A structural lightweight concrete composition comprising cement, a fine aggregate such as sand, a natural coarse aggregates, such as limestone, scoria or perlite or mixtures thereof, a synthetic coarse aggregate comprising a polymeric material, such as polypropylene beads, an industrial waste byproduct in the form of fine particles, such as silica fume or heavy oil ash, a superplasticizer, such as a polycarboxylate ether and water demonstrating lower thermal conductivity and sufficient compressive strength. Concrete products made therefrom and methods for producing such products are also provided.

Disclosed are methods for producing carbon foam in which using the vitrinite reflectance values of coals are used to form a blended coal precursor having a targeted vitrinite reflectance value. The targeted vitrinite reflectance value can be used to create similar carbon foam products from one production batch to the next.

A method and device for producing lightweight panels with a core of gypsum or of cement and gypsum, with pores for decreasing volumetric weight, and with a covering made of cardboard or of a sheet of glass fibers. The production line does not change except for the addition of a device which forms closed hollow cavities within a suspension in an area where an upper sheet covers the suspension. Air pressure which is fed into the formed cavities is slightly higher than the hydraulic pressure of the suspension, so as to prevent the gaps being filled by the suspension. The layers are less thick, and the type and dimensions of the cavities and the thickness of the walls are varied depending on the desired qualities of the panels.

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.

The present invention relates to geopolymer compositions, sintered geopolymer articles from the geopolymer compositions and processes for manufacturing sintered geopolymer articles from the geopolymer compositions. The invention provides a process of producing a sintered geopolymer article containing a sintered geopolymer composition, wherein the sintered geopolymer composition comprises a sintered geopolymeric matrix, said process comprising the steps of: (1) forming a geopolymer composition comprising at least one aluminosilicate precursor, an alkali activating agent and water, wherein in the geopolymer article, the aluminosilicate precursor particles are at least partially coated by the alkali activating agent; and (2) firing the geopolymer article to sinter the geopolymer composition, wherein the alkali activating agent is capable of at least partially activating and dissolving the aluminosilicate precursor particles during at least a portion of the firing step, and wherein the firing of the geopolymer article includes a geopolymer composition sintering stage.

Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets and low density fillers distributed throughout. The combination of entrained air pockets and low density fillers provide a low density fiber cement matrix with physical and mechanical properties similar to comparable low density fiber cement matrix without entrained air pockets.

A method of cementing may include preparing a cement composition comprising water, a hydraulic cement, and an agglomerated zeolite catalyst; placing the cement composition in a wellbore.

A low-density, high-strength concrete composition that is both self-compacting and lightweight, with a low weight-fraction of aggregate to total dry raw materials, and a highly-homogenous distribution of a non-absorptive and closed-cell lightweight aggregate such as glass microspheres or copolymer polymer beads or a combination thereof, and the steps of providing the composition or components. Lightweight concretes formed therefrom have low density, high strength-to-weight ratios, and high R-value. The concrete has strength similar to that ordinarily found in structural lightweight concrete but at an oven-dried density as low as 40 lbs./cu.ft. The concrete, at the density ordinarily found in structural lightweight concrete, has a higher strength and, at the strength ordinarily found in structural lightweight concrete, a lower density. Such strength-to-density ratios range approximately from above 30 cu.ft/sq.in. to above 110 cu.ft/sq.in., with a 28-day compressive strength ranging from about 3400 to 8000 psi.

The present invention relates to a method of making a fiber-reinforced cementitious composite material which finds widespread applicability in a variety of construction and related applications. The composite comprises cellulosic fibrous material in order to provide the composite with the desired performance characteristics. Notably, at least a portion of the cellulosic fibrous material comprises surfaced enhanced pulp fiber, which desirably enhances the processing characteristics of the material, as well enhancing the characteristics of the finished composite product. The method of making a fiber-reinforced cementitious composite comprising the steps of providing a cementitious composition, and providing cellulosic fibrous material. The present method further includes blending the cementitious composition and the cellulosic fibrous material to form the cementitious composite. The surface enhanced pulp fiber preferably comprises approximately 1-10%, by weight, of the cellulosic fibrous material, and the cellulosic fibrous material exhibits an enhanced Bauer-McNett long fiber fraction. The cellulosic fibrous material preferably exhibits at least a 10% increase in length-weighted average fiber length (LWAFL), in comparison to a cellulosic fibrous material which is devoid of surface enhanced pulp fiber. The cellulosic fibrous material requires relatively reduced refining energy, in comparison to a cellulosic fibrous material which is devoid of surface enhanced pulp fiber, to reach a predetermined freeness CSF (Canadian Standard Freeness) value.

Described are dry cast lightweight veneer blocks and a system and method of installing lightweight veneer blocks. The courses can be assembled without mortar between the courses. As an example, sides of the veneer blocks have areas that recede from an imaginary plane between adjacent veneer blocks to give a deep texturing and a shadow effect between veneer blocks. The installation system and method include a substrate, an air barrier applied to the substrate, a plurality of veneer blocks, and an adhesive applied between the plurality of veneer blocks and the air barrier.