Lightweight synthetic particles that replace traditional aggregates and methods of producing the same are disclosed herein.

Lightweight synthetic particles that replace traditional aggregates and methods of producing the same are disclosed herein.

The present disclosure concerns expandable silica particles having a coating comprising talc powder and kaolin powder provided on the outer surface of the expandable silica particle and expandable and expanded silica particles comprising silica fume and/or ultrafine quartz silica sand beneath the surface of the particles. Methods for producing expandable and expanded silica particles are disclosed, including a method using a vibration plate and a furnace having a vibration plate for carrying out that method. The expanded silica particles have high compressive strength, substantially uniform cell size and distribution, low water absorption, and low porosity on the outer surface. They are useful as a filler in matrix materials, like concrete or epoxy, as insulation material with various binder materials, and as water filtration medium.

The present disclosure concerns expandable silica particles having a coating comprising talc powder and kaolin powder provided on the outer surface of the expandable silica particle and expandable and expanded silica particles comprising silica fume and/or ultrafine quartz silica sand beneath the surface of the particles. Methods for producing expandable and expanded silica particles are disclosed, including a method using a vibration plate and a furnace having a vibration plate for carrying out that method. The expanded silica particles have high compressive strength, substantially uniform cell size and distribution, low water absorption, and low porosity on the outer surface. They are useful as a filler in matrix materials, like concrete or epoxy, as insulation material with various binder materials, and as water filtration medium.

The present invention relates to an admixture composition for the production of lightweight concretes containing polystyrene beads, which comprises a mixture of organic and inorganic substances which consists of the reaction products of polyurethane resin, tetraethyl orthosilicate, a glycol compound, an aromatic vinyl compound containing an unsaturated double bond, preferably styrene, and an inorganic silicate compound and preferably comprises the following components: glycol copolymer type compounds, in an amount of 15-10 w/w %, glycol polymer-silica type compounds, in an amount of 45-50 w/w %, polyurethane-based resin, in an amount of 13-22 w/w % polystyrene in an amount of 2-3% w/w %, and foam glass beads in an amount of 25-15 w/w %, and a) for the production of a liquid product, based on the total mass of the above composition, organic solvents in an amount of 15-20 w/w %, and water in an amount of 10-5 w/w %; or b) for the production of a solid preparation, based on the total mass of the above composition, polyvinyl acetate or polyvinyl alcohol in an amount of 10-5 w/w %; aluminium hydroxide in an amount of 2-5 w/w %, and calcined limestone powder in an amount of 8-10 w/w %. The invention also relates to the production and use of the above admixture composition.

The present invention relates to an admixture composition for the production of lightweight concretes containing polystyrene beads, which comprises a mixture of organic and inorganic substances which consists of the reaction products of polyurethane resin, tetraethyl orthosilicate, a glycol compound, an aromatic vinyl compound containing an unsaturated double bond, preferably styrene, and an inorganic silicate compound and preferably comprises the following components: glycol copolymer type compounds, in an amount of 15-10 w/w %, glycol polymer-silica type compounds, in an amount of 45-50 w/w %, polyurethane-based resin, in an amount of 13-22 w/w % polystyrene in an amount of 2-3% w/w %, and foam glass beads in an amount of 25-15 w/w %, and a) for the production of a liquid product, based on the total mass of the above composition, organic solvents in an amount of 15-20 w/w %, and water in an amount of 10-5 w/w %; or b) for the production of a solid preparation, based on the total mass of the above composition, polyvinyl acetate or polyvinyl alcohol in an amount of 10-5 w/w %; aluminium hydroxide in an amount of 2-5 w/w %, and calcined limestone powder in an amount of 8-10 w/w %. The invention also relates to the production and use of the above admixture composition.

An insulating material, in particular a permeable fire-proof insulating material comprising water glass and polystyrene, consisting of a hardening mixture which contains 1 to 32.4 wt % of expanded polystyrene, 57.5 to 96.0 wt % of aqueous sodium silicate solution, 2 to 6 wt % of aluminium hydroxide, 0.8 to 2.6 wt % water glass hardener and 0.1 to 0.5 wt % of water glass stabilizer, while the surface of the expanded polystyrene is provided with carbon black, the carbon black making up 0.1 to 1 wt % of total weight. A method for the production of insulating material, in particular a method for the production of permeable fire-proof insulating material comprising water glass and polystyrene, according to which firstly the polystyrene beads are mixed with an aqueous solution of carbon black so as to coat their entire surface, then is added to the aqueous sodium silicate solution aluminium hydroxide and the whole is mixed so as to form an insulating mixture, and then a water glass stabilizer is added to the aqueous sodium silicate solution, and then to this solution is mixed water glass hardener, with this solution being further stirred for 1 to 10 minutes to form a binder solution, and the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is then poured into the application site.

A method for production of coated mineral grit for the manufacture of coating elements with a bituminous support, or with a support comprising a vinyl or acrylic adhesive, for roofing of buildings, the method includes: adding rough mineral grit to a mixer together with a first treatment mixture; mixing the rough mineral grit and the first treatment mixture until a coated mineral grit is obtained; heating the coated mineral grit to a predetermined firing temperature (Tc); and after heating the coated mineral grit, cooling the coated mineral grit to a predetermined intermediate cooling temperature (Tri). The first treatment mixture comprises: water; at least one pigment; at least one selected from the group consisting of sodium silicate and potassium silicate; kaolin; and at least one selected from the group consisting of an organo-siloxane and an organo-silane.

A method for production of coated mineral grit for the manufacture of coating elements with a bituminous support, or with a support comprising a vinyl or acrylic adhesive, for roofing of buildings, the method includes: adding rough mineral grit to a mixer together with a first treatment mixture; mixing the rough mineral grit and the first treatment mixture until a coated mineral grit is obtained; heating the coated mineral grit to a predetermined firing temperature (Tc); and after heating the coated mineral grit, cooling the coated mineral grit to a predetermined intermediate cooling temperature (Tri). The first treatment mixture comprises: water; at least one pigment; at least one selected from the group consisting of sodium silicate and potassium silicate; kaolin; and at least one selected from the group consisting of an organo-siloxane and an organo-silane.

The present disclosure relates to roofing granule having a base granule with at least one layer on the base granule that includes hollow glass spheres embedded in a ceramic matrix and a roofing article having a substrate and a plurality of any embodiment of roofing granules described above. The disclosure additionally relates to a roofing granule precursor mixture containing base granules, an aluminum silicate, an alkali metal silicate, and hollow glass spheres. The disclosure also relates to a method of making roofing granules including providing base granules; applying a coating containing hollow glass spheres, an aluminum silicate, an alkali metal silicate to the base granules; and heating the coated granules to a temperature between about 550° F. and about 1000° F.