Abstract: A process for providing a fiber cement product is provided the process comprising the steps of: —providing an uncured fiber cement product; —curing said uncured fiber cement product; —drying said cured fiber cement product to obtain a humidity of said cured fiber cement product being less than or equal to about 8% w; —abrasive blasting at least part of the surface of said dried fiber cement product.

Abstract: A cementitious composite includes a first layer, a second layer, and a cementitious mixture disposed between the first layer and the second layer. The cementitious mixture includes (i) cementitious materials and (ii) a viscosity modifier and/or an accelerator. The cementitious materials provide a void fraction between 0.64 and 1.35. The void fraction is defined as the ratio of the volume of the voids within the cementitious mixture per unit area of the cementitious composite to the volume of the cementitious materials per unit area of the cementitious composite. The cementitious mixture is configured to absorb a mass of water that provides a maximum 28 day compressive strength of the cementitious composite. A ratio of the mass of the water relative to the mass of the cementitious materials of the cementitious mixture per unit area of the cementitious composite that provides the maximum 28 day compressive strength of the cementitious composite is between 0.25 and 0.55.

Abstract: Some implementations herein described improvements to concrete products and processes for producing concrete products that may provide a positive environmental impact and that can be stronger relative to the percent of cement used. Particular examples include improvements to zero-slump to near-zero-slump concrete mixture design, material storage and handling, batching, mixing, sequencing and curing processes, as well as forming and curing techniques.

Abstract: A cementitious composite includes a first layer, a second layer spaced from the first layer, a cementitious mixture disposed between the first layer and the second layer, and a structure layer disposed between the first layer and the second layer. The cementitious mixture is disposed within the structure layer. The cementitious mixture includes cementitious materials. The cementitious mixture is configured to absorb a mass of water that provides a maximum 28 day compressive strength of the cementitious composite upon curing which is represented by Mw=x·Mc. Mw is the mass of water per unit area of the cementitious composite. Mc is a mass of cementitious materials of the cementitious mixture per unit area of the cementitious composite. x is a ratio of the mass of water relative to the mass of cementitious materials of the cementitious mixture per unit area of the cementitious composite. x is between 0.25 and 0.55.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: A cementitious composite for in-situ hydration includes a first layer, a second layer spaced from the first layer, and a cementitious mixture disposed between the first layer and the second layer. The cementitious mixture includes cementitious materials. The cementitious mixture is configured to absorb a mass of water that provides a maximum 28 day compressive strength of the cementitious composite upon curing which is represented by Mw=x·Mc. Mw is the mass of the water per unit area of the cementitious composite. Mc is a mass of the cementitious materials of the cementitious mixture per unit area of the cementitious composite. x is a ratio of the mass of the water relative to the mass of the cementitious materials of the cementitious mixture per unit area of the cementitious composite that provides the maximum 28 day compressive strength of the cementitious composite. x is between 0.25 and 0.55.

Abstract: The present disclosure relates to a bentonite modifier, comprising a water-soluble thiosulfate, a water-soluble alcohol compound, and a water-soluble amine compound, wherein the amounts of thiosulfate, the alcohol compound, and the amine compound are in the ratio of (0.3˜1):(0.3˜1):(0.3˜1). The present disclosure further relates to a bentonite-containing cement additive capable of resisting permeation and salt corrosion, comprising bentonite and said modifier, wherein the content of the bentonite modifier is 0.2˜5% of the bentonite by weight. Meanwhile, the present disclosure also provides use of the modified bentonite.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: An apparatus, method and insulation medium for inserting and insulating a charge medium within a borehole includes a charge tube comprised of an elongate tube having a length and diameter sufficient for containing a desired quantity of a charge medium. A charge medium in a pumpable form is provided for substantially filling the charge tube. An insulation medium in a pumpable form is provided for substantially encapsulating the charge tube and substantially filling an annular space between the charge tube and the borehole for insulating the charge tube from a downhole environment in which the charge tube is to be inserted. A detonator is inserted within the charge medium proximate a distal end of the charge tube and a charge cable extends from the detonator through the charge tube and exits from the charge tube.

