CA1038892A - Construction cement composition - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A construction composition developed to provide a material of construction which can be utilized to build essentially all types of structures, including houses, office buildings, and the like, which composition is capable of being wet mixed and subsequently molded into convenient and useful shapes, is described. The composition in question comprises the following ingredients: (2) gypsum;
(2) an expanded material such as for example vermiculite;
(3) cement; and (4) polypropylene fiberglass or sisal fibers;
and may additionally include (5) limestone dust or fly ash;
and (6) wood fibers. If desired, there may also be included (7) an alkali metal halide or alkaline earth metal halide to induce rapid setting of the composition, or (8) an alkali metal salt of an organic acid such as sodium oitrate, where it is desired to retard setting of the composition. The above ingredients are employed in the following proportions, by volume:
Gypsum: from about 15% to about 40%;
Component (2): from about 9% to about 29%;
Cement: from about 15% to about 40%;
Component (4): from about 1% to about 2%;
Component (5) (if present): from about 5% to about 10%;
Component (6) (if present): about 8%; to about 28%;
Component (7) (if present): about 1%; and Component (8) (if present): about 1%.

The aforesaid composition has great strength, excellent shrink resistance properties, is highly shock resistant, provides good insulation for structures, and is adapted for use with suitable molds to form the entire wall structure of a house or other building in a single pouring.

Description

~038892 FIELD OF THE INVENTION
This invention relates to a new composition for use in building structures, and more particularly, to a new composition which may be poured as a liquid and when allowed to cure, combines the features of strength, shock resistance, insulation, and waterproofing qualities in a single material.
The material can be easily formed into substantially any desired shape and thickness depending upon the forms utilized.
DESCRIPTION OF THE PRIOR ART
Conventional building techniques may be typified by the construction of a conventional home, office building, or other structure, in which the following sequence is used:
the lot or ground area upon which the structure i8 to be constructed must first be graded ana the slab poured after footings are dug and forms set. Among the skilled labour needed in setting the slab are carpenters for setting tho forms, roofers to handle waterproofing of the slab~ iron workers to tie in reinforcing steel and lay wire mesh, plumbers, whose functio~ i~ to install necessary piping and fixtures, and cement finishers to place and finish the concrete. After pouring the slab, carpenters must again be utilized to strip the forms and labourers must be directed to move the necessary material and clean excess debris from the lot. Carpenters are then again required to frame the house, electricians must be used to wire it, and a crew of insulators utilized to apply sheeting and to insulate ~he interior walls. Roofers must then be directed to apply the roofing, and yet another crew to apply the sheet rock.
Painters must then tape, float and paint the structure -- } -- ~L
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interior, tile men must be available to install the floors, and carpenters directed to place the cahinets and "Formica"*.
Next, the bricklayers must brick the exterior of the structure and the operating engineer must return to grade the lot to final specifications.
From a consiaeration of the above simplified illu5-tration, it is obvious that current construction techniques involve the use of many skilled crafts, which, in combination with high material cost, effects a high cost of construction which must be passed on to the owner of the home or other structur~ being built. Furthermore, studies conclusively show that the cost of construction has increased each year `
from year to year, and is likely to continue doing so for the foreseeable future.
Alternative materials of construction designed to reduce costs may be exemplified by use of concrete blocks i~
erecting structures, but this material is subject to severe limitations, chief among which are poor appearance, lack of sufficient insulating properties, and the expense of pro-viding necessary strength. Nor does the addition of brick to provide the necessary structural strength and a pleasing appearance solve the problem, since a brick wall ha~ing com-- parable strength must be built to a minimum thickness of eight inches, and requires the services of a bricklayer to construct, thereby again increasing construction costs.
While it has long been known that conventional structural and structural lightweight concretes may be utilized as construction materials, these materials have been found

