Abstract: A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar and repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium aluminate cement, a calcium sulfate and a chemical activator with water.

Abstract: A freeze-thaw durable, dimensionally stable, geopolymer composition including: cementitious reactive powder including thermally activated aluminosilicate mineral, aluminate cement preferably selected from at least one of calcium sulfoaluminate cement and calcium aluminate cement, and calcium sulfate selected from at least one of calcium sulfate dihydrate, calcium sulfate hemihydrate, and anhydrous calcium sulfate; alkali metal chemical activator; and a freeze-thaw durability component selected from at least one of air-entraining agent, defoaming agent, and surface active organic polymer; wherein the composition has an air content of about 4% to 20% by volume, more preferably about 4% to 12% by volume, and most preferably about 4% to 8% by volume. The compositions are made from a slurry wherein the water/cementitious reactive powder weight ratio is 0.14 to 0.45:1, preferably 0.16 to 0.35:1, and more preferably 0.18 to 0.25:1. Methods for making the compositions are also disclosed.

Abstract: A freeze-thaw durable, dimensionally stable, geopolymer composition including: cementitious reactive powder including thermally activated aluminosilicate mineral, aluminate cement preferably selected from at least one of calcium sulfoaluminate cement and calcium aluminate cement, and calcium sulfate selected from at least one of calcium sulfate dihydrate, calcium sulfate hemihydrate, and anhydrous calcium sulfate; alkali metal chemical activator; and a freeze-thaw durability component selected from at least one of air-entraining agent, defoaming agent, and surface active organic polymer; wherein the composition has an air content of about 4% to 20% by volume, more preferably about 4% to 12% by volume, and most preferably about 4% to 8% by volume. The compositions are made from a slurry wherein the water/cementitious reactive powder weight ratio is 0.14 to 0.45:1, preferably 0.16 to 0.35:1, and more preferably 0.18 to 0.25:1. Methods for making the compositions are also disclosed.

Abstract: A water-resistant preformed polystyrene foam product with improved adhesive properties is provided. A water-resistant coating for preformed polystyrene products is also provided. The coating can be formulated as a sprayable composition and is easy to apply. Methods for making the coating formulations and water-resistant preformed polystyrene products are also provided.

Abstract: Disclosed are cementitious product, as well as cementitious slurry, and method of forming the product. To reduce density in the cementitious product, foam is included in the slurry and in the method of forming the product. The slurry includes cementitious particles, water, and air bubbles such as from compressed air. Instead of using detergent chemistry at the gas/water interface of bubbles, the present invention uses a surface modifying agent for the cementitious particles in the slurry. The modified particles act to produce stable foam in the slurry. As an example mode of introduction, the surface modifier can be added (e.g., as solid or solution) directly into a bulk cementitious slurry that forms the product. As another example, the surface modifier can be added in a separate solution with water, air bubbles, and cementitious particles that serve as additive to the main cementitious slurry, where the separate solution is then added to the main cementitious slurry.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. These waterproof gypsum panels have many uses, such as, tile backer board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, interior wall and ceiling, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, preferably silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Abstract: A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar, patching materials for road repairs and other repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium sulfoaluminate cement, a calcium sulfate and a chemical activator with water.

Abstract: A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar and repair materials, and the like is disclosed.

Abstract: A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar and repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium aluminate cement, a calcium sulfate and a chemical activator with water.

Abstract: In a preferred embodiment, a floor crack isolation system includes a membrane and a deformable adhesive. The membrane includes a basemat, having at least three plies, a ply of a meltblown polymer sandwiched between two plies of spunbond polymer; and a flexible coating applied to the basemat, the coating having a cementitious hydraulic component, a polymer comprising a water-soluble, film-forming polymer; and water. The finished membrane is flexible and is bonded to a subfloor with a deformable adhesive. A method of making the floor crack isolation system includes obtaining a coated, three-ply, flexible membrane and applying it to a subfloor with a deformable adhesive.

