The present invention relates to fiber cement products comprising a first layer, which first layer is covered by at least one second layer, characterized in that said first layer is the top layer and the first layer material has a density of between about 0.4 and about 0.9 g/cm.sup.3 inclusive, and at least comprises cement and between 1 wt % and 70 wt % (relative to the total dry weight of said first layer material) of a lightweight filler, and said at least one second layer is the bottom layer and covers only one of the main surfaces of the first layer, thereby forming a bi-layered fiber cement product, wherein the second layer material has a density of between about 0.9 and about 1.4 g/cm.sup.3 inclusive, and at least comprises fibers and cement.

Systems and methods are disclosed for producing a shaped cementitious article comprising mixing foamed glass aggregate particles, Portland cement, and water, placing the mixture into a mold, applying vibration and/or pressure to the mold, removing the mold, and then curing the molded concrete article. The shaped cementitious article may be a concrete block (e.g., a solid block, a hollow block, a flue, a curb, or a paver). The concrete block may be a relatively lightweight formed concrete block defining a hollow interior portion (e.g., “cinder block” shaped).

Disclosed is a concrete product incorporating rubber aggregate produced by casting under pressure. The concrete product may optionally be cast at 6.9-27.7 MPa for periods of, for example, 24 hours. In one embodiment the rubber aggregate may comprise coarse and/or fine rubber aggregate to replace natural sources of coarse and fine aggregate. Casting under pressure was found to generally improve the performance characteristics of the concrete when compared to corresponding concrete cast without pressure.

A process of fabricating a static structure including an interior volume that includes the steps of mixing coal combustible residual (CCR) with structural reinforcing materials to form a construction material and utilizing the construction material to fabricate exterior enclosure-forming components of the static structure. The enclosure-forming components are sufficiently reinforced, enhanced and/or thick to provide protection against exterior forces directed against the structure.

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 method of forming a lightweight polished concrete and the resulting composition. Calcium sulfoaluminate (CSA) cement and specialized grout may be 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) may be added to the blended CSA cement, specialized grout, and water to form a mixture. The mixture may be poured over a fiberglass rebar, vibrated, screeded, and allowed to set. The set mixture may be smoothed with float blades. The smoothed mixture may be hardened with metal blades, such that the hardened mixture becomes reflective. A concrete densifier may be applied to the hardened mixture to form the lightweight polished concrete. Optionally, one or more saw cuts may be formed in the lightweight polished concrete and a coating to may be applied to fill the one or more saw cuts.

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.

A method of forming a lightweight concrete comprising lightweight aggregates (LWA) made from recycled materials and the resulting composition. The lightweight concrete may be formed by adding calcium sulfoaluminate (CSA) cement and a specialized grout to an amount of water in a mixer, wherein a ratio of the water to the CSA cement is 1 quart to every 10 lbs of CSA cement. The CSA cement, specialized grout, and water may be blended to a smooth consistency. LWA may be added to the blended CSA cement, specialized grout, and water, wherein a ratio of the CSA cement to LWA is 60/40 by weight. The mixture of LWA, CSA cement, specialized grout, and water may be poured over a fiberglass rebar. The mixture may be allowed to cure and before being densified with a lithium densifier.

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 are described, including compressed air storage facilities and a pumped hydroelectric facility, including such a facility adapted for use with a lock system of a waterway.

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 are described, including compressed air storage facilities and a pumped hydroelectric facility, including such a facility adapted for use with a lock system of a waterway.