Abstract: A building product comprises calcium sulphate dihydrate particles bound by an organic binder. The calcium sulphate dihydrate particles each have a longest dimension and a lateral dimension, wherein the lateral dimension corresponds to the maximum breadth of the particle about the axis defined by the longest dimension. The calcium sulphate dihydrate particles have a low aspect ratio such that for at least 75% of the calcium sulphate dihydrate particles, the value of the lateral dimension is at least 20% of the value of the longest dimension.

Abstract: A dry papercrete mix containing a pulp of fiber material such as newsprint and sharp sand, Portland cement and adding additional sand and/or pumice. The resulting dry, granular mix can then be handled stored and used in the manner which is conventional for concrete. The dry papercrete mix can be fortified with a fiber form of basalt which can be added to or substituted for all or a portion of the cellulose fiber content of the dry papercrete mix to provide a stronger structure when hydrated and cast into a desired shape with only a small increase in weight. Basalt reinforcing bars and meshes may be included in shapes cast from the hydrated mix in combination with or substitution for steel reinforcing structures. Including basalt in the mix and in reinforcing systems allows the design of joints between structural modules to provide exceptional strength in a unitary structure so formed.

Abstract: Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets and low density fillers distributed throughout. The combination of entrained air pockets and low density fillers provide a low density fiber cement matrix with physical and mechanical properties similar to comparable low density fiber cement matrix without entrained air pockets.

Abstract: The present invention provides a gypsum composition, a gypsum board and their preparation method and the use of DHA as an anti-sagging additive in a gypsum product. Said gypsum board comprises set gypsum prepared from the composition; while said composition comprises gypsum, and an anti-deformation additive, wherein the anti-deformation additive comprises at least one selected from a group consisting of dehydroascorbic acid, dehydroascorbate and semidehydroascorbic acid. The set gypsum prepared from the said composition shows better anti-sagging or deformation resisting property. The gypsum product of the present invention is hardly distorted and has stronger stability even in the condition of high humidity, thus improve the quality of the gypsum product to meet the demands of the customer.

Abstract: A novel mortar mix and mortar formed therewith. The mortar contains sand, lime, cement and microtubes in a mixture thereof. The microtubes assist in wicking moisture directly through a wet mortar compound formed by adding water to the mortar mix. Wicking moisture directly through the mortar decreases the reliance on a continuous, unobstructed cavity behind the masonry wall, as well as prevent cracking from water's freeze-thaw cycle. It also allows water to pass through the mortar in a similar manner as the masonry, creating two in-sync cycles, rather then two disparate cycles for water flow. In various embodiments, the microtubes could be composed of cellulose, fabricated polymer or graphite.

Abstract: Disclosed herein are composites capable of self-repairing. In some examples, the composites include a binding medium and a plurality of binding medium-repairing particles. The binding medium-repairing particles disclosed herein comprise a reactive agent encapsulated in a shell, where the reactive agent can interact with the binding medium to form an aggregate in the presence of an aqueous medium. Also disclosed herein are methods for making the composites and methods for making the binding medium-repairing particles.

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 cement composition: (a) a hydraulic cement; (b) water; and (c) an alkyl polyglycoside derivative, wherein the alkyl polyglycoside derivative is selected from the group consisting of: sulfonates, betaines, an inorganic salt of any of the foregoing, and any combination of any of the foregoing. A method comprising the steps of: (A) forming the cement composition; and (B) introducing the cement composition into the well. Preferably, the cement composition is foamed.

Abstract: A variety of methods and compositions are disclosed, including, in one embodiment a method a cementing in a subterranean formation comprising: providing a set-delayed cement composition comprising water, pumice, hydrated lime, and a set retarder; foaming the set-delayed cement composition; activating the set-delayed cement composition; introducing the set-delayed cement composition into a subterranean formation; and allowing the set-delayed cement composition to set in the subterranean formation. Additional methods, foamed set-delayed cement composition, and systems for cementing are also provided.

Abstract: A dry papercrete mix is formed by preparing a wet pulp of fiber material such as newsprint and sharp sand by mixing sand, fiber material and water in a batch or continuous mixer, drying the pulp to a moisture content below that which will cause a reaction with Portland cement and adding additional sand and/or pumice and Portland cement. The resulting dry mix can then be handled, stored and used in the manner which is conventional for concrete. The dry papercrete mix can also be applied by pouring the dry papercrete mix into a form in a dry state and injecting water into the dry mix until the mix is sufficiently wetted without mixing in the manner common for concrete. Structural modules and a technique for joining them into a structure are particularly appropriate to the use of dry application papercrete.

