Abstract: Class C fly ash-based cementitious materials, concretes, and related techniques are disclosed. In accordance with some embodiments, an activated class C fly ash-based cementitious material may be produced by intergrinding class C fly ash (e.g., classified to remove quartz and/or other contaminants and, thus, increase the reactive materials present), an activator, sodium citrate, borax, and a polycarboxylate material. The class C fly ash may have an amorphous glass content of about 60 wt % or more, a calcium oxide (CaO2) content of about 20 wt % or more, and a quartz content of about 10 wt % or less. The activator may be a chemical which reacts with class C fly ash to form strätlingite structures therein when introduced with water. In some cases, the cementitious material may be provided as an all-in-one powder blend. In some cases, techniques disclosed herein may be utilized in providing a fast-setting flowable fill material.

Abstract: Methods and systems for reclaiming materials from a mixed waste landfill containing coal combustion byproducts (CCBs) are disclosed. The methods and systems can be used to reclaim CCBs from ponds or dry landfills by obtaining mixed waste, crushing the mixed waste to form crushed mixed waste, drying the crushed mixed waste to form dried crushed mixed waste, and combining the dried crushed mixed waste with other compounds to form a blend. The blends can then be incorporated into a cement material, which may be used to form concrete.

Abstract: Class C fly ash-based cementitious materials, concretes, and related techniques are disclosed. In accordance with some embodiments, an activated class C fly ash-based cementitious material may be produced by intergrinding class C fly ash (e.g., classified to remove quartz and/or other contaminants and, thus, increase the reactive materials present), an activator, sodium citrate, borax, and a polycarboxylate material. The class C fly ash may have an amorphous glass content of about 60 wt % or more, a calcium oxide (CaO2) content of about 20 wt % or more, and a quartz content of about 10 wt % or less. The activator may be a chemical which reacts with class C fly ash to form strätlingite structures therein when introduced with water. In some cases, the cementitious material may be provided as an all-in-one powder blend. In some case, techniques disclosed herein may be utilized in providing a fast-setting flowable fill material.

Abstract: Methods and systems for reclaiming materials from a mixed waste landfill containing coal combustion byproducts (CCBs) are disclosed. The methods and systems can be used to reclaim CCBs from ponds or dry landfills by obtaining mixed waste, crushing the mixed waste to form crushed mixed waste, drying the crushed mixed waste to form dried crushed mixed waste, and combining the dried crushed mixed waste with other compounds to form a blend. The blends can then be incorporated into a cement material, which may be used to form concrete.

Abstract: Lithium-treated calcium aluminate cement (CAC)-based products, concretes, and related techniques are disclosed. In accordance with some embodiments, a lithium-treated CAC mixture may be produced by intergrinding ground-down CAC, class C fly ash, a lithium compound, and a polycarboxylate material. In accordance with some embodiments, a cementitious material may be produced by intergrinding said lithium-treated CAC mixture with class C fly ash, sodium citrate, and a polycarboxylate material. In accordance with some embodiments, a concrete may be produced by mixing said cementitious material (including said lithium-treated CAC mixture) with rock, sand, and water.

Abstract: Lithium-treated calcium aluminate cement (CAC)-based products, concretes, and related techniques are disclosed. In accordance with some embodiments, a lithium-treated CAC mixture may be produced by intergrinding ground-down CAC, class C fly ash, a lithium compound, and a polycarboxylate material. In accordance with some embodiments, a cementitious material may be produced by intergrinding said lithium-treated CAC mixture with class C fly ash, sodium citrate, and a polycarboxylate material. In accordance with some embodiments, a concrete may be produced by mixing said cementitious material (including said lithium-treated CAC mixture) with rock, sand, and water.

Abstract: A hydrated cementitious blend, and method of using same, the blend comprising: a dry cementitious blend comprising the following, based on the total weight of the dry cementitious blend: aggregate comprising less than 3 wt. % calcium, based on the total weight of the aggregate; from about 75 wt. % to 82 wt. % pozzolonic material comprising improved ash comprising particles meeting the ASTM C 989-2010 testing protocol for grade 100 slag quality or higher, the improved ash being selected from the group consisting of fly ash, calcined or uncalcined volcanic ash, rice hull ash, and combinations thereof; a catalytically effective quantity of catalyst selected from the group consisting of alkali-containing zeolite, alkali-containing feldspathoid, and combinations thereof; and, an amount of water reducing component; the hydrated cementitious blend further comprising an amount of water producing a ratio of water to cementitious blend of from about 0.20 to about 0.

Abstract: A hydrated cementitious blend, and method of using same, the blend comprising: a dry cementitious blend comprising the following, based on the total weight of the dry cementitious blend: aggregate comprising less than 3 wt. % calcium, based on the total weight of the aggregate; from about 75 wt. % to 82 wt. % pozzolonic material comprising improved ash comprising particles meeting the ASTM C 989-2010 testing protocol for grade 100 slag quality or higher, the improved ash being selected from the group consisting of fly ash, calcined or uncalcined volcanic ash, rice hull ash, and combinations thereof; a catalytically effective quantity of catalyst selected from the group consisting of alkali-containing zeolite, alkali-containing feldspathoid, and combinations thereof; and, an amount of water reducing component; the hydrated cementitious blend further comprising an amount of water producing a ratio of water to cementitious blend of from about 0.20 to about 0.

