Freeze/thaw resistant cementitious adhesive for composite materials and method for production thereof

A non-foamed cementitious composition operative upon setting to form a substantially homogenous, pervious rigid mass, comprising a substantially surfactant-free mixture of:

• (i) a fines component selected from a group consisting of cement and a blend of cement and a pozzolonic material;
• (ii) inert aggregate particles;
• (iii) water;
• and
• (iv) between about 0.001 and about 0.0315 percent by weight of a water-soluble polymer capable of adhesion to said aggregate particles and of a type that takes up and releases water when incorporated into said mixture, and wherein said fines component, said water, and said polymer having proportions with respect to one another and together in a proportion with respect to said aggregate particles sufficient in an absence of surfactant to form a substantially uniform adhesive coating on said aggregate particles such that, upon setting, said aggregate particles are bonded to one another at contact areas thereof.

A method of forming a substantially homogenous, pervious cementitious rigid body comprising the steps of:

• (a) forming a mixture including between about 0.001 and about 0.0315 percent by weight of a polymer powder, cement, inert aggregate particles and water in an absence of any foamed surfactant, said polymer capable of taking up and releasing water in said mixture, and wherein said polymer, said cement and said water are in proportions to one another and together in proportion to said inert aggregate particles sufficient to form an adhesive coating on said aggregate particles;
• (b) mechanically mixing said mixture in an absence of any foamed surfactant for an interval of time sufficiently long to form said adhesive coating on said aggregate particles and thereby produce a flowable slurry;
• (c) flowing said slurry as a cohesive mass into a desired three-dimensional configuration;
• and
• (d) allowing said cohesive mass to set into said rigid body.