Importance

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Abstract

A low cost, lightweight, high strength, long lasting, crack resistant, monolithically formed composite structural material and the method of making the same in which the composite consists of a core constructed from lightweight, granulated scrap or waste plastic bonded together with a relatively inexpensive cementitious slurry binder. The core is covered on one or more of its surfaces with a high strength outer layer constructed of layers of non-woven fabric material impregnated with a cementitious slurry binder having a different formulation than the core cementitious slurry binder to effectively bond with the fibers in the layers of non-woven fabric material to form a three-dimensional reinforcement matrix for the outer layer cementitious slurry binder. The composite of the core and covering is co-formed and cured monolithically with the outer layer cementitious slurry binder being continuous throughout the fibers of the layers of non-woven fabric and the core cementitious slurry being continuous throughout the waste plastic core material with the lightweight scrap or waste plastic serving as an aggregate for the core.

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First Claim