Abstract: A mold used for manufacturing an inorganic board and a method of manufacturing an inorganic board by employing said mold are provided in the present invention. Said mold consists of a mold part made of a fiber reinforced plastic and a metal part attached to the back of said mold part, and because of said metal part, the difference in the coefficient of thermal expansion between said mold and an inorganic board manufactured on said mold is small.

Abstract: A vibrating screed with rollers for use in leveling a concrete pour. The screed comprises an elongate screed member defining opposed first and second ends and extensible between a pair of screed rails. A first and second roller are rotatably mounted to the screed member and protrude from respective ones of the first and second ends thereof. The rollers are rotatably movable along respective ones of the first and second screed rails. The screed additionally may comprise a motor to rotate the rollers and/or vibrate the screed member.

Abstract: A method for manufacturing artificial stone having a curved surface or a deformed shape including the steps of heating a plate-like artificial stone forming body, whose surface has previously been polished or roughened, to a temperature ranging from 120° C. to 200° C. under a pressurized atmosphere equal to or higher than 3 atms so as to soften and deform it to a predetermined curved surface or deformed shape and cooling it to a temperature not higher than 90° C.

Abstract: An improved method for texturing gypsum fiber panels and producing surface textured panels, edge tapers, and deeper patterned wainscot-type panels, involving the use of a flexible die with a textured surface. The die is pressed onto the panel in its slurry state just after the onset of an exothermic rehydration reaction. Partial hydration and setting occur during pressing by the die to form a textured mat. The mat is removed from contact with the die at a point along the rehydration temperature curve about at or less than one-half of the rise to the greatest rehydration temperature.

Abstract: A wire reinforced cast member is produced by providing inner and outer mold forms. At least one mounting projection of a wire reinforcement support member is supported in at least one opening in one of the inner and outer mold forms. A plurality of support members cooperate to support and substantially accurately position a wire reinforcement member, which member is mounted into support slots in the support member, which slots may snap-fittingly receive the wire reinforcement. The support members maintain the wire reinforcements in proper position during the introduction of the cast material. After the cast material has set, the cast member is removed from the mold. The support members have mounting portions which easily break away from the main body of the support members as the wire reinforced cast member is removed from the mold.

Abstract: The present invention relates to a cementitious structural panel and its method of manufacture. The method of manufacture involves encapsulating a top and bottom layer of porous reinforcing material with a cementitious mixture by vibration. The structural panel may be coated with a layer of waterproof material.

Abstract: A mold box is flexibly mounted to a product forming machine having upper and lower vertically displaceable beams. A feed drawer dispenses concrete material into the mold box while a vibration system vertically vibrates the mold box while dampening horizontal vibration. The vibration system is driven by a single drive shaft that actuates first and second vibrator rods while at the same rotating a counter-weight in a counter-rotating direction. A set of alignment brackets lock the mold box into a predetermined aligned relationship while being mounted in the product forming machine. The bottom side of each mold box is mounted to the product forming machine in the same relative position to reduce machine readjustments. A set of telescoping legs hold the feed drawer assembly variable distances above the mold box. A unitized pallet feeder quickly moves pallets one at a time from an “on-deck” position to a “receiving” position underneath the mold box.

Abstract: The invention relates to a first gypsum-based composite article reinforced with glass fibers. This first article has a first member made of a hard gypsum, a second member made of a soft gypsum, and a mat made of the glass fibers. The mat is embedded in the article in a manner that the first and second members are bonded together by means of the mat. This first article is superior in resistance to external force acting thereon and to severe environmental conditions, even if the gypsumbased article is light in weight and thin in thickness. The invention further relates to a second gypsum-based composite article having a base plate, a glass fiber mat bonded to the base plate, and a gypsum layer formed on the glass fiber mat such that glass fibers of the glass fiber mat are embedded in the gypsum layer. This second article also has superior characteristics as those of the first article.