Abstract: The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.

Abstract: A slurry for manufacturing gypsum board is disclosed. The slurry comprises calcined gypsum, water, a foaming agent, and a thickening agent. The thickening agent of the present disclosure acts to improve the cohesiveness of the slurry without adversely affecting the setting time of the slurry, the paper-to-core bond (wet and dry), or the head of the slurry by acting as a defoaming agent or coalescing agent. Examples of suitable thickening agents include cellulose ether and co-polymers containing varying degrees of polyacrylamide and acrylic acid. A gypsum board and method of forming the slurry and the gypsum board are also disclosed. The gypsum board comprises a gypsum layer formed from the slurry.

Abstract: Porogen containing calcium phosphate cement compositions are provided. Aspects of the cement compositions include a dry calcium phosphate reactant component, a setting fluid component and a porogen component. The porogen component includes at least first and second porogens having different pore forming profiles. Aspects of the invention include combining the cement components to produce a settable composition. Aspects of the invention further include the settable compositions themselves as well as kits for preparing the same. Methods and compositions as described herein find use in a variety of applications, including hard tissue repair applications.

Abstract: Sheathing panels are produced by methods which do not require natural resources such as wood and use significantly reduced embodied energy when compared with the energy used to fabricate gypsum sheathing panels. A novel binder, consisting in one embodiment of monopotassium phosphate and magnesium oxide, and combined with various fillers, is used to provide a controlled exothermic reaction to create a gypsum board-like core which can be formed into a suitable sheathing panel handled and installed in a typical manner. The panel is manufactured to have a desirable shear resistance and water vapor permeability, important performance elements in building envelope design. The manufacturing process results in a panel that does not require mature trees as source material, does not off gas, and involves much lower greenhouse gas emissions than the processes used to make traditional wood or gypsum-based sheathing panels.

Abstract: A method of producing gypsum building board, comprises allowing a layer of an aqueous gypsum slurry to set so as to form a board, in which the improvement comprises mixing the gypsum slurry with an aqueous foam produced by foaming water containing at least one non-ionic alkylpolysaccharide foaming agent of the general formula (I) R—O-(G)x ??(I) where: R represents a linear or branched alkyl group having from 6 to 20 carbon atoms; G represents a reducing saccharide moiety connected to R via an ethereal O-glycosidical bond; and x is 1 to 10.

Abstract: Compositions and methods for reducing the impact of hard water on gypsum board foaming are provided. The compositions include adding a foam to water and a calcined slurry. The foam includes water, dispersed air and a surfactant. Surfactants for use include a hydrophobic portion having an alkyl chain length distribution of about 20% to about 60% C8 chains; about 20% to about 60% C10 chains; about 14% to about 36% C12 chains and about 2% to about 20% C14 chains and also having a hydrophilic portion having about 0.2 to 3.0 ethoxy groups.

Abstract: A compressed building block formed of a pre-mix of fly ash, either of the Class C type, is combined with either ground or pulverized wood chips, or with fine sand, and a plasticizer, and accelerator, then moisturized, and lastly either extruded or compressed in a mold into the configuration of a block. The block lacks a binder, except Portland cement for select military applications. A mold retardant may be added to the mixture, to provide the formed block with further beneficial attributes. The blocks may be formed by a system for extruding such blocks from the formulation, or they may be formed by means of a hydraulic or other press and pressed into the configuration of the desired block, needed for the construction.

Abstract: Effective use of dispersants in wallboard containing foam results from a method where stucco is mixed with a first dispersant and a first quantity of water to form a gypsum slurry. A soap is blended with a second dispersant and a second quantity of water to make a foam. Subsequently, the foam is combined with the slurry. Choice of different first and second dispersants and their relative amounts allows control of the size distribution of the foam bubbles in the slurry and the resulting voids in the gypsum core. Use of the same dispersant in both the mixer and the foam water provides a boost in efficacy of the dispersant.

Abstract: This invention relates to a cement, which comprises in its main phase of microcrystalline magnesium ammonium phosphate and nanoapatite after hardening and thus at the same time has considerable strength. The material is biologically degradable and is suitable for application in tooth cements, as bone replacement, as bone filler, as bone cement or as bone adhesive.

