Abstract: A cementitious product has an exposed surface finish which is applied during formation of the product by a pressing process and which simulates the surface and aspect of natural stone provided by secondary processing.

Abstract: An aqueous dispersion containing a latex, an alkaline earth metal formate, cellulose ether and lauryl sulphonate can be added to a concrete mixture as an auxiliary agent to make the concrete more flexible and reduce shrinkage during setting. Adding the dispersion to concrete mixtures allows also addition of fillers hitherto regarded as toxic to cement.

Abstract: An admixed and kneaded material of a mixture of a hydraulic powder, a potentially hydraulic powder, water, and fine and coarse aggregates, if necessary is molded and hardened. Then the hardened body is heat cured to form silicic acid anions of at least a trimer. This molded and hardened body has a compression strength at least 1000 kgf/cm.sup.2 and a bending strength of at least 150 kgf/cm.sup.2 so that hardened cement body having a high mechanical strength can be obtained without using a special reinforcing member or fiber. The hardened concrete product of this invention has a high bending strength, compression strength and modulus of elasticity. A glaze can be applied and fired to obtain beautiful concrete products.

Abstract: A CO.sub.2 pre-curing period is used prior to accelerated (steam or high-pressure steam) curing of cement and concrete products in order to: (1) prepare the products to withstand the high temperature and vapor pressure in the accelerated curing environment without microcracking and damage; and (2) incorporate the advantages of carbonation reactions in terms of dimensional stability, chemical stability, increased strength and hardness, and improved abrasion resistance into cement and concrete products without substantially modifying the conventional procedures of accelerated curing. Depending on the moisture content of the product, the invention may accomplish CO.sub.2 pre-curing by first drying the product (e.g. at slightly elevated temperature) and then expose it to a carbon dioxide-rich environment. Vigorous reactions of cement paste in the presence of carbon dioxide provide the products with enhanced strength, integrity and chemical and dimensional stability in a relatively short time period.

Abstract: The invention's first embodiment uses shape memory alloy (SMA) fibers that are blended into a concrete composite material as straight fibers and are made to deform themselves and anchor and interlock themselves after dispersement in the composite material resulting in a more evenly distributed and interlocked fiber reinforcement of the cementitious material. A self-shaping fiber can be imparted to the concrete material by making the fibers out of SMA such as nickel-titanium alloy known as nitinol where the cementitious composite material mixture is briefly heated above the "transition" temperature prior to hardening that causes the fibers to change shape. Nitinol fibers are used alone in place of conventional steel fibers.

Abstract: This invention relates to a novel ceramic mass or material and the use of same in the building materials industry for manufacturing bricks, ceramic stones, roofing tiles, large block and the like. A formable ceramic mass is prepared by mixing clay, a filler such as sand, calcium hydroxide, which can be in the form of slaked lime, and an aqueous solution of solidification activating agent. The formable mass is then shaped, e.g. by plastic moulding into uncured building elements which are in turn subjected to heat treatment, including a preliminary drying, a thermal treatment in a saturated vapour atmosphere, and a subsequent further heating and drying with a gradual lowering of moisture content. The preliminary drying is carried out at a temperature of 60.degree.-70.degree. C. to reduce the moisture content to 12-14%. The thermal treatment is performed at a temperature of 95.degree.-100.degree. C.

Abstract: A method of manufacturing wood-cement board and an apparatus used in the method are provided in the present invention. The method of manufacturing wood-cement board comprising strewing a raw materials mixture of wood-cement board on a mold panel to form a mat, piling up a plural number of the mats with the mold panels, pre-pressing the piled mats to reduce the thickness of each mat, piling up a plural number of the pre-pressed mat, main-pressing the pre-pressed and piled mats and curing the piled mats being main-pressed and the apparatus used in the method consists of a piling up machine piling up a plural number of mats formed on a mold panel, a pre-press machine pre-pressing the piled mats to reduce the thickness of each mat, a main-piling up machine piling up a plural number of the pre-pressed mats, a main-pressing machine main-pressing the pre-pressed and piled mats, and a curing chamber curing the piled mats being main-pressed.