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: A method of manufacturing a calcium silicate board having a bulk specific gravity of approximately 0.5 to 0.8, which method achieves a decrease in the bulk specific gravity and an increase in the matrix strength of the board without impairing productivity, and the calcium silicate board obtained by this method. The method is characterized in that a material slurry comprising 5 to 30 wt % of calcium silicate hydrate slurry as a solid component, 17 to 50 wt % of calcareous material, 13 to 45 wt % of silica containing material, 2 to 8 wt % of fiber material, and 5 to 40 wt % of inorganic fillers is formed through conventional processes and the obtained molded body is subjected to a hydrothermal reaction in a pressure container.

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: A process for producing a concrete product, which includes a step of preparing a primary concrete by mixing a super dry consistency concrete having a unit amount of water of at most 100 kg/cm.sup.3, a step of preparing a secondary concrete by weighing a suitable amount of the primary concrete and adding at least water, a water reducing agent and a setting accelerator thereto, followed by remixing, and a step of molding the secondary concrete in a formwork.

Abstract: A method for making aggregate includes the following steps: (a) preparing a wet mixture by mixing water with a combination of ingredients in a mixer, the combination of ingredients including by weight about, 68% to 95% fly-ash and 2% to 10% lime; (b) dropping the wet mixture into at least one pile on a base surface; (c) allowing the wet mixture in the pile to substantially completely hydrolyze into a hard product; and (d) crushing the product to form the aggregate. Preferably, step (b) further includes forming an arcuate stack having multiple overlapping conical piles of the dropped wet mixture such that the stack extends a circular distance over the surface. The wet mixture may be transported from the mixer to a height above the surface and dropped to the surface by a radial stacker. The combination of ingredients, preferably, further includes by weight 0.5% to 12% alkali hydroxide and, more particularly, sodium hydroxide.

Abstract: A structural member for reinforcement of asphalt and concrete roadways and other products, and which includes a gridwork of warp strands and weft strands which are disposed at right angles to each other and so as to define an open structure. In one embodiment, the gridwork is impregnated with a thermosettable B-stage resin so as to interlock the strands at their crossover points and maintain the gridwork in a semi-flexible state, and after being applied to the product to be reinforced, the resin is heated to convert the same into a fully cured composite to thereby rigidize the gridwork and reinforce the product. In cases where the product to be reinforced is heated, such as asphalt paving, the heat of the product provides the heat necessary to fully cure the resin in situ. In another embodiment, the resin is fully cured to rigidize the gridwork prior to its being applied to the structure to be reinforced. A method of producing the resin impregnated gridwork is also disclosed.

Abstract: A concrete footing for the construction of a wall is created by the placement of a guide member with a series of very large holes, which is supported with adjustable threaded stake supports. This guide is situated along a location which will become the top surface of that footing, typically within the confines of a footing trench. Concrete is conventionally placed via a pump through the large holes thus filling the trench void up to the guide element underside. Adjacent guides are attached with plastic connectors which also fixture vertical reinforcing elements which disassemble to strip guides, typically immediately after concrete has been placed.

Abstract: An attachment mechanism for a hole form that is used to secure the hole form to a form wall during a casting process. The attachment mechanism includes a hole form having an opening formed in the face thereof and a magnet assembly which is received in the opening of the hole form. The magnet assembly can include a flange portion which can be received in a corresponding stepped portion of the opening. The magnet assembly is removable and can be used in other hole forms.

Abstract: A water repellent composition for gypsum containing masonry materials is disclosed. The composition contains as organohydrogensiloxane and polyvinyl alcohol, the combination of which provides unexpectedly high water repellency.

Abstract: A method and apparatus for making concrete pipe with a packerhead concrete pipe making machine having a lift operable to selectively raise and lower the packerhead during the forming of a concrete pipe in a mold while a conveyor delivers a constant supply of concrete to the mold. The operating speed of the conveyor only increases or decreases when the motor load signal which is proportional to the load on the motor that turns the packerhead falls below or goes above lower and upper motor load reference limits. The lift speed of the packerhead varies with the vertical positions of the packerhead relative to the mold.

Abstract: A forming system for constructing stone benches which incorporates a forming tray that has a central support extending therethrough. The central support is temporarily supported at opposite ends and temporary shoring is provided beneath the length of the forming tray. Concrete and stone are placed in the forming tray and allowed to set. Next, the set concrete and stone are removed from the forming tray and support legs are placed under the concrete and stone and they are lowered into final position.

