Lightweight aggregate unit and method of manufacture

Abstract

A water channeling system includes at least one channeling member comprising fixed aggregate forming a solid body. In this embodiment, the at least one channeling member has a first end, a second end, and a plurality of fluidly connecting interstices therewithin. In this version, the at least one channeling member is water permeable longitudinally between the first end and the second end. The at least one channeling member may be installed below ground to channel water from a first location to a second location. The channeling member may be an elongate member or a vertical panel. The channeling member may comprise comprises polymeric aggregate particles having irregular shapes. The fixed aggregate may have a density of less than or equal to about 1 lb per cubic foot. Multiple channeling members may be placed end-to-end.

1 . A water channeling system at a site, comprising:
 a first location and a second location a horizontal distance away from said first location, at said site; and   at least one elongate member comprising fixed aggregate forming a solid body, wherein the at least one elongate member has a first end, a second end, a greatest linear dimension comprising a length between said first end and said second end, and a plurality of fluidly connecting interstices therewithin, wherein the at least one elongate member is water permeable longitudinally between said first end and said second end,   wherein the at least one elongate member is installed below ground and channels water from said first location to said second location.   
   
   
       2 . The system of  claim 1  further comprising a plurality of elongate members, wherein the first end of a first one of the plurality of elongate members is adjacent the second end of a second one of the plurality of elongate members. 
   
   
       3 . The system of  claim 1  in which the at least one elongate member comprises polymeric aggregate particles bound together. 
   
   
       4 . The system of  claim 3  in which said polymeric aggregate particles comprise expanded polystyrene. 
   
   
       5 . The system of  claim 2  in which said polymeric aggregate parties are bound together by fusing. 
   
   
       6 . The system of  claim 2  in which said polymeric aggregate parties are bound together by a binder material, wherein the binder material is selected from the group consisting of a bitumen material, an acrylic material, and combinations thereof. 
   
   
       7 . The system of  claim 1  further comprising a layer of barrier material adjacent at least one of the at least one elongate member. 
   
   
       8 . The system of  claim 7  wherein said layer of barrier material is bonded to said at least one of said elongate members. 
   
   
       9 . The system of  claim 1  in which the at least one elongate member comprises a length of pipe at least partly encased lengthwise therein. 
   
   
       10 . A pipeline unit, comprising:
 a solid body having a first end, a second end, a linear dimension comprising a length between said first end and said second end, and a plurality of fluidly connecting interstices therewithin;   wherein said plurality of fluidly connecting interstices are formed by a plurality of fixed aggregate members bound together; and   a length of pipe at least partially encased within said solid body along said length.   
   
   
       11 . The pipeline unit of  claim 10 , wherein said pipe is selected from the group consisting of perforated pipe, non-perforated pipe, and combinations thereof. 
   
   
       12 . The pipeline unit of  claim 10 , wherein said elongate solid body comprises polymeric aggregate particles bound together. 
   
   
       13 . The pipeline unit of  claim 12 , wherein said polymeric aggregate particles comprise expanded polystyrene. 
   
   
       14 . The pipeline unit of  claim 12  in which said polymeric aggregate parties are bound together by fusing. 
   
   
       15 . The pipeline unit of  claim 12  in which said polymeric aggregate parties are bound together by a binder material. 
   
   
       16 . The pipeline unit of  claim 10  further comprising a layer of barrier material bonded to said elongate solid body. 
   
   
       17 . A method for producing a pipeline unit, comprising the steps of:
 supplying a length of pipe;   placing said length of pipe in a mold;   supplying polymeric aggregate particles; and   introducing said aggregate particles into said mold, and at least partially about said length of pipe.   
   
   
       18 . The method of  claim 17 , further comprising the step of heating said aggregate particles to cause them to fuse. 
   
   
       19 . The method of  claim 17 , further comprising the steps of:
 supplying a binder material; and   applying said binder material to said aggregate particles.   
   
   
       20 . The method of  claim 19 , further comprising the step of agitating said aggregate particles with said binder material. 
   
   
       21 . The method of  claim 19 , further comprising the step of spraying said aggregate particles with said binder material. 
   
   
       22 . The method of  claim 19 , wherein the binder material is selected from the group consisting of a liquid bitumen material, an acrylic material, and combinations thereof. 
   
   
       23 . The method of  claim 19 , further comprising the step of applying heat to said aggregate particles after they are introduced into said mold. 
   
   
       24 . A water channeling system at a site, comprising:
 a first location and a second location a horizontal distance away from said first location, at said site;   at least one channeling member comprising fixed aggregate forming a solid body,   wherein the at least one channeling member has a first end, a second end, and a plurality of fluidly connecting interstices therewithin, wherein the at least one channeling member is water permeable longitudinally between said first end and said second end;   wherein the at least one channeling member comprises polymeric aggregate particles bound together, wherein said polymeric aggregate particles comprise irregular shapes;   wherein said fixed aggregate is of a density of less than or equal to about 1 lb per cubic foot; and   wherein the at least one channeling member are installed at least partially below ground and channel water from said first location to said second location.   
   
   
       25 . The system of  claim 24  further comprising a plurality of channeling members, wherein said first end of one of the plurality of channeling members is adjacent the second end of another one of the plurality of channeling members. 
   
   
       26 . The system of  claim 24 , wherein the at least one channeling member comprises a vertical channeling panel having a first surface, a second surface, a greatest linear dimension comprising a height between said first surface and said second surface, and a plurality of fluidly connecting interstices therewithin. 
   
   
       27 . A method of producing a water channeling system comprising the steps of:
 supplying polymeric aggregate particles;   supplying a binder material;   mixing the polymeric aggregate particles and the binder material, wherein the polymeric aggregate particles and the binder material form a fluid concrete mixture;   creating a void at an installation site, wherein the void comprises one or more walls; and   introducing the fluid concrete mixture into the void, such that the one or more walls provide support to the fluid concrete mixture thereby allowing the fluid concrete mixture to solidify within the void;   wherein the fluid concrete mixture comprises a plurality of fluidly connecting interstices therewithin after solidification.