Abstract: An increased efficiency method and apparatus for lining a section of pipe with a cement mortar. After a wet cement mortar has been applied to a cleaned interior surface of a pipe, carbon dioxide is introduced into the freshly lined section of the pipe in such quantity that a crust of calcium carbonate will be formed on the interior surface of the wet cement mortar lining as the carbon dioxide reacts with calcium compounds of the wet cement mortar in a relatively short period of time. This crust is provided to protect the underlying mortar from scouring, while tolerating a low-velocity flow of water, until the normal hardening of the underlying mortar through hydration can take place so as to substantially reduce the out-of-service time of the section of pipe which is being lined.

Abstract: Cement comprising hydraulic cement and polymer precursor such as alcohol-soluble phenol resin precursor that is substantially anhydrous and generates water by polymerization.

Abstract: Compositions useful for making lightweight roof tiles. The compositions comprise in percent by weight: between about 2.0 to 4.1 latex (solids basis), between about 20.0 to 28.0 cement, between about 28.0 to 55.0 lightweight aggregate, between about 9.0 to 15.0 water, between about 5.0 to 35.0 standard weight aggregate such as sand, between about 0.0 to 8.0 filler such as limestone, and between 0.0 to 1.5 accelerating additive such as calcium chloride. Methods for making the compositions e.g. into lightweight roof tiles, are also disclosed.

Abstract: A concrete product which uses 100% of the melt slags and pulverizes the melt slags into aggregates and fine powders, grinds the aggregates so that the percentage of absolute volume of the aggregates is over 60%, mixes the aggregates, fine powders, water and cement, and forms the mixture into the concrete product by vibration or press molding.

Abstract: A design optimization process used to determine the proportions of sand, cement, coarse aggregate, water, fly ash, water reducers, air entraining agents and fillers needed to produce a concrete mixture that has desired strength and slump properties and a minimal cost. The optimization process comprises a combination of models that accurately reflect the properties of a concrete mixture based on the properties of its individual components. The process is further capable of optimizing the durability of the cementitious mixture and of accurately calculating the expected yield of the mixture.

Abstract: Cured cement matrices are exposed to dense-phase or supercritical CO.sub.2 which enters the matrix through passages therein to neutralize the natural alkalinity of the cement so that alkali-intolerant materials can be incorporated in the cement. The CO.sub.2 converts calcium hydroxide in the cement to calcium carbonate and water, and the high pressure of the dense-phase or supercritical CO.sub.2 forms rounded, closely packed and aligned crystals with few or no visible pores or capillaries to enhance the homogeneity and strength of the cured cement and its bonding with, for example, uncoated reinforcing glass fibers. The supercritical CO.sub.2 can be used to transport other organic or inorganic materials, including pulverized metal, in solution or suspension into the interior of the cement matrix to alter its chemical and/or physical characteristics. The supercritical CO.sub.

Abstract: A method of fabricating a concrete floor having an autogenous hard high gloss finish that does not require further coatings includes pouring a designed concrete mix to establish a slab having an upper surface slightly below the level determined for the finished floor. A finishing floor surface layer is created by applying an amount of a dry shake dressing material containing quartz crystals and a coloring agent, but no coarse aggregate, to the upper surface of the slab and floating the surface until the finishing layer reaches predetermined amount which cures to form a generally monolithic structure with the slab but having a higher compressive strength when fully cured. Necessary expansion joints are provided. The floor is coated with a curing sealer and allowed to cure for approximately 30 days, or until it reaches a predetermined compressive strength. The sealer material is removed and the expansion joints are sealed.

Abstract: A process of molding a building panel which includes the steps of combining about 25 pounds of Portland Cement Type I, about 15 pounds of water at around 21.degree. Centigrade, added about 1 ounce of aluminum, calcium, magnesium, and silica, respectively, and about 12 ounces of synthetic fibers with about 0.1 ounce of ferro chloride in 40% solution by volume, and pouring the mixture into the lower portion of a mold to about 1/2 its depth and waiting for approximately 4 hours for the mixture to increase by about 100% of its original volume to fill the mold and thereafter stripping the mold from the form and placing it in a heated environment for curing for a period of approximately 24 hours and thereafter removing the panel from the heated environment.

