A lightweight thermal insulating cement-based material is formed from a mixture that includes cement, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature of about 900 degrees Celsius or more.

A lightweight thermal insulating cement-based material is formed from a mixture that includes cement, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature of about 900 degrees Celsius or more.

Manufactures, methods and apparatus are provided through which in some implementations a structural cellular lightweight concrete comprises a concrete mixture that is no more than 65% by volume of the manufacture of structural cellular lightweight concrete, the concrete mixture including concrete conforming to the requirements of ASTM C33; foam that has a density of at least 5 lbs./ft.sup.3, having high stability characteristics, and having a closed cell bubble structure; mix water being potable and free of contamination or deleterious materials; and Portland cement conforming to ASTM C150, the Portland cement being Type I, Type III or White Portland cement, and at least 35% air by volume of the manufacture of structural cellular lightweight concrete.

Manufactures, methods and apparatus are provided through which in some implementations a structural cellular lightweight concrete comprises a concrete mixture that is no more than 65% by volume of the manufacture of structural cellular lightweight concrete, the concrete mixture including concrete conforming to the requirements of ASTM C33; foam that has a density of at least 5 lbs./ft.sup.3, having high stability characteristics, and having a closed cell bubble structure; mix water being potable and free of contamination or deleterious materials; and Portland cement conforming to ASTM C150, the Portland cement being Type I, Type III or White Portland cement, and at least 35% air by volume of the manufacture of structural cellular lightweight concrete.

A lightweight thermal insulating cement-based material is formed from a mixture that includes cement, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature of about 900 degrees Celsius or more.

A lightweight thermal insulating cement-based material is formed from a mixture that includes cement, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature of about 900 degrees Celsius or more.

The present invention relates to a process for producing a foam ceramic comprising the steps: producing an aqueous suspension of a first mineral raw material; foaming the suspension with air while adding a foaming agent and a binder to form a light foam; mixing the light foam with a powder or slip of a second ceramic raw material to form a heavy foam; pouring the heavy foam into a mold; drying the molded heavy foam in the mold to form a solid foam; and firing the solid foam in the mold to form the foam ceramic.

The present invention relates to a process for producing a foam ceramic comprising the steps: producing an aqueous suspension of a first mineral raw material; foaming the suspension with air while adding a foaming agent and a binder to form a light foam; mixing the light foam with a powder or slip of a second ceramic raw material to form a heavy foam; pouring the heavy foam into a mold; drying the molded heavy foam in the mold to form a solid foam; and firing the solid foam in the mold to form the foam ceramic.

The present invention relates to a system for the production of thermal insulating, architectural and structural foam materials cast in molded volumes configured for a subsequent milling process, wherein molded foam volumes are cut into dimensional products or product components.

A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.