Field of the invention
The present invention relates to a light weight concrete normally produced from organic compounds and aqueous alkali metal silicates.
Background of the invention
The Lightweight concrete is not a new concept and normally produced from organic compounds and aqueous alkali metal silicates etc. There are inventions reported where Light Weight Materials have been prepared by using ceramic microspheres and natural clays like vermiculite and perilite.
In the field of preparation and use of lightweight cementitious materials, such as so-called lightweight concrete, the materials that have been available to the trades up until now have generally required the addition of various constituents to achieve a strong but lightweight concrete mass that has a high homogeneity of constituents and which is uniformly bonded throughout the mass.
Prior-art
U.S. Pat. Nos. 3,214,393, 3,257,338 and 3,272,765 disclose concrete mixtures that contain cement, a primary aggregate, particulate expanded styrene polymer, and a homogenizing and/or a surface-active additive.
U.S. Pat. No. 3,021,291 discloses a method of making cellular concrete by incorporating into the concrete mixture, prior to casting the mixture, a polymeric material that will expand under the influence of heat during curing. The shape and size of the polymeric particles is not critical.
U.S. Pat. No. 5,580,378 discloses a lightweight cementitious product made up of an aqueous cementitious mixture that can include fly ash, Portland cement, sand, lime and, as a weight saving component, micronized polystyrene particles having particle sizes in the range of 50 to 2000 \m and a density of about 1 lb/ft 3 . The mixture can be poured into molded products such as foundation walls, roof tiles, bricks and the like. The product can also be used as a mason's mortar, a plaster, a stucco or a texture.

JP 9 071 449 discloses a lightweight concrete that includes Portland cement and a lightweight aggregate such as foamed polystyrene, perlite or vermiculite as a part or all parts of the aggregate. The foamed polystyrene has a granule diameter of 0.1-10 mm and a specific gravity of 0.01-0.08.
U.S. Pat. Nos. 5,580,378, 5,622,556, and 5,725,652 disclose lightweight cementitious products made up of an aqueous cementitious mixture that includes cement and expanded shale, clay, slate, fly ash, and/or lime, and a weight saving component, which is micronized polystyrene particles having particle sizes in the range of 50 to 2000 ^m, and characterized by having water contents in the range of from about 0.5% to 50% v/v.
U.S. Pat. No. 4,265,964 discloses lightweight compositions for structural units such as wallboard panels and the like, which contain low density expandable thermoplastic granules; a cementitious base material, such as, gypsum; a surfactant; an additive which acts as a frothing agent to incorporate an appropriate amount of air into the mixture; a film forming component; and a starch. The expandable thermoplastic granules are expanded as fully as possible.
WO 98 02 397 discloses lightweight- concrete roofing tiles made by molding a hydraulic binder composition containing synthetic resin foams as the aggregate and having a specific gravity of about 1.6 to 2.
WO 00/61519 discloses a lightweight concrete that includes a blend of from around 40% to 99% of organic polymeric material and from 1% to around 60% of an air entraining agent. The blend is used for preparing lightweight concrete that uses polystyrene aggregate. The blend is required to disperse the polystyrene aggregate and to IMprove the bond between the polystyrene aggregate and surrounding cementitious binder.
WO 01/66485 discloses a lightweight cementitious mixture containing by volume: 5 to 80% cement, 10 to 65% expanded polystyrene particles; 10 to 90% expanded mineral particles; and water sufficient to make a paste with a substantially even distribution of expanded polystyrene after proper mixing.
U.S. Pat. No. 6,851,235 discloses a building block that includes a mixture of water, cement, and expanded polystyrene (EPS) foam beads that have a diameter from 3.18 mm (V» inch) to