Abstract: This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.

Abstract: An improved freeze-thaw durability wet cast cementitious composition is provided that uses in-situ production of gas by gas generating additives and optionally polymeric microspheres that are blended directly into the mixture. The gas generating additives and the polymeric microspheres provide void spaces in the material matrix, and such void spaces act to increase freeze-thaw durability of the material.

Abstract: A method and cement composition is provided for sealing a subterranean zone penetrated by a well bore, wherein the cement composition comprises zeolite, cementitious material, and water sufficient to form a slurry.

Abstract: Methods and cement compositions are provided for sealing a subterranean zone penetrated by a wellbore, wherein the cement composition comprises zeolite, cementitious material, and a mixing fluid.

Abstract: The invention includes a method for constructing buildings using non-wood construction products and buildings constructed from such non-wood construction products. The invention further includes a method and apparatus for manufacturing high-performance fiber-reinforced cellular concrete (HPFRCC) products and the use of such products as replacements for conventional wood lumber construction products. The products of the invention have the necessary strength, durability, nailability, and sawability for direct substitution for dimensional wood lumber in wood-frame construction applications. The invention also includes externally reinforced retaining wall systems that include stackable blocks formed of fiber-reinforced cellular concrete.

Abstract: This invention discloses a new technology related to cellulose fiber reinforced cement composite materials using the loaded cellulose fibers. This invention discloses four aspects of the technology: fiber treatment, formulation, method and final product. This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. This invention also impart the final products improved freeze-thaw resistance, reduced efflorescence, reduced chemical dissolution and re-deposition, and improved rot and fire resistances, compared to conventional fiber cement products. These improved attributes are gained without loss in dimensional stability, strength, strain or toughness.

Abstract: Methods of cementing in subterranean zones, improved cement compositions and improved additives are provided. The compositions are basically comprised of a hydraulic cement, sufficient water to form a slurry and an additive for providing improved rheology, fluid loss control and set retardation comprised of carboxymethylhydroxyethylcellulose having in the range of from about 0.62 to about 2.21 moles of hydroxyethyl substitution and in the range of from about 0.44 to about 0.52 degrees of carboxymethyl substitution and a 2% by weight aqueous solution of the carboxymethylhydroxyethylcellulose has a Höppler viscosity in the range of from about 55 mPa.s to about 359 mPa.s.

Abstract: A sprayable composition and a method of protecting material with the composition is disclosed. The composition comprises a bulking/setting material, a water soluble polymer and water to provide a cover layer which, after spraying, is tough, flexible and water-repellent. Other materials such as clay, fibrous material, a foam producing agent and a hardening retarder can be included in the composition. The composition is effective as a cover layer over material such as soil, refuse at a dump site, stockpiled material, a temporary cover for remediation sites, or tire piles.

Abstract: Compositions useful for the preparation of lightweight, high strength wallboards, and methods of making same are disclosed. The composition includes a slurry of calcium sulfate hemihydrate (stucco), water, starch, and a foam. The foam acts to provide large bubbles within the core slurry, thereby lightening the weight of the wallboard. The composition and method provide wallboards having lighter weights compared to standard wallboard, increased core strength, and increased paper-to-core bonding.

Abstract: This invention discloses a new technology related to cellulose fiber reinforced cement composite materials using the loaded cellulose fibers. This invention discloses four aspects of the technology: fiber treatment, formulation, method and final product. This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. This invention also impart the final products improved freeze-thaw resistance, reduced efflorescence, reduced chemical dissolution and re-deposition, and improved rot and fire resistances, compared to conventional fiber cement products. These improved attributes are gained without loss in dimensional stability, strength, strain or toughness.

Abstract: Compositions useful for the preparation of lightweight, high strength wallboards, and methods of making same are disclosed. The composition includes a slurry of calcium sulfate hemihydrate (stucco), water, starch, and a foam. The foam acts to provide large bubbles within the core slurry, thereby lightening the weight of the wallboard. The composition and method provide wallboards having lighter weights compared to standard wallboard, increased core strength, and increased paper-to-core bonding.

