Abstract: A method for forming a gypsum slurry comprises the steps of combining gypsum and water to form a slurry, combining cellulose ether with at least a second material configured to delay solubilization of the cellulose ether, and adding the combined cellulose ether and at least a second material to the slurry.

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: In order to also be able to economically use iron ore dust which is created by the extraction and preparation of iron ore and has not been usable until now, the invention proposes an agglomerated stone comprising (in wt. %) 6-15% of a cement binding agent, up to 20% of a carbon carrier, up to 20% of residual and recyclable substances, optionally up to 10% of a coagulation and solidification accelerator and the remainder consisting of iron ore in a stone format in the form of particles having a particle size of less than 3 mm as well as possessing after three days an initial strength of at least 5 N/mm2 and after 28 days a cold compression strength of at least 20 N/mm2. As a result of the particular hardness St and form stability thereof even at high temperatures T, agglomerated stones according to the invention are especially suitable for use in shaft, corex or blast furnaces. The invention also relates to a method for producing agglomerated stones according to the invention.

Abstract: A mixture of metal fiber concrete based on cement, granular elements and water, comprising metal fibers whose diameter ranges from 1.15 mm to 1.8 mm, wherein the form coefficient thereof is between 35 and 45. The dosing of metal fibers is at least 80 kg/m3. This concrete mixture is particularly adapted to the creation of structural elements such as floor slabs without traditional reinforcements.

Abstract: Articles, including fiberboard, are made from a pumpable, flowable slurry including alpha-calcined calcium sulfate hemihydrate anchored in pores of host particles, alpha-calcined calcium sulfate hemihydrate, a silicone compound, magnesium oxide, and water. The magnesium oxide catalyzes the reaction of the silicone compound into a silicone resin. In a preferred method of making a water resistant fiberboard calcium sulfate dihydrate is combined with the host particles and water to form a slurry which is heated under pressure to calcine the calcium sulfate dihydrate to form alpha-calcined calcium sulfate hemihydrate. After relieving the pressure, a silicone compound and magnesium oxide are added to the slurry. The slurry is dewatered to form a filter cake, which is then formed into a desired shape and allowed to set.

Abstract: A method for producing concrete or mortar based on an exclusively vegetal aggregate, a mineral binding agent, and mixing water is described. Instead of the vegetal aggregate being premineralized in a separate step of the operation, 4 to 14 kg of a non-hydratizable, finely ground mineralizator is added for each cubic meter of vegetable aggregate when the concrete or mortar is being mixed. Raw calcium carbonate is a preferred mineralizator.

Abstract: A method for generating foam for gypsum product manufacturing includes injecting water through a conduit and injecting a foaming agent through the conduit to form a first solution comprising the water and the foaming agent. The method includes straining the first solution in the conduit and injecting air through the conduit to form a second solution comprising the water, the foaming agent and the air. The method also includes straining the second solution in the conduit to form foam and communicating the foam to a gypsum product manufacturing device.

Abstract: A composite material is obtained by mixing with water 100 parts in weight of binder, between 250 and 800 parts in weight of steel-based shot having a granulometric distribution comprised between 120 jim and 3000 jim, between 10 and 15 parts in weight of non-densified silica fume and a highly water-reducing superplasticizer. The ratio between the weight quantity of water and the weight quantity of hydraulic binder is comprised between 0.16 and 0.25. The composite material presents a very high abrasion resistance, an abrasion index measured according to the C.N.R protocol comprised between 0.15 and 1.0, the value of the D10 grain size of the shot being at least eight times greater than the value of the D90 grain size of the hydraulic binder.

Abstract: A method for producing a block having a flat bottom, a flat top which is parallel to the bottom and sidewalls which extend between the bottom and the top is disclosed. At least three cooperating mold parts are assembled on a first plate to produce assembled mold parts having interior surfaces which conform with the shape of the sidewalls of the block and flat, coplanar tops and bottoms. The assembled mold parts are clamped together, and a high slump concrete which is hardenable by hydration of cement therein is charged and worked as required into close proximity to the interiors of the mold parts and to the plate inside the mold parts. A foamable composition capable of forming a body of a thermoset, closed cell, urethane foam having a density of about 10 to 60 pounds per cubic foot which fills the interior of the assembled mold parts above the concrete therein is then charged, and a second plate is clamped over the tops of the mold parts.

