Bioceramic Idea:

/!\ This whole section is AI-sourced and not yet confirmed to be exact in composition/ratios

Panel concept: two bioceramic skins (3–6 mm each) laminated to a separately grown mycelium core (don’t try to grow mycelium against fresh phosphate—phosphate and pH will suppress growth). Core can be grown in a breathable mold, then dry-cured, then laminated into the shells with a thin, compatible adhesive layer.

A starter “winter-proof” skin mix (by mass)

Target: low water uptake, good freeze–thaw, reasonable work time.

• MgO (medium reactivity) ………………… 100

• MKP (KH₂PO₄) ……………………………… 45–50

• Metakaolin (or Class F fly ash) ……… 15–25

• Silica flour (or very fine sand) ……… 25–40

• Borax (retarder) …………………………… 2–4

• Water (by total binder mass*) ……… 17–22

*Binder mass = MgO+MKP+metakaolin (not counting sand).
Fiber mesh: 160–220 g/m² basalt mesh or alkali-resistant glass set near the tensile face of each skin.

What this gives you

• MgO:MKP molar ≈ 4:1 (water-resistant end of the sweet spot)

• Work time: ~12–20 min (dial with borax and water temp)

• Cold-weather performance: low free water, dense matrix, pozzolan filler → better freeze–thaw & wet durability.

Batching & lay-up (small shop method)

1. Dry blend: MgO, MKP, metakaolin, silica, borax for 2–3 min.

2. Add water (cool, ~10–15 °C for more pot life). Mix 60–90 s to pancake-batter consistency.

3. Mold prep: light mist of PVA or vegetable-based release on your form.

4. Face coat: trowel ~1.5–2 mm. De-air with quick vibration or tapping.

5. Lay mesh: place basalt mesh; press in.

6. Back coat: trowel to final skin thickness (3–6 mm).

7. Cure: 24 h at 15–25 °C; keep covered the first 2–4 h so it doesn’t skin-dry.

8. Post-cure: 3–7 days before aggressive water/freeze testing.

Optional winterization boosts

• Replace 10–15% of silica with microsilica for tighter pore structure.

• After 7 days, apply a penetrating silane/siloxane sealer to the exterior face only (still lets the panel dry to the inside).

• Tiny dose (≤0.3%) of latex powder can add flex toughness.

Mycelium core workflow (keeps biology happy)

1. Grow separately: use sterilized ag-waste in a breathable mold sized to your panel.

2. Dry to low moisture (≤10%)—critical for freeze resistance.

3. Seal faces lightly with a breathable mineral wash (thin clay slip or lime casein) if you need dust control—avoid heavy polymer films.

4. Laminate to the cured skins with a thin MKPC slurry (same binder, no sand, peanut-butter thick). It bonds well to porous cores. Press gently and cure 24 h.

If you ever want a fully inorganic core for severe exposures, swap to foamed MKPC (add tiny % of aluminum powder or a protein foaming agent) or a cork/expanded-glass core—both are winter-friendly and hydrophobic.

Example recipe for one skin (1.0 m² at 5 mm)

• MgO …………………………………… 2.1 kg

• MKP …………………………………… 1.0 kg

• Metakaolin ………………………… 0.45 kg

• Silica flour ………………………… 0.8 kg

• Borax ………………………………… 60 g

• Water ………………………………… 0.65 kg (adjust ±50 g for workability)

• Basalt mesh ……………………… 1.8–2.2 m² per full panel (two skins)

Canadian winter: how to validate quickly (shop tests)

1. Soak–freeze–thaw:

   • Cure 7 days → 24 h water soak → 25 cycles (−20 °C to +20 °C).

   • Pass = no cracks/delam, <5% mass gain, <20% flexural loss.

2. Ponding test (snowmelt): dome a skin, pond 5 mm water for 72 h at 0–5 °C: look for chalking or softening.

3. Bond test to core: pull-off with a simple eye-bolt glued to the skin; you want core failure before glue line failure.

Tooling & molds (to keep it “easy to mold”)

• Molds: melamine or HDPE sheets with 3–5 mm perimeter dams.

• Release: PVA or a wipe of canola works; avoid silicone if you plan secondary bonding.

• Edges: form a small drip edge/return on exterior skins to shed meltwater.

• Joinery: MKPC loves cold joints—you can butter edges with a fresh slurry at assembly and get rock-solid seams.

Sourcing (Canada-friendly pointers)

• MKP is sold as “MKP 0-52-34” water-soluble fertilizer at ag suppliers (it’s the same KH₂PO₄).

• MgO: look for “caustic calcined magnesia” (reactive) and “dead-burned magnesia” (DBM). Ceramic/raw chemical suppliers carry it; some concrete admixture suppliers now stock MKPC kits.

• Metakaolin: ceramic/pottery suppliers or concrete supply houses.

• Basalt mesh: FRP reinforcement vendors (same folks who sell AR-glass mesh and basalt rebar).

• Silane/siloxane: masonry suppliers (clear, penetrating water repellent).