Abstract: A system and method of manufacturing a synthetic construction element that replaces wood lumber. A synthetic composition is provided containing cementitious material, aggregate, fibers, and low-density particulate material. The density of the synthetic composition is controlled by varying the volume of the low-density particulate material in the mix. Reinforcement elements are provided. The reinforcement elements are positioned within the synthetic construction element and are stressed in tension. The reinforcement elements and the shape of the synthetic construction element are symmetrically disposed on either side of an imaginary mid-plane and maintain the synthetic construction element in compression.

Abstract: An improved concrete mix composition and its associated method of manufacture. A traditional concrete mix is created by mixing cementitious material with sand, aggregate, admixture chemicals and water. After the traditional mix has been thoroughly mixed, reinforcement fibers of polyvinyl alcohol are added to the mix. The reinforcement fibers chemically bond to the cementitious material, thereby chemically integrating the reinforcement fibers into the mixture. The reinforcement fibers are supplied in multiple sizes. The reinforcement fibers include both long thick fibers and short thin fibers. In this manner, the smaller reinforcement fibers can fill voids around the larger, thicker reinforcement fibers. This helps prevent the development of stress cracks in the concrete and significantly increases the strength, durability, and life expectancy of the concrete.

Abstract: A dosing bag filled with dry additive material is made using a dissolvable starch-based film. When the dosing bag with its contents are introduced into a mixture with water, it dissolves and releases its contents. The dosing bags are made in a chain. In this manner, any number of the dosing bags can be removed from the chain for use. The dosing bags are made from film material that is formed into a tube structure. While the tube structure is being partially filled, a section on the interior of the tube structure is shielded from contamination. After the partial filling, the tube is heat sealed closed in the area that was previously shielded. The shielded area is clean of contaminants and enables a high-quality seam to be formed. The shielding, filling, and sealing process is repeated multiple times to create the chain of dosing bags.

Abstract: An improved concrete mix composition and its associated method of manufacture. A traditional concrete mix is created by mixing cementitious material with sand, aggregate, admixture chemicals and water. After the traditional mix has been thoroughly mixed, reinforcement fibers of polyvinyl alcohol are added to the mix. The reinforcement fibers chemically bond to the cementitious material, thereby chemically integrating the reinforcement fibers into the mixture. The reinforcement fibers are supplied in multiple sizes. The reinforcement fibers include both long thick fibers and short thin fibers. In this manner, the smaller reinforcement fibers can fill voids around the larger, thicker reinforcement fibers. This helps prevent the development of stress cracks in the concrete and significantly increases the strength, durability, and life expectancy of the concrete.

Abstract: A system and method of manufacturing synthetic construction elements that replaces lumber. A synthetic composition is provided containing cementitious material, synthetic fibers, and low-density particulate material. At least one polymer may be added to improve performance. The density of the synthetic composition is controlled by varying the volume of the low-density particulate material in the mix. Reinforcement elements are provided. The reinforcement elements are preferably pre-stressed or post-stressed in tension. The synthetic compound is molded around the reinforcement elements to form a construction element of a particular shape. The molding of the synthetic material around the reinforcement elements can be a two-step process. In the first step, a first synthetic compound of a high density is molded into a rough form around the reinforcement elements. A second synthetic compound of a lower density and strength is then molded around the rough form to complete the construction element.

Abstract: A metal fiber reinforced composition and its method of fabrication. Metal fibers are created by broaching or shaving metal wool from stock material. The wool is straightened and cut into short lengths. Each of the metal fibers has an average maximum diameter of between 0.005 millimeters and 0.2 millimeters, and a cut length no greater than two-hundred times the average maximum diameter. A volume of a curable composition is provided. The metal fibers are mixed into the curable composition to create a fiber reinforced composition. The fiber reinforced composition is then formed into a selected shape, such as a construction element. The selected shape is then cured. Since the metal fibers are dispersed uniformly throughout the selected shape, curing or re-heating of the selected shape can be facilitated using an induction coil that heats the various metal fibers within the selected shape.

Abstract: A dosing bag for additives that are mixed into a cementitious mixture, wherein the dosing bag is made from a dissolvable starch-based film material. When the dissolving dosing bag with its contents are introduced into a mixture that uses water as an ingredient, the dosing bag dissolves at a particular rate such that the additives are released into the mixture in an even manner. The dosing bag has structural features that enable it to dissolve and release material over an extended period of time. Consequently, the material in the dissolving dosing bag is not released as a clump, but is rather released in a manner that ensures is even distribution during mixing. When the additives are more evenly dispensed throughout a mixture, the quality of the final product is greatly improved.