- 2 -* Trademark for various types of laminated sheets of melamine-formaldehyde and phenol-formaldehyde plastics with a highly-resistant decorative facing layer for such uses as table or counter tops.
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to be unsat~s~actory ~ a pou~ed~n~pla~e,--all lnclusi~e material of construction since the cost i~ so great and the materials are su~ject to severe limitations regarding such necessary qualities as insulation and shock res~stance.
Furthermore, the cost of precast panels ~uilt of these materials is gene~ally prohibitive because of high transportation and~erection costs.
Summary of the Inveh~ion Accordingly, it is a purpose of this inve~ion to provide a composition of matter which may be used to form ; the structure, which composition has the necessary density, durability, and strength for functional use. The composition may be readily poured into any suitable mold, may be easily nailed, sawed and drilled, and is readily formed to provide a simulated brick or other outer structure having a pleasing appearance, and simulated sheetrock or other desired interior structure. The composition is also firepro~f, waterproof, vermin resistant, ~ot pro~f, wind resistant, erosion proof and storm proof, and is characterized by high shock resistance and good insul~ting pxopertîes. In a typical em~odiment of the invention, the composition may function AS a single wall material of construction having the above-noted characteristics with the exterior walls having the same appearance as ordinary brick, and the interior walls simulating textured g~psum board. The forms utilized to cast this material have ~een s~ecially designed for fast, efficient erection, and are equipped with ~racing, which effect an a~solutely straig~t and true surface with desired ornamentation on both the exterior and interior wall. The composition has proved to be relatively inexpens~ve since it has been found that a savings of up to one~third ~f con~ent~onal material and labor costs may be realized in the wall construction p~ase alone -~ _3_ 1~)38892 by application of t~s ~nYent~on.
It has ~een found that the follo~ng ~asic ingred~
ients may be com~ined to provide a composition having the characteristics heretofore noted: Water, to make the composit~on fluid; gypsum, for structural strength; an expanded material, such as expanded ore, to fill and insulate; cement, for .:

