Abstract: Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant. The reactive powder includes fly ash and a tricalcium aluminate additive. In some examples, the reactive powder comprises less than 5% by weight portland cement. The tricalcium aluminate is present in an amount of 0.5% or greater by weight of the reactive powder. Also described herein are building materials including the compositions.

Abstract: Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant. The reactive powder includes fly ash, calcium sulfoaluminate cement, and less than 10% by weight portland cement. In some examples, the composition is substantially free from alkanolamines. In some examples, the ratio of water to reactive powder is from 0.06:1 to less than 0.2:1. Also described herein are building materials including the compositions.

Abstract: Retardant-free inorganic polymer compositions and methods for their preparation are described herein. The methods include mixing reactants comprising a reactive powder and an activator in the presence of water and forming an inorganic polymer product. In some examples, the method includes continuously feeding the resultant mixture to produce the inorganic polymer product. Also described herein are mixtures and inorganic polymer compositions. Further described are building materials formed according to the methods.

Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one sacrificial agent is also included in the mixture. The sacrificial agent is a material or mixture of materials that is not required to act as an air entrainment agent but interacts preferentially with components of the fly ash that otherwise neutralize, repress or depress the activity of the air entrainment agent. The invention includes cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, and processes for selecting suitable sacrificial agents.

Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one sacrificial agent is also included in the mixture. The sacrificial agent is a material or mixture of materials that is not required to act as an air entrainment agent but interacts preferentially with components of the fly ash that otherwise neutralize, repress or depress the activity of the air entrainment agent. The invention includes cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, and processes for selecting suitable sacrificial agents.

Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one sacrificial agent is also included in the mixture. The sacrificial agent is a material or mixture of materials that is not required to act as an air entrainment agent but interacts preferentially with components of the fly ash that otherwise neutralize, repress or depress the activity of the air entrainment agent. The invention includes cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, and processes for selecting suitable sacrificial agents.

Abstract: The present invention is a fly ash filler or filler blend having a particle size distribution with at least three modes that can be combined with a polymer at higher filler loadings to produce a filled polymer for polymer composites that, in many cases, can produce improved mechanical properties for the polymer composites over polymer composites using conventional fillers. As a result, superior polymer composites (e.g. those used in carpet backing) can be produced at a lower cost than conventional polymer composites. The present invention also includes a method for producing a polymer composite, comprising the steps of combining a polymer with a fly ash filler or a filler blend having a particle size distribution with at least three modes to produce a filled polymer and producing a polymer composite with the resulting filled polymer. The present invention further includes a method of determining what fly ashes can be used as fillers for polymer composites.

Abstract: The present invention is a method and composition for controlling the viscosity of latex compositions that include fly ash. The composition is an aqueous dispersion comprising water, at least one polymer latex, from about 50 to about 600 parts by weight fly ash per 100 parts by weight dry polymer, and a viscosity stabilizing composition that preferably comprises at least one borate compound. The method includes adding a viscosity stabilizing composition to an aqueous polymer latex composition that includes fly ash. The viscosity stabilizing composition can be used to produce a stirred viscosity of the aqueous dispersion 7 days after mixing that is less than 30% greater than the viscosity of the aqueous composition immediately after mixing.

Abstract: Methods for forming foamed polyurethane composite materials in an extruder including a vacuum section are described. One method includes introducing a polyol, a di- or poly-isocyanate, and an inorganic filler to a first section of an extruder and mixing the components. After mixing, the composite material is advanced to a second section of the extruder, which is maintained at a vacuum pressure. The composite material can begin foaming in the second section and then be extruded from the output end of the extruder. The vacuum pressure of the second section removes non-foaming related gasses entrained in the composite material. A further method includes directing the extruded composite material into a mold.

Abstract: Methods for forming composite materials containing fiber in an extruder are described. A first method includes introducing a polymeric material, an inorganic filler, and a fiber to an extruder. A fiber metering device is used to control the rate the fiber is introduced to the extruder based on the extrusion rate of the extruder. A further method is described that includes introducing a polymeric material and an inorganic filler to an extruder. Then, downstream of the polymeric material and inorganic filler, a fiber metering device introduces a constant weight percentage of fiber to the extruder based on the amount of polymeric material and inorganic filler introduced to the extruder. After the polymeric material, inorganic filler, and fiber are introduced to the extruder by either method, the components are mixed to produce a composite material.

Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions is described. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one amine sacrificial agent is included in the mixture. The cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, are also described.