Abstract: A method of autoclaving porous piece-goods, by steam under pressure, wherein the autoclaving operation includes sequential phases of heating with steam, holding, and then relaxing the pressure and temperature, wherein the holding phase includes a drying process. In order to obtain as dry a product as possible with the smallest possible energy input, it is provided that a drying process is carried out within the holding phase in which the autoclave is heated more than to compensate for heat losses and to a temperature above the temperature of vaporization of the water so that the material is dried by controlled discharge of steam from the interior of the autoclave. The steam discharged from one or more autoclaves during the drying process is used to heat up at least partially an autoclave to be heated.

Abstract: The present invention relates to hydraulically bonded cement compositions and methods of manufacture. Hydraulically bonded cement compositions and methods of manufacture include materials prepared by manipulating under pressure powdered hydraulic cement compositions using known or novel powder packing, casting, or expanding techniques, such that air within the powdered hydraulic cement is successfully removed while the cement is formed into a self-supporting near net final position. Thereafter, the formed hydraulic cement article is hydrated without mechanical mixing of the cement and water.

Abstract: Incorporation of solid removable aggregates into powdered cement which later completely dissolve, evaporate, volatilize, or melt leaving voids in the cement composition is discussed. Cementitious articles are prepared by manipulating powdered hydraulic cement or cement paste compositions into mechanically self-supporting structures of a predetermined configuration and thereafter hydrating the hydraulic cement compositions without mechanical mixing of the cement and water.

Abstract: A hydraulic composition comprising blast furnace slag powder, a water-soluble polymer and an alkaline substance, and a high-strength composite material produced by kneading and molding a composition which comprises blast furnace slag powder, a water-soluble polymer, an alkaline substrate and water, and wet curing the molded composition. The high-strength composite material has high bending strength and excellent water resistance by using uncostly blast furnace slag powder.

Abstract: A method is described for making concrete from an initially dry mixture including Portland cement, a fine aggregate, and a coarse aggregate. The method is effective for curing mixtures which contain rubble, as well as for mixtures which contain primarily virgin aggregate. In the method, substantially dry steam is introduced to the mixture at elevated temperature and pressure. Air injection may be utilized to further increase the pressure. An improved concrete is also described. The concrete exhibits unexpectedly high compressive strength.

Abstract: A single wood concrete layer, sound absorption panel is formed as a single wood concrete layer, cast panel body of kaolin mineralized organic fiber chips encased in Portland cement with steel reinforcement. The panels have a noise reduction coefficient of at least about 0.85 for a panel thickness of about 10 cm and a panel density of 86.5 kg/m.sup.2.

Abstract: A method of making a construction material luminous in response to ultraviolet rays. An inorganic material containing an ultraviolet luminous substance can be used as pigment after formed into gravelish, sandy or fragmentary material and, thus, a sufficient amount of luminance thereof can be ensured over long years while being prevented from deterioration with time of pigment. In particular, when using as inorganic materials ores containing ultraviolet luminous substance which is obtainable at a low price, pigment can be prepared at a low cost and patterned and decorated construction materials can also be manufactured at a low cost. Further, with the use of a large number of small pieces containing ultraviolet luminous substances as a pattern composing pieces, patterns complicated in shape and various in color can easily be produced on the surface of a construction material.

Abstract: Green concrete products, such as building products, are placed on pallets. Those pallets are transported to a kiln for curing and from the kiln after cure by an overhead crane. Pallets are lowered into and removed from open top kilns layer by layer being supported by movable support ledges, for example rotatable toggles, at each layer position which permit vertical entry and removal of the pallet layers. Three kiln compartments permit continuous production, one being filled, one being emptied and the third curing a load of pallet layers.

Abstract: A method and composition for making concrete includes an antifreeze admixe which is added to the concrete to prevent the freezing of water in the concrete when the concrete is cured during the winter or other cold conditions. The concrete admixture includes sodium nitrate and sodium sulfate combined with one another in a predetermined ratio. In a preferred a embodiment the ratio of sodium nitrate to sodium sulfate equals 3:1. A dosage of greater than 2% by weight of cement of the above described admixture was found to significantly increase the compressive strength of concrete cast of cold (below freezing, or 0 degrees celsius) temperatures, and dosages of 6% and 8% by weight of cement of the specified admixture were found to be particularly effective.

Abstract: The present inventions relates to a method for the controlled hardening of cid-setting cements and binders by first providing an acid-setting binder within a selected mold. Mixing with the binder an electrolyte to form a paste or slurry within the mold. Subjecting the paste or slurry mixture to electrolysis for a selected period of time or until the binder is sufficiently hardened whereby a hardened article is produced. Finally, removing the produced article from the mold.