Abstract: A composition for synthetic structural building materials, such as lumber, and the method used to fabricate such building materials. The synthetic building materials are molded from a composition that contains cement, sand, curing agents, water, synthetic fibers, a low density particulate and a curable polymer. These ingredients and a few others are mixed in unique ratios to produce a synthetic material that mimics the strength, flexibility, and weight of natural wood. The composition cures with time. Prior to curing, the composition is molded into the form of structural building materials, such as framing lumber and planks. Depending upon the intended purpose of the building materials, the composition can be molded around reinforcement elements that internally strengthen the composition when it is cured. The final piece of structural building material has a weight, strength and flexibility comparable to wood, yet is resistant to rot and insects.

Abstract: A process for making reformed fiber from waste carpet material including separating into their individual strands, in well-graded lengths by mechanically disrupting, milling and granulating the waste carpet material and a further process for inserting and uniformly distributing such fibers throughout congealable materials such as asphalt and concrete, thereby providing improved physical properties to the resultant solids.

Abstract: A process for effectively mechanically disrupting fiber pellets produced from waste carpet material into their individual strands and for insertion and uniform distribution of such fibers through congealable materials such as asphalt and concrete, thereby providing improved physical properties to the resultant solids and, by providing a use for such waste carpeting, minimizing their deposition in landfills.

Abstract: A process and machine for receiving and processing to a transportable and usable condition, water soaked waste dredge removed from watery bodies. The process includes the steps of separating oversize material from the watery bulk waste, grinding organic oversize material to pulp, adding the pulp to the watery bulk, adding stabilizers to the bulk, conveying the aggregate to a transporting vehicle and performing the mixing process within the vehicle. The process further includes transporting the mixture to a point of use, spreading the mixture, spreading a pozzolanic binder on the mixture and mixing the binder with the mixture in situ.

Abstract: The described process utilizes the ash from a trash-to-steam plant and a cementitous binder along with the hot output of an earth purification process and a strictly defined quantity of water in calculated amounts to produce an aggregate which satisfies leach and strength tests and qualifies for use in road building and as a landfill cover.

Abstract: A method for processing water-bound wastes and for adjusting quantities and for combining ingredients to achieve a desired mechanical property of the mixture. The process includes the establishment of at least one input parameter for the ingredients. The ingredients include heated granular solids and contaminated water-bound wastes. The mixing process causes the water-bound waste to be heated to a temperature which assures neutralization or purification of any waste borne contamination and which simultaneously cools the granular solid. The method includes testing the mixture for satisfaction of at least one of the established mixture physical property limits and, if necessary, adjusting at least one input parameter to achieve the desired physical property value.

Abstract: This invention relates to an improved aggregate drying apparatus and method where the dried aggregate is particularly useful for making hot mix asphalt. In accordance with the system, heat typically lost in exhaust gases and moisture evaporated in a heater is recovered to dry and preheat the aggregate. The invention also relates to novel components used in the system, including an improved aggregate dryer and an improved mass flow apparatus for use in an aggregate dryer or otherwise in aggregate feed bins.

Abstract: A drum mixer having an countercurrent flow drying zone and a parallel flow mixing zone is provided for producing an asphaltic composition. The drum mixer utilizes a heat source located at an intermediate position therein for generating three streams of hot gases. The first stream of hot gases is directed towards the receiving end of the drum mixer in a countercurrent direction to the flow virgin aggregate entering the drying zone of the drum mixer. Recycle material is introduced into the drum mixer between the heat source and the discharge end thereof. The recycle material and the heated virgin aggregate are combined within the mixing zone. As both materials travel towards the discharge end of the drum mixer the second stream of hot gases is directed towards the discharge end of the drum mixer in a parallel direction to the flow of the mixing materials for heating said materials.

Abstract: This application discloses several components relating to a heating apparatus which preferably are used in conjunction with each other in an apparatus for heating solid granular or particulate material, such as aggregate used to make asphalt concrete. One component of the present invention includes a heater-condenser unit which indirectly heats the material by circulating heat transfer fluid within hollow plates contained in a housing holding the material. The material is heated, the heat transfer fluid is condensed and a condensate removal means associated with the hollow plates removes the condensate from the housing. The heat transfer fluid used in the heater-condenser preferably is supplied in the form of a vapor or gas evolved from liquid contained in material heated by another type of heater. In this other type of heater, the material to be dried enters a chamber containing hollow heat exchange plates through which a primary heat transfer fluid is circulating.

Abstract: A process for making asphalt concrete comprises mixing starting materials including aggregate and binder material and optionally, other additives, to a final temperature of about 60.degree. C. to about 150.degree. C. in an indirectly heated mixing chamber which is sealed. The moisture content of the asphalt concrete mixture is controlled as