Abstract: A gypsum composition comprising water, stucco, clay, an amine compound, a polyoxyalkylene, and a comb-branched copolymer is disclosed. The gypsum composition has improved fluidity. A method for preparing the gypsum composition is also disclosed. The method comprises mixing the components to form a slurry, casting the slurry into a product, and drying the product.

Abstract: This invention is directed to a method of reducing the water demand of expanded perlite that includes obtaining a vibrating screen supported at an angle and placing expanded perlite on the vibrating screen. The expanded perlite is moved over the screen past toward a burner at a rate that heats the expanded perlite to a temperature sufficient to anneal it. The expanded perlite is then moved away from the burner and allowed to cool. Another embodiment of this invention is directed to a method of making a gypsum product. The method includes annealing perlite by the method described above, then preparing a slurry of calcium sulfate hemihydrate, additives, water and the annealed perlite. The slurry is formed into the shape of the gypsum product and allowed to set. This process is particularly useful in making gypsum panels and acoustical panels that benefit from the use of lightweight materials.

Abstract: In conjunction with water, a mixture can be used to prepare a sprayable slurry that hydrates to form a machinable plaster composition. The mixture includes from about 80% to about 98% by weight calcium sulfate hemihydrate, from about 1% to about 5% by weight adhesive binder for adhering said plaster mixture to a substrate and from about 0.001% to about 10% of a polysaccharide. The mixture is made into a slurry by the addition of from 10% to about 50 weight water based on the weight of the mixture.

Abstract: A method for installing a fiberglass or stainless steel liner into a steel casing which results in a reduction of strain on the casing. Conventional means are used to place the liner into the casing and to fill the annular space with cement. Thereafter, maximum design operating pressure on the liner is maintained while the pressure on the annular space is reduced; maintenance of those pressures keep the liner in an expanded state while the grout cures. As a result, the liner shares the load with the casing; pressure from the fluids contained in the system during operation is not transferred to the casing through the grout until the liner's preset internal pressure is reached. The use of the method greatly reduces the possibility of flowline failure.

Abstract: A casting system and method for producing a veneer product is provided. The casting system of the instant invention includes a feed system containing casting material and a receiver for receiving the casting material from the feed system. The receiver includes a pliable casting member having at least one casting compartment for receiving and forming the casting material, and may have a releasable rigid frame. The receiver and the feed system are operatively joined to guide the casting material into the at least one casting compartment. The method includes the steps of: first, conveying a receiver to a feed system; next, charging the feed system with a casting material; next, discharging the feed system, wherein the casting material is deposited into the at least one casting compartment; then, curing the casting material to form a veneer product; and finally, removing the veneer product from the at least one casting compartment.

Abstract: Certain embodiments of the present technology provide reinforcing guide systems used in fabrication of concrete elements and methods of constructing reinforcing guides used in fabrication of concrete elements. For example, in one embodiment, a reinforcing guide system used in fabrication of a concrete element comprises: a guide; and a plurality of brackets attached to the guide, wherein each bracket is configured to receive and secure a reinforced bar. For example, in one embodiment, a method of fabricating a concrete element comprises: providing a guide with a plurality of brackets attached thereto; securing a plurality of reinforced bars to the guide using the brackets, thereby constructing a reinforcing guide; placing the reinforcing guide in a mold; and pouring mixed concrete into the mold.

Abstract: A block forming apparatus is provided. The block forming apparatus includes first and second jackets detachably secured to a base pallet. The first and second jackets may be removed from the base pallet during the curing period of a block for use with a second base pallet. A transport is provided for removing and transporting the first and second jackets. A method of manufacturing concrete blocks with the block forming apparatus is also provided.

Abstract: Concrete products and mixes with reinforcing carbon graphite fibers, the carbon fibers being provided in the form of resin coated warped beam fabric, and a method for producing reinforced concrete products, where semi-cured carbon fibers are mixed with concrete and then cured through the hydration step to result in the formation of strengthened concrete products.