Abstract: A system for curing concrete products resident in a kiln, in particularly for producing high strength building blocks from relatively dry green concrete, controls temperature and humidity in the kiln as a function of time in the curing cycle from a water pool heated by underwater grates near the upper water surface. Heated air and air/CO.sub.2 mixture also is circulated in the kiln during relevant portions of the curing cycle. Accelerated evaporation from the water well is induced by ruffling the water surface with the circulated air with enough intensity that the grates are uncovered to quickly evaporate water films wetting the grate surfaces. A baffle structure thus directs circulating air into the water surface. Individual grates are heated at critical times during the heating cycle in a manner to control temperature of different zones within the kiln by means of circulating hot liquids, such as oil.

Abstract: An improved method for lining a section of pipe with a cement mortar. After a wet cement mortar has been applied to a cleaned interior surface of a pipe, carbon dioxide is introduced into the freshly lined section of the pipe in such quantity that a crust of calcium carbonate will be formed on the surface of the wet cement mortar lining as the carbon dioxide reacts with calcium compounds of the wet cement mortar in a relatively short period of time. This crust is provided to tolerate a low-velocity flow of water to protect the underlying mortar from scouring until the normal hardening of the underlying mortar through hydration can take place so as to substantially reduce the out-of-service time of the section of pipe which is being lined.

Abstract: A novel and stable solution that can be applied on already existing cementitious structures or mixed with the cementitious matter prior to casting, is described. This solution is a simple, stable and environmentally safe material containing a sodium silicate, a dispersing agent and water containing a polysiloxane. Structures that have this material coated thereon or mixed therewith exhibit significant resistance to water penetration and resulting corrosion of re-bar elements and spalling of the concrete.

Abstract: A process is disclosed for fast and uniform hydration of uncured concrete products. Pressurized and superheated water is supplied to a manifold supporting a plurality of small diameter orifice nozzles housed inside a curing room which also houses the products during curing. Water is ejected by the nozzles in very fine particulate form, creating a mist or suspension of superheated water particles that surrounds the products and creates the desired high humidity, moderately high temperature environment for promoting hydration. The water preferably is softened before it is pressurized and supplied to the nozzles. Under favorable conditions, the hydration reaction supplies sufficient heat to maintain a desired temperature within the curing room, eliminating the need to heat the water before it is supplied to the nozzles.

Abstract: A form device for cellular concrete, including a number of piled-up form units having a heat-insulating bottom and shell, a heat-insulating top board, and a bottom-to-shell joint. A cellular concrete manufacture is produced by mixing cement with warm water at a temperature of 40.degree. to 75.degree. C. to form a warm cement mortar, mixing the mortar with a bubbled warm frother solution to form a warm cellular concrete paste, and hardening the paste using such heat-insulating form device.

Abstract: A surface of a fresh concrete body is dried by first covering the surface to be dried with a layer of bibulous granules having a great internal surface area for a time sufficient to draw generally all of the water out of the body via the surface and then preventing water from entering the layer from its side turned away from the body. The granules are finely divided hygroscopic particles, with an internal surface area of at least 200 m.sup.2 /g, preferably at least 800 m.sup.2 /g. The hydrophilic particles take up the moisture from the concrete and hold it in the layer of particles lying on the surface. This reduces the partial vapor pressure on the surface of the concrete body which effectively draws further liquid out of the concrete. The particles are a mixture of a cross-linked polymer that only swells in water and silica. The particles are carried in a coherent mat and are applied as a layer to the surface by laying the mat thereon.

Abstract: A process for fast and uniform hydration of uncured concrete products includes supplying pressurized and superheated water to a manifold supporting a plurality of small diameter orifice nozzles housed inside a curing room which also houses the products during curing. The superheated water is ejected by the nozzles in very fine particulate form, creating a mist or suspension of water particles that surrounds the products and creates the desired high humidity, moderately high temperature environment for promoting hydration. The water preferably is softened before it is pressurized and supplied to the nozzles. Under favorable conditions, the hydration reaction supplies sufficient heat to maintain a desired temperature within the curing room. The water is heated before it is supplied to the nozzles after pressurization.

