A density controlled cold fusion concrete cementitious spray applied fireproofing material including a mixture of water, one or more of silicon dioxide, expanded glass, vermiculite, bottom ash, perlite, expanded shale, or other lightweight aggregates of various diameter sizes ranging from about 0.025 mm to about 12.5 mm in diameter; anhydrous or hydrous sodium or potassium metasilicate; waste from steel production consisting of Granulated Ground Blast Furnace Slag (GGBFS); high calcium or low calcium waste from coal combustion (fly ash or bottom ash); sodium tetraborate, sodium citrate dihydrate, citric acid, or boric acid; and an alkali-resistant micro-.

Disclosed is a foamed cementitious composition which limits or eliminates aggregate, especially porous lightweight aggregate and uses a lower than usual water to cementitious composition weight ratio. The stable cementitious foam mixtures may be employed to make cement boards and other cement products. The foamed cementitious composition was made with additions of PVOH foaming stabilizer and surfactant foaming agents to make foam water or by entrain air into cementitious slurry mixtures. The cementitious mixtures have a limited amount or preferably no perlite and no lightweight aggregate. The resulting foamed mixture had foam bubbles with size in the range of 50 to 200 m. After setting the foamed cementitious composition the resulting set board has air cells with size in the range of 50 to 200 m.

Disclosed is a foamed cementitious composition which limits or eliminates aggregate, especially porous lightweight aggregate and uses a lower than usual water to cementitious composition weight ratio. The stable cementitious foam mixtures may be employed to make cement boards and other cement products. The foamed cementitious composition was made with additions of PVOH foaming stabilizer and surfactant foaming agents to make foam water or by entrain air into cementitious slurry mixtures. The cementitious mixtures have a limited amount or preferably no perlite and no lightweight aggregate. The resulting foamed mixture had foam bubbles with size in the range of 50 to 200 m. After setting the foamed cementitious composition the resulting set board has air cells with size in the range of 50 to 200 m.

Disclosed herein is a fiber reinforced cementitious composition comprising a cementitious binder and at least one synthetic inorganic reinforcing fiber type, wherein the synthetic inorganic reinforcing fiber type comprises at least one of a man-made mineral fiber type such as basalt fibers, an aluminosilicate wool fiber type or an alkaline earth silicate wool fiber type.

Disclosed herein is a fiber reinforced cementitious composition comprising a cementitious binder and at least one synthetic inorganic reinforcing fiber type, wherein the synthetic inorganic reinforcing fiber type comprises at least one of a man-made mineral fiber type such as basalt fibers, an aluminosilicate wool fiber type or an alkaline earth silicate wool fiber type.

A method of producing an additively manufactured casting mould for the production of components using the cold casting process or lamination process, comprising the steps of a) determining a three-dimensional structure of the casting mould, b) providing a mixture, the mixture comprising a binding agent and an aggregate, c) providing a printing fluid comprising an aqueous solution of magnesium chloride or magnesium sulfate, d) applying a layer of the mixture to a support, e) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, f) applying a further layer of the mixture to the previous layer of the mixture, g) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, h) repeating steps f) and g) until the desired shape of the casting mould is achieved, i) allowing those parts of the mixture to set which have been mixed with the aqueous solution of magnesium chloride or magnesium sulfate, j) removing the mixture which has not been mixed with an aqueous solution, and coating with a formwork skin at least those parts of the casting mould which come into contact with the material of the cold-casting lamination process.

A method of producing an additively manufactured casting mould for the production of components using the cold casting process or lamination process, comprising the steps of a) determining a three-dimensional structure of the casting mould, b) providing a mixture, the mixture comprising a binding agent and an aggregate, c) providing a printing fluid comprising an aqueous solution of magnesium chloride or magnesium sulfate, d) applying a layer of the mixture to a support, e) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, f) applying a further layer of the mixture to the previous layer of the mixture, g) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, h) repeating steps f) and g) until the desired shape of the casting mould is achieved, i) allowing those parts of the mixture to set which have been mixed with the aqueous solution of magnesium chloride or magnesium sulfate, j) removing the mixture which has not been mixed with an aqueous solution, and coating with a formwork skin at least those parts of the casting mould which come into contact with the material of the cold-casting lamination process.

A concrete composition and concrete coating material are proposed. The concrete composition may contain bacteria having a carbon dioxide adsorption mechanism in order to improve the durability of concrete structures and adsorb carbon dioxide in the air regardless of light and dark conditions. The concrete composition may contain a cement-based inorganic binder and an aggregate mixture. The cement-based inorganic binder may include at least one of type 1 ordinary Portland cement, blast furnace slag, or fly ash. The aggregate mixture may include a normal aggregate, and a porous material impregnated with alkalophilic bacteria having a carbon dioxide adsorption mechanism and forming a glycocalyx. The concrete coating material may contain the cement-based inorganic binder, the aggregate mixture, and a fiber material. The fiber material may include at least one of polyethylene or nylon.

A concrete composition and concrete coating material are proposed. The concrete composition may contain bacteria having a carbon dioxide adsorption mechanism in order to improve the durability of concrete structures and adsorb carbon dioxide in the air regardless of light and dark conditions. The concrete composition may contain a cement-based inorganic binder and an aggregate mixture. The cement-based inorganic binder may include at least one of type 1 ordinary Portland cement, blast furnace slag, or fly ash. The aggregate mixture may include a normal aggregate, and a porous material impregnated with alkalophilic bacteria having a carbon dioxide adsorption mechanism and forming a glycocalyx. The concrete coating material may contain the cement-based inorganic binder, the aggregate mixture, and a fiber material. The fiber material may include at least one of polyethylene or nylon.

A density controlled cold fusion concrete cementitious spray applied fireproofing material including a mixture of water, one or more of silicon dioxide, expanded glass, vermiculite, bottom ash, perlite, expanded shale, or other lightweight aggregates of various diameter sizes ranging from about 0.025 mm to about 12.5 mm in diameter; anhydrous or hydrous sodium or potassium metasilicate; waste from steel production consisting of Granulated Ground Blast Furnace Slag (GGBFS); high calcium or low calcium waste from coal combustion (fly ash or bottom ash); sodium tetraborate, sodium citrate dihydrate, citric acid, or boric acid; and an alkali-resistant micro-.