Abstract: Method for processing of pozzolans comprising fly ash such as Class F and/or Class C fly ash used for preparation of mortars and concretes, characterized in, that the pozzolans is subjected to a high energetic mechanical processing by means of grinding in a grinding equipment to a fineness of the final product with a retention on a sieve 30 microns being less than 5%, whereby the pozzolan particles receive mechanical impulses when non-cenosphere in the form of coarse scoria particles are disintegrated and whereby the surface of cenosphere grinded particles is activated.

Abstract: A rapid setting, controlled low strength composition of Class C fly ash is provided having a quantity of hydrated lime and an iron chelating compound in an amount sufficient to accelerate the hydration and set time of the fly ash. In some examples, a filler material is added. A method for acceleration of the hydration and set time of a cementitious mixture is provided wherein hydrated lime is added to the cementitious mixture in an amount in the range of 0.1% to 15% by weight and an iron chelating compound in an amount in the range of 0.01% to 5.0% by weight of the cementitious material. Further, a calcium source and an iron chelating compound may be added to a Class C fly ash to accelerate the hydration and set time of the ash.

Abstract: Method for processing of pozzolans comprising fly ash such as Class F and/or Class C fly ash used for preparation of mortars and concretes, characterized in, that the pozzolans is subjected to a high energetic mechanical processing by means of grinding in a grinding equipment to a fineness of the final product with a retention on a sieve 30 microns being less than 5%, whereby the pozzolan particles receive mechanical impulses when non-cenosphere in the form of coarse scoria particles are disintegrated and whereby the surface of cenosphere grinded particles is activated.

Abstract: A rapid setting, controlled low strength composition of Class C fly ash is provided having a quantity of hydrated lime and an iron chelating compound in an amount sufficient to accelerate the hydration and set time of the fly ash. In some examples, a filler material is added. A method for acceleration of the hydration and set time of a cementitious mixture is provided wherein hydrated lime is added to the cementitious mixture in an amount in the range of 0.1% to 15% by weight and an iron chelating compound in an amount in the range of 0.01% to 5.0% by weight of the cementitious material. Further, a calcium source and an iron chelating compound may be added to a Class C fly ash to accelerate the hydration and set time of the ash.

Abstract: A rapid setting, controlled low strength composition of Class C fly ash is provided having a quantity of hydrated lime and an iron chelating compound in an amount sufficient to accelerate the hydration and set time of the fly ash. In some examples, a filler material is added. A method for acceleration of the hydration and set time of a cementitious mixture is provided wherein hydrated lime is added to the cementitious mixture in an amount in the range of 0.1% to 15% by weight and an iron chelating compound in an amount in the range of 0.01% to 5.0% by weight of the cementitious material. Further, a calcium source and an iron chelating compound may be added to a Class C fly ash to accelerate the hydration and set time of the ash.

Abstract: This invention pertains to a process of making ASTM quality masonry cement, mortar cement, and stucco cement (also called plastic cement) and to the products themselves which are useful in making ASTM quality mortar for masonry construction or ASTM quality stucco for plastering construction. These cements are classified as hydraulic cements and are made using selected pozzolan(s), such as natural pozzolan and fly ashes, Portland Cement, hydrated lime, and an air-entraining agent. Other additives, such as fibers, may be added to further modify its properties. The pozzolans act as functional ingredients in the mix rather than as a filler. As a result, concentrations of greater than 25 wt. % and more pozzolan can be produced.

Abstract: Asphaltic roofing material, such as roll or shingle roofing, employs Class F fly ash as the filler to the asphaltic base material. The fly ash is readily heated and promotes a more rapid cooling of the composite asphaltic web prior to rolling or cutting into shingles. The Class F fly ash comprises between 40% and 70% of the hot asphaltic mixture, by weight. It may be delivered to the roofing plant in a state of elevated temperature from the fly ash source to reduce the requirement for preheating the fly ash or eliminating the preheating step altogether. The slightly acidic content of fly ash discourages the growth of fungus and mold on the roofing material in hot and humid climates, and the resulting shingle has enhanced overall flexibility and resistance to cracking at low temperatures.

Abstract: A method of treating fly ash which has a moisture content and which also has a high carbon particle content includes the steps of heating the fly ash to a temperature sufficient to break the bond between the fly ash and the carbon particles caused by the moisture content, applying the heated fly ash in a relatively thin layer to the surface of a belt-type conveyor and subjecting the layer of heated fly ash to the effects of an electrostatic charging zone while repeatedly mechanically rearranging the orientation of the fly ash particles in the zone for causing the carbon particles to take a charge and become attracted to an electrode so that the same may be separated from the layer. Apparatus for separating carbon particles from fly ash includes a generally horizontal conveyor, and a hopper which applies fly ash to be treated in a layer on the surface of a conductive belt.

Abstract: Asphaltic roofing material, such as roll or shingle roofing, employs Class F fly ash as the filler to the asphaltic base material. The fly ash is more readily heated than conventional crushed limestone which has been used as a filler, and further promotes a more rapid cooling of the composite asphaltic web prior to rolling or cutting into shingles. The Class F fly ash comprises between 40% and 70% of the hot asphaltic mixture, by weight. It may be delivered to the roofing plant in a state of elevated temperature from the fly ash source to reduce the requirement for preheating the fly ash or eliminating the preheating step altogether. The slightly acidic content of fly ash discourages the growth of fungus and mold on the roofing material in hot and humid climates, and the resulting shingle has greater overall flexibility and resistance to cracking at low temperatures, as compared to a shingle in which crushed limestone is used as the inert filler.