Abstract: The invention relates to an apparatus for the production of building units from an afterhardening mixture containing cement and/or lime as binding material. The raw mixture is continuously fed and pressed by stamping into a die with CO.sub.2 gas at a pressure higher than atmospheric being passed through the raw mixture in the die space. Through an instantaneous reaction of carbonation, the material is hardened to a formed body. The CO.sub.2 gas is prevented from escaping by a gastight seal in the vicinity of the inlet port of the die. Further towards the outlet port, the pressure of the CO.sub.2 gas is decreased. In the vicinity of the outlet port only as much CO.sub.2 gas is fed as is necessary for the completing of the chemical reaction. Thus, any loss of gas will be minimized. The continuously discharged body is cut to size by using a saw.

Abstract: An improved method for moving a large, heavy, fragile, freshly-made concrete pipe section, with top and bottom pallets but without jacket protection, out of a casting machine, and directly into a kiln, for curing; moving the cured pipe section from the kiln to an unloading station, automatically removing the top pallet, removing the pipe section from the bottom pallet, cleaning the top pallet and then placing the top pallet on a reinforcing cage that has been set on the bottom pallet, ready for the next cycle. The cycle is continuously intermittant.

Abstract: A method of manufacturing a metallurgical addition agent, especially an agent comprising silicon carbide fines, comprises a first step of forming a mix of at least 30% fines, cement and at least 20% water. The next step comprises pressing the wet mix in a mold while squeezing out excess water but leaving sufficient water for hydration of the cement. The pressed shapes are cured at ambient temperatures.

Abstract: A fast-cure process of manufacturing concrete products of critical shapes and strength requirements such as block, tile and pipe provides substantially maximum strength in a few hours as compared with the many months it would take in an ambient atmosphere. Critical shape is maintained without cracks, etc., by control of temperature, humidity and atmospheric CO.sub.2 within a kiln in which the uncured concrete products reside. The humidity is kept at saturation until substantially all the concrete reacts chemically with the water. The temperature is controlled to prevent excessive temperatures at critical times and to accelerate cure when the products can stand higher temperatures. Free hydrated lime is fast cured by a CO.sub.2 rich atmosphere at elevated temperature.

Abstract: A process for making beams of prestressed concrete in an assembly for casting and curing beams of prestressed reinforced concrete, having an individual prestress frame allowing tensioning of longitudinal reinforcements between two fixed end elements maintained in spaced-apart relationship by longitudinal elements; and an individual impression cooperating hermetically with the frame so that the walls of the impression and the walls of the end elements of the frame, connected together, form the sides of a mould receiving the cast concrete, the impression being adapted to be separated from the frame without detensioning of the reinforcements.

Abstract: A concrete tile is disclosed having a preformed substrate member backing comprising a substantially rigid, polymeric material. The lower surface of the substrate member defines the shape of the lower surface of the tile. A concrete layer is disposed on and secured to the upper surface of the substrate member and defines the shape of the upper surface of the tile. In manufacturing the tile, a plurality of through openings in the substrate member are filled with the concrete when the concrete is applied to the substrate member. The concrete is cured on the substrate member and the hardened concrete in the openings of the substrate member forms studs securing the substrate member and concrete layer together. The use of a polymeric substrate member backing provides a tile which uses less concrete and is therefore substantially lighter in weight than other tiles of corresponding strength. The method of manufacturing the tiles utilizes the substrate member as a support for the concrete applied to its upper surface.

Abstract: The invention relates to a process for accelerating hardening of cement in fibre-reinforced and cement-bond plates and solids respectively. The essence of the process lies in that a composition known in itself containing water, fibrous material and cement is placed between the pressure plates of a press, compressed, simultaneously with pressing a flange of increased density is formed on the profile to be produced; the medium between the gasproof or quasi gasproof boundary surface is carbonized wih CO.sub.2 gas thereafter pressure is reduced.

Abstract: An additive used in the production of concrete blocks comprises a mixture of water with attapulgite or peptized calcium bentonite. Problem concrete blocks which previously were normally subject to improper molding or cracking during the molding, unmolding, handling and curing steps during the manufacture thereof, are now easily produced and properly molded without cracking resulting during any of these steps. Whereas, it was previously nearly impossible to manufacture any acceptable concrete blocks without employing sufficient quantities of fines in the concrete block mix, the additive allows formation of acceptable concrete blocks in the absence of any fines at all, thereby enabling much more reliable production of standard blocks, thin-walled blocks, and even more lightweight blocks than heretofore possible, because the gradation and characteristics and relative proportions of the coarse and fine constituents of the aggregate in the mix are rendered far less critical than heretofore.

