Cementitious composition

Claim 2

A curable cementitious composition which is curable under atmospheric conditions and which is characterized by the substantial absence of sand and gravel aggregate, having a density of less than about 75 lbs/cu. ft., a compressive strength of as high as 30,000 psi, zero flame spread characteristics and a total thermal resistance in the range of 4.33 Hr-ft 2 -F 0 /Btu, capable of being cured to form an article of construction, said composition comprising: a liquid vehicle including about 25 parts by weight of a latex acrylic emulsion extender, about 10 parts by weight of a water soluble melamine formaldehyde-based polymeric plasticizer, and about 100-300 parts by weight water, the weight ratio of extender to plasticizer in the liquid vehicle being about 2.5:1; and the liquid vehicle being combined with dry ingredients including fly ash, Portland cement, polypropylene fiber and polystyrene beads to form the curable cementitious composition, the weight ratio of the liquid vehicle to the dry ingredients being in the range from about 1:2.9 to 1:5.

Claim 3

The curable cementitious composition of claim 1, further comprising: an accelerator for decreasing the curing time of the cementitious composition.

Claim 4

A curable cementitious composition which is curable under atmospheric conditions and which is characterized by the substantial absence of sand and gravel aggregate, having a density of less than about 75 lbs/cu. ft., a compressive strength of as high as 30,000 psi, zero flame spread characteristics and a total thermal resistance in the range of 4.33 Hr-ft 2 -F 0 /Btu, capable of being cured to form an article of construction, said composition comprising: a liquid vehicle including about 25 parts by weight of a latex acrylic emulsion extender which is an acrylic emulsion polymer having a solids percent by weight of 47%, a pH of 9.0-10.0, a viscosity of 50 cps, and a weight per gallon of 8.8 pounds, about 10 parts by weight of a water soluble melamine formaldehyde-based polymeric plasticizer, and about 100-300 parts by weight water, the weight ratio of extender to plasticizer in the liquid vehicle being about 2.5:1; the liquid vehicle being combined with dry ingredients including fly ash, Portland cement, polypropylene fiber and polystyrene beads to form the curable cementitious composition, the weight ratio of the liquid vehicle to the dry ingredients being in the range from about 1:2.9 to 1:5; and wherein the polypropylene fiber is provided as a fibrillated bundle which opens when placed into the cementitious composition, the fiber having a specific gravity of about 0.91, a density of about 56 lbs/cu.ft., a modulus of elasticity of about 0.70×10 6 psi, and a tensile strength of 70,000 psi.

Claim 5

A curable cementitious composition which is curable under atmospheric conditions and which is characterized by the substantial absence of sand and gravel aggregate, having a density of less than about 75 lbs/cu. ft., a compressive strength of as high as 30,000 psi, zero flame spread characteristics and a total thermal resistance in the range of 4.33 Hr-ft 2 -F 0 /Btu, capable of being cured to form an article of construction, said composition comprising: a liquid vehicle including about 25 parts by weight of a latex acrylic emulsion extender which is an acrylic emulsion polymer having a solids percent by weight of 47%, a pH of 9.0-10.0, a viscosity of 50 cps, and a weight per gallon of 8.8 pounds, about 10 parts by weight of a water soluble melamine formaldehyde-based polymeric plasticizer, and about 100-300 parts by weight water, the weight ratio of extender to plasticizer in the liquid vehicle being about 2.5:1; the liquid vehicle being combined with dry ingredients including fly ash, Portland cement, polypropylene fiber and polystyrene beads to form the curable cementitious composition, the weight ratio of the liquid vehicle to the dry ingredients being in the range from about 1:2.9 to 1:5; and wherein the polypropylene fiber is provided as a fibrillated bundle which opens when placed into the cementitious composition, the fiber having a specific gravity of about 0.91, a density of about 56 lbs/cu.ft., a modulus of elasticity of about 0.70×10 6 psi, and a tensile strength of 70,000 psi.

Claim 6

The curable cementitious composition of claim 3, wherein the polypropylene fibers within said curable cementitious composition have a fiber length in the range from about 3/4" to 11/2".

Claim 7

The curable cementitious composition of claim 4, wherein the polystyrene beads dispersed within said curable cementitious composition are a regrind of 1 lb./cu.ft. density polystyrene and have an average bead size of approximately 2 mm.

Claim 8

The curable cementitious composition of claim 3, further comprising a plurality of steel fibers dispersed within said curable cementitious composition.