Durable magnesium oxychloride cement and process therefor

1. A magnesium oxychloride cement (MOC) composition comprising:

reactive MgO 7-50% by weight

magnesium chloride 3-20% by weight,

H 2 O 9-50% by weight,

phosphoric acids or corresponding salts 0.05-5% by weight calculated as P 2 O 5 , and

exfoliated vermiculite 1-80% by weight.

2. The MOC of claim 1 further comprising 0-20% by weight of components selected from the group consisting of additives, fillers, and stabilizers.

3. The MOC of claim 1 , wherein the amount of vermiculite is from 1 to 30% by weight.

4. The MOC of claim 1 , wherein the MOC further comprises at least one stabilizer to improve water resistance, selected from the group consisting of organic acids, alkyl silicates, hydrophobic silicon siloxane compounds, and mixtures thereof.

5. The MOC of claim 1 , wherein the MOC is obtained by mixing

reactive MgO 7-50% by weight,

MgCl 2 3-20% by weight,

H 2 O 9-50% by weight,

phosphoric acid or corresponding salts 0.05-5% by weight calculated as P 2 O 5 ,

exfoliated vermiculite 1-80% by weight, and

additives or fillers 0-20% by weight.

6. The MOC of claim 1 , wherein the acid or corresponding salt is selected from the group consisting of ortho-phosphoric acid, tri-sodium phosphate and its hydrates, sodium polyphosphate and its hydrates, aluminium phosphate and its hydrates, and mixtures thereof.

7. The MOC of claim 2 , wherein the additive is selected from the group consisting of setting accelerators setting retarders, foaming agents, air entrainers, water repellents, super plasticizers, and mixtures thereof.

8. The MOC of claim 1 , wherein the exfoliated vermiculite has a bulk density of less than 0.300 g/cm 3 .

9. The MOC of claim 5 , wherein the additives or fillers are selected from the group of CaCO 3 , fly ash from thermal power plant, bottom ash from thermal power plant, saw dust, expanded perlite, foaming agents and/or air entrainers, cellulose fiber, chopped glass fiber, glass fiber mat, silica fume, talc, saw dust, mica and mixtures thereof.

10. The MOC of claim 9 , wherein the calcite has a particle size less than 200 μm.

11. The MOC of claim 1 , wherein the amount of vermiculite is from 1 to 20% by weight.

12. The MOC of claim 1 , wherein the amount of vermiculite is from 5 to 20% by weight.

13. The MOC of claim 7 , wherein the setting accelerator is hydrochloric acid.

14. The MOC of claim 7 , wherein the setting retarder is sulphuric acid.

15. The MOC of claim 1 , wherein the exfoliated vermiculite has a bulk density of between 0.050 and 0.200 g/cm 3 .

16. The MOC of claim 1 , wherein the exfoliated vermiculite has a bulk density between 0.100 and 0.150 g/cm 3 .

17. The MOC of claim 9 , wherein the calcite has a particle size from 5 to 100 μm.

18. The magnesium oxychloride cement (MOC) of claim 1 further comprising calcite (CaCO 3 ) in an amount from 0.1 to 20% by weight.

19. A product a consisting of the magnesium oxychloride cement (MOC) of claim 1 in casted or sprayed form.

20. A process of making a magnesium oxychloride cement (MOC) comprising the step of mixing reactive MgO 7-50% by weight, MgCl 2 3-20% by weight, H 2 O 9-50% by weight, phosphoric acid or a corresponding salt 0.05-5% by weight calculated as P 2 O 5 , exfoliated vermiculite 1-80% by weight and optionally calcite 0.1 to 20% by weight.

21. The process of claim 20 , further comprising the step of mixing 0-20% by weight additives or fillers.

22. A process of making a MOC matrix with reduced HCl release in case of fire comprising the step of adding a calcite (CaCO 3 ) as an additive into the MOC matrix, wherein the MOC matrix comprises reactive MgO 7-50% by weight, magnesium chloride 3-20% by weight, H 2 O 9-50% by weight, phosphoric acids or corresponding salts 0.05-5% by weight calculated as P 2 O 5 , and exfoliated vermiculite 1-80% by weight.