US 12,269,772 B2
Polished lightweight structural concrete and method of formation
Bart Rockett, Marlton, NJ (US)
Filed by Bart Rockett, Marlton, NJ (US)
Filed on Mar. 1, 2022, as Appl. No. 17/683,723.
Claims priority of provisional application 63/158,591, filed on Mar. 9, 2021.
Prior Publication US 2022/0289628 A1, Sep. 15, 2022
Int. Cl. C04B 18/02 (2006.01); B28B 11/08 (2006.01); B28B 11/24 (2006.01); B28B 23/00 (2006.01); C04B 7/32 (2006.01); C04B 18/20 (2006.01); C04B 22/02 (2006.01); C04B 28/06 (2006.01); C04B 41/48 (2006.01); C04B 103/44 (2006.01); C04B 111/40 (2006.01); C04B 111/00 (2006.01); C04B 111/70 (2006.01)
CPC C04B 18/027 (2013.01) [B28B 11/0845 (2013.01); B28B 11/24 (2013.01); B28B 23/0087 (2013.01); C04B 7/323 (2013.01); C04B 18/20 (2013.01); C04B 22/02 (2013.01); C04B 28/065 (2013.01); C04B 41/4884 (2013.01); C04B 2103/44 (2013.01); C04B 2111/00939 (2013.01); C04B 2111/40 (2013.01); C04B 2111/70 (2013.01); C04B 2201/20 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A method of forming a lightweight polished concrete comprising:
adding calcium sulfoaluminate (CSA) cement to an amount of water in a mixer, wherein a ratio of the water to the CSA cement is 1 quart to every 10 lbs of CSA cement;
adding a grout comprising one or more types of Portland cement to the mixer;
blending the CSA cement, the grout, and the water in the mixer for a period of time;
adding lightweight-foamed glass aggregates (FG-LWA) to the mixer after a period of time to form a mixture, wherein the ratio of the CSA cement to FG-LWA is 60/40 by weight;
pouring the mixture over a fiberglass rebar;
vibrating and screeding the poured mixture;
allowing the vibrated and screeded mixture to set to form a set mixture;
smoothing a top surface of the set mixture with a first type of blades to form a flattened surface;
hardening the flattened surface with a second type of blades, such that the flattened surface becomes reflective; and
applying a concrete densifier to the reflective flattened surface.