# US 2019/0315658 A1 · High-performance concrete mix for precast wythes > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0315658 A1 - Document ID: US20190315658A1 - Status: Published application - Kind: A1 - Application number: 16/383,058 - Filed: 2019-04-12 - Published: 2019-10-17 - Earliest claimed: 2018-04-12 - Assignees: UT-Battelle, LLC; University of Tennessee Research Foundation - Applicants: Ut-Battelle, LLC; University of Tennessee at Chattanooga - Inventors: Diana E. Hun; Catherine H. Mattus; Mbakisya Onyango; Joseph Owino; Alex Brent Rollins - Web page: https://patentgrep.com/patent/US20190315658A1 ## CPC - C04B 28/04: Portland cements - C04B 28/065: {Calcium aluminosulfate cements, e.g. cements hydrating into ettringite} - C04B 14/106: {Kaolin} - C04B 14/42: Glass - C04B 18/027: {Lightweight materials} - E04C 2/044: {of concrete (E04C2/049 takes precedence)} - C04B 2103/22: Set retarders - C04B 2103/302: {Water reducers} - C04B 2111/40: Porous or lightweight materials - C04B 2201/20: for the density - C04B 2201/50: for the mechanical strength - 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 - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract A lightweight concrete composition includes the concrete components, per yd3 of concrete: Type III Portland cement (lb/yd3) 200-900; metakaolin (lb/yd3) 100-520; calcium sulfoaluminate cement (CSA) (lb/yd3) 40-840; 3/8″ lightweight expanded slate aggregate (lb/yd3) 70-550; lightweight fine expanded slate aggregate (lb/yd3) 300-550; expanded glass fine aggregate (0.5-1 mm) 35-90 (lb/yd3); expanded glass fine aggregate (1-2 mm) 35-90 (lb/yd3); water (lb/yd3) 300-350; CSA cement set retarder 0.015 to 0.06 oz per lb of CSA cement; high-range water-reducing admixture 120-1000 (fl. oz/yd3); hydration controlling admixture 0-80 (fl. oz/yd3); reinforcing non-metallic lightweight fibers <1.5″ in length 0-8 (lb/yd3); wherein the concrete has a flexural strength of at least 600 psi at 12 hours, a density of 95 to 110 lb/ft3, and a compressive strength at 28 days of at least 7,000 psi. A lightweight concrete wythe and method of making a lightweight concrete wythe are also disclosed. ## Claims ### Claim 1 A lightweight concrete composition, comprising the concrete components, per yd3 of concrete: type III Portland cement (lb/yd3) 200-900 metakaolin (lb/yd3) 100-520 calcium sulfoaluminate cement (CSA) (lb/yd3) 40-840 ⅜″ lightweight expanded slate aggregate (lb/yd3) 70-550 lightweight fine expanded slate aggregate (lb/yd3) 300-550 expanded glass fine aggregate 35-90 0.02 to 0.04″ (0.5-1 mm) (lb/yd3) expanded glass fine aggregate 35-90 0.04 to 0.08″ (1-2 mm) (lb/yd3) water (lb/yd3) 300-350 CSA cement set retarder 0.015 to 0.06 oz per lb of CSA cement high-range water-reducing 120-1000 admixture (fl. oz/yd3) hydration controlling admixture (fl. oz/yd3) 0-80 reinforcing non-metallic lightweight 0-8 fibers < 1.5″ in length (lb/yd3) wherein the concrete has a flexural strength of at least 600 psi at 12 hours, a density of 95 to 110 lb/ft3, and a compressive strength at 28 days of at least 7,000 psi. ### Claim 2 (depends on 1) The concrete composition of claim 1, consisting essentially of the concrete components. ### Claim 3 (depends on 1) The concrete composition of claim 1, consisting of the concrete components. ### Claim 4 (depends on 1) The concrete of claim 1, wherein: type III Portland cement (lb/yd3) 800 metakaolin (lb/yd3) 200 calcium sulfoaluminate cement (lb/yd3) 40 ⅜″ lightweight expanded slate aggregate(lb/yd3) 485 