9.53 mm (% inch) in the proportions of from 68 to 95 liters (18 to 25 gallons) water; from 150 to 190 kg (325 to 425 lb) cement; and from 850 to 1400 liters (30 to 50 cubic feet) Prepuff beads.
U.S. Pat. No. 5,913,791 discloses a building block that has a cement-based attachment layer on one or both exterior surfaces of the block that receives and holds a penetrating fastener such as a nail, screw, staple, or the like. One cement-based layer contains water, cement, and expanded polystyrene foam beads in first proportions and a second exterior surface contains water, cement, and expanded polystyrene foam beads in second proportions different than the first proportions.
Generally, the prior art recognizes the utility of using expanded polymers, in some form, in concrete compositions, to reduce the overall weight of the compositions. The expanded polymers are primarily added to take up space and create voids in the concrete and the amount of "air space" in the expanded polymer is typically maximized to achieve this objective. Generally, the prior art assumes that expanded polymer particles will lower the strength and/or structural integrity of lightweight concrete compositions. Further, concrete articles made from prior art lightweight concrete compositions have at best inconsistent physical properties, such as Young's modulus, thermal conductivity, and compressive strength, and typically demonstrate less than desirable physical properties.
Therefore, there is a need in the art for lightweight concrete compositions that provide lightweight concrete articles having predictable and desirable physical properties that overcome the above-described problems.
Object of the invention
The object of this invention is to produce Light Weight Concrete and Formed Mortar which
can be used as cost effective hydrophobic substrate and also provide Thermal Insulation.
These Light Weight Materials can be used for filling the spaces for e.g. bathroom and the most
important thing is this mortar in concrete reduces the weight of roof and wall and contribute
positive concept environmentally freindly Green Concrete.The other highlight of this mvention
is to use inexpensive materials and some of the industrial waste which we have successfully
accomplished.

Summary of the invention
A light weight concrete plaster comprising mineral slag 20 to 65%,sodium bentonite 5 to 25%,gypsum 10 to 43%,marble powder 10 to 65%,china clay powder 5 to 30%,metakolin 5 to 30%,zeolite 20 to 55%,quartz sand 5 to 18%,foamed additive 5 to 16%,talc 5 to 8%,celite 2 to 5%,cellulose 0.5 to 5% and necessary amount of water .wherein ingredients are mixed in a mixer to get a homogeneous solution hereinafter called as concrete or mortar plaster.
Statement of the invention
Light Weight Concrete are also called formed Concrete is a type of porous concrete which we convert into complete hydrophobic material. These types of concrete have several advantages besides reducing the weight from the structure and the Thermal Insulation and Cost Effective. While perlite and vermiculite concrete are very conmionly used but they are very porous and profusely observe water, moreover they are soft and therefore not trafficable so it is recommended that tiles are laid over them which make this material expensive. According to an embodiment of the invention, a process for preparing Light weight concrete plaster comprises the following steps:
a) Taking 20 to 65% w/v of mmeral slag in an open vessel fitted with a mixer,
b) Adding 5 to 25% w/v of sodium bentonite,
c) Adding 10 to 43% w/v of gypsum,
d) Adding 10 to 65% w/v of marble powder,
e) Adding 5 to 30% w/v of china clay powder,
f) Adding5to30%w/vofmetakoalm,
g) Adding 20 to 55% w/v of zeolite,
h) Adding 5 to 18% w/v of quartz sand,
i) Stirring the said composition till the homogeneous composition is formed, j) Adding 5 to 16% w/v of foamed additive,
k) Stirring the said composition for 20-25 minutes to get a homogeneous solution of Light weight concrete plaster.

According to another embodiment of the invention, a process for preparing light weight concrete plaster further comprises adding to the said homogeneous solution 5 to 8% w/v of talc,2 to 5% w/v of celite.O.S to 5% w/v of cellulose and the desired amount of water.stirring for 30 minutes at normal R.P.M. to get a homogeneous solution of plaster of light weight concrete hereinafter called as concrete or mortar plaster.
According to another embodiment of the invention, the said mineral slag is vermiculite.
According to another embodiment of the invention, a light weight concrete plaster comprises mineral slag 20 to 65%,sodium bentonite 5 to 25%,gypsum 10 to 43%,marble powder 10 to 65%,china clay powder 5 to 30%,metakolin 5 to 30%,zeolite 20 to 55%,quartz sand 5 to 18%,foamed additive ,wherein ingredients are mixed in a mixer to get a homogeneous solution hereinafter called as concrete or mortar plaster.
According to another embodiment of the invention,a light weight concrete plaster comprises mineral slag 20 to 65%,sodium bentonite 5 to 25%,gypsum 10 to 43%,marble powder 10 to 65%,china clay powder 5 to 30%,metakolin 5 to 30%,zeolite 20 to 55%,quartz sand 5 to 18%,foamed additive 5 to 16%,talc 5 to 8%,ceUte 2 to 5%,ceUulose 0.5 to 5% and necessary amount of water ,wherein ingredients are mixed in a mixer to get a homogeneous solution hereinafter called as concrete or mortar plaster.
Detailed Description of the invention
A waterproofed Light Weight Concrete can be produced from Fly Ash, Slag from Fumess of boilers and also using vermiculite, perilite with this novel process.
Green concrete or lightweight concrete or brick mortar is the necessity and helps in arresting global heating. Let us concentrate on some of the major factors contributing to this state of affairs related to construction industry. Every responsible citizen would continue in adopting environmental objectives. The following table will show the energy demand and emissions generated emitted in production of 1 kg of cement.


