Foamed fiber compositions and processes of making said compositions. Compositions include a hydraulic mixture including (i) a polymer and (ii) one or more of gypsum, fly ash, and cement; and a foam including a foaming agent, a foam stabilizer, and 0.5-35% fibers by weight. The process for forming the foamed fiber composition includes providing a stable foam including a foaming agent and a foam stabilizer; mixing fibers into the stable foam until the fibers are uniformly distributed in the foam to form a fiber-containing foam, wherein the fiber-containing aqueous foam contains 0.5-35% fibers by weight; and mixing the fiber-containing foam into a hydraulic slurry including (i) a polymer and (ii) one or more of gypsum, fly ash, and cement. The composition is suitable for use in roof tiles, underlayments, backerboards, cement composites, foam fills, bricks, cement sidings, etc.

Foamed fiber compositions and processes of making said compositions. Compositions include a hydraulic mixture including (i) a polymer and (ii) one or more of gypsum, fly ash, and cement; and a foam including a foaming agent, a foam stabilizer, and 0.5-35% fibers by weight. The process for forming the foamed fiber composition includes providing a stable foam including a foaming agent and a foam stabilizer; mixing fibers into the stable foam until the fibers are uniformly distributed in the foam to form a fiber-containing foam, wherein the fiber-containing aqueous foam contains 0.5-35% fibers by weight; and mixing the fiber-containing foam into a hydraulic slurry including (i) a polymer and (ii) one or more of gypsum, fly ash, and cement. The composition is suitable for use in roof tiles, underlayments, backerboards, cement composites, foam fills, bricks, cement sidings, etc.

A fiber reinforced concrete composition which cures to a cured fiber reinforced concrete composite following addition of water, the cured fiber reinforced concrete composite having a density from about 700 to 1000 kg/m.sup.3 and a compressive strength from about 5 to 15 MPa. A fiber reinforced concrete composition includes a brittle inorganic matrix precursor, a plurality of reinforcing fibers present in a range from 0.5 volume percent to less than 4 volume percent based on the total volume of the cured fiber reinforced concrete composite, and lightweight aggregate having a mean particle size in the range of 10 m to 1000 m, in an amount effective to achieve a target density in the cured composite not more than 1000 kg/m.sup.3. The reinforcing fibers include polypropylene fibers. The lightweight aggregate can include hollow fly ash spheres and glass microspheres. An acrylic admixture can be added to the composition.

Polyurethane composites and methods of preparation are described herein. The polyurethane composites can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols, (b) a particulate filler having a bulk density of 1 g/cm.sup.3 or greater, (c) optionally a fiber material, and (d) a lightweight filler having a bulk density from 0.01 g/cm.sup.3 to less than 1 g/cm.sup.3. In some examples, the lightweight filler can be selected from expanded perlite, expanded clay, foamed glass, and combinations thereof. Articles such as building materials comprising the polyurethane composites are also disclosed.

Polyurethane composites and methods of preparation are described herein. The polyurethane composites can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols, (b) a particulate filler having a bulk density of 1 g/cm.sup.3 or greater, (c) optionally a fiber material, and (d) a lightweight filler having a bulk density from 0.01 g/cm.sup.3 to less than 1 g/cm.sup.3. In some examples, the lightweight filler can be selected from expanded perlite, expanded clay, foamed glass, and combinations thereof. Articles such as building materials comprising the polyurethane composites are also disclosed.

An extrudable gypsum-based material is formed from a mixture that includes gypsum in the range of about 40 to 90% by dry weight percent, a secondary material in the range of about 0.1 to 50% by dry weight percent, a reinforcement fiber in the range of about 1 to 20% by dry weight percent, a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent, a retarder in the range of about 0.1 to 8% by dry weight percent, a water in the range of 10 to 50% of a total wet material weight.

An extrudable gypsum-based material is formed from a mixture that includes gypsum in the range of about 40 to 90% by dry weight percent, a secondary material in the range of about 0.1 to 50% by dry weight percent, a reinforcement fiber in the range of about 1 to 20% by dry weight percent, a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent, a retarder in the range of about 0.1 to 8% by dry weight percent, a water in the range of 10 to 50% of a total wet material weight.

A porous formed plate includes 35 to 70% by mass of a substance not involved in a pozzolanic reaction; 20 to 61.5% by mass of a cement; 1 to 3% by mass of synthetic fibers; and 2.5 to 7% by mass of a pulp, wherein, in a pore size distribution of the formed plate that is determined by a mercury intrusion method, a ratio (B)/(A) of a pore volume (B) in a range of 6 to 560 nm with respect to a pore volume (A) in a range of 660 to 9,100 nm is 1.70 to 6.0.

A porous formed plate includes 35 to 70% by mass of a substance not involved in a pozzolanic reaction; 20 to 61.5% by mass of a cement; 1 to 3% by mass of synthetic fibers; and 2.5 to 7% by mass of a pulp, wherein, in a pore size distribution of the formed plate that is determined by a mercury intrusion method, a ratio (B)/(A) of a pore volume (B) in a range of 6 to 560 nm with respect to a pore volume (A) in a range of 660 to 9,100 nm is 1.70 to 6.0.

A reinforcing fiber and reinforced material, which includes a fiber having a first radical wave therein, wherein said first radical wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, and a leading run and trailing run of at least about 0.75.