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 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: A composition comprising fly ash particles with an average particle diameter of not greater than 100 micrometers and a moisture content of not greater than 0.25 percent by weight. The compositions are useful as both a filler and a colorant in polymer containing compositions, particularly polyvinyl chloride compositions for extruding pipes and conduits. Desirably, the composition is used at a filler loading level of from about 1 to about 80 parts by weight of the fly ash per hundred parts of the polymer. Fly ash-filled polyvinyl chloride compositions containing the fly ash as described meet commercial requirements and are economically and environmentally beneficial.