Abstract: Provided are construction products with a density in the range from about 10 pcf to about 125 pcf and comprising an inorganic filler cross-linked in a polyurethane matrix produced by an exothermic reaction between at least one alcohol having two or more reactive hydroxyl groups per molecule and at least one isocyanate having more than one reactive isocyanate group per molecule, wherein a molar ratio of the alcohol to the isocyanate is in the range from 0.25:1 to 5:1. Methods for making the products are provided as well.

Abstract: In a preferred embodiment, a membrane for use as an underlayment includes a basemat, which includes at least three plies, a ply of a meltblown polymer sandwiched between two plies of spunbond polymer; and a flexible coating applied to the basemat, the coating having a cementitious hydraulic component, a polymer comprising a water-soluble, film-forming polymer; and water. The finished membrane is flexible. Another embodiment for an underlayment for use underneath ceramic tiles includes a basemat and a coating of a set hydraulic component less than ?? inches thick. A method of making the flexible membrane includes assembling components including a hydraulic component, a water-soluble, film-forming polymer and water, then mixing them to form a coating. A basemat is provided onto which the coating is applied over a flexible surface or no surface. After coating at least one face of the basemat, the coating is dried to form the membrane.

Abstract: Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and otheroptional additives.

Abstract: Disclosed is a method of preparing a mat-faced cementitious article composite. A mat-faced article (e.g., board) is formed and the composite is formed upon application of a finish composition (e.g., hydrophobic). In one aspect, the mat-faced gypsum article comprises a mat having an inner surface adjacent to a cementitious core first surface and an opposite outer mat surface. An aqueous cementitious finish composition is applied to the outside mat surface to form the mat-faced cementitious article composite. Desirably, the finish composite can suitably be applied by a roller assembly comprising a finish roller. In some embodiments, the finish roller has an uneven surface, including for example, grooves or depressions (e.g., circumferential or longitudinal) defined therein.

Abstract: A water-resistant preformed polystyrene foam product with improved adhesive properties is provided. A water-resistant coating for preformed polystyrene products is also provided. The coating can be formulated as a sprayable composition and is easy to apply. Methods for making the coating formulations and water-resistant preformed polystyrene products are also provided.

Abstract: Disclosed are cementitious product, as well as cementitious slurry, and method of forming the product. To reduce density in the cementitious product, foam is included in the slurry and in the method of forming the product. The slurry includes cementitious particles, water, and air bubbles such as from compressed air. Instead of using detergent chemistry at the gas/water interface of bubbles, the present invention uses a surface modifying agent for the cementitious particles in the slurry. The modified particles act to produce stable foam in the slurry. As an example mode of introduction, the surface modifier can be added (e.g., as solid or solution) directly into a bulk cementitious slurry that forms the product. As another example, the surface modifier can be added in a separate solution with water, air bubbles, and cementitious particles that serve as additive to the main cementitious slurry, where the separate solution is then added to the main cementitious slurry.

Abstract: A cementitious board system which is reinforced on its opposed surfaces by an improved glass fiber mesh scrim with thicker yarn and larger mesh openings to provide a cementitious board with improved handling properties while retaining tensile strength and long term durability. The fabric is constructed as a mesh of high modulus strands of bundled glass fibers encapsulated by alkali and water resistant material, e.g. a thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides a board system with long-lasting, high strength tensile reinforcement and improved handling properties regardless of their spatial orientation during handling. Included as part of the invention are methods for making the reinforced board.

Abstract: A mixture for making a high strength phosphate cement includes monopotassium phosphate, a Group IIA metal oxide in amounts of about 20 to about 100 parts per 100 parts of the monopotassium phosphate and monocalcium orthophosphate in amounts of from about 3 to about 30 parts per 100 parts of the monopotassium phosphate. Products made from the phosphate cement have a pH of less than about 9 and the product develops a compressive strength greater than 2000 psi in 24 hours.

Abstract: A cementitious board system which is reinforced on its opposed surfaces by an improved glass fiber mesh scrim with thicker yarn and larger mesh openings to provide a cementitious board with improved handling properties while retaining tensile strength and long term durability. The fabric is constructed as a mesh of high modulus strands of bundled glass fibers encapsulated by alkali and water resistant material, e.g. a thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides a board system with long-lasting, high strength tensile reinforcement and improved handling properties regardless of their spatial orientation during handling. Included as part of the invention are methods for making the reinforced board.