lightweight fine expanded slate aggregate (lb/yd3) 545 expanded glass fine aggregate 35 0.02 to 0.04″ (0.5-1 mm) (lb/yd3) expanded glass fine aggregate 35 0.04 to 0.08″ (1-2 mm) (lb/yd3) water (lb/yd3) 300 CSA cement set retarder 0.015 to 0.06 oz per lb of CSA cement high-range water-reducing 225.4 admixture (fl. oz/yd3) hydration controlling admixture (fl. oz/yd3) 32 reinforcing non-metallic lightweight 4.1 fibers < 1.5″ in length (lb/yd3) ### Claim 5 (depends on 1) The concrete of claim 1, wherein the concrete has a compressive strength at 28 days of from 7,000 to 10,000 psi. ### Claim 6 A lightweight concrete wythe, comprising the concrete components, per yd3 of concrete: type III Portland cement (lb/yd3) 200-900 metakaolin (lb/yd3) 100-520 calcium sulfoaluminate cement (lb/yd3) 40-840 ⅜″ lightweight expanded slate aggregate (lb/yd3) 70-550 lightweight fine expanded slate aggregate (lb/yd3) 300-550 expanded glass fine aggregate 35-90 0.02 to 0.04″ (0.5-1 mm) (lb/yd3) expanded glass fine aggregate 35-90 0.04 to 0.08″ (1-2 mm) (lb/yd3) water (lb/yd3) 300-350 CSA cement set retarder 0.015 to 0.06 oz per lb of CSA cement high-range water-reducing 120-1000 admixture (fl. oz/yd3) hydration controlling admixture (fl. oz/yd3) 0-80 non-metallic lightweight 0-8 fibers < 1.5″ in length (lb/yd3) wherein the wythe has a flexural strength of at least 600 psi at 12 hours, a density of 95 to 110 lb/ft3, and a compressive strength at 28 days of at least 7,000 psi. ### Claim 7 (depends on 6) The concrete wythe of claim 6, wherein the wythe has a thickness of less than 2″. ### Claim 8 (depends on 6) The concrete wythe of claim 6, wherein the wythe has a thickness of no more than 1.5″. ### Claim 9 (depends on 6) The concrete wythe of claim 6, wherein the wythe consists essentially of the concrete components. ### Claim 10 (depends on 6) The concrete wythe of claim 6, wherein the wythe consists of the concrete components. ### Claim 11 (depends on 6) The concrete wythe of claim 6, wherein the concrete wythe has a compressive strength at 28 days of from 7,000 to 10,000 psi ### Claim 12 A method of making a lightweight concrete wythe, comprising the steps of: providing concrete components comprising, per yd3 of concrete: type III Portland cement (lb/yd3) 200-900 metakaolin (lb/yd3) 100-520 calcium sulfoaluminate cement (lb/yd3) 40-840 ⅜″ lightweight expanded slate aggregate (lb/yd3) 70-550 lightweight fine expanded slate aggregate (lb/yd3) 300-550 expanded glass fine aggregate 35-90 0.02 to 0.04″ (0.5-1 mm) (lb/yd3) expanded glass aggregate 35-90 0.04 to 0.08″ (1-2 mm) (lb/yd3) water (lb/yd3) 300-350 CSA cement set retarder 0.015 to 0.06 oz per lb of CSA cement high-range water-reducing 120-1000 admixture (fl. oz/yd3) hydration controlling admixture (fl. oz/yd3) 0-80 reinforcing non-metallic lightweight 0-8 fibers < 1.5″ in length (lb/yd3) placing the concrete into a mold; allowing the concrete to cure over a period of at least 12 hours to create a wythe; removing the wythe from the mold; wherein the wythe has a flexural strength of at least 600 psi at 12 hours, a density of 95 to 110 lb/ft3, and a compressive strength at 28 days of at least 7,000 psi. ### Claim 13 (depends on 12) The method of claim 12, wherein the wythe is less than 2″ in thickness. ### Claim 14 (depends on 12) The method of claim 12, wherein the wythe has a thickness of no more than 1.5″. ### Claim 15 (depends on 12) The method of claim 12, wherein the concrete has a compressive strength at 28 days of from 7,000 to 10,000 psi.