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 ulstrastable cementitious material and a process for making the tile backer board.

A method to make an ultra-stable structural laminate of a cementitious material with a nano-molecular veneer and a foam component catalytically reacted into an expanded closed cell foam having a thickness from .sup.th inch to 8 inches, a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot that inter-engages the cementitious material forming a matrix creating the ultra-stable structural laminate with fire resistance; a lateral nail pull strength from 44 pounds to 300 pounds of force; an insulation R value from 1 to 40; a resistance to seismic impact for earthquakes over 3.1 on the Richter Scale; a break point from 7 lbs/inch to 100 lbs/inch; and a resistance to wind shear equivalent to a 15 mph downburst.

A composite product includes gypsum in an amount of 60 to 90% by weight, fibers in an amount of 1.5 to 26% by weight substantially homogeneously distributed through the composite, and a rheology-modifying agent in an amount of 0.5 to 6% by weight. The composite is caused or allowed to cure to form a cured composite. The cured composite is a fire resistant component used in a fire-rated door core, a fire-rated door or a fire-rated building panel. The fire resistant component may include a building panel, a door panel, a door core, a door rail, a door stile, a door lock block, a door border, or a door insert.

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.

A 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 tile backer board has 29 wt % to 40 wt % of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide, 14 wt % of 18 wt % of a magnesium chloride dissolved in water; 0.1 wt % to 10 wt % of a stabilizing material with a phosphorus-containing compound, reacting into an amorphous phase cementitious material. The phosphorus-containing compound is a phosphorous acid (A) or a phosphoric acid (B). 0.1 wt % to 30 wt % of an aggregate is added and then a reinforcing component is mixed in or the cement is poured onto the reinforcing component forming a tile backer board.

A process to make a tile backer board includes using a stabilizing material with a phosphorus-containing compound, reacting magnesium containing starting materials into an amorphous phase cementitious material, and adding 0.1 wt % to 30 wt % of an aggregate and a reinforcing component by mixing in or pouring over the reinforcing component and allowing the amorphous phase cementitious material to cure into a tile backer board.

A process to make a cementitious material includes 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. A portion of the amorphous phase cementitious material grows a plurality of crystals. The plurality of crystals is encapsulated by the amorphous phase cementitious material forming a nano-molecular veneer.

Crumb Rubber augmented masonry blocks including cement, aggregate, water, and crumb rubber. Crumb rubber is extracted from scrape tires after being processed and then mixed in specified percentages with aggregate, cement and water. In the present disclosure sand, which is used in the formation of conventional blocks, is replaced with crumb rubber to produce a sand-free masonry block containing crumb rubber. The developed crumb rubber masonry blocks satisfied the ASTM non-load bearing requirements in addition to satisfying the water absorption test.

Crumb Rubber augmented masonry blocks including cement, aggregate, water, and crumb rubber. Crumb rubber is extracted from scrape tires after being processed and then mixed in specified percentages with aggregate, cement and water. In the present disclosure sand, which is used in the formation of conventional blocks, is replaced with crumb rubber to produce a sand-free masonry block containing crumb rubber. The developed crumb rubber masonry blocks satisfied the ASTM non-load bearing requirements in addition to satisfying the water absorption test.