Abstract: A method of treating fly ash and fly ash treated thereby, the method involving contacting ammonia-laden fly ash with an organic base-containing treatment composition, where the organic base causes the ammonia within the fly ash to evolve from the fly ash. The treatment composition preferably includes an effective amount of one or more amines. The treatment compound may be applied to the fly ash in any manner effective to disperse the treatment compound among the fly ash.

Abstract: A method of treating fly ash and fly ash treated thereby, the method involving contacting ammonia-laden fly ash with an organic base-containing treatment composition, where the organic base causes the ammonia within the fly ash to evolve from the fly ash. The treatment composition preferably includes an effective amount of one or more amines. The treatment compound may be applied to the fly ash in any manner effective to disperse the treatment compound among the fly ash.

Abstract: A method of treating fly ash and fly ash treated thereby, the method involving contacting ammonia-laden fly ash with an organic base-containing treatment composition, where the organic base causes the ammonia within the fly ash to evolve from the fly ash. The treatment composition preferably includes an effective amount of one or more amines. The treatment compound may be applied to the fly ash in any manner effective to disperse the treatment compound among the fly ash.

Abstract: A method of treating fly ash and fly ash treated thereby, the method involving contacting ammonia-laden fly ash with an organic base-containing treatment composition, where the organic base causes the ammonia within the fly ash to evolve from the fly ash. The treatment composition preferably includes an effective amount of one or more amines. The treatment compound may be applied to the fly ash in any manner effective to disperse the treatment compound among the fly ash.

Abstract: The present invention is a fly ash filler or filler blend having a particle size distribution with at least three modes that can be combined with a polymer or bitumen at higher filler loadings to produce a filled polymer or bitumen for composites that, in many cases, can produce improved mechanical properties for the composites over composites using conventional fillers. As a result, superior composites (e.g. those used in carpet backing) can be produced at a lower cost than conventional composites. The present invention also includes a method for producing a composite, comprising the steps of combining a polymer or bitumen with a fly ash filler or a filler blend having a particle size distribution with at least three modes to produce a filled polymer or bitumen and producing a composite with the resulting filled polymer or bitumen. The present invention further includes a method of determining what fly ashes can be used as fillers for composites.

Abstract: The present invention is a fly ash filler or filler blend having a particle size distribution with at least three modes that can be combined with a polymer at higher filler loadings to produce a filled polymer for polymer composites that, in many cases, can produce improved mechanical properties for the polymer composites over polymer composites using conventional fillers. As a result, superior polymer composites (e.g. those used in carpet backing) can be produced at a lower cost than conventional polymer composites. The present invention also includes a method for producing a polymer composite, comprising the steps of combining a polymer with a fly ash filler or a filler blend having a particle size distribution with at least three modes to produce a filled polymer and producing a polymer composite with the resulting filled polymer. The present invention further includes a method of determining what fly ashes can be used as fillers for polymer composites.

Abstract: A method and system for treating fly ash with a treating fluid by evenly dispersing a treating fluid into a flowing stream of fly ash. By dispersing the treating fluid into the fly ash as the fly ash is flowing, the method takes advantage of natural mixing and particle motion that occurs during flow of the bulk solid. The application of treating fluid is advantageously controlled by an automated controller that has inputs and outputs that allow the controller to adjust flow rate of the treating fluid in correspondence with a measured flow rate of the fly ash.

Abstract: The present invention is a fly ash filler or filler blend having a particle size distribution with at least three modes that when combined with asphalt produces asphalt composites such as roofing shingles with improved mechanical properties at a lower cost than asphalt shingles produced using conventional calcium carbonate fillers. The present invention also includes a method for producing an asphalt composite, comprising the steps of combining asphalt with a fly ash filler or a filler blend having a particle size distribution with at least three modes and producing an asphalt composite with the resulting filled asphalt. The present invention further includes a method of determining what fly ashes can be used as fillers for asphalt composites such as roofing shingles.

Abstract: The present invention is an admixture for cementitious compositions that provides both good flowability and high early strength as is desired in the art. The admixture of the invention includes a superplasticizer comprising a water-soluble modified acrylic copolymer and at least one accelerant selected from the group consisting of salts of thiocyanic acid, water-soluble alkanolamines, ethylene oxide adducts of ethylenediamine, and morpholine derivatives. The combination of the superplasticizer and the accelerant used in the invention surprisingly has a synergistic effect on the early compressive strength of the cementitious composition and also enhances the W/CM ratio and the flowability of the cementitious composition.