The different type of construction materials are
- Fluid Screeds
- Cementitious Screeds
- Standard Mortars
- Lightweight concrete from Lightweight Aggregates
- Aerated Lightweight concretes/mortar
- Void Fillers
Concrete made from good mortar in fast mixers with a foam. Lightweight concrete and normal concrete:
- Main difference is in gross density:
- Normal concrete : > 2.000 kg/m
- Lightweight concrete: 400-approx. 1.600 kg/m'
Fields of Application
- Partition walls
- Frost resistant and insulating equalizmg layers on wall and roof elements, precast
elements from home building.
- Sub soils for industrial buildings, sport centres, agricultural bams
- Masonry mortar and blocks
- Sub concrete and supporting layers in road construction and underground engineering
- Filling of old sewage systems, mine ducts, trenches of all kinds swimming pools

- Insulation layers underneath buildings
- Void filling in building construction in general
Flat roof to reduce the weight and provide thermal insulation.

Advantages and Disadvantages Advantages:
- less weight
- cost effectiveness
- insulation properties
- frost-resistance
Disadvantages
- High porosity resulting in reduced strength
- Limited pumpability on long distances
The applicant has overcome both these disadvantages.
The green building program has identified a set of considerations that should be taken into account when choosing building materials.
By-Product
Unused or waste material from one manufacturing or energy-producing process that can be used in another manufacturing or energy-producing process.
Agricutural by-product: Unused or waste material from farming operations, several of which can be used in building products. E.g. strawboard panels, soybean laminates, etc.
Industrial by-product: Unused or waste material from power plants or manufacturing operations, several of which can be used in building products, e.g. flyash concrete, synthetic gypsum, fumes slag etc..
Lightweight concrete has been tried and made using different product for example Perilite concrete roof deck insulation is an ideal base for built-up and single-ply roofing systems. It has superior wind and fire resistance over other roof insulation materials and with the addition of polystryrene insulation board sandwiched in the perlite concrete, high thermal resistance values, are economically achieved.

In brief lightweight concrete or mortar is a type of pores material, for example
1. Aerated concrete
2. Lightweight concrete
3. Porous concrete
Even in the walls lightweight mortar is better.
Standard mortar contains aggregates like natural sand or crushed limestone fines. The outcome of this is a heavy and firm mortar featuring a high dry density and poor thermal insulatmg properties. On the contrary, lightweight mortar utilizing expanded clay is characterized by a low dry density and good thermal insulating properties. Compared vdth standard mortar, the thermal insulation of the entire wall improves up to 30 percent.
The other lightweight material produced from other clay materials.
Foamed concrete/ lightweight concrete
Foamed Cocnrete:
Foamed concrete is a highly workable, low-density material which can incorporate up to 50% entrained air. It is generally self-leveling, self-compacting and may be pumped. Foamed concrete is ideal for filling redundant voids such as disused fuel tanks, sewer systems, pipelines, and culverts - particularly where access is difficult. It is a recognised medium for the reinstatement of temporary road trenches. Good thermal insulation properties make foamed concrete also suitable for sub-screeds and filling under-floor voids.
Lightweight Aggregate Concrete
Lightweight aggregate concrete can be produced using a variety of lightweight aggregates. Lightweight aggregates originate from either:
• Natural materials like volcanic pumice
• The thermal treatment of natural raw materials like clay, slate or shale i.e. Leca
• Manufacture from industrial by-products such as fly ash, i.e. Lytag
• Processing of industrial by-products like FB A or slag

Protekta KR-2 : can be used for precast and wet concrete:
Protekta Emulsion KR2 is a solvent-free aqueous silane siloxane ester emulsion. It is designed to be used as an admixture during the in-plant manufacture of low slump cement containing blocks, paving products, and as an admixture in RMC, freshly made concrete and mortar for plaster. Protekta Emulsion KR2 impregnates into pores and capillaries to form a hydrophobic zone and gets permanently bonded to the substrate and cannot be washed out.
Mechanism
The water repellent material lines the pores of the masonry (figure 1) and on curing, the water repellent causes a modification of the interfacial tension between the wall of the pore and the water.
In an untreated pore the 'contact angle' is less than 90° and the interfacial tension causes the water to rise. Following application of the water repellent the interfacial tension changes. The
contact angle becomes greater than 90o and the resulting tension now cause a slight downward 'pressure' so preventing the future rise of water.
PROCESS: (LIGHT WEIGHT CONCRETE) EXAMPLE-1
Take a 50 Itr open vessel fitted with a mixer. Add 20 to 60 % of mineral slag / Vermaculite 5 to 20 % of Sodium Bentonite, 10 to 40 % of gypsum, 10 to 60 % Marble Powder, 5 to 25% China Clay Powder, 5 to 25% Metakoalin, 25 to 50 % of Zeolite 5 to 15% of Quartz Sand and 5 to 10% of Foamed Additive and stir for 15 to 20 minutes. The final product is known as Protekta Light weight Concrete hereafter called as Product A. This can be mixed with the necessary amount of water and used as concrete or mortar plaster.

