Lightweight synthetic particle and method of manufacturing same

Abstract

Lightweight synthetic particles that replace traditional aggregates and methods of producing the same are disclosed herein.

1 . A light weight synthetic particle consisting of a core and wetting agent where the wetting agent is a water soluble, glass forming silicate salt, where a coating of the water-soluble wetting agent is substantially applied on the surface of the core and is then essentially dried. 
     
     
         2 . The light weight synthetic particle of  claim 1  where the core is at least one material taken from the group consisting of: EPS, perlite, vermiculite, bamboo, wood chips, wood pellet fragments, rice, coffee, cocoa husks, cocoa shells, husks from wheat, shells from wheat, husks from other plants, shells from other plants, seeds, cores, stalks, plant strands, plant fibers, sea shell fragments, paper fragments paper pellets, rubber fragments and rubber particles. 
     
     
         3 . (canceled) 
     
     
         4 . The light weight synthetic particle of  claim 1  where the water soluble, glass forming silicate salt is potassium silicate. 
     
     
         5 . The light weight synthetic particle of  claim 1  wherein said water soluble, glass forming silicate salt is sodium silicate. 
     
     
         6 . The light weight synthetic particle of  claim 1  further consisting of a coating agent applied on the surface of the wetting agent. 
     
     
         7 . The light weight synthetic particle of  claim 6  where the coating agent is at least one taken from the group consisting of: acrylic, bio-char, cementitious materials, pozzolanic materials, Portland cement, masonry cement, plastic, high-early slag cement, fly ash, silica fume, metakolin, pigments, iron oxide, gypsum, fibers, PVA fibers, nylon fibers, steel fibers, fiberglass and organic materials. 
     
     
         8 . A light weight synthetic particle of  claim 1 , where the dry coating of the water-soluble wetting agent on the core is performed under ambient pressure and temperature.