In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses described, including survival bunkers, composting pits, mine reclamation encapsulation and carbon sequestration facilities, water storage facilities, compressed air storage facilities, carbon sequestration/mineral carbonation facilities and a pumped hydroelectric facility adapted for use with a lock system of a waterway.

Various cement-containing forms and related compositions and methods are disclosed herein. Some cement-containing forms disclosed in this application include cement and expanded polystyrene. The cement forms, in some cases, are formed by a process that involves combining cement and expanded polystyrene with one or more liquids that interact with the expanded polystyrene to improve adhesion between the cement and the expanded polystyrene. The resulting forms may provide insulating properties. Some of the disclosed cement-containing forms and compositions may also have a relatively low density in comparison with other cement-containing compositions.

In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.

A process for controlling the embedding depth of reinforcing mesh to a cementitious board is disclosed. The process comprises applying a pressure from a plate to a reinforcing mesh on a core mix moving downstream on a conveyor, wherein the plate vibrates at a rate that assists in embedding the reinforcing mesh at a depth within the core mix such that the reinforcing mesh is barely visible.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses described, including survival bunkers, composting pits, mine reclamation encapsulation and carbon sequestration facilities, water storage facilities, compressed air storage facilities, carbon sequestration/mineral carbonation facilities and a pumped hydroelectric facility adapted for use with a lock system of a waterway.

In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.

In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.

A process for the formation of highly durable cementitious board using lightweight aggregate is disclosed. The process comprises pouring a core mix onto a conveyor, wherein the core mix is comprised of one or more lightweight aggregate filler in the amount of 0.5 to 5 weight percent of the core mix, one or more binders in the amount of 35 to 75 weight percent of the core mix, rheological admixture in the amount of about 0.5 to 5 weight percent of the core mix, surfactant in the amount of 0 to 0.1 weight percent of the core mix, one or more normal weight aggregate filler in the amount of 5 to 50 weight percent of the core mix, and water in the amount of 5 to 20 weight percent of the core mix. The process further comprises passing the core mix under a screed roller to flatten the core mix to produce an extruding board with a desired thickness.

A method of forming a lightweight concrete block and the resulting structure. Calcium sulfoaluminate (CSA) cement and specialized grout maybe added to an amount of water in a mixer. The CSA cement, specialized grout, and water may be blended to a smooth consistency. Lightweight aggregates (LWA) maybe added to form a mixture. The mixture may be poured into a mold, allowed the mixture to cure, and removed from the mold to form the lightweight concrete block. The lightweight concrete block may have a first side and a second side joined by a plurality of interposing walls, the interposing walls defining one or more inner cavities and one or more outer cavities. The lightweight concrete block may have features that allow for the insertion of fiberglass rebar to aide in stacking and filling to form a wall.