Spall-Resistant Cementitious Material

Abstract

Disclosed is an essentially shaped cementitious product wherein the direct tensile strength of the product as determined by ASTM C307 is at least 120% of a predicted direct tensile strength of the product per an equation selected from the group consisting of f′dt=0.06*f′c, f′dt=0.07*f′c, f′dt=0.08*f′c and f′dt=0.11*f′c, and wherein the flexural strength of the product as determined by ASTM C348 is at least 150% of a predicted flexural strength of the product per an equation selected from the group consisting of f′r=0.1*f′c, f′r=0.17*f′c, f′r=9.5*((f′c)̂0.5) and f′r=7.5*((f′c)̂0.5).

1 . An essentially shaped cementitious product manufactured by steps comprising:
 (a) admixing a liquid medium, a hydraulic binding agent, a latex polymer and optionally one or more other components, wherein the mass ratio of hydraulic binding agent to latex polymer is between about 1:1000 and about 1000:1, to form a mixture;   (b) placing the mixture in an essentially prismatic disposition wherein the mixture sets, thereby forming a set essentially shaped mixture; and   (c) permitting the set essentially shaped mixture to harden, thereby forming the essentially shaped cementitious product;   
       wherein a 51-mm-thick sample of the product halts a full metal jacket bullet fired into the sample's thickness from a 9 mm handgun at a distance of 15 meters and wherein spallation resulting from entry of the projectile into the thickness occurs in a zone on the entry surface not greater than about 50 times the area of the bullet hole resulting from the bullet's entry into the thickness of the sample. 
     
     
         2 . A product according to  claim 1 , wherein the material is load-bearing. 
     
     
         3 . A product according to  claim 1 , wherein the material is not load-bearing. 
     
     
         4 . An essentially shaped cementitious product manufactured by steps comprising:
 (a) admixing a liquid medium, a hydraulic binding agent, a latex polymer and optionally one or more other components, wherein the mass ratio of hydraulic binding agent to latex polymer is between about 1:1000 and about 1000:1, to form a mixture;   (b) placing the mixture in an essentially prismatic disposition wherein the mixture sets, thereby forming a set essentially shaped mixture; and   (c) permitting the set essentially shaped mixture to harden, thereby forming the essentially shaped cementitious product;   
       wherein the direct tensile strength of the product as determined by ASTM C307 after curing for 7 days at ambient laboratory temperature of 23° C. and relative humidity less than 85% to ensure proper polymer film formation is at least 120% of a predicted direct tensile strength of the product per an equation selected from the group consisting of f′dt=0.06*f′c, f′dt=0.07*f′c, f′dt=0.08*f′c and f′dt=0.11*f′c. 
     
     
         5 . A product according to  claim 4  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 200% of the predicted direct tensile strength of the product. 
     
     
         6 . A product according to  claim 4  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 300% of the predicted direct tensile strength of the product. 
     
     
         7 . A product according to  claim 4  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 400% of the predicted direct tensile strength of the product. 
     
     
         8 . An essentially shaped cementitious product manufactured by steps comprising:
 (a) admixing a liquid medium, a hydraulic binding agent, a latex polymer and optionally one or more other components, wherein the mass ratio of hydraulic binding agent to latex polymer is between about 1:1000 and about 1000:1, to form a mixture;   (b) placing the mixture in an essentially prismatic disposition wherein the mixture sets, thereby forming a set essentially shaped mixture; and   (c) permitting the set essentially shaped mixture to harden, thereby forming the essentially shaped cementitious product;   
       wherein the flexural strength of the product as determined by ASTM C348 is at least 150% of a predicted flexural strength of the product per an equation selected from the group consisting of f′r=0.1*f′c, f′r=0.17*f′c, f′r=9.5*((f′c)̂0.5) and f′r=7.5*((f′c)̂0.5). 
     
     
         9 . A product according to  claim 8  wherein the flexural strength of the product as determined by ASTM C348 is at least 200% of a predicted flexural strength of the product. 
     
     
         10 . A product according to  claim 8  wherein the flexural strength of the product as determined by ASTM C348 is at least 300% of a predicted flexural strength of the product. 
     
     
         11 . A product according to  claim 8  wherein the flexural strength of the product as determined by ASTM C348 is at least 400% of a predicted flexural strength of the product. 
     
     
         12 . An essentially shaped cementitious product manufactured by steps comprising:
 (a) admixing a liquid medium, a hydraulic binding agent, a latex polymer and optionally one or more other components, wherein the mass ratio of hydraulic binding agent to latex polymer is between about 1:1000 and about 1000:1, to form a mixture;   (b) placing the mixture in an essentially prismatic disposition wherein the mixture sets, thereby forming a set essentially shaped mixture; and   (c) permitting the set essentially shaped mixture to harden, thereby forming the essentially shaped cementitious product;   
       wherein the direct tensile strength of the product as determined by ASTM C307 is at least 150% of a predicted direct tensile strength of the product per an equation selected from the group consisting of f′dt=0.06*f′c, f′dt=0.07*f′c, f′dt=0.08*f′c and f′dt=0.11*f′c, and wherein the flexural strength of the product as determined by ASTM C348 is at least 150% of a predicted flexural strength of the product per an equation selected from the group consisting of f′r=0.1*f′c, f′r=0.17*f′c, f′r=9.5*((f′c)̂0.5) and f′r=7.5*((f′c)̂0.5). 
     
     
         13 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 200% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 200% of a predicted flexural strength of the product. 
     
     
         14 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 250% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 250% of a predicted flexural strength of the product. 
     
     
         15 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 300% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 300% of a predicted flexural strength of the product. 
     
     
         16 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 325% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 325% of a predicted flexural strength of the product. 
     
     
         17 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 350% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 350% of a predicted flexural strength of the product. 
     
     
         18 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 375% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 375% of a predicted flexural strength of the product. 
     
     
         19 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 400% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 400% of a predicted flexural strength of the product. 
     
     
         20 . A product according to  claim 12  wherein the direct tensile strength of the product as determined by ASTM C307 is at least 500% of the predicted direct tensile strength of the product and wherein the flexural strength of the product as determined by ASTM C348 is at least 500% of a predicted flexural strength of the product.