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strength; wood fibers, to impart shock resistance; and a fibrous material such as sisal, polypropylene, or fiberglass fibers, to add shock resistance. Additional preferred ingredients which may be added to aid shrink resistance, minimize porosity and retard excessively rapid setting, are an alkaline earth metal halide such as calcium chloride;
fly ash, silica powder, volcanic rock powder or limestone;
and an acid salt, organic acid salt, or an alkali metal or alkaline earth metal organic acid salt such as sodium or potassium citrate, respectively.
The present invention resides in a composition, which upon mixing with water and subsequent setting forms a material of construction, comprising: gypsum, an expanded material, cement, and polypropylene, sisal or fiberglass fibers; said composition being characterized in that it is devoid of wood fibers, and in that (a) said gypsum is present in the composition in a volume percentage of from about 15% to about 40%;
(b) said expanded material is present in said composition in a volume percentage of from about 17% to a~out 57~;
(c) said cement is present in said composition in a volume percentage of from about 15% to about 40%; and (d) said polypropylene, sisal or fiberglass fibers are present in said composition in a volume percentage of from about 1% to about 2%;
the percentages of ingredients being so chosen as to total 100% by volume of said composition.
In a further, more particular aspect, this inven-tion resides in a composition, which upon mixing with water ~ - 4 -~(~3~89Z ~
and subsequent setting forms a material of construction, comprising: gypsum, vermiculite or perlite, Portland cement, polypropylene, sisal or fiberglass fibers, and limestone dust or fly ash;
said gypsum and said Portland cement each being present in said composition in a volume percentage of from about 15% to about 40%;
said vermiculite or perlite being present in said composition in a volume percentage of from ab~ut 17% to 0 about 57%;
said polypropylene, sisal or fiberglass fibers being present in a volume percentage o~ from about 1~ to about 2~;
and said-limestone dust or fly ash being present in a vol~me percentage of from about 5% to about 10~;
said composition being devoid of wood fibers;
the percentages of ingredients being so chosen as to total 100% by volume of said composition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be recognized that the materials used ln the composition of this invention can be prepared in varying proportions to provide compositions suitable for various enviror,mental conditions according to the teachings of this invention. For example, the gypsum material is utilized in the composition along with cement, and preferably Portland cement, which is a high quality cement composition, to pro-vide the necessary structural strength. Both the cement and the gypsum are preferably mixed in powder form in the compo-sition in the range of from about 15% to about 40~ by volume each.
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. ~)3~3892 An expanded material produced from heated ores, or clays or chemically expanded, such as expanded mica, known in the art as "vermiculite" and marketed under the trademark "Zonolite", by W.R. Grace Company, is also preferably added to the composition in the proportion of from about 9~ to about 29~ by volume. Other expanded ore materials, such as volcanic rock and pumice aggregate, and including the ex-panded hydro-silicate ores exemplified by that known in the art as "perlite", all of which carry captive water which effects exfoliation of the material lamina upon heating, may also be used. Additional expanded materials which may be utilized in the invention to insulate and act as a filler in the composition are expanded clays such as expanded hadide, produced by heating moisture-containing clays until the material "bloats" and sinters. The expanded product is then ground to suitable sizes for use. Other materials suitable for use in the composition are chemically expanded materials, such as expanded styrene and polystyrene beads, and like compositions, which are "puffed" and cause air to be trapped :ZO in the bead structure. These materials are preferably added - 4b -103~92 to the compos~t~on m~xture a~ expanded g~anules whlch are relatively soft and are of average size sufficient to pass a 20 mesh screen. The granules generally maintain their original size and shape after curing of the composition, and also retain moisture, which aids in setting of the cement ingredient and eliminates any necessity for special curiny of the composition.
The granules also serve to provide good insulation, fireproofing and shock resistant qualities to the ~inished composition.
A fibrous material, such as wood, asbestos or sugar cane fibers m~y be added to the composition in a volume percentage r~nge of from about 8% to about 28%, in order to aid moisture re-~tention and flexural strength o~ the composit~on. Tke fiber~, Which may be adde~diin the fo~n of~sa~dust or chips not exceeding about seven-eighths of an inch in diameter, also serve to provide reinforcement and shock resistance ;n -the composition, for particular use in earthquake prone areas such as California, where such resistance may be necessary. In the latter case, where high shock resistance is des~red, other fibrous material 9 such as sisal, ~ylon, fi~erglass, polypropylene, polyethylene (or other similar poly~.erized compound) fibers may be used in the composition. An alkali metal halide or alkaline earth metal halide such as calcium chloride or potassium chloride ma~ also be added to the mixture as desired, preferably in -the volume percentage range of from a~out 0.25~ to about 1%, in order to induce rapid setting of the composition, limit shrinkage, and to increase the strength of the composition as it sets. It should be pointed out that under circums~ances where such a material is used in the composition, it is generally preferred not to use an amount greater than 1% hy volume ~ecause such an excess tends to cause an excessively rapid sett~ng of the composi-tion mixture, and frequently inhibits proper forming of the mixture as it is poured. However, under certain c~nd~tions where : ~()38~9;:
it is desired to effect a fast setting of ~he building material composition, larger percentages of the alkaline earth metal halide, and preferably, calcium chloride, may be used. Fly ash may also be selectively utilized in the composition to enhance waterproofing characteristics, and thls ingredient is prefera~ly added as a powder in a volume percentage of from about 5~ to about 10~ has been found that particulate ~ly ash or, in the alternative, lLmestone dust, will act as a filling agent to fill the porous structure of the composition and to provide the necessary waterproofing qualities. A fibrous material such as sisal, nylon, polyester, polyamide, polypropylene or iberglass, is also preferably utilized in the composition as a reinforcing agent to complement the gypsum and cement, and is preferably addeddas fibers having a length-of from about one inch to about three inches, in a volume percentage range o~ from about 1~ to about 2~. Preferred among these are polypropylene, sisal and fiberglass fibers, and if fi~erglass fibers are utilized in the composition, the fibers should be suitably treated prior to introduction into the composition in order to prevent fiber decomposition due to action of the calcium chloride and cement ingredients in the formulation. Water is then added ~o the mixture in the proportion of about 3.S gallons per cubic foot of mixture to provide the necessary fluidity. It will be appreciated that the concentration of water in the compos~tion is not critical, it being necessary only to provide the necessary fluidity to effectuate pumping or otherwise facilitating entry of the composition mixture into the forms.
It will be recognized that different ~ypes and grades of materials noted above, such as gypsum, used for plaster~
board, for example, may be utilized in the composition. Preferred ; among the mineral CaSO4 .2X2O which may be used are those gypsum compesitions having the trademarks ~'Hydrostone~', manufactured ~)388~Z
by U.S. G~psu~ Company~, and i~Den~acal Pl~s~tex~ manufactured by Georg~a Pacific Company, both prod~cts of which relate to high density CaSO4.2H20, or gypsum. Ordinary gypsum may be utilized in the invention, but the a~ove high density compositions are preferred due to ~he high strength of these products.
The expanded material ingredient in the formulation is preferably selected from the group of micaceous minerals, hydrous silicates or mixtures of these, such as the ore composition generally known in the trade or industry as "perlite", ~6a-1'~388~Z
and particularly, those derived from alteration of mica, "vermiculite", heretofore mentioned, the granules of which expand at high temperature to yield a lightweight, highly water absorbent material. If desired, the expanded material may be substituted for wood fibers or other fibrous material in the composition, with the expanded granules added in the same proportion as the fibrous material. In such event, the volume percentage of the expanded material would be in the range of about 17% to about 57% by volume of the total compo-sition. Under these circumstances, the expanded ingredientore may also be used as a primary ingredient. Furthermore, the fly ash may be substantially any combustible ash which is a by-product of a combustible fuel, and the fibrous material, preferably sisal or polypropylene, should be introduced as small diameter cordage of short nap length, or, in the case of polypropylene, small diameter particles o~ short length, (preferably two inches), which will easily blend into the composition mixture.
Since the alkaline earth metal halides and alkali metal salts of organic acids, such as calcium chloride and sodium citrate, respectively, have an opposite effect on the setting time of the composition mixture, the former causing rapid setting and the latter retarding setting time, these ingredients are normally not used together in the composition.
Under circumstances where rapid setting of the formulation is desired, an alkaline earth metal halide, and preferably calcium chloride, may be added in a volume percentage of up to about one percent. Such addition results in a setting time of approximately four times less than the time required for the composition to set without the addition of calcium ~ - 7 -,~

