A structural material composition comprises: a geopolymer matrix, the geopolymer matrix formed from an alumina silicate source and an alkaline activator; and an antibacterial agent (e.g. biocide and/or heavy-metal based antibacterial agent) encapsulated in an antibacterial agent carrier to form a first plurality of encapsulated antibacterial agent particles. The first plurality of encapsulated antibacterial agent particles is integrated with the geopolymer matrix during polymerization.

A structural material composition comprises: a geopolymer matrix, the geopolymer matrix formed from an alumina silicate source and an alkaline activator; and an antibacterial agent (e.g. biocide and/or heavy-metal based antibacterial agent) encapsulated in an antibacterial agent carrier to form a first plurality of encapsulated antibacterial agent particles. The first plurality of encapsulated antibacterial agent particles is integrated with the geopolymer matrix during polymerization.

A polymer-modified hybrid-fibers cementitious composition has a one-day compressive strength of at least approximately 17 MPa, a 28-day tensile strength of at least approximately 3.8 MPa, an ultimate tensile strain of approximately 3% to approximately 9%, and a 7-day bond strength of at least approximately 2.3 MPa. A binder of ordinary Portland cement, fly ash, and silica fume is provided. Other components include limestone powder, sand, superplasticizer, and water. The composition further includes one or more of styrene butadiene rubber or ethylene-vinyl acetate copolymer in an amount ranging between approximately 2% and approximately 8% by mass of binder. Fiber additives include steel fibers in an amount ranging between approximately 0.3% and approximately 3.0% by volume of the cementitious composition and polymer fibers in an amount less than approximately 1.0% by volume of the cementitious composition. Chamfers made of the composition are positioned at beam-column joints.

Coated inorganic expanding agent particles comprise a core of an inorganic expanding agent and a sol/gel-formed coating comprising a mixed oxide of two or more metals and/or metalloids, in particular a mixed oxide of silicon and at least one metal and/or metalloid selected from aluminum, boron, titanium, zirconium and zinc. The coated inorganic expanding agent particles are added to cementitious systems to avoid shrinkage during hardening. The coating is effective to delay the expanding effect.

Coated inorganic expanding agent particles comprise a core of an inorganic expanding agent and a sol/gel-formed coating comprising a mixed oxide of two or more metals and/or metalloids, in particular a mixed oxide of silicon and at least one metal and/or metalloid selected from aluminum, boron, titanium, zirconium and zinc. The coated inorganic expanding agent particles are added to cementitious systems to avoid shrinkage during hardening. The coating is effective to delay the expanding effect.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A conductive cementitious material is disclosed that may be applied by conventional techniques. The conductive cementitious material has a plurality of metal-coated fibers precision chopped to longer lengths and a cementitious material base. The metal-coated fibers are dispersed throughout the cementitious material base to create a complex electron transport system facilitating conductivity sufficient to meet or exceed desired thresholds of conductivity. The complex electron transport system created facilitates conductivity with lower loadings. The additional unloaded portion of cementitious material base may receive other multifunctional materials. Exemplary conductive cementitious materials provide controlled heating of the cementitious material by applying an electrical current.

A conductive cementitious material is disclosed that may be applied by conventional techniques. The conductive cementitious material has a plurality of metal-coated fibers precision chopped to longer lengths and a cementitious material base. The metal-coated fibers are dispersed throughout the cementitious material base to create a complex electron transport system facilitating conductivity sufficient to meet or exceed desired thresholds of conductivity. The complex electron transport system created facilitates conductivity with lower loadings. The additional unloaded portion of cementitious material base may receive other multifunctional materials. Exemplary conductive cementitious materials provide controlled heating of the cementitious material by applying an electrical current.

A polymer-modified hybrid-fibers cementitious composition has a one-day compressive strength of at least approximately 17 MPa, a 28-day tensile strength of at least approximately 3.8 MPa, an ultimate tensile strain of approximately 3% to approximately 9%, and a 7-day bond strength of at least approximately 2.3 MPa. A binder of ordinary Portland cement, fly ash, and silica fume is provided. Other components include limestone powder, sand, superplasticizer, and water. The composition further includes one or more of styrene butadiene rubber or ethylene-vinyl acetate copolymer in an amount ranging between approximately 2% and approximately 8% by mass of binder. Fiber additives include steel fibers in an amount ranging between approximately 0.3% and approximately 3.0% by volume of the cementitious composition and polymer fibers in an amount less than approximately 1.0% by volume of the cementitious composition. Chamfers made of the composition are positioned at beam-column joints.