EXAMPLE - 2
Take a 50 Itr open vessel fitted with a mixer. Add 25 to 65 % of mineral slag / Vermaculite 10 to 25 % of Sodium Bentonite, 12 to 43 % of gypsum, 11 to 65 % Marble Powder, 15 to 30% China Clay Powder , 10 to 30% Metakoalin, 20to 55 % of Zeolite 8 to 18% of Quartz Sand and 9 to 16% of Foamed Additive and stir for 20 to 25 minutes. Add Talc 5 to 8 %, Celite 2 to 5 %, Cellulose 0.5 to 5 %. The final product is known as Protekta Light weight Concrete hereafter called as Product A. This can be mixed with the necessary amount of water and used as concrete or mortar plaster. USES
• Roof and floor
• Used for the manufacture of precast blocks and panels for curtain and partition walls, slabs, false ceilings, thermal insulation, soundproofing screeds in multrlevel residential and commercial buildings.
PROPERTIES
• Light weight
• Cost effective
• Provides Insulation properties
• U.V & water resistance.
• Sound Proof
• Provides Waterproofing
DESCRIPTION
Protekta Lightweight Concrete is a self-leveling light weight material that does not require compaction. It is a mortar based on clay and mineral fill material that is normally made to a low density by air entraining or foaming.

TECHNICAL DATA
Appearance ; Grey Powder
Density : 625 kg/m3
Reduction in water absorption by mass : 92%
Compressive strength : 3 Mpa
pH : 10-11

We claim;
1. A process for preparing Light weight concrete plaster comprising the following steps:
1) taking 20 to 65% w/v of mineral slag in an open vessel fitted with a mixer, m) adding 5 to 25% w/v of sodium bentonite, n) adding 10 to 43% w/v of gypsum, o) adding 10 to 65% w/v of marble powder, p) adding 5 to 30% w/v of china clay powder, q) adding5to30%w/v of metakoalin, r) adding 20 to 55% w/v of zeolite, s) adding 5 to 18% w/v of quartz sand,
t) stirring the said composition till the homogeneous composition is formed, u) adding 5 to 16% w/v of foamed additive,
v) stirring the said composition for 20-25 minutes to get a homogeneous solution of Light weight concrete plaster.
2. A process for preparing light weight concrete plaster as claimed in claim 1, wherein to
the said homogeneous solution is added 5 to 8% w/v of talc,2 to 5% w/v of celite,0.5 to
5% w/v of cellulose and the desired amount of water,
Stirring for 30 minutes at normal R.P.M. to get a homogeneous solution of plaster of light weight concrete hereinafter called as concrete or mortar plaster.
3. A process for preparing light weight concrete plaster as claimed in any of the preceding claims, wherein the said mineral slag is vermiculite.
4. A light weight concrete plaster as claimed in claim 1 comprising mineral slag 20 to 65%,sodium bentonite 5 to 25%,gypsum 10 to 43%,marble powder 10 to 65%,china clay powder 5 to 30%,metakolin 5 to 30%,zeolite 20 to 55%,quartz sand 5 to 18%,foamed additive ,wherein ingredients are mixed in a mixer to get a homogeneous solution hereinafter called as concrete or mortar plaster.

5. A light weight concrete plaster as claimed in claim 1 comprising mineral slag 20 to
65%,sodium bentonite 5 to 25%,gypsum 10 to 43%,marble powder 10 to 65%,china
clay powder 5 to 30%,metakolin 5 to 30%,zeolite 20 to 55%,quartz sand 5 to
18%,foamed additive 5 to 16%,talc 5 to 8%,celite 2 to 5%,cellulose 0.5 to 5% and
necessary amount of water .wherein ingredients are mixed in a mixer to get a
homogeneous solution hereinafter called as concrete or mortar plaster.
6. A process for preparing light weight concrete plaster substantially as hereinbefore
described with reference to the accompanying examples.
7. A light weight concrete plaster substantially as hereinbefore described with
reference to the accompanymg examples.