Abstract: A method of preparing a light weight concrete composition using expanded polymer particles that includes a) replacing from about 10 to about 50 volume percent of the coarse aggregate in the concrete composition with prepuff particles; and b) preparing the concrete composition by combining ingredients comprising 3-40 volume percent cement, 1-50 volume percent fine aggregate, 0-40 volume percent coarse aggregate, 10-22 volume percent water, and 5-40 volume percent of prepuff particles. The prepuff particles have an average particle diameter of from 0.2 mm to 5 mm, a bulk density of from 0.02 g/cc to 0.56 g/cc, an aspect ratio of from 1 to 3. The concrete composition has a density of from about 90 to about 135 lb./ft3 and after it is set for 28 days, has a compressive strength of at least 1800 psi as tested according to ASTM C39.

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 method of preparing a light weight concrete composition using expanded polymer particles that includes a) replacing from about 10 to about 50 volume percent of the coarse aggregate in the concrete composition with prepuff particles; and b) preparing the concrete composition by combining ingredients comprising 3-40 volume percent cement, 1-50 volume percent fine aggregate, 0-40 volume percent coarse aggregate, 10-22 volume percent water, and 5-40 volume percent of prepuff particles. The prepuff particles have an average particle diameter of from 0.2 mm to 5 mm, a bulk density of from 0.02 g/cc to 0.56 g/cc, an aspect ratio of from 1 to 3. The concrete composition has a density of from about 90 to about 135 lb./ft3 and after it is set for 28 days, has a compressive strength of at least 1800 psi as tested according to ASTM C39.

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.