across multiple scales. Meanwhile, friction resistance is accurately calculated based on the constructed interface model to accurately test a performance of the polycarboxylate superplasticizer, thereby shortening a screening cycle of the polycarboxylate superplasticizer and improving a performance optimization efficiency.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses described, including survival bunkers, composting pits, mine reclamation encapsulation and carbon sequestration facilities, water storage facilities, compressed air storage facilities, carbon sequestration/mineral carbonation facilities and a pumped hydroelectric facility adapted for use with a lock system of a waterway.

A roofing tile composed of concrete material and a method for producing such a roofing tile. The concrete material contains a binder, a gravel, a light-weight aggregate, and added water. The roofing tile has at least one watercourse and a lateral interlocking joint having a covering fold and a water fold. The ratio of water to binder is less than 0.3, the light-weight aggregate is composed of a material that is hydrophobic and/or not hygroscopic, and the roofing tile has a density in the range of 1.6 g/cm.sup.3 to 1.9 g/cm.sup.3 after the hardening. The roofing tile has a thickness of 5 mm to 9 mm, preferably 7 mm to 8 mm, in the highly loaded regions, preferably in the region of the watercourse.

Disclosed are dry methods of making a composite concrete material using a water-free precursor composition. Also disclosed herein are composite concrete materials.