Abstract: A method for producing colored concrete bodies, particularly colored concrete roof tiles, whereby pigment is added to the unprocessed concrete mix. In order to provide the production of permanently colored concrete bodies with reasonably priced pigments which are stable in outdoor exposure and are resistant to light, particularly UV, alkalis and heat. A cement compatible aqueous polymer dispersion in which organic pigment is dispersed is added to the unprocessed concrete mix. Suitable cement compatible polymer dispersions are aqueous polymer dispersions based on styrene and/or pure acrylate. Phthalocyanine and quinacridone pigments are particularly suitable as organic pigments.

Abstract: Bamboo fibers are utilized to serve as a reinforcing material and for manufacturing an inorganic molded body. In order to produce the bamboo fibers with excellent durability, in a first step bamboo material is compressed to be roughly crushed and in a second step the roughly crushed bamboo material is fiberized using a grinding machine. The moisture content of the bamboo material subjected to the first step is set to be more than 65%. After the completion of at least one of the first and second steps a drying step is taken so that the moisture content of the bamboo material is adjusted to within the range of 3 to 35%.

Abstract: The present invention generally relates to a system for manufacturing horizontally precast panels of moldable material which panels require shaped surface patterns. More particularly, the invention relates to a system for manufacturing horizontally precast concrete panels formed of concrete, for use in vertical wall systems, with one or more shaped surfaces.

Abstract: A method of making a building block from waste particulate siliceous materials, such as fly ash, bottom ash, and rock mineral fines, includes employing a major amount of such waste particulate materials in combination with a calciferous additive and water to cure and shape the same under the influence of controlled pressure and temperature for a predetermined time to create building block which is characterized by a mineralogical crystalline phase. Preferred ratios of fine waste particulate material and coarser waste particulate materials are disclosed. The product produced by the method is also disclosed.

Abstract: An improved, method of making a lightweight synthetic stone product mixing a white powdery mixture comprising approximately 20-90 parts by volume of Al.sub.2 O.sub.3 .multidot.3H.sub.2 O and about 10-80 parts by volume polyolefin, preferably a polyethylene such as LLPE, HDPE and Super Linear PE and polypropylene in a ratio of 30-60% by volume with a clear thermosetting resin in a ratio of about 40-70% by volume and a peroxide catalyst in about 0.1-5.0% by volume, and a pigment, if desired, with the clear thermosetting resin selected from the group of unsaturated polyesters, acrylic-modified polyesters and acrylics.

Abstract: The temperature and/or moisture profile over time of gypsum boards is monitored as the boards harden, to facilitate effective curing of the boards prior to removing excess water therein in an industrial dryer. A substrate is moved by a curing conveyor beneath a gypsum slurry mixer, and the mixer pours slurry onto the substrate. Just prior to the substrate passing under the mixer, an operator places a monitor onto the substrate. The monitor can include a temperature sensor, a conductivity sensor, and a microprocessor that receives and stores the signals from the sensors. The monitor is configured such that the height of the sensor or sensors is equal to one-half the height of the hardening boards. The slurry that has poured onto the monitor hardens into a test board, and when the test board arrives at the end of the curing conveyor, an operator breaks open the test board, removes the monitor, and connects the microprocessor in the monitor to a computer via a serial port cable.

Abstract: Gypsum-based composite boards or shaped bodies can be manufactured from a mixture comprising calcium sulfate dihydrate and water, and optionally reinforcement materials or fillers, and conventional additives, by shaping the mixture to a raw form and hardening the raw form with water at a pressure exceeding the saturation pressure of calcium sulfate dihydrate.

Abstract: A thermal insulating material with a cellular structure is disclosed which comprises a bound SiO.sub.2 -containing material converted to at least 90% into a tobermorite phase. The SiO.sub.2 -containing material is diatomaceous earth, the density of the thermal insulating material is less than 150 kg/m.sup.3 and the thermal conductivity (declared value)is less than 0.05 (W/m.sup..multidot. K).