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~38~92 chloride. For example, if the composition normally sets in about twenty minutes, the addition of about one percent by volume of calcium chloride effects a setting time of about five minutes. Variations between these extremes may, of course, be achievea by varying the amount of calcium chloride in the mixture.
In contrast, under circumstances where it is desired to delay the composition setting time to insure elim-ination of "cold'l joints and other mechanical problems accom-panying rapid setting, an alkali metal salt of an oxganic acid, - 7a -~3~39Z
and preferabl~ sodium c~trate, can ~e added to the formulation in proportions up to a~out 1.~ percent ~y ~olume. Addition of such a concentration of sodium citrate e~tends the composition setting ime from a.normal time of about twent~ minutes to a retarded setting time of about sixty m~nutes~
In a preferred embodiment of this inventian, gypsum is present in the composition in a volume percentage of from about 15% to about 40%; the expanded material is present in a volume percentage of from a~out 9% to about 29~; the cement is introduced lQ in a volume percentage of from about 15% to about 40%; and poly-propylene, fiberglass or sisal fibers are used in a volume percent-age of from about 1% to about 2~.
In yet another preferred embodiment o~ the invention, under construction circums~ances which dictate a normal composit-ion setting time of about twenty minutes, the formulation of this invention is composed of the following ingredients in the following volumetric proportions:
Gypsum 21 Expanded Ore 28%
Portland Cement 21 Wood Fibers 21 Limestone Dust or Fly ~h 7%

Sisal of Polypropylene Fibers 2~
Water - 3-4 gallons per cubic foot of mixture.
In a more preferred embodiment o~ the invention, under construction circumstances which dictate an accelerated setting time, the formulation of this invention is composed of the following ingredients in the following volumetric proportions:

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~38892 ~p~um, 21~.
: Yermi,cul~te 28%.
Portland Cement 21%
Wood Fibers 21%
Calcium Chloride 1%
Limestone Dust or ~ly Ash 7%

Sisal or Polypropylene:
Fibers 1%
': Water ~ 3.5 gallons per cubic foot of mixture.
In yet another more preferred embod~.ment o~ the invention wherein the composition set forth immediately above.
is utilized, the wood fibers are replaced b~ vermicu:Lite in the same proportions as the ~ood fibers.
In a mosk preferred embodiment o~ the invention, the construction composition o~ this invention is composed of the following ingredients in the following volumetric proportions to effect optimum setting and curing conditions:
Gypsum 21 Vermiculite 28 Portland Cement 21~
ood Fibers 21%
Sodium Citrate 1%