Abstract: A concrete dispensing apparatus is used in a manufacturing process for producing pre-cast concrete structures, which are conventionally used to form a foundation for a residential or commercial building. The dispensing apparatus includes a hopper that funnels to a discharge opening extending along the entire transverse length of the dispensing apparatus. A plurality of individually controlled gates cover the entire discharge opening for selectively controlling the length and location of the discharge opening through which concrete is dispensed. The dispensing apparatus also includes a finishing mechanism including a vibratory screed and a rotational finishing roller. The form can be moved relative to the dispensing apparatus or vice versa. A form vibrator induces a vibratory motion into the form to remove air from the dispensed concrete mixture.

Abstract: Disclosed is an improved alpha-type calcium sulfate hemihydrate. Methods of producing an improved powdered calcium sulfate hemihydrate (CaSO4.½H2O) [alpha-type] compound are disclosed, at least one method including forming calcium sulfate dihydrate (CaSO4O.2H2O) into a briquette, calcining the briquette to transform the calcium sulfate dihydrate to calcium sulfate hemihydrate [alpha-type], drying the calcium sulfate hemihydrate [alpha-type] briquette, and optionally grinding the briquette. Also disclosed are methods of producing an improved gypsum plaster including producing the disclosed powdered calcium sulfate hemihydrate [alpha-type] and mixing the powdered calcium sulfate hemihydrate [alpha-type] with water.

Abstract: In a method for forming concrete structures a form having at least one elongate body has an L-shaped strip attached along the lower edge of the elongate body. The L-shaped strip has an inside corner radius. Concrete is then poured into the form and against the inside corner radius of the L-shaped strip. After the concrete has set, the form and L-shaped strip are removed from the concrete, which is partially cured, to provide a concrete body having a curved edge that corresponds to the L-shaped strip. Thereafter, the curved edge is finished with a hand tool to provide a smooth drip edge. Once the finishing is completed, the concrete is allowed to fully cure.

Abstract: According to various embodiments, methods, apparatuses, and products are provided that use an S-shaped die mold and a scoring/knifing process to produce two types of dies (S-shaped tiles and C-shaped tiles) from the S-shaped tile mold. The scoring/knifing process forms one or more channels or other suitable shapes in the S-shaped tile. At least one of the channels creates the appearance that the S-shaped tile comprises two separate and cooperating tile sections, each having a generally C-shaped cross section. In a further embodiment, at least one of the channels may be painted, colored, or otherwise darkened to accent a “shadow” effect, further creating the appearance that the C-shaped portions of the S-shaped tile are separate. In another embodiment, a method is provided that allows the S-shaped tiles to be broken or not broken along one or more of the channels, depending on the installer's preference.

Abstract: A method for installing a fiberglass or stainless steel liner into a steel casing which results in a reduction of strain on the casing. Conventional means are used to place the liner into the casing and to fill the annular space with cement. Thereafter, maximum design operating pressure on the liner is maintained while the pressure on the annular space is reduced; maintenance of those pressures keep the liner in an expanded state while the grout cures. As a result, the liner shares the load with the casing; pressure from the fluids contained in the system during operation is not transferred to the casing through the grout until the liner's preset internal pressure is reached. The use of the method greatly reduces the possibility of flowline failure.

Abstract: A form for creating cavities within large concrete structures, wherein the formed is created by interconnecting a plurality of section members, the section members having flexible mold skeleton members retaining polymer-aggregate panel members, and wherein the form may be internally pressurized to increase its rigidity and weight-bearing capability. The mold skeleton members have annular and longitudinal flanges that are used as planing guides to form the external surface of the polymer-aggregate panel members. Preferably, spacer members are inserted between the annular and longitudinal flanges and the spacer members are used as planing guides. The adjacent section members are mechanically joined to each other, such that the form may be disassembled and re-used.

Abstract: A reef artifact for simulating a coral reef includes a reef-like formation, which forms a base structure for simulating coral. The reef-like formation also has structures on it that simulate reef organisms. The reef-organism structures enhance the varied and diverse coral-like surface of the reef-like formation. The reef artifact is also configured to be mounted on a sea wall or a sea floor. The reef artifact dampens the force of waves and water currents thereby reducing erosion of the sea wall. The reef artifact also provides a suitable marine environment for microorganisms and small marine animals, thereby creating a diverse marine habitat. In yet another use, the reef artifact is suited for use as a sculpture in a garden or on a patio.

