Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticizer is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.

Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.

Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.

Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.

Abstract: The present invention provides a method of forming a shaped article having a matrix that contains sintered fly ash. The method comprises the step of blending fly ash together with water to produce a fly ash dough. The water is added in excess of that which is absorbed by the fly ash so that the dough contains free water so as to be in at least a partially fluid state. The method also comprises the steps of forming a green article in a desired shape from the fly ash dough, and removing at least a portion of the free water from the fly ash dough during and/or after forming of the green article. The green article is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. The present invention also provides a building element having a matrix of sintered fly ash.

Abstract: The present invention provides a method of forming a shaped article having a matrix that contains sintered fly ash. The method comprises the step of blending fly ash together with water to produce a fly ash dough. The water is added in excess of that which is absorbed by the fly ash so that the dough contains free water so as to be in at least a partially fluid state. The method also comprises the steps of forming a green article in a desired shape from the fly ash dough, and removing at least a portion of the free water from the fly ash dough during and/or after forming of the green article. The green article is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. The present invention also provides a building element having a matrix of sintered fly ash.

Abstract: The present invention relates generally to a method of forming a lightweight fly ash aggregate together with the resultant fly ash aggregate. The invention further relates to various aspects of the method of forming the lightweight fly ash aggregate including methods of forming fly ash slurry, briquettes, or lightweight fly ash particles. The general steps involved in forming a lightweight fly ash aggregate are as follows: I. blending fly ash together with a plasticiser and a reduced quantity of water; II. compacting or compressing the resultant fly ash slurry or dough; III. cutting or otherwise forming the dough into briquettes; IV. heating the briquettes to effectively cure the dough; V. firing the briquettes to sinter the fly ash; VI. crushing the sintered briquettes and sizing, preferably screening, the resultant fly ash particles to provide the lightweight fly ash aggregate of a predetermined size range.

Abstract: The present invention relates generally to a method of forming a lightweight fly ash aggregate together with the resultant fly ash aggregate. The invention further relates to various aspects of the method of forming the lightweight fly ash aggregate including methods of forming fly ash slurry, briquettes, or lightweight fly ash particles.