Abstract: A heating system which may include a bonding membrane having a water permeable lamina, an electrically conductive ink-based radiant heater, and a first adhesive adapted to adhere to both the conductive ink-based radiant heater and the bonding membrane. The heating system may be incorporated in a floor including a substrate, the heating system and a decorative floor surface. The heating system may also be in the form of a multilayer panel having a bonding membrane, an electrically conductive ink-based heater including a plurality of electrically resistive strips printed on a first polymer sheet connected by electrically conductive buses, and electrical conductors extending from the buses to at least an edge of the panel.

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: Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.

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 process for making a fiber reinforced cementitious product such as a panel which hardens to an ultra-high compressive strength composite for use in making panels with ballistic and blast resistant properties. The panel has a continuous phase resulting from curing an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, pozzolanic mineral filler, and polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also include alkanolamine and acid or acid salt. The continuous phase may be reinforced with fiber distributed in the continuous phase before curing to form a panel. The panel may be reinforced with a fiber reinforced skin attached to at least one surface of the core, e.g., by lamination with an adhesive, e.g., epoxy, to form a ballistic and blast resistant cementitious armor panel.

Abstract: Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.

Abstract: Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.

Abstract: A cementitious panel with ballistic and blast resistant properties having a core layer of ultra-high compressive strength composite and at least one skin layer. The panels can also be used in walls, ceiling and flooring panels which require high compressive strength for resistance to earthquakes and surfaces resistant to surface abuse such as in prison and other institutions. The panel core layer has a continuous cementitious phase resulting from the curing of an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, polycarboxylate based superplasticizer, alkanolamine and acid or alkali metal acid salt; and water. The mixture may be uniformly reinforced with fiber added before curing. The cementitious core layer is then reinforced with the skin, such as fiber reinforced polymer, attached to at least one panel surface.

Abstract: A cementitious armor panel assembly including cementitious armor panel with ballistic and blast resistant properties attached to a frame structure to produce a protective structure. The cementitious armor panels have a continuous phase resulting from the curing of an aqueous mixture of an inorganic cement binder, an inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, a polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also contain alkanolamine, and acid or acid salt. Prior to curing, the continuous phase is reinforced with fiber uniformly distributed in the continuous phase before it is cured to form the panel. The panel may be reinforced with a skin attached to at least one surface of the panel.

Abstract: Structural cement panel for resisting transverse and shear loads equal to transverse and shear loads provided by plywood and oriented strain board, when fastened to framing for use in shear walls, flooring and roofing systems. The panels provide reduced thermal transmission compared to other structural cement panels. The panels employ one or more layers of a continuous phase resulting from curing an aqueous mixture of calcium sulfate alpha hemihydrate, hydraulic cement, coated expanded perlite particles filler, optional additional fillers, active pozzolan and lime. The coated perlite has a particle size of 1-500 microns, a median diameter of 20-150 microns, and an effective particle density (specific gravity) of less than 0.50 g/cc. The panels are reinforced with fibers, for example alkali-resistant glass fibers. The preferred panel contains no intentionally added entrained air. A method of improving fire resistance in a building is also disclosed.

Abstract: A heating system in the form of a multi-layer, yet relatively thin and flexible panel. The panel contains a number of layers including first, second and third electrically insulating layers. A first electrically conductive resistive layer (heater layer) is sandwiched between the first and second insulating layers. A second electrically conductive resistive layer (resistive neutral plane layer) is sandwiched between the second and third insulating layers. The heater layer has a neutral electrical connection and a live electrical connection. The neutral and live electrical connections are electrically connected to each other at the panel only by electrically resistive material of the heater layer extending between the neutral and live electrical connections. The resistive neutral plane layer has a neutral electrical connection electrically connected with the neutral connection of the heater layer.

