Methods for manufacturing articles of manufacture from hydraulically settable mixtures

A method for manufacturing an article having a hydraulically settable matrix, the method comprising the steps of:

• (a) mixing together a hydraulically settable binder, a nonfibrous inorganic aggregate filler, a rheology-modifying agent, optionally fibers, and water to form a hydraulically settable mixture, the optional fibers being included in an amount in a range from about 0.2% to about 50% by volume of the hydraulically settable mixture;
• (b) pressing the hydraulically settable mixture into a desired shape of the article, wherein water removed from the hydraulically settable mixture is in a vapor state;
• (c) heating the hydraulically settable mixture so as to yield an article that is form stable in less than about 10 seconds after the mixture is first pressed into the desired shape of the article;
• and
• (d) allowing the hydraulically settable mixture to harden into the desired shape of the article, the hydraulically settable matrix of the hardened article including greater than about 50% by volume of combined amounts of at least partially hydrated hydraulically settable binder and the nonfibrous inorganic aggregate filler.

A method for manufacturing a cementitious container having a cementitious structural matrix, the method comprising the steps of:

• (a) mixing together a hydraulic cement, a rheology-modifying agent, a nonfibrous inorganic aggregate filler, water, and optionally fibers to form a cementitious mixture, the optional fibers being included in an amount less than about 30% by volume of the cementitious mixture;
• (b) positioning the cementitious mixture between a heated male die and a heated female die;
• (c) pressing the cementitious mixture between the heated male die and the heated female die into a desired shape of the container wherein water removed from the cementitious mixture is in a vapor state, the cementitious mixture being form stable in less than about 10 seconds after first being pressed into the desired shape of a container;
• (d) removing the male die and the female die from the container after the molded container has achieved form stability;
• and
• (e) allowing the cementitious mixture to harden in the desired shape of the container, the cementitious matrix of the hardened container including greater than about 70% by volume of combined amounts of at least partially hydrated hydraulic cement and the nonfibrous inorganic aggregate filler.

A method for manufacturing an article having a hydraulically settable matrix, the method comprising the steps of:

• (a) mixing together a hydraulically settable binder, a nonfibrous inorganic aggregate filler, water, a rheology-modifying agent, and optionally fibers to form a hydraulically settable mixture, the optional fibers being included an amount in a range from about 1% to about 30% by volume of the hydraulically settable mixture;
• (b) molding the hydraulically settable mixture into a desired shape of the article, the article being form stable in less than about 10 seconds after the hydraulically settable mixture is first molded into the desired shape, wherein the water within the hydraulically settable mixture remains bound within the hydraulically settable matrix of the article or is removed in a vapor state from the mixture;
• and
• (c) allowing the molded hydraulically settable mixture to harden in the desired shape of the article, the hydraulically settable matrix of the hardened article including greater than about 70% by volume of combined amounts of at least partially hydrated hydraulically settable binder and the nonfibrous inorganic aggregate filler, the hardened article including a base and at least one sidewall.