Abstract: This invention discloses a new technology related to cellulose fiber reinforced cement composite materials using the loaded cellulose fibers. This invention discloses four aspects of the technology: fiber treatment, formulation, method and final product. This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. This invention also impart the final products improved freeze-thaw resistance, reduced efflorescence, reduced chemical dissolution and re-deposition, and improved rot and fire resistances, compared to conventional fiber cement products. These improved attributes are gained without loss in dimensional stability, strength, strain or toughness.

Abstract: Producing both colored and noncolored lightweight aggregates. The processes involve mixing a lightweight fine material such as ash with cement, and optionally pigment, then agglomerating the mixture, curing, and sizing the lightweight aggregate. Calcium stearate is added to the lightweight aggregate for reducing the moisture permeability of the lightweight aggregate end product. The colored and noncolored lightweight aggregate may be used in a variety of ways such as to provide a lightweight concrete mix with the same exterior and interior color, and for other asphalt pavement, geotechnical, horticulture, and specialty uses.

Abstract: The present invention provides a lightweight clay which can be easily molded into a given shape, exhibits proper lightweight characteristics and storing characteristics, and can be manufactured at a low cost, and a manufacturing method thereof. In such a lightweight clay and the manufacturing method thereof, an average particle size of the organic hollow micro spheres is set to a value which falls within a range of 15 to 150 &mgr;m and, an addition quantity of the organic hollow micro spheres is set to a value which falls within a range of 0.1 to 6 weight % with respect to a total quantity of the lightweight clay, and whiteness degree(WL) measured in accordance with JIS L 0803 is set to not less than 50.

Abstract: Methods and compositions for forming permeable cement sand screens in well bores are provided. The compositions are basically comprised of a hydraulic cement, a particulate cross-linked gel containing an internal breaker which after time causes the gel to break into a liquid and water present in an amount sufficient to form a slurry.

Abstract: A method of making a composite product such as a building board, includes the steps of mixing together finely divided lignocellulosic fibres, a hydraulic binder, and water optionally containing a polyvinyl alcohol, to form a paste; introducing a foam generated from a polyvinyl alcohol into the paste and mixing to form a foamed product; forming the foamed product into a desired shape; and allowing the hydraulic binder to set to form the composite product.

Abstract: A fiber cement composite material providing improved rot resistance and durability, the composite material incorporating biocide treated fibrous pulps to resist microorganism attacks. The biocide treated fibers have biocides attached to inner and outer surfaces of individualized fibers to protect the fibers from fungi, bacteria, mold and algae attacks. The biocides selected have strong affinity to cellulose and do not interfere with cement hydration reactions. This invention also discloses the formulation, the method of manufacturing and the final fiber cement products using the biocide treated fibers.

Abstract: Disclosed is a concrete composition that comprises water, a cementitious material, and an aggregate material, the aggregate material comprising a granular starch. In accordance with preferred embodiments of the invention, the granular starch is a washed, pre-swollen starch, and is added to the composition in an amount ranging from about 1% to about 20% by weight of the cementitious material. The starch granules are swollen in the uncured composition but liberate water and shrink to their unswollen size as the concrete cures, thus providing a cured lightweight concrete. Also disclosed is a method for preparing a concrete composition. The disclosed method comprises providing starch granules, mixing the starch granules with water and a cementitious material to form an uncured concrete composition, and subsequently curing the uncured concrete composition thus formed.

Abstract: Methods and compositions for forming permeable cement sand screens in well bores are provided. The compositions are basically comprised of a hydraulic cement, an acid soluble particulate solid, a liquid hydrocarbon solvent soluble particulate solid, a particulate cross-linked gel containing an internal breaker which after time causes the gel to break into a liquid, water present in an amount sufficient to form a slurry, a gas present in an amount sufficient to form a foam and a mixture of foaming and foamed stabilizing surfactants.

Abstract: A mixture of a binder and a particle material, the mixture having 50 to 90 volume percent of the particle material. The binder is curable in a temperature range of 50° F. to 90° F. The volume percent of the present composition provides an inherent permeability in any conventional application method. It can be sprayed or applied by hand and yet it still maintains an intrinsic permeability.

Abstract: This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.

Abstract: A mixture of a binder and a particle material, the mixture having 50 to 90 volume percent of the particle material. The binder is curable in a temperature range of 50° F. to 90° F. The volume percent of the present composition provides an inherent permeability in any conventional application method. It can be sprayed or applied by hand and yet it still maintains an intrinsic permeability.