Abstract: A self-leveling cementitious mixture with excellent flow properties and which hardens with a controlled rate of strength development to an ultra-high compressive strength composite composition for use in making articles such as cementitious armor panel with ballistic and blast resistant properties including: a continuous phase resulting from the curing of an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, pozzolanic mineral filler, polycarboxylate based self-leveling agent and water. The cementitious mixture may include alkanolamine, such as triethanolamine, and acid or acid salt, such as tartaric acid. The cementitious composition may be reinforced with reinforcing fibers, e.g. glass fibers, in an amount of about 0.5-6.0% by volume of the overall cementitious composition. The fibers are uniformly dispersed in the cementitious composition before it is cured to form a final cementitious armor panel.

Abstract: A building composite panel including at least one longitudinal edge is made of a core of hydraulic cement and a multi-ply edge facing material covering and attached to at least one of the longitudinal edges. The facing material includes at least a first ply configured for attachment to the core as it sets and at least a second, water-impermeable ply.

Abstract: A cementitious armor panel assembly including cementitious armor panel with ballistic and blast resistant properties attached to a frame structure to produce a protective structure. The cementitious armor panels have a continuous phase resulting from the curing of an aqueous mixture of an inorganic cement binder, an inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, a polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also contain alkanolamine, and acid or acid salt. Prior to curing, the continuous phase is reinforced with fiber uniformly distributed in the continuous phase before it is cured to form the panel. The panel may be reinforced with a skin attached to at least one surface of the panel.

Abstract: A process for making a fiber reinforced cementitious product such as a panel which hardens to an ultra-high compressive strength composite for use in making panels with ballistic and blast resistant properties. The panel has a continuous phase resulting from curing an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, pozzolanic mineral filler, and polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also include alkanolamine and acid or acid salt. The continuous phase may be reinforced with fiber distributed in the continuous phase before curing to form a panel. The panel may be reinforced with a fiber reinforced skin attached to at least one surface of the core, e.g., by lamination with an adhesive, e.g., epoxy, to form a ballistic and blast resistant cementitious armor panel.

Abstract: A cementitious panel with ballistic and blast resistant properties having a core layer of ultra-high compressive strength composite and at least one skin layer. The panels can also be used in walls, ceiling and flooring panels which require high compressive strength for resistance to earthquakes and surfaces resistant to surface abuse such as in prison and other institutions. The panel core layer has a continuous cementitious phase resulting from the curing of an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, polycarboxylate based superplasticizer, alkanolamine and acid or alkali metal acid salt; and water. The mixture may be uniformly reinforced with fiber added before curing. The cementitious core layer is then reinforced with the skin, such as fiber reinforced polymer, attached to at least one panel surface.

Abstract: An embedment device for use in a cementitious panel production line such as a structural cementitious panel (SCP) production line wherein hydraulic cement slurry is transported on a moving web on a support frame, and chopped fibers are deposited upon the slurry. The device includes as one embodiment, a wire grid structure mounted on a reciprocating shaft driven by a piston which moves the grid down into the slurry and then up out of the slurry transverse of the travel of the slurry layer on the web. An alternative embodiment device includes a grid cell structure with thin walls extending upward from the grid surface in contact with the slurry that is moved up and down in a reciprocating motion transverse of the travel of the slurry layer on the web. The intermeshing relationship of the grid cell with the fiber and slurry enhances embedment of the fibers into the slurry and also prevents clogging of the device by fibers and prematurely set slurry particles.

Abstract: A structural cementitious panel, produced by a multi-layer process including providing a moving web; b. one of depositing a first layer of loose fibers upon the web and c. depositing a layer of settable slurry upon the web; d. depositing a second layer of loose fibers upon the slurry; e. embedding said second layer of fibers into the slurry; and f. repeating steps c. through e. until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. Also provided are an apparatus suitable for producing structural cementitious panels according to the present process, and a structural cementitious panel having multiple layers, each layer created by depositing a layer of settable slurry upon a moving web, depositing fibers upon the slurry and embedding the fibers into the slurry such that each layer is integrally formed with the adjacent layers.