A light weight geopolymer concrete, having a specific gravity less than 2.0, more typically between 1 and 1.3, is provided that has compressive strength comparable to or greater than ordinary Portland concrete. The light weight geopolymer concrete has low shrinkage, expansion, and cracking, and substantially no loss of compressive strength when exposed to high temperatures of 800° C. or greater, as would occur in a fire. To be useful as a load bearing member for general applications, such as residential housing, the compressive strength of the light-weight geopolymer concrete should be at least 10 MPa, preferably greater than 12 MPa, for example greater than 15 MPa. For more demanding uses, the compressive strength should be near or at the compressive strength of concrete, that is, greater than 20 MPa, preferably greater than 30 MPa, and optimally greater than 35 MPa. To be useful during and after a fire, the strength must not be reduced by more than 20%, preferably not less than 10%, optimally not reduced at all when exposed to heat up to 800° C. Embodiments of the invention include low-density high-temperature-resistant geopolymer concrete which increases load bearing strength when exposed to temperatures above 400° C., preferably at 800° C. Key constituents for forming most embodiments include a geopolymer source such as fly ash, a cement-coated expanded vermiculite, a fiber such as wollastonite, and soluble silicates such as alkali silicates.

A method of cementing in a subterranean formation may include, activating an extended-life cement composition by mixing at least the extended-life cement composition with a liquid activated pozzolan additive comprising a carrier fluid and an activated pozzolan, wherein the extended-life cement composition comprises water, pumice, hydrated lime, and a set retarder; introducing the extended-life cement composition into a subterranean formation; and allowing the extended-life cement composition to set to form a hardened mass in the subterranean formation.

A method of cementing in a subterranean formation may include, activating an extended-life cement composition by mixing at least the extended-life cement composition with a liquid activated pozzolan additive comprising a carrier fluid and an activated pozzolan, wherein the extended-life cement composition comprises water, pumice, hydrated lime, and a set retarder; introducing the extended-life cement composition into a subterranean formation; and allowing the extended-life cement composition to set to form a hardened mass in the subterranean formation.

An interlocking system of modular units engageable to form vertically and horizontally stable assemblies. The modular units include blocks and modular panels, each having vertical and optional horizontal bores that provide passage for plumbing, electrical wiring, and other connectivity. The modular units may be formed of lightweight cementitious materials, and may find use in assemblies such as walls, floors, ceilings, roofs, and entire building structures.

An interlocking system of modular units engageable to form vertically and horizontally stable assemblies. The modular units include blocks and modular panels, each having vertical and optional horizontal bores that provide passage for plumbing, electrical wiring, and other connectivity. The modular units may be formed of lightweight cementitious materials, and may find use in assemblies such as walls, floors, ceilings, roofs, and entire building structures.

Methods for increasing the hardness of aggregate include applying a hardener to the aggregate. The hardener may react with a material of the aggregate and/or a material on a surface of the aggregate. For example, an alkali metal silicate, such as lithium polysilicate, or a colloidal silica may chemically react with calcium oxide and/or calcium hydroxide of an aggregate or on an aggregate to create cementitious material, which may at least partially fill pores in the surface of the aggregate, harden an existing microtexture of the aggregate and/or enhance the microtexture of the aggregate. These characteristics may enhance frictional characteristics, the wear characteristics and the durability of the aggregate, and of any structures formed from composite materials that include the aggregate.

Methods for increasing the hardness of aggregate include applying a hardener to the aggregate. The hardener may react with a material of the aggregate and/or a material on a surface of the aggregate. For example, an alkali metal silicate, such as lithium polysilicate, or a colloidal silica may chemically react with calcium oxide and/or calcium hydroxide of an aggregate or on an aggregate to create cementitious material, which may at least partially fill pores in the surface of the aggregate, harden an existing microtexture of the aggregate and/or enhance the microtexture of the aggregate. These characteristics may enhance frictional characteristics, the wear characteristics and the durability of the aggregate, and of any structures formed from composite materials that include the aggregate.

The present disclosure relates to roofing granule having a base granule with at least one layer on the base granule that includes hollow glass spheres embedded in a ceramic matrix and a roofing article having a substrate and a plurality of any embodiment of roofing granules described above. The disclosure additionally relates to a roofing granule precursor mixture containing base granules, an aluminum silicate, an alkali metal silicate, and hollow glass spheres. The disclosure also relates to a method of making roofing granules including providing base granules; applying a coating containing hollow glass spheres, an aluminum silicate, an alkali metal silicate to the base granules; and heating the coated granules to a temperature between about 550° F. and about 1000° F.

The present disclosure relates to roofing granule having a base granule with at least one layer on the base granule that includes hollow glass spheres embedded in a ceramic matrix and a roofing article having a substrate and a plurality of any embodiment of roofing granules described above. The disclosure additionally relates to a roofing granule precursor mixture containing base granules, an aluminum silicate, an alkali metal silicate, and hollow glass spheres. The disclosure also relates to a method of making roofing granules including providing base granules; applying a coating containing hollow glass spheres, an aluminum silicate, an alkali metal silicate to the base granules; and heating the coated granules to a temperature between about 550° F. and about 1000° F.

A composite material and process for forming composite material. The composite material comprises a quantity of plastinated plant distributed within a matrix material. The process comprises separating a plant material into plant fibers plastinating the plant fibers and combining the plastinated plant fibers with a matrix material. The plant fibers may be selected form the group consisting of bamboo, hemp and flax. The plant fibers may be formed by crushing a portion of a plant. The matrix material may comprise Polyethylene Terephthalate (PET). The PET may be shredded and heated. The heated composite material may be formed into rebar and be arranged in a pattern within a concrete slurry.