Abstract: The strength of the stainless steel containing cementitious composite material of U.S. Pat. No. 4,482,385 is improved by curing it according to a specific schedule which includes the steps of curing in a mold, steam curing after demolding, slow drying and dry thermal curing.

Abstract: An additive used in the production of concrete blocks comprises a mixture of water and sodium bentonite. Problem concrete blocks which previously were normally subject to improper molding or cracking during the molding, unmolding, handling and curing steps during the manufacture thereof, are now easily produced and properly molded without cracking resulting during any of these steps. Whereas, it was previously nearly impossible to manufacture any acceptable concrete blocks without employing sufficient quantities of fines in the concrete block mix, the additive allows formation of acceptable concrete blocks in the absence of any fines at all, thereby enabling much more reliable production of standard blocks, thin-walled blocks, and even more lightweight blocks than heretofore possible, because the gradation and characteristics and relative proportions of the coarse and fine constituents of the aggregate in the mix are rendered far less critical than heretofore.

Abstract: A glass fiber-reinforced cement non-plate article which is composed of an inside mortar layer comprising a mixture of normal Portland cement and glass fiber chopped strand, an outside mortar layer comprising a mixture of normal Portland cement and glass fiber chopped strand, and a regulated set cement mortar layer interposed between said both layers and between a pair of continuous glass fiber layers, is formed.

Abstract: A method and apparatus for rapidly manufacturing concrete or like products having an advanced state of cure by blending together a calcareous cementitious binder, aggregate, and water to form a mix, molding the mixture to have a predetermined shape and exposing the shape to an atmosphere in a chamber consisting essentially of carbon dioxide gas, wherein carbon dioxide gas is fed under controlled conditions into said chamber through a series of tubes having a multiplicity of spaced orifices during the movement of the shape therein and continuing the feed so as to cause an exothermic temperature rise in the shape.

Abstract: The invention provides a process for producing fabric-reinforced, thin concrete panels suitable as a backer board for construction materials such as ceramic tile, slate or thin brick. A process is described whereby the components of the panel are deposited on a web of release-agent-treated, water-absorbent paper while moving on a conveyor belt to form a continuous strip, the strip is cut into panels and the wet, uncured panels are stacked by means of an air-float stacking unit, then subsequently cured with the paper web between adjacent panels.

Abstract: The invention relates to a pad for concrete intended to appreciably reduce the setting time of concrete. This pad comprises an essentially water an air tight flexible cover enclosing a heat insulating cushion resting directly over a lower part intended to be laid in contact with the surface of concrete. This lower part is made up of ribbons woven together in the form of a network in such a manner as to have a good mechanical resistance to wear by friction and so as to create a zone between the heat insulating cushion and the surface of the concrete capable of allowing the excess water oozing through the concrete surface to flow only slowly away, thereby avoiding the need of water from an outside source, allowing also the heat resulting from the setting reaction of concrete to accumulate inside the interstices of said network thus to accelerate the setting of the concrete. This pad is particularly useful and efficient during the year's period of cold weather where the setting of concrete is particularly long.

Abstract: Hydrothermally cured articles are formed by mixing a filler and a binder, moulding this mixture and coating said moulded articles with silica or calcium hydroxide particles. Hydrothermal curing may comprise a first step, wherein the steam pressure in the autoclave is increased, thereafter the steam pressure is decreased and subsequently the pressure is increased to a steam pressure being higher than in the first step.

Abstract: A method for manufacturing cementitious products are provided in which microwave radiation energy is applied to cementitious products that have been at least partially cured by a moist curing method such as low pressure steam, water vapor or autoclave curing. Microwave radiation energy applied is sufficient to provide rapid cure completion and drying of the cementitious material.

Abstract: This invention concerns a method of manufacturing cementitious articles such as parpens, in which the articles are moulded, preferably by compression, on a base plate serving for handling the articles for the drying operations, especially steam drying.

Abstract: Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.