Low density particles for use in concrete and other mixtures

A lightweight composite composition comprising:

• a plurality of lightweight particles comprising a volume of at least about 10% of a total volume of the lightweight composite composition, the plurality of lightweight particles comprising an average bulk density within a range from about 0.001 grams per cubic centimeter to about 1.5 grams per cubic centimeter and an average particle size within a range from about 0.01 microns to about 90 millimeters, wherein the plurality of lightweight particles comprise a non-volcanic ash material comprising one or more of acrylic, acrylonitrile based copolymer, graphene, a ceramic material, an alumina material, synthetic glass microspheres, polymer microspheres, ceramic microspheres, foamed rubber, crumb rubber, an EPDM material, polyamide, polyolefin, polystyrene, polyvinyl chloride, PMMA, PMU, melamine, urea formaldehyde, ABS, LDPE, HDPE or PVDC;
• one or more of an additive or an admixture comprising a volume up to about 20% of the total volume of the lightweight composite composition, the additive or admixture comprising one or more of acrylic fiber, carbon fiber, graphene, basaltic fiber, glass fiber, soda lime glass, calcium carbonate, silicates, clay, alumina, calcium stearate, magnesium stearate, zinc stearate, coloring agents, corrosion inhibitors, shrinkage reducers, fly ash, foaming agents and or defoamers, air entrainers, fire retardants, fungicide, mildewcide, biocide, rodenticide, insecticide, high-range water reducer, mid-range water reducer, plasticizer, polycarboxylate, wood pulp, metakaolin, polymer resin additive, vinyl acetate and ethylene based redispersible powders, set retarding and or accelerating admixtures, strength enhancing admixtures, silanes, siloxane, surfactants, coupling agents, silica fume, micro-silica, slag, calcium hydroxide, calcium sulfate, wollastonite, thixotropes and or rheology modifiers, cellulosics, fumed silicas, zinc borate or boric acid, chlorinated paraffin, antimony oxide, alumina trihydrate, or magnesium hydroxide;
• and
• a binder material in contact with the plurality of lightweight particles, and the one or more of the additive or the admixture such that the plurality of lightweight particles, and the one or more of the additive or the admixture are dispersed within the binder material and wherein the plurality of lightweight particles are in contact with the binder material such that the plurality of lightweight particles are homogenously dispersed and mixed throughout the binder material, the binder material comprising a volume within a range from about 5% to about 40% of the total volume of the lightweight composite composition, the binder material comprising one or more of a cement, pozzolan, gypsum, Portland cement, calcium aluminate, or calcium sulfoaluminate, wherein the lightweight composite composition comprises a compressive strength of at least 10 pounds/in2, and a bulk density within a range from about 15 pounds per cubic foot to about 135 pounds per cubic foot.

A lightweight composite composition comprising:

• a plurality of lightweight particles comprising a volume of at least about 10% of a total volume of the composite composition, the plurality of lightweight particles comprising an average bulk density within a range from about 0.001 grams per cubic centimeter to about 1.5 grams per cubic centimeter and an average particle size within a range from about 0.01 microns to about 90 millimeters, further comprising a binder material in contact with the plurality of lightweight particles, the binder material comprising a volume within a range from about 5% to about 40% of the total volume of the lightweight composite composition, the binder material comprising one or more of a cement, pozzolan, gypsum, Portland cement, calcium aluminate, or calcium sulfoaluminate, wherein the plurality of lightweight particles comprise a non-volcanic ash material comprising one or more of polymer pellets, polymer foam beads, crushed glass, foamed glass spheres, hollow glass microspheres, polymer microspheres, polymer capsules, polymer micro-balloons, or carbon-based pellets;
• and
• an aggregate up to about 60% of the total volume of the lightweight composite composition, the aggregate comprising one or more of recycled concrete, reclaimed material, sand, gravel, clay or crushed stone, wherein the plurality of lightweight particles and the aggregate are homogenously dispersed and mixed throughout the binder material, wherein the lightweight composite composition comprises a compressive strength of at least 10 pounds/in2, and a bulk density within a range from about 15 pounds per cubic foot to about 135 pounds per cubic foot.