# US 10,865,142 B2 · Method of making cementitious compositions > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,865,142 B2 - Document ID: US10865142B2 - Status: Granted - Kind: B2 - Application number: 16/831,785 - Filed: 2020-03-26 - Published: 2020-07-16 - Granted: 2020-12-15 - Earliest claimed: 2013-12-06 - Assignees: Construction Research & Technology GmbH - Applicants: Construction Research & Technology GmbH - Inventors: Frank Shaode Ong; Rick Paponetti; James C. Smith; Stefan Muessig - Web page: https://patentgrep.com/patent/US10865142B2 ## CPC - C04B 16/08: porous, e.g. expanded polystyrene beads {or microballoons} - C04B 14/00: Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone (expanding or defibrillating materials C04B20/00) - C04B 24/023: {Ethers} - C04B 24/10: Carbohydrates or derivatives thereof - C04B 28/02: containing hydraulic cements other than calcium sulfates - C04B 28/04: Portland cements - C04B 30/00: Compositions for artificial stone, not containing binders - C04B 2111/29: {Frost-thaw resistance} - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE ## Abstract A method of manufacturing a cementitious composition comprising: dispersing expanded polymeric microspheres into a liquid dispersion, optionally wherein the liquid dispersion comprises an aqueous dispersion; and incorporating the liquid dispersion comprising expanded polymeric microspheres into the cementitious composition; wherein the expanded polymeric microspheres are present in the liquid dispersion in an amount of about 0.1 to about 15 percent by weight, based on the total weight of the dispersion, prior to incorporation into the cementitious composition. An admixture for cementitious compositions comprising unexpanded polymeric microspheres and sodium hydroxide. ## Claims ### Claim 1 A method of manufacturing a cementitious composition comprising: dispersing expanded polymeric microspheres into an aqueous liquid to create an aqueous liquid dispersion of expanded polymeric microspheres, wherein the expanded polymeric microspheres are present in the aqueous liquid dispersion in an amount of about 0.1 to about 15 percent by weight, based on the total weight of the liquid dispersion; adding the aqueous liquid dispersion to a majority of mixing water for a cementitious composition, to which other ingredients of the cementitious composition are subsequently added, to disperse the expanded polymeric microspheres in the mixing water; and subsequently adding cement, sand, and stone to said mixing water containing the aqueous liquid dispersion of expanded polymeric microspheres to create a cementitious composition comprising the cement, the sand, the stone, and the expanded microspheres dispersed in the cementitious composition, wherein the expanded polymeric microspheres are present in the cementitious composition in an amount of from about 0.1 to about 3 percent by volume, based on the total volume of the cementitious composition, wherein said cementitious composition exhibits a Durability Factor of 65 or greater after 300 freeze-thaw cycles as tested in accordance with ASTM D666. ### Claim 2 (depends on 1) The method of claim 1, wherein the expanded polymeric microspheres are present in the aqueous liquid dispersion in an amount of about 0.3 to about 7.5 percent by weight, based on the total weight of the dispersion, prior to incorporation into the cementitious composition. ### Claim 3 (depends on 2) The method of claim 2, wherein the expanded polymeric microspheres are present in the aqueous liquid dispersion in an amount of about 0.75 to about 3 percent by weight, based on the total weight of the dispersion, prior to incorporation into the cementitious composition. ### Claim 4 (depends on 1) The method of claim 1, wherein the expanded polymeric microspheres are present in the cementitious composition in an amount of from about 0.75 percent to about 1.5 percent by volume, based on the total volume of the cementitious composition. ### Claim 5 (depends on 1) The method of claim 1, wherein the expanded polymeric microspheres are added to the cementitious composition an amount of from about 0.25 percent to about 1 percent by volume, based on the total volume of the cementitious composition. ### Claim 6 (depends on 1) The method of claim 1, wherein the majority of the mixing water comprises from about 70 to about 85 percent of the mixing water for the cementitious composition. ### Claim 7 (depends on 1) The method of claim 1, wherein said cementitious composition exhibits a Durability Factor of 75 or greater after 300 freeze-thaw cycle as tested in accordance with ASTM D666. ### Claim 8 (depends on 1) The method of claim 1, wherein said cementitious composition exhibits a Durability Factor of 85 or greater after 300 freeze-thaw cycle as tested in accordance with ASTM D666. ### Claim 9 (depends on 1) The method of claim 1, wherein said cementitious composition exhibits a Durability Factor of 95 or greater after 300 freeze-thaw cycle as tested in accordance with ASTM D666. ### Claim 10 (depends on 1) The method of claim 1, further comprising expanding unexpanded expandable polymeric microspheres prior to said dispersing expanded polymeric microspheres in the aqueous liquid dispersion. ### Claim 11 (depends on 10) The method of claim 10, wherein the step of expanding the unexpanded expandable polymeric microspheres is proximate to and/or during manufacture of the cementitious composition. ### Claim 12 (depends on 1) The method of claim 1, wherein the aqueous liquid dispersion further comprises at least one additional component. ### Claim 13 (depends on 12) The method of claim 12, wherein the at least on additional component comprises at least one of a viscosity modifier or sodium hydroxide. ### Claim 14 (depends on 13) The method of claim 13, wherein the at least on additional component comprises sodium hydroxide. ### Claim 15 (depends on 13) The method of claim 13, wherein the viscosity modifier comprises at least one of a high molecular weight polymeric solution, polyethylene glycols, or polysaccharides. ### Claim 16 (depends on 15) The method of claim 15, wherein the high molecular weight polymeric solution comprises celluloses. ### Claim 17 (depends on 15) The method of claim 15, wherein the polysaccharides comprise at least one of diutan gum or welan gum. ### Claim 18 (depends on 1) The method of claim 1, wherein the expanded polymeric microspheres have densities in the range of from about 0.01 g/cm3 to about 0.06 g/cm3. ### Claim 19 (depends on 1) The method of claim 1, wherein the unexpanded expandable polymeric microspheres have an average diameter of about 100 μm or less. ### Claim 20 (depends on 1) The method of claim 1, wherein the unexpanded expandable polymeric microspheres have a density from about 0.015 g/cm3 to about 0.025 g/cm3 and a diameter in the range of from about 20 μm to about 80 μm.