Various cement-containing compositions are disclosed, including insulating cement, forms, and prefabricated building materials produced from cement-containing compositions with insulating properties. Some of the preferred embodiments include expanded polystyrene and an acrylic component to provide enhanced insulating properties, or have a lower density, lighter weight, and increased insulating R-value in comparison with other cement-containing compositions.

Various cement-containing compositions are disclosed, including insulating cement, forms, and prefabricated building materials produced from cement-containing compositions with insulating properties. Some of the preferred embodiments include expanded polystyrene and an acrylic component to provide enhanced insulating properties, or have a lower density, lighter weight, and increased insulating R-value in comparison with other cement-containing compositions.

Methods, compositions, and apparatuses are provided herein that utilize polystyrene from recycled products to make a high strength composite concrete that can be used for subgrade utility vaults, utility trenches, etc. Polystyrene is a widely-used plastic that can be collected and then densified at particular parameters including temperature to transform the polystyrene to a usable form. Then, the densified polystyrene is combined with other resin materials and dry materials to form a high-strength concrete material. The amount of densified polystyrene that is combined with the other materials is critical to control shrinkage and expansion of the concrete material during manufacturing.

Methods, compositions, and apparatuses are provided herein that utilize polystyrene from recycled products to make a high strength composite concrete that can be used for subgrade utility vaults, utility trenches, etc. Polystyrene is a widely-used plastic that can be collected and then densified at particular parameters including temperature to transform the polystyrene to a usable form. Then, the densified polystyrene is combined with other resin materials and dry materials to form a high-strength concrete material. The amount of densified polystyrene that is combined with the other materials is critical to control shrinkage and expansion of the concrete material during manufacturing.

A composition that controls and delays generation of foam in geopolymer pastes, mortars and concretes. Embodiments include a one-part anhydrous formula for the production of geopolymer foam that requires only the addition of water. The formula includes specific and variably designed admixtures that manage a time release delivery of alkali activation components, foaming agents, and blends thereof.

A composition that controls and delays generation of foam in geopolymer pastes, mortars and concretes. Embodiments include a one-part anhydrous formula for the production of geopolymer foam that requires only the addition of water. The formula includes specific and variably designed admixtures that manage a time release delivery of alkali activation components, foaming agents, and blends thereof.

A manufacturing method of a plugged honeycomb structure including a plugging material preparing step of mixing a ceramic raw material, a pore former, a thickener, an organic binder, a dispersing agent, and water and preparing the plugging material which is slurried, to form the plugging portions, wherein the plugging material preparing step includes: a powder mixing step of mixing the ceramic raw material, the pore former, the organic binder and the dispersing agent each of which is constituted of powder, at predetermined blend ratios, a thickener mixing step of adding and mixing the thickener to a powder mixture obtained by the powder mixing step, and a kneading step of adding the water to a thickener added mixture obtained by the thickener mixing step, to perform kneading.

A manufacturing method of a plugged honeycomb structure including a plugging material preparing step of mixing a ceramic raw material, a pore former, a thickener, an organic binder, a dispersing agent, and water and preparing the plugging material which is slurried, to form the plugging portions, wherein the plugging material preparing step includes: a powder mixing step of mixing the ceramic raw material, the pore former, the organic binder and the dispersing agent each of which is constituted of powder, at predetermined blend ratios, a thickener mixing step of adding and mixing the thickener to a powder mixture obtained by the powder mixing step, and a kneading step of adding the water to a thickener added mixture obtained by the thickener mixing step, to perform kneading.

An ultrastable cementitious material with nano-molecular veneer makes a cementitious material by blending 29 wt % to 40 wt % of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide based on a final total weight of the cementitious material, with 14 wt % to 18 wt % of a magnesium chloride dissolved in water and reacting to form a liquid suspension, mixing from 2 to 10 minutes, adding a phosphorus-containing material, and allowing the liquid suspension to react into an amorphous phase cementitious material, wherein a portion of the amorphous phase cementitious material grows a plurality of crystals. The plurality of crystals are encapsulated by the amorphous phase cementitious material forming a nano-molecular veneer. A process to make the ultrastable cementitious material. A tile backer board incorporating the ultrastable cementitious material and a process for making the tile backer board.

An ultrastable cementitious material with nano-molecular veneer makes a cementitious material by blending 29 wt % to 40 wt % of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide based on a final total weight of the cementitious material, with 14 wt % to 18 wt % of a magnesium chloride dissolved in water and reacting to form a liquid suspension, mixing from 2 to 10 minutes, adding a phosphorus-containing material, and allowing the liquid suspension to react into an amorphous phase cementitious material, wherein a portion of the amorphous phase cementitious material grows a plurality of crystals. The plurality of crystals are encapsulated by the amorphous phase cementitious material forming a nano-molecular veneer. A process to make the ultrastable cementitious material. A tile backer board incorporating the ultrastable cementitious material and a process for making the tile backer board.