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: The invention relates to a method for encapsulating lead paint on a surface comprises the steps of applying a glass mesh to the surface containing the lead paint and applying an encapsulating mixture in a continuous layer over the glass mesh and to the encapsulated lead paint surface. The invention completely seals and encapsulates the lead paint and has significant structural integrity to prevent exposure to lead paint.

Abstract: The temperature profile over time of gypsum boards is monitored as the boards harden, to facilitate effective curing of the boards prior to removing excess water therein in an industrial dryer. A substrate is moved by a curing conveyor beneath a gypsum slurry mixer, and the mixer pours slurry onto the substrate. Just prior to the substrate passing under the mixer, an operator places a temperature monitor onto the substrate. The temperature monitor includes a temperature sensor and a microprocessor that receives and stores the signal from the temperature sensor. The temperature monitor is configured such that the height of the sensor is equal to one-half the height of the hardening boards. The slurry that has poured onto the monitor hardens into a test board, and when the test board arrives at the end of the curing conveyor, an operator breaks open the test board, removes the monitor, and connects the microprocessor in the monitor to a computer via a serial port cable.

Abstract: A manufacturing process produces an article in slab form and more precisely an article made from a hydrated matrix which contains cement, sand, water and reinforcing fibers. The process includes the steps of mixing the constituents until a substantially homogeneous mineral paste is obtained; extruding the mineral paste in the form of a sheet having a thickness approximately equal to that of the article; and cutting the sheet to the size of the article. The article is made in the form of a slab and may be an imitative slate piece to be used as a roofing cover element.

Abstract: A premix composition for producing an inorganic solid foamed mass by mixing component (A) an aqueous acidic phosphate solution of mainly polyvalent cations and phosphoric acid wherein between 0.8 and 1.75 protons of the phosphoric acid molecule of said phosphate are neutralized by the cations, which also contains one or more fillers dispersed therein, with (B) an oxide, hydroxide or polyvalent salt of a weak acid as hardener and a carbonate foaming agent. A process of producing an inorganic foamed mass using the premix composition and a solid foamed mass produced by the process are also disclosed. The process produces a relatively elastic cross-linked structure due to mainly the secondary phosphates being neutralized versus the tertiary phosphate groups.

Abstract: Process for insolubilizing and consolidating in pellet form the spent linings from electrolysis cells for the production of aluminium comprising grinding said spent linings and mixing them thoroughly with various pulverulent refractory additives before heating, characterized in that after the addition of:a first additive intended to fix the alkali metals during firing, which is chosen from the group of aluminosilicates,and subsequently a second additive intended firstly to combine with the impregnating fluoride compounds during firing to form new stable, insoluble compounds, and secondly through its non-combined excess part to assure the consolidation of the mixture, and is chosen from the group of calcium oxides and salts, preferably limestone cements and mortars,the intimate mixture of ground, spent linings and said first and second pulverulent additives is agglomerated into pellet form before firing at a temperature in the range of from 700.degree. C. to 950.degree. C.

Abstract: A method of and apparatus for molding and texturizing the upper surfaces of concrete products such as patio and paving stones following the steps of densifying and molding the concrete products and releasing them on pallets to a substantially horizontally traveling, longitudinally extending conveyor, then passing the concrete products continuously on the conveyor past an overhead force spraying station at a predesignated speed and directing a predetermined volumetric, overhead spray of liquid at a predetermined spray angle and pressure to progressively loosen some of the material and texturize the upper surfaces as the products move past the spraying station, and then before they have absorbed enough liquid to deleteriously affect their strength, either in the uncured or cured state, and, while they are continuing to travel along the conveyor, directing a flow of gas at the upper surfaces at a pressure to blow off the liquid and loosened material from the surfaces.

Abstract: A mold box assembly includes a rectangular mold box frame having a substantially vertical divider plate mounted on the frame and extended part-way into it from an the upper side of the frame. A pair of rectangular restrictor plates are disposed vertically in the mold box from side to side and extend to the same depth as the divider plate. Wet product mix is dropped onto the box and is thereafter compressed with a shoe assembly. The shoe assembly includes a pair of shoes that extend from one side of the mold box to the other and have a thickness that allows them to be interleaved with the restrictor plates. The shoes are lowered to the lower edge of the restrictor plates. Simultaneously, another shoe mounted on the head plate compresses product on the other side of the divider plate so a higher level thus forming a header block having a first lower height formed beneath the restrictor plates and a second higher height formed on the other side of the divider plate.

