Importance

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Abstract

A composite building component is formed of a cement composition having a sufficient amount of diatomaceous earth and/or other thermally insulating material(s), in specific ratio to entrained air contained in fluid pockets, to provide substantial thermal insulation and resistance to decomposition which would otherwise occur at very high temperatures. The cement composition is poured/placed in a 2 to 6 sided pre-formed box or half box with integral insulating core. The pre-formed box becomes bound to the poured/placed cement composition and upon curing, becomes an integral part of the final product. The cement composition may also include an amount of fibrous material and/or organic binder(s) (integrally and/or impregnated) sufficient to increase the tensile strength, handleability, and machineability of the building components. A cement composition is initially created to include a plurality of fluid pockets as the basis for achieving the features cited. The number and size of the fluid pockets is adjusted to provide different strength verses weight ratio products. The building components include a surface material that has an organic polymer applied to a first side thereof. The cement composition is provided with a sufficient amount of a chemically active component to bind with the organic polymer applied to the surface material so that the surface material is substantially integrally formed with the building component. The ratio of building component weight versus strength versus size can be readily adjusted by varying the internal core geometry and size, versus total end product size, versus density/strength of cement composition filler material.

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First Claim