Abstract: An improved process calcining a gypsum/cellulosic fiber slurry to produce a composite gypsum/cellulosic fiber product resides in adding a selected crystal modifier to the gypsum/cellulosic fiber slurry prior to the heating step to reduce the time necessary to carry out the calcination process, to reduce the temperature at which the calcination process is run or to increase the aspect ratio of the acicular calcium sulfate alpha hemihydrate crystals formed during the calcination process. Useful crystal modifiers include aluminum sulfate, aluminum chloride, chlorine, zinc sulfate, iron (III) sulfate, aluminum sulfate hexadecahydrate, iron (II) sulfate heptahydrate, iron (III) sulfate pentahydrate, zinc sulfate heptahydrate, copper sulfate pentahydrate, copper chloride dehydrate, manganese sulfate monohydrate and trisodium phosphate.

Abstract: Method and apparatus for converting wet synthetic gypsum from a flue desulphurization process (FGD) to easily handled and metered briquettes by mixing a hydraulic additive such as by-pass dust from a cement kiln with synthetic gypsum and allowing the heat from the resulting hydraulic reaction to reduce the water content of the mixture to a formable consistency without adding external heat to the mixture as it is formed into briquettes.

Abstract: A building element may be formed from a first cementitious mixture and a second cementitious mixture containing a photocatalytic cementitious mixture. The first cementitious mixture and the photocatalytic cementitious mixture may be co-formed into a shaped uncured two layer monolith having a base layer of the first cementitious mixture and a top layer of the photocatalytic cementitious mixture. The shaped uncured two layer monolith is then cured. The resulting building element may be algae-resistant.

Abstract: The present invention provides a method of forming a shaped article having a matrix that contains sintered fly ash. The method comprises the step of blending fly ash together with water to produce a fly ash dough. The water is added in excess of that which is absorbed by the fly ash so that the dough contains free water so as to be in at least a partially fluid state. The method also comprises the steps of forming a green article in a desired shape from the fly ash dough, and removing at least a portion of the free water from the fly ash dough during and/or after forming of the green article. The green article is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. The present invention also provides a building element having a matrix of sintered fly ash.

Abstract: The present invention is drawn toward materials, methods and systems for solid free-form fabrication of three dimensional objects. In one embodiment, a method can comprise a) applying a particulate blend in a layer, wherein the particulate blend includes calcium aluminate particulates and polymeric binder particulates; b) dispensing an aqueous polyol-containing liquid vehicle onto a predetermined area of the particulate blend to form hydrated cement in the predetermined area; c) hardening the hydrated cement; and d) repeating steps a) through c) such that multiple layers of the cement are formed that are bound to one another, thereby forming the three dimensional object.

Abstract: A method of manufacturing molded concrete products including, but not limited to, precast concrete panels having at least one decorative design on the surface(s) of such panels. At least one chemical cement retarder to a substrate. Thereafter, a stencil pattern embodying a desired pattern is placed on the retarder-laden substrate and secured in place. The substrate with the affixed stencil is then placed in a casting bed and secured from movement within such casting bed. Concrete mixed to desired specifications is poured or otherwise introduced into the casting bed. If colored panels are desired, colored aggregates can be added to the concrete by replacing portions of certain fine aggregates normally found in concrete with colored aggregates. The concrete in the casting bed is allowed to harden, thereby forming a concrete panel in the casting bed. The concrete panel is lifted from the casting bed and the retarder-laden substrate is then removed from the panel.

Abstract: Molds and processes that permit high-speed, mass production of retaining wall blocks having patterned or other processed front faces, as well as retaining wall blocks formed by such processes. The invention permits the front face of the block to be impressed with a pattern or otherwise directly processed, to allow the formation of pre-determined block front faces, while at the same time facilitating high-speed, high-volume production of blocks. A mirror image of the desired pattern can be created on a stripper shoe by selecting a desired three-dimensional surface from a naturally occurring or man made object and digitally scanning the selected three-dimensional pattern to create scanned data. The scanned data can then be used to machine a face of the stripper shoe that is the mirror image of the selected pattern.

