Abstract: A plastic may be selected for a thin web application by finite element analysis of the part including the properties, including Poission's ratio of potential polymers from which the part may be made and subjecting the computer model of the part to loads to determine the deflection of the part under a specified series of loads or when the part breaks or subjecting the part to a number of use cycles to determine when the part fails. The process is iteratively repeated for each plastic and the results are compared to select a preferred plastic for the part.

Abstract: A concrete wall forming system including interconnected mold units that include a top surface containing a first portion bond beam form, a first top ledge, a first top lip seal portion, a second top ledge, and a second top lip seal portion; a bottom surface containing a second portion bond beam form, a first bottom ledge, a first bottom lip seal portion, a second bottom ledge, and a second bottom lip seal portion; and two or more column forms extending from the top depression to the bottom depression. The first top lip seal portion and first bottom lip seal portion and second top lip seal portion and second bottom lip seal portion are adapted to form a seal between two mold units such that the bond beam form portions are combined to form a bond beam form. The system can be used to form an insulated concrete wall.

Abstract: A plastic may be selected for a thin web application by finite element analysis of the part including the properties, including Poission's ratio of potential polymers from which the part may be made and subjecting the computer model of the part to loads to determine the deflection of the part under a specified series of loads or when the part breaks or subjecting the part to a number of use cycles to determine when the part fails. The process is iteratively repeated for each plastic and the results are compared to select a preferred plastic for the part.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: Methods of controlling the durability of and/or the amount of air in concrete formulations that include combining cement, water, and optionally aggregates, admixtures and/or additives to form a cement mixture; and adding prepuff particles to the cement mixture to form a concrete formulation. The prepuff particles have an average particle diameter of from 0.2 mm to 3 mm, a bulk density of from 0.015 g/cc to 0.35 g/cc, an aspect ratio of from 1 to 3, and a smooth continuous outer surface. The cured and hardened concrete formulation typically has a relative dynamic modulus of at least 70% determined according to Procedure A of ASTM C666 (2003). The amount of air in the concrete typically increases over the amount of air in similar formulations not containing prepuff particles, as determined according to ASTM C231, based on the volume percent of prepuff. The concrete formulations can be used to make articles.

Abstract: A concrete wall forming system including a plurality of mold units for forming a wall of concrete. The mold units include a bond beam form extending into the body lengthwise, defined by a first wall, a second wall, a bond beam form bottom, a first end and a second end where the first wall and second wall extend a depth defined by a portion of the distance from the top surface to the bottom surface and where the bond beam form does not touch the first side or the second side. First and second ledges extend lengthwise along the body from the first and second sides respectively to the first and second walls respectively of the bond beam form. The bond beam form bottom extends from the first wall to the second wall. At least two column forms extend from the bond beam form bottom to a bottom surface.

Abstract: A lightweight cementitious composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 10 to 50 volume percent of sand and/or other fine aggregate, where at least a portion of the sand and/or fine aggregate has a fineness modulus of less than 2; where the sum of components used does not exceed 100 volume percent, and where after the lightweight cementitious composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The cementitious composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: Methods of controlling the durability of and/or the amount of air in concrete formulations that include combining cement, water, and optionally aggregates, admixtures and/or additives to form a cement mixture; and adding prepuff particles to the cement mixture to form a concrete formulation. The prepuff particles have an average particle diameter of from 0.2 mm to 3 mm, a bulk density of from 0.015 g/cc to 0.35 g/cc, an aspect ratio of from 1 to 3, and a smooth continuous outer surface. The cured and hardened concrete formulation typically has a relative dynamic modulus of at least 70% determined according to Procedure A of ASTM C666 (2003). The amount of air in the concrete typically increases over the amount of air in similar formulations not containing prepuff particles, as determined according to ASTM C231, based on the volume percent of prepuff. The concrete formulations can be used to make articles.

Abstract: A concrete wall forming system of mold units that include first and second panel members and a plurality of connecting members. The panel members each have a horizontal length of three to thirty feet and a vertical height of three to twenty feet. The inner sides of the panels include slots extending vertically therethrough. The connecting members are detachable and securable with respect to the panels and extend the length vertically therebetween to maintain a spatial distance for defining a molding chamber. The connecting members include flanges detachably and securably extending within the slots in the panels. A mid-section portion in the connecting members contains a plurality of pour holes spaced along its length vertically. Concrete can be poured into the molding chamber and through the pour holes and once allowed to set and harden forms an insulated concrete wall.

Abstract: Foamed plastic structures that include one or more foamed plastic bodies containing a polymer matrix that includes one or more polymers formed by polymerizing a monomer mixture that includes vinyl aromatic monomers and divinyl aromatic monomers. The structures formed can include, as non-limiting examples, pallets, containers, stackable containers, produce boxes, seafood shipping containers, geofoam blocks, and insulated concrete forms.

Abstract: A concrete wall forming system including a plurality of mold units for forming a wall of concrete. The mold units include a bond beam form extending into the body lengthwise, defined by a first wall, a second wall, a bond beam form bottom, a first end and a second end where the first wall and second wall extend a depth defined by a portion of the distance from the top surface to the bottom surface and where the bond beam form does not touch the first side or the second side. First and second ledges extend lengthwise along the body from the first and second sides respectively to the first and second walls respectively of the bond beam form. The bond beam form bottom extends from the first wall to the second wall. At least two column forms extend from the bond beam form bottom to a bottom surface.

Abstract: A concrete wall forming system including interconnected mold units that include a top surface containing a first portion bond beam form, a first top ledge, a first top lip seal portion, a second top ledge, and a second top lip seal portion; a bottom surface containing a second portion bond beam form, a first bottom ledge, a first bottom lip seal portion, a second bottom ledge, and a second bottom lip seal portion; and two or more column forms extending from the top depression to the bottom depression. The first top lip seal portion and first bottom lip seal portion and second top lip seal portion and second bottom lip seal portion are adapted to form a seal between two mold units such that the bond beam form portions are combined to form a bond beam form. The system can be used to form an insulated concrete wall.

Abstract: A lightweight cementitious composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 10 to 50 volume percent of sand and/or other fine aggregate, where at least a portion of the sand and/or fine aggregate has a fineness modulus of less than 2; where the sum of components used does not exceed 100 volume percent, and where after the lightweight cementitious composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The cementitious composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.