A method in which a stream of dry cementitious powder from a dry powder feeder passes through a dry cementitious powder inlet conduit to feed a first feed section of a fiber-slurry mixer. An aqueous medium stream passes through at least one aqueous medium stream conduit to feed a first mixing section the fiber-slurry mixer. A stream of reinforcing fibers passes from a fiber feeder through a reinforcing fibers stream conduit to feed a second mixing section of the fiber-slurry mixer. The stream of dry cementitious powder, aqueous medium stream, and stream of reinforcing fibers combine in the fiber-slurry mixer to make a stream of fiber-cement mixture which discharges through a discharge conduit at a downstream end of the mixer.

A method of preparing a gypsum-based product comprises the steps of mixing calcined gypsum with polymer particles and water to provide a slurry. The polymer particles comprise principally polyvinyl acetate, and have a particle size distribution, measured using laser diffractometry, such that particles having a diameter of 4.5 ?m or less provide at least 90% of the total particle volume.

To provide a concrete-reinforcing shaped body containing concrete-reinforcing fibers and having a plate-like shape. The concrete-reinforcing fibers each preferably have a diameter of 0.3 mm smaller and a length of 5 mm or larger and 25 mm or smaller.

A method in which a stream of dry cementitious powder from a dry powder feeder passes through a dry cementitious powder inlet conduit to feed a first feed section of a fiber-slurry mixer. An aqueous medium stream passes through at least one aqueous medium stream conduit to feed a first mixing section the fiber-slurry mixer. A stream of reinforcing fibers passes from a fiber feeder through a reinforcing fibers stream conduit to feed a second mixing section of the fiber-slurry mixer. The stream of dry cementitious powder, aqueous medium stream, and stream of reinforcing fibers combine in the fiber-slurry mixer to make a stream of fiber-cement mixture which discharges through a discharge conduit at a downstream end of the mixer.

Continuous method including: mixing water and cementitous powder to form slurry; mixing the slurry and reinforcement fibers in a single pass horizontal continuous mixer to form fiber-slurry mixture, the mixer including an elongated mixing chamber having a reinforcement fiber inlet port, and upstream of the fiber inlet port is an inlet port to introduce water and cementitous powder together as one stream or at least two inlet ports to introduce water and dry cementitous powder separately as separate streams into the chamber, a rotating horizontal shaft/s within the chamber, part of the chamber for mixing the fibers and slurry and moving the fiber-slurry mixture to a mixture outlet; discharging the fiber-slurry mixture from the mixer outlet; forming and setting the fiber-slurry mixture on a moving surface; cutting the set mixture into fiber reinforced concrete panels and removing the panels from the moving surface.

A method in which a stream of dry cementitious powder passes through a first conduit and aqueous medium stream passes through a second conduit to feed a slurry mixer to make cementitious slurry. The cementitious slurry passes through a third conduit and a reinforcement fiber stream passes through a fourth conduit to feed a fiber-slurry mixer which mixes the slurry and discrete fibers to make a stream of fiber-slurry mixture. An apparatus for performing the method is also disclosed.

A concrete product set by pouring a concrete slurry includes a concrete mixture, an aluminum-coated colloidal silica admixture, and optionally, at least one reinforcing fiber selected from the group of fibers. As the poured concrete slurry cures, the poured slurry hardens into a composite material product, and the concrete product defines capillary structures that at least in part fill with aluminum-coated silica and lime. Optional graphene oxide may be used in the concrete slurry, in which embodiment the surrounding aggregate and cement is embedded with graphene oxide flakes. A process for placing a jointless and/or fiberless slab made from the concrete product includes preparing a concrete slurry, pouring the concrete slurry onto substrate, and allowing the concrete slurry to cure.

The present invention relates to an apparatus for manufacturing fiber-reinforced concrete through shooting after inserting bubbles into normal concrete and a method for manufacturing the same, which: form fiber-mixed concrete in which the bubbles, fiber-mixed materials, and silica fume are mixed in the normal concrete or form the fiber-mixed concrete in which aggregates, water, and the bubbles are put into and mixed with a mixture, in which cement, the fiber-mixed materials, and silica fume are mixed; and then shoots the fiber-reinforced concrete in which excessive air included in the fiber-mixed concrete is reduced by spraying the fiber-mixed concrete with the high-pressure air when the fiber-mixed concrete is discharged, and of which a slump, drastically increased due to the large amount of bubbles, is reduced to a range of the slump of the normal concrete, thereby improving the production capacity of the fiber-reinforced concrete and shortening operating time.

A concrete product set by pouring a concrete slurry includes a concrete mixture, an aluminum-coated colloidal silica admixture, and optionally, at least one reinforcing fiber selected from the group of fibers. As the poured concrete slurry cures, the poured slurry hardens into a composite material product, and the concrete product defines capillary structures that at least in part fill with aluminum-coated silica and lime. Optional graphene oxide may be used in the concrete slurry, in which embodiment the surrounding aggregate and cement is embedded with graphene oxide flakes. A process for placing a jointless and/or fiberless slab made from the concrete product includes preparing a concrete slurry, pouring the concrete slurry onto substrate, and allowing the concrete slurry to cure.

Disclosed is a composite gypsum board comprising a set gypsum core disposed between face (e.g., Manila) and back (e.g., Newsline) cover sheets. The set gypsum core is formed from a core slurry comprising stucco, water, and optional additives, such as foaming agent, migrating starch, accelerator, retarder, dispersant, etc. A dense layer formed from a dense layer slurry comprising stucco, water, fiber (e.g., paper fiber), and optionally, strength-enhancing starch, is disposed between the core and the face paper. The dense layer slurry contains a greater concentration of fiber, and optionally, strength-enhancing starch, than the core slurry, but the concentration of one or more other additives (e.g., accelerator, retarder, dispersant, or combinations thereof) is lower or the same in the dense slurry as compared with the core slurry. Also disclosed is a method of making board using one board mixer. In embodiments, paper fiber is added to water to form a suspension. The suspension is introduced, while in a non-laminar state, into the dense slurry. Further disclosed is apparatus, such as an extractor and an additive injection system, which can be a part of a cementitious slurry mixing and dispensing assembly.