Abstract: Bonded aggregate compositions such as concrete, concrete repair products, high temperature refractories, high temperature insulation and fire resistant insulation are made from an aqueous solution of phosphoric acid and a separate, storable dry mixture of suitable aggregate, monocalcium phosphate, and calcium in the form of calcium aluminate cement or calcium oxide. The proportion of wet to dry constituents is variable so as to select the working time and strength of the aggregate composition, typically on the order of ten to fifteen minutes. The mixture of the preferred dry constituents, and the binder to be mixed with the aggregate to yield the preferred dry mixture, are also disclosed.

Abstract: A composition comprising calcined gypsum, trimetaphosphate ion, and a water-soluble linear polymer formed by the addition reaction of ethylene oxide and/or alkoxy-substituted ethylene oxide with water, having enhanced strength when set and exhibiting high plasticity and workability such that it readily can be applied to a substrate, is disclosed.

Abstract: The invention relates to a finishing mortar for sound-absorbing coating of inner walls, ceilings and the like in buildings. It may be applied directly on concrete or some other carrying material or on underlying insulation material, such as mineral wool. The finishing mortar according to the invention is characterized in that it comprises cotton fibres and expanded mineral, such as perlite.

Abstract: A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a wallboard composition comprising primarily gypsum, and in a wallboard composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises an optional covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

Abstract: A method of continuously producing a cementitious composition such as joint compound includes pre-mixing at least two dry ingredients and pre-mixing at least two liquid ingredients. The ingredients are provided in a continuous mixing apparatus and at least substantially continuously blended.

Abstract: A lightweight gypsum board is provided, including, by dry weight, gypsum as the largest single ingredient, perlite as the second largest single ingredient, and starch as a minor ingredient, in the board. The starch may be pre-cooked prior to mixing, and is dispersed in the core of the board to act as a binder for binding the gypsum to the perlite. Gypsum board made according to the invention is lighter in weight, yet has a comparable nail pull value to conventional wallboard.

Abstract: A composition suitable for making acoustical tiles in a water-felting process comprises expanded perlite, clay, a binder component selected from the group consisting of starch, latex, cellulosic fiber and mixtures thereof and optionally mineral wool. The use of an expanded perlite having a relatively high density, preferably between about 9 pounds per cubic foot to about 20 pounds per cubic foot, enables the formation of a suitable slurry with a relatively low amount of water and enables a more complete dewatering of the mat prior to drying.

Abstract: Bonded aggregate compositions such as concrete, concrete repair products, high temperature refractories, high temperature insulation and fire resistant insulation are made from an aqueous solution of phosphoric acid and a separate, storable dry mixture of suitable aggregate, monocalcium phosphate, and calcium in the form of calcium aluminate cement or calcium oxide. The proportion of wet to dry constituents is variable so as to select the working time and strength of the aggregate composition, typically on the order of ten to fifteen minutes. The mixture of the preferred dry constituents, and the binder to be mixed with the aggregate to yield the preferred dry mixture, are also disclosed.

Abstract: The object of the present invention is to prevent delamination of an inorganic board. To attain this object, a method of manufacturing an inorganic board comprising forming a single mat by the paper making method by using slurry of raw material mixture substantially consisting of cement material, fiber material and inorganic filler inside of which is empty wherein said empty inorganic filler is effected on an alkali treatment; laminating the plural number of said single mats to form a laminated mat; and molding, incubating and curing said laminated mat.

Abstract: A roof tile which is lightweight and yet strong has a dry component that includes cement, gypsum, perlite aggregate, lava stone and a powder that may be perlite powder or volcanic ash. Water and a styrene acrylic catalyst are mixed with the dry constituents. The composition can be formed into the shape of roof tiles by conventional equipment.

Abstract: This invention is directed to a lightweight concrete combination. The combination includes a lightweight concrete product having auxiliary structures, such as at least one fastener, embedded therein. The lightweight concrete product comprises (a) cement and (b) a lightweight additive material. The invention also relates to a method for using the lightweight concrete product, and to a method for producing the lightweight concrete combination.

Abstract: A premixed ultra-light sandless mortar for use with clay and concrete tiles. The mortar uses ASTM standard C-332 aggregate, vermiculite or perlite aggregate in place of heavy aggregates such as sand. The mortar cement is made from portland cement, lime, air entraining agents, and water repelling agents. The resulting compound retains large amounts of moisture which increases hydration time resulting in improved bonding strength, and increased tile uplift strength. The light weight of the mortar also allows a full bed of mortar to be laid on the roof with the resulting benefit of an addition insulating layer for the building. The mortar is suitable for roofing or floor tile applications.