Abstract: This disclosure is a system which includes processes, machines, articles of manufacture and compositions of matter required to construct a habitable structure comprised of a cementitious product, preferably autoclaved aerated concrete (“AAC”), formed in unique blocks, panels and beams. This results in an extremely environmentally friendly habitable dwelling, residential or commercial, which, due to the resultant synergy of embodiments, when compared to a similar structure employing prior art and/or current industry's standard materials and methods of construction, is structurally superior and simultaneously yields substantial savings in labor, time and costs.

Abstract: A method and apparatus for molding a reproducible uniform concrete test cylinder. Concrete is poured into a concrete test cylinder mold. A cap having at least one excretion hole is placed on the top portion of the concrete test cylinder mold. The cap is pressed against the top portion of the concrete test cylinder mold thereby excreting excess concrete through the excretion hole in the cap. After the cap is separated from the poured concrete, the poured concrete is allowed to cure within the concrete test cylinder mold for a predetermined time. Then, the cured concrete is removed from the concrete test cylinder mold thereby producing a uniform and reproducible concrete test cylinder.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: A method for making a regenerated soil material for the production of a structural unit includes the steps of: a) obtaining a raw soil material containing aluminum and silicon from a natural source; b) adding an active mineral containing aluminum and silicon to the raw soil material; c) cleaving the raw soil material and the active mineral in a base so as to dissociate aluminum monomer and silicon monomer out of the mixture of the raw soil material and the active mineral; and d) polymerizing the aluminum monomer and the silicon monomer so as to form silicon-oxy tetrahedron and aluminum-oxy tetrahedron in the mixture.

Abstract: The present invention discloses a method for making a porous calcium phosphate article including i) preparing a shaped article from a paste containing a calcium phosphate cement, a pore-forming powder and a setting liquid; ii) immersing the shaped article in an immersing liquid for a period of time so that the pore-forming powder is dissolved in the immersing liquid, creating pores in said shaped article; and iii) removing the resulting porous shaped article from the immersing liquid, wherein the resulting porous shaped article has an improved compressive strength. The porous shaped calcium phosphate article of the present invention may be used as a tissue-engineered scaffold, medical implant or a reinforcing constituent of a composite.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: To provide a composite for a building material capable of manufacturing a building material that is harmless to living environment and global environment and can be recycled. The composite for a building material contains diatomaceous earth, waste lumber, and inorganic hardener, or further contains field earth, and, as necessary, contains used paper and/or crushed pieces of used tatami mat and used tile, and crushed earth. The composite for a building material is prepared by homogeneously mixing the components, and then the building material is manufactured by molding and curing the composite. The manufactured building material has a high humidity conditioning property as in the case of the conventional mud wall made of coarse clay, and is easily recycled by being crushed.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a method for making a molded calcium phosphate article including impregnating a rigid shaped article of calcium phosphate in an impregnating liquid for a period of time so that a compressive strength of the resulting impregnated article removed from the impregnating liquid is increased compared to that of the rigid shaped article. The molded calcium phosphate article made according to the present invention may be used as a medical implant or a reinforcing constituent of a composite.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a method for making a porous calcium phosphate article including i) preparing a shaped article from a paste containing a calcium phosphate cement, a pore-forming powder and a setting liquid; ii) immersing the shaped article in an immersing liquid for a period of time so that the pore-forming powder is dissolved in the immersing liquid, creating pores in said shaped article; and iii) removing the resulting porous shaped article from the immersing liquid, wherein the resulting porous shaped article has an improved compressive strength. The porous shaped calcium phosphate article of the present invention may be used as a tissue-engineered scaffold, medical implant or a reinforcing constituent of a composite.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a method for making a porous calcium phosphate article including i) preparing a shaped article from a paste containing a calcium phosphate cement, a pore-forming powder and a setting liquid; ii) immersing the shaped article in an immersing liquid for a period of time so that the pore-forming powder is dissolved in the immersing liquid, creating pores in said shaped article; and iii) removing the resulting porous shaped article from the immersing liquid, wherein the resulting porous shaped article has an improved compressive strength. The porous shaped calcium phosphate article of the present invention may be used as a tissue-engineered scaffold, medical implant or a reinforcing constituent of a composite.

Abstract: The present invention relates compositions containing acetoacetylated polyvinyl polymers obtained from polyvinyl polymers, such as polyvinyl butyrals. These coating compositions are especially suitable for use as wash primers in automotive OEM and refinish coating applications.