An aggregate includes a polymeric foam present in a range of about 80 vol % to about 85 vol % of the aggregate. A cementitious matrix is present in a range of about 10 vol % to about 13 vol % of the aggregate. One or more resins are present in an amount of less than about 2 vol % of the aggregate, and one or more reinforcing fibers are present in an amount of less than about 1 vol % of the aggregate.

The present disclosure provides designs and methods for manufacturing precast fully-encapsulated bilayered fiberglass Styro-aircrete building blocks. The disclosure comprises forming a super-light air-entrained Styro-aircrete building panel for a wall, roof, or beam. The Styro-aircrete is made with a novel composition/formula using shredded Styrofoam and other traditional Styro-aircrete ingredients that are mixed. Wire meshes and fiberglass fibers are pre-embedded in the panel frame to keep the structure in place. The Styro-aircrete is poured into a fiberglass panel frame from an opening, set aside to dry for a few days, and then sealed with a fiberglass cover. This frame and cover are double-layered fiberglass and form an all six-side enclosed casing. The method and designs improve a Styro-aircrete building block with the following: (1) much lighter weight; (2) longed durability; (3) increased compressive strength for load-bearing support; (4) reduced cost and installation time.

An aggregate includes a polymeric foam present in a range of about 80 vol % to about 85 vol % of the aggregate. A cementitious matrix is present in a range of about 10 vol % to about 13 vol % of the aggregate. One or more resins are present in an amount of less than about 2 vol % of the aggregate, and one or more reinforcing fibers are present in an amount of less than about 1 vol % of the aggregate.