Abstract: Insulation barriers incorporating a cementitious structural matrix formed from a cementitious mixture including a hydraulic cement and water. The insulation barriers are manufactured from cementitious materials in order to be lightweight, insulative, less expensive, and more environmentally compatible than those currently used; they may augment, and even take the place of, traditional insulation materials including insulations made of glass fibers, polyurethane foam, urea-formaldehyde foam, polystyrene, wood fiber, cellulose fiber, rock-wool, etc. The cementitious structural matrix of the insulation barriers usually includes a hydraulic cement paste (formed from the reaction of water with, e.g., a portland-type cement) in combination with a rheology-modifying agent, such as methylhydroxyethylcellulose, and a lightweight aggregate material, which lowers the density of the insulation barrier and increases its insulation ability.

Abstract: A premixed ultra-light sandless mortar for use with clay and concrete tiles. The mortar uses vermiculite or perlite aggregate in place of heavy aggregates such as sand. The mortar cement is made from portland cement, lime, air entraining agents, and water repelling agents. The resulting compound retains large amounts of moisture which increases hydration time resulting in improved bonding strength, and increased tile uplift strength. The light weight of the mortar also allows a full bed of mortar to be laid on the roof with the resulting benefit of an addition insulating layer for the building. The mortar is suitable for roofing or floor tile applications.

Abstract: A blend for producing refractory imitation fireplace objects comprises between 30% and 50% amorphous aluminum siliceous mineral silicate, between 1% and 5% fibre and between 40% and 60% high temperature cement. A method of producing a slurry for casting the refractory objects consists of blending the amorphous aluminum siliceous mineral silicate, the fibre, an aggregate and colorant, adding and blending a high temperature cement and a dispersant and adding between 35% and 45% by weight of water.

Abstract: An improved fire retardant insulation material for buildings is disclosed. The insulation material comprises a mixture of perlite and natural or synthetic zeolite bound together by a lime-cement mixture. The insulation is reinforced by a three dimensional inorganic fiber network which bonds with the other materials to form exceptionally stable insulation materials. Natural volcanic rock may also be added to the lime cement binder as a replacement for a part of the perlite/zeolite mixture.

Abstract: A synthetic cover for bulk material piles and loads in transit may be formed from a mixture of liquid, binder, and fibers. These constituents may be mixed and applied to cover a waste pile. The cover will harden to minimize water infiltration, wind blown dust, odor and affinity to birds, flies and other insects. The liquid may include water; the binder may include portland cement, portland cement with flyash, cement kiln dust with or without bentonite, or stone dust. The fibers may comprise shredded paper or wood or plastic fibers.

Abstract: A method of, and compositions for, the making of a fire-resistant door core assembly. Doors produced from the door core assemblies. In the making of a door core assembly, an aqueous slurry containing gypsum cement and diatomaceous earth is prepared. The slurry may also include expanded mineral ore material and Portland cement. The slurry preliminarily hardens during a green cure stage.

Abstract: A structural article of manufacture having a specific gravity less than about 1.5, composed of a compressed, dry cementitious composition comprising a particulate aggregate substantially free from particles smaller than about minus 80 mesh.

Abstract: A clay-free, asbestos-free and glass microbubble-free, drying type Joint compound containing an in-situ or associative thickener as a substitute for asbestos and any clay substitute therefor. In particular, these drying type joint compounds contain no attapulgus clay thereby improving viscosity stability, crack resistance and shrinkage. The lightweight joint compounds contain treated expanded perlite, treated to render it water-insensitive. The preferred in-situ thickeners are acidic acrylate copolymers. It has been found that the in-situ thickeners should be used in combination with the normal cellulosic thickeners used in joint compounds Instead of as replacements therefor. The joint compounds contain the usual fillers and latex emulsion binders, with at least about 50% by weight of the drying type joint compound being a filler selected from the group consisting of calcium carbonate and calcium sulfate dihydrate.

Abstract: A pumpable backfill grout which hardens into a controlled low strength material and an additive for making up such a backfill grout. The grout consists essentially of portland cement, a smooth surfaced vesicular expanded perlite, fly ash, fine aggregate, water, an air entraining agent, a quick dispersing thixiotropic suspending agent and a bentonite thickening agent.

Abstract: A formula of lightweight aggregates, fiber, and Portland Cement, which, when graded, prepared and mixed as described produces a lightweight, fire and thermal resistive concrete which can be successfully and easily extruded into shapes for use in construction, principally, roofing tiles, shingles and shakes. This mix can also be pressed into the same shapes and brick and block shapes. The resultant compressed product is homogeneous and uniform thus creating superior strength characteristics. This "concrete" is approximately half the weight of traditional concrete (specific weight is 0.85 to 1.0, or expressed in metric, 0.85 gr. per cc.) and is greater than half as strong and absorbs the same amount of water.

Abstract: An insulating board is provided in which the capacity to absorb the moisture exemplified by wood fiber based board, cellulose fiber based board and perlite based board is coupled with the high permeability of fiberglass insulation to provide a board having a balance between the capacity to hold moisture and sufficient permeance to allow the board to give up the moisture as the board is passed through a cycle of absorption and desorption, whether it be on a daily or seasonable cycle.

