Abstract: Lightweight, fiber reinforced, cementitious panels possessing exceptional toughness for use as building components in applications such as roofing elements, siding elements, framing and sheathing elements, and substrate elements for installation of floor finishes in residential and other building construction types. The panels employ a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, PVA fibers and lightweight filler. The inorganic binder may be, for example, hydraulic cement alone, or a combination of hydraulic cement and pozzolan/s, or a combination of hydraulic cement, alpha hemihydrate, active pozzolan and optionally lime. The PVA fibers reinforce the continuous phase and are randomly distributed throughout the composite. Typical panels of the invention have a density of 60-85 pcf.

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 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 process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.

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 process employing a wet mixer having a vertical mixing chamber for forming a wet slurry of a cementitious powder and liquid. The vertical mixing chamber is designed to provide the required amount of mixing to provide thoroughly mixed, uniformly thin slurry within a mixing residence time that allows for adequate supply of slurry to ensure continuous operation of an associated cement panel production line. Gravity feed for supply of cementitious powder and water to the slurry mixing area of the chamber is also 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 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.

Abstract: A composition for making flexible articles includes a hydraulic component of at least 50 weight % fly ash, a water-soluble, film-forming polymer and water. Articles are made from this composition by making a slurry of the components, forming the article and allowing it to set.

Abstract: A multi-layer process for producing structural cementitious panels, includes, a. 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 a structural panel produced by the present process, 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.

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 process employing a wet mixer having a vertical mixing chamber for forming a wet slurry of a cementitious powder and liquid. The vertical mixing chamber is designed to provide the required amount of mixing to provide thoroughly mixed, uniformly thin slurry within a mixing residence time that allows for adequate supply of slurry to ensure continuous operation of an associated cement panel production line. Gravity feed means for supply of cementitious powder and water to the slurry mixing area of the chamber is also disclosed.

Abstract: A composition for making flexible articles includes a hydraulic component of at least 50 weight % fly ash, a water-soluble, film-forming polymer and water. Articles are made from this composition by making a slurry of the components, forming the article and allowing it to set.

Abstract: A composition for making flexible articles includes a hydraulic component of at least 50 weight % fly ash, a water-soluble, film-forming polymer and water. Articles are made from this composition by making a slurry of the components, forming the article and allowing it to set.

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: A process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.

Abstract: A packaged membrane is adapted to be sold, stored and transported to the site of use. The membrane includes a base mat and a flexible cement-based coating applied to the base mat. The coating includes a hydraulic component and water. The membrane is then rolled and packaged in a tubular package. Preferably, the coating also includes a water-soluble, film forming polymer. It is also preferred that the hydraulic component include at least 50% fly ash by weight.

Abstract: Lightweight, fiber reinforced, cementitious panels possessing exceptional toughness for use as building components in applications such as roofing elements, siding elements, framing and sheathing elements, and substrate elements for installation of floor finishes in residential and other building construction types. The panels employ a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, PVA fibers and lightweight filler. The inorganic binder may be, for example, hydraulic cement alone, or a combination of hydraulic cement and pozzolan/s, or a combination of hydraulic cement, alpha hemihydrate, active pozzolan and optionally lime. The PVA fibers reinforce the continuous phase and are randomly distributed throughout the composite. Typical panels of the invention have a density of 60-85 pcf.

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: 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.