Limestone Dust or Fly Ash 7 Sisal or Polypropylene Fibers l~
The invention ~ill be better understood by a consider-ation of the following examples:
` EXAMPLE 1 ; Six cubic feet of gypsum, six cubic feet of Portland cement, two cubic feet of limestone dust, eight cubic feet of vermiculite, one-half of a cubic foot of polypropylene fibers, one-half of:a cubic oot of calcium chloride and six cubic feet 103~89~
of dry shredded wood fi~er~ ~ere placed in a ~ix~ng container, ; and into t~is mixture was added n~nety~t~o gallons of water.
The composition ~as stirred to a uniform consistency and was noted to be viscous. The mixture was then p-a~red into several forms, each in the shape of a cylinder haY~ng a diameter o~
approximately six inches and a height of a~out twelve inches, for testing and was allowed to stand for twenty~eight da~s to cure (setting of the mixture was obserYed to occur in about fifteen minutes). After the curing period, a specimen~ which was observed to be a greyish brown in color, was broken under ASTM compressive testing conditions. The density of the mix was found to be ninety-one po~nds per cu~ic foot on a.wet basis, and sixty-eight po~nds per cubic foot on a dry ~asis.
The compressive strength o~ this and other samples computed as a function of time was found to be as follows:
2 hours - 250 psi 7 days ~ 650 psi 28 days - 1,000 psi E2AMPLF,-II
A composition mixture having the same ingredient~ in the same proportions as set forth in Example I, except for substitution of sodium citrate for the calcium chloride, was mixed and poured into the forms described in Example I for testing. Setting time was o~served to ~e one hour, and ~he composftion was allowed to cure for twenty~eight days. The ~ results of compressive testing and density measurements were essentially the same as those set forth in Example I.
EXAMPLE~
A sample of the product having the composition se~
3~ forth in Example I was.immersed in ~ater for 48 hours, ~iped dry, weighed, placed in an oven and heated at 230.F for 48 hours. The sample was then cooled in a sealed c~am~er, ~e~ghed and 889;~
the dry~ng and aool~ng c~cle'repeatea for an add~t~onal 48 hour period. The gravimetric re~ults uere as follows:

Initial Wt. Wt. after 48 Wt. after rnitial Linear (lbs.) hrs. sat ~lbs'.~ drying (l~s.~ Shrinkaqe (~) 5.27 5.87 4.05 0.03~1 EXAMP'LE IV
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Five samples of the product having the composition set forth in Example I and measuring 3" x 3" x 12" were subjected to a test for flexural strength in aacordance with ASTM standards, Federal Specification SS-B-663, which strength as a function of load was found to be as ollows:
Test No. Total Load (~bs.) - FleXural Stren~th (psi) ....
1 850 330.5 2 550 213.8 3 700 272.2

4 800 311.2 900 350.1 ~EXAMPL~ V

A sample of the product havi~ng tfie comp~s~t~on ~et ~orth in Example I was su~ected to successive water i~mersion, freezing and thawing conditions as follows: The sample was first 2~ weighed, then immersed in water for 8 hours, removed, and again weighed. It was then placed in a ~35~ cham~er and frozen for 8 hours, removed, and placed in an oven and heated at 350~ for 8 hours, after which it was removed and again weighed. The results were as follows:

No. of Wt. after 8 Dry ~t. After freezing Initial Wt. hrs. sat 8 hrs.& t~aw~ng Ad~erse (lbs.) (lbs.) (lbs~ - cycles ~fects

5.25 5.80 4.0 90 None EX~MPLE'~I
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Six samples- of the product fiav~ng the composition set forth in Example I were cured for 28 days and su~ected to a splitting tensîle strength test ~y appl~cation of ~ST~ test ~11~

number C 496~69,,and t~e res~ults ~ere'~s f~llow~:
Maximu~LoAd~~pl~t~ e~ e Cylinder No. ' ~(BQUnds);(Stre,ng h tP~I) 9W 9,50~ 84 9X ll~0~0 ~7 9Y 10,5aO g3 9Z 13,'~ ll9 9Zl ll,0~ 97 9Z2 1~,5aOlQ2 Averages 99 Five samples of the product having the composition set forth in Example I and measùring 3" x 3" x 12'l1 were cured, placed in waker for 48 hours, wiped dry and weighed, placed in an oven at 230F for 48 hours, cooled in sealed chambers, and measured. The drying and cooling cycle was then repeated for an additional 48 hours, and the results were as follows:

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EXA~PLE ~I~
A cured ~all section formed of the composition product set forth in Example ~ and having dimensions of 6' x 6' x 4" was set up for application of a seven day simulated environmental test.
Raiming conditions were simulated ~y use oiE water ~oses with spray nozzles and wind effect was s~mulated ~ use of a ~ydraulic jack positioned horizontally against the wall section. Water was continuously applied to the wall section for seven clays and a horizontal load of 625 P5F was continuously applied over the test period h~ use of the jack, The 625 PSF was measurad by use of a 10,000 pound capacity Marshall Proving Ring, No. 1181, ; and the deflection of the wall was checked with a 0.001 inch dial indicator. At the end of the seven day test period the horizontal load was steadily increased to determine at what point the wall would fail. The results of this load application ' were as follows:
Total load applied for seven days ~ 625 PSF
Total deflection over test period ~ 0.0~17 inches ~otal load required to cause failure - 2,100 PSF
-EXA~lPLE IX
A cured roof section measuring 15.7' x 11.7i x 6"
and formed o the composition set forth in Example I was set up for testing and a total load of 38,170 pounds (207 PSF~ applied.
There was no visible failure of the roof section upon application of the load, and it was removed.
While it will be recogn~zed that the composition of this invention may ~e ~ntroduced into forms des~gned to produce a selected product by a variety o~ techni~ues, it is preferred to pump the mixture into the forms. This procedure insures that the forms are uniformly filled, and effeats a continuous and uninterrupted flow to avoid "cold" joints in the composit~on as it hardens; after a firm set has been achieved the ~orms are removed. Curing of the composition is effected by allo~ing t~e .

mixture to ~et for a $~ec~ed ~e~od Q~ t~e. ~nder ord~nary circumstances, the compos-~t~on setting t~e prior to remo~al of the forms should not exceed about two hours. ~s heretofo~e noted, depending upon the particular design of the forms - utilized, the outside of the structure ma~ be formed to simulate a brick or conc~ete surface, and the inside can be designed to resemble textured gypsum, which may be easily painted or other-wise decorated for finishing purposes. Other materials may be simulated as desi~ed, depending upon the form design, and use of the mo~olithic pour technique vastly reduces the chance of overturning and collapse under load. The material may be mill mixed to exact specifications with strict quality control, requiring only the addition of water at the job site with no special plank or equipment needed, to e~ect the de~ired composit-ion. Furthermore, the capability for producing a wall or structure having particular specifications is limited only b~ the avail-ability of the proper forms, an appropriate m~xer, and equipment ~o pump the mix to the forms.
It is significant that under circumstances where additional insulating properties are reguired, either the wall or other structural mem~er thickness may be increased, the density o the mix reduced, or particular ingredients, such as wood fibers and vermiculite or other expanded material may be added in increased quantities. Furthermore, the durability and permanency of the composition structure is essentially ~hat of conventional concrete, and maintenance on such surfaces as the interior wall is limited only to that ~hich would normally ~e re~uired in conventional structures, such as painting, paneling, wallpapering and/or texturing. Since the ~all and other struct-ural parts are solid, the necessity of replacing torn and brokensheetrock as in conventional hausing is eliminated, and t~e walls are capable of being nailed for installation of panel~ng, i~