Abstract: A lightweight wallboard having a density in the range of 10 pcf to 30 pcf and comprised of a faced layer of expanded siliceous inorganic particles, such as expanded perlite, bonded together by inorganic binder, such as sodium silicate. The board is made by depositing a mixture of particles, binder and water onto a moving web of facing material, contacting the mixture with an upper moving web of facing material, compacting the mixture to the desired shape and density and drying the resulting board. Fire resistant and water repellent versions of the formula are also disclosed.

Abstract: An inorganic board having excellent dimensional stability and excellent insulating properties comprises a pair of surface layers consisting of a hardened mixture of 30 to 60% by weight of cement, 30 to 60% by weight of a silica-containing material, 0 to 15% by weight of pearlite and 5 to 25% by weight of flake and/or wood powder, and a porous core layer consisting of a hardened mixture of 30 to 60% by weight of cement, 30 to 60% by weight of a silica-containing material, 0 to 15% by weight of pearlite and 5 to 25% by weight of wood-fiber bundle.

Abstract: An improved composite material is prepared by first uniformly mixing cement and perlite fines. The perlite fines comprise particles that are less than 200 mesh. The mixture of perlite fines and cement is then mixed with water, formed into a desired shaped, and allowed to dry. The dried material is useful in many applications where cement is used and has fireproofing and strength characteristics superior to ordinary concrete.

Abstract: Process for making a cement mixture containing fibers wherein a paste is formed by mixing cement and, per 100 parts by weight of cement, approximately 5 to 20 parts by weight of a first pulverized material of which the grains have an average diameter of between 1/5 and 1/10 of the average diameter of the grains of the cement and approximately 20 to 35 parts by weight of water. The paste is then mixed with reinforcing fibers. The paste may also include a second pulverized material the average grain diameter of which is between 1/5 and 1/10 of the average diameter of the first pulverized material. The invention further includes products made from a cement mixture manufactured according to one of the foregoing processes.

Abstract: A high strength concrete particularly useful for precast, prestressed products comprising by weight of the wet concrete mix, 8 to 60 percent cement, 0.5 to 20 percent smooth-surfaced, vesicular, expanded perlite, 5 to 30 percent water, 0 to 12 percent pozzolan, and fine aggregate and coarse aggregate as appropriate and available in the circumstances. The concrete provides superior bond to reinforcing strands. The smooth-surfaced, vesicular, expanded perlite is unique and novel.

Abstract: A process for the production of concrete roofing products of reduced weight loading having a thickness in section of not greater than 15 mm. The process involves forming an asbestos-free cementitious composition comprising (i) lightweight aggregate, (ii) hydraulic cement, (iii) water and (iv) reinforcing fibers in an amount of not more than 4% by weight of the total weight of the composition but the fibers being present in an amount sufficient to provide a reinforcing effect and impact strength in the roofing product, the cementitious composition being capable of being shaped by a roller and slipper method, and thereafter shaping the cementitious composition by the method to provide a shaped extrudate, dividing the extrudate to form sections and curing the sections to provide roofing products, wherein the reinforcing fibers have lengths of 0.5 mm to 20 mm. The impact resistant roofing products are useful as roofing tiles, or a replacement for shingles, shakes and slates.

Abstract: An improved composite material is prepared by first uniformly mixing cement and perlite fines. The perlite fines comprise particles that are less than 200 mesh. The mixture of perlite fines and cement is then mixed with water, formed into a desired shaped, and allowed to dry. The dried material is useful in many applications where cement is used and has fireproofing and strength characteristics superior to ordinary concrete.

Abstract: A process for manufacturing composite materials of high quality whatever be the respective amount, proportion and kind of constituents used in the starting mixture which comprises a binder made of two components capable of reacting with each other, at least one of these two components being in a liquid form, at least one filler, and reinforcing fibers, the binder being selected from the group of binders made of the following components: hydraulic cement and water; potassium and sodium silicate and water, colloidal silica and water; and organic resins and resin hardeners or catalysts. According to this process, all the liquid component of the binder is impregnated into an absorbing substance preferably consisting of vermiculite, which is compatible with the binder, the filler and the fibers.

Abstract: There are disclosed high temperature refractory mixes especially adapted for relining and resizing chimney flues, comprising from 65 to 70 weight percent of portland cement, from 21 to 25 weight percent of volcanic glass, from 6 to 10 weight percent of microsilica, from 0.05 to 0.12 weight percent of at least one air entraining agent and from 0.5 to 1.0 weight percent of at least one plasticizer.

Abstract: A product and method for conditioning fabrics, especially denim, is disclosed. The product is an artificial stone made up of an inorganic filler, inorganic abrasive particles and an inorganic bond for the filler and abrasive. The method is the use of the stone to condition fabrics.