Abstract: A waterproof material is disclosed herein which is obtainable by laminating many sheets of a photo-setting type fiber reinforced thermosetting resin composition comprising a resin composition containing a thermosetting resin, a photopolymerization initiator and a thickener, and a fiber reinforced material, or by laminating plural sheets of a synthetic polymer, and a waterproof application method using the waterproof material is also disclosed herein. According to the present invention, the waterproof layer can be formed on the surface of a civil engineering works or a building in a short time of about 30 minutes by a few steps without polluting a working environment. Furthermore, the waterproof layer, needless to say, has water resistance, weathering resistance, anticorrosion and substrate adhesion. In addition, it is further excellent in follow-up properties to cracks of the substrate, and walking on the waterproof layer is possible.

Abstract: A method for forming a test specimen from an asphalt concrete mixture includes providing a mold to receive a quantity of the mixture and adding a predetermined quantity of the mixture to the mold. The mixture in the mold is compressed at a pressure of at least about 7 psi while vibrating the mixture in the mold at a rate of at least about 2400 cycles per minute. The method also includes maintaining the vibration of and the application of compressing pressure to the mixture in the mold until the mixture obtains a predetermined mix design density within a range of about 90-97%.

Abstract: A method of making an article from a lightweight cementitious composition includes molding a castable cementitious mixture including an aqueous slurry of at least perlite and concrete into an article, such as a hollow, decorative article. The castable cementitious mixture can include a fibrous material, for reinforcing the cement and perlite, and an air entraining agent, for facilitating mixability and reducing a density of the cementitious mixture and facilitating casting. The mold can include an external mold form that contains the cementitious mixture and an internal mold form that displaces the cementitious mixture within the external mold form to cast the hollow article in various shapes and with various surface textures. The external and internal mold forms include liners made of a lightweight flexible material that can be removed, unfolded, and prepared and/or cleaned.

Abstract: A method for manufacturing a reinforced cementitious columnar structure comprising: (a) providing a mold having a cavity which corresponds to a shape and size of the columnar structure; (b) filling the cavity with dry coarse particulates to form a formed dry body comprising 50-90 volume percent coarse particulates having a particle size between about 1 and 60 mm so as to form a core volume; (c) introducing a slurry of cementitious material containing an amount of fine material which has been determined beforehand, the fine material having a particle size smaller than the size of interstitial voids of the coarse particulates into the core volume, the fine material and the cementitious material filling the core volume and the cementitious material infiltirating and encapsulating the coarse particulates, and the fine material remaining within the core volume; (d) curing the slurry of cementitious material to form the reinforced cementitious columnar structure; and (e) separating the mold from the reinforced ceme

Abstract: A method of forming a patterned wall includes the step of aligning a linear edge of a first linear base form liner with a linear edge of a second linear base form liner to form a non-contoured composite notch surface between a first contoured surface of the first linear base form liner and a second contoured surface of the second linear base form liner. A coupling form liner is then positioned on the non-contoured composite notch surface to produce a continuous pattern between the first contoured surface and the second contoured surface. A mold is then constructed using the first linear base form liner, the second linear base form liner, and the coupling form liner. A hardenable material is then poured into the mold. The mold is removed when the hardenable material has dried to expose a patterned wall.

Abstract: A method of producing a cambered composite joist and concrete panel assembly, and the assembly so produced, comprising the steps of providing a negatively cambered casting mold, positioning at least one negatively cambered composite joist with a bottom chord joined to a web member having non-attached top apices into the mold such that the top apices rest within the mold, pouring concrete into the mold and allowing it to harden to form a cambered concrete panel with the joists extending from the panel, removing the assembly from the mold and inverting it such that the precast camber in the panel flattens out from the effects of the weight of the panel and creep during final curing.

Abstract: A mold for producing a masonry unit with a roughened texture side surface having a plurality of side walls defining a mold cavity open at its top and bottom, adapted to receive masonry fill material by way of its open top, and to discharge molded fill material in the form of a block of predetermined height by way of its open bottom; and opposed, inwardly extending generally parallel upper and lower lips along at least one of said side walls, the upper lip being located at a predetermined height above the lower lip and the lower lip being located at the bottom of the mold cavity.

Abstract: A concrete column forming tube and method of making same for receiving poured concrete column therein to produce a concrete column is characterized by a smooth inside coated surface in the forming tube to eliminate spiral seam lines and other undesirable characteristics on the outside surface of the formed concrete column. The tube is formed from spirally-wound plies of paper adhered together and has a centrifugally-cast epoxy resin coating sprayed onto the inside surface of the spirally-wound tube while the tube is rotating to produce a smooth inside coated surface on the forming tube.

Abstract: A wood-cement board is manufactured by a method comprising mixing 30 to 40% by weight of cement material, 20 to 27% by weight of wood flake, and 30 to 40% by weight of fly ash to prepare a raw material mixture, strewing said raw material mixture on a mold panel to form a mat, pressing and pre-curing said mat with moisture, and main-curing said pre-cured mat in an autoclave. Preferably the particle size of said fly ash is selected so that less than 10% by weight of fly ash may remain on the sieve whose opening size is 150 .mu.m and said main-curing process is carried out at a temperature of the saturated aqueous vapor in a range between 140.degree. to 165.degree. C. for 7 to 10 hours.

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: An apparatus for making a lightweight, thin wall, seamless, hollow structural profile using a simple mold. The apparatus includes a base for supporting a mandril and a two piece outer form which bolts together assembled. A mixture is poured or injected into the space between the mandril and the form to produce a profile upon hardening of the mixture of either cement, fiberglass or polymers. The hollow area of the structural profile may be filled with various materials. The base comprises a plurality of upwardly rising columns or blocks and posts around the inside perimeter of the mandril and blocks around the outside perimeter of the form for proper positioning of the mandril and the form, which are separated by a predetermined distance in accordance with the desired features and dimensions of the structural profile.

Abstract: A method of controlling the ratio of hydration time (HT) to open time (OT) in the manufacture of composite materials from a mixture containing hydratable calcium sulphate such as gypsum binders, aggregates, fibers, water additives and other additives is disclosed. The method includes adding a retarder-accelerator combination such as Retardan and potassium sulphate to the mixture and applying pressure. The retarder-accelerator combination and application of pressure provide advantageous reduction in the ratio HT:OT. More particularly, HT:OT can be reduced to less than 1.

Abstract: This invention aims to provide an inorganic porous body which can be ensured with high strength and high porosity and which is applicable to soil conditioners. The inorganic porous body has a pellet-shape having pores, includes 50% and more silica by weight, and 20% and more alumina by weight. Also, the inorganic porous body has a porosity of 40% and more by volume. The sludge, which discharged from casting foundries as sludge-wastes and which has an ignition loss of 20%, is utilized as a starting material. The starting material is mixed with water to make a mixture, the mixture is formed to become pellets, and the pellets are burned.

Abstract: A woody group material and cement are combined to form a construction material. The material has an aggregate of finely split pieces formed by splitting wood, bamboo or the like in a fiber direction. The split pieces are formed in one or more layers and are surrounded by, and buried in, a mortar. A construction material can be provided which is fire resistant and has a strength comparable to a lumbered product such as wood material obtained by cutting raw wood. The finely split pieces of wood, bamboo or the like are very strong and tough because they closely adhere to the mortar. Moreover, it is possible to use a fiber structure of raw material. Since the finely split pieces can use a small diameter wood, lumbering byproducts, and other waste material, it is possible to achieve effective use of forest resources and low manufacturing costs.

Abstract: This invention relates to heat cured binder systems comprising as separate Parts: Part I comprising (a) a soluble source of silica, (b) an alcohol, and preferably (c) a surfactant; and Part II comprising an alkali aluminate. The binder systems are mixed with a refractory to form a refractory mix. The resulting refractory mix is shaped and heated at an elevated temperature to form a cured refractory shape, particularly a preform. Heat is applied by warm air, baking in an oven, microwave, or preferably by hot-box equipment.