~15 -1~31389Z
desired, ~urthermore, ~rim, mo~ding, and acCessories may be installed and adhesives applied for hang~ng wallpaper, as in conventional structures.
In addition to the superior qualities characteristic of the composition enumerated a~ove, it is further significant that pouring of the product composition of this invention and the product itself is unaffected by wide temperature variation, since the composition will not freeze when poured in subzero temperatures due to the heat of hydration generated - 10 in the setting material. So long as the water can ~e added before it reezes, the mixture will not be adversely af~ected by either low or high temperatures, and it can ~e poured when outside temperatures are as low as -20Fahrenheit. (-29C) Furthermore, the pouring technique itself, as well as the compesition mixture, is unaffected by hot and cold weather, freezing and thawing conditions, as well as var~ing humidity and other adverse weather cond$tions.
It is also significant that t~e composition of this invention may be readily adapted for use in an~ part of the United States as a material of aonstruction due to its versatil-ity. For example, it may be designed to withstand earthquake shocks prevalent on the West Coast, by incorporating a high flexure strength made possible by addition of higher concentra-tions of the wood fiber and sisal or polypropylene ingreaients.
The produc,t may be made resistant to wind and ice storms by incorporating higher concentrations of cement and fly ash for example, to enhance strength and water-impermea~le characteristics, and the composition is impervious to the adverse affects of salty air found in coastal areas.
Other advantages of the composition of this invention are found in the features of self-reinforcement, w~ic~ eliminates the need for steel reinforcement necessar~ in con~entional .~

concrete structures, and t~e capa~ t~ of m~ll m~xing to exact specifications, w~ic~ produces a m~xture requir~ng only the addition of water and mix~ng to ready the composition for pouring.
As heretofore noted, the composition is also characterized by a controlled curing period after which the forms may be removed, and is shrink resistant, a feature which eliminates cracking and checking in the finished product ana enables the forming of selected fine detail in both the interior and exterior surfaces.
The composition has an average flexural strength of about 340 psi, which compares to approximately 100 ps~ for conventional concrete, and is essentially completely inert, as heretQ,fQr~e noted. The poured wall is also characterized by low density, a factor which produces excellent noise reduction qualities.
; It will be appreciated by those skilled in the art that while it is ~referred to use a waterpro~fing agent such as fly ash or limestone dust in the composition, waterproofing of the finished product can be alternativély effected by conventional techniques known in the art. For example, the composition product can be formed and cured without using a waterproofing agent mixed therein, and can be water and weatherproofed by application of a conventional mastic or spray after curing.

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Claims (10)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A composition which, upon mixing with water and subsequent setting, forms a material of construction, comprising: gypsum, an expanded material, cement, and poly-propylene, sisal or fiberglass fibers; said composition being characterized in that it is devoid of wood fibers, and in that (a) said gypsum is present in the composition in a volume percentage of from about 15% to about 40%;
(b) said expanded material is present in said composition in a volume percentage of from about 17% to about 57%;
(c) said cement is present in said composition in a volume percentage of from about 15% to about 40%; and (d) said polypropylene, sisal or fiberglass fibers are present in said composition in a volume percentage of from about 1% to about 2%;
the percentages of ingredients being so chosen as to total 100% by volume of said composition.

2. The composition of claim 1 further comprising fly ash or limestone dust.

3. The composition of claim 1 wherein said expanded material is an expanded ore.

4. The composition of claim 1 wherein fly ash or limestone dust is present as an ingredient and wherein the expanded material is an expanded ore or clay or expanded polystyrene.

5. The composition of claim 4 wherein the ex-panded material is vermiculite or perlite.

6. A composition which, upon mixing with water and subsequent setting, forms a material of construction, comprising: gypsum, vermiculite or perlite, Portland cement, polypropylene, sisal or fiberglass fibers, and limestone dust or fly ash;
said gypsum and said Portland cement each being present in said composition in a volume percentage of from about 15% to about 40%;
said vermiculite or perlite being present in said composition in a volume percentage of from about 17% to about 57%;
said polypropylene, sisal or fiberglass fibers being present in a volume percentage of from about 1% to about 2%;
and said limestone dust or fly ash being present in a volume percentage of from about 5% to about 10%;
said composition being devoid of wood fibers;
the percentages of ingredients being so chosen as to total 100% by volume of said composition.

7. The composition of claim 6 further comprising calcium chloride.

8. The composition of claim 6 further comprising sodium citrate.

9. The composition of claim 7 wherein said calcium chloride is present in said composition in a volume percentage of about 1%.

10. The composition of claim 8 wherein said sodium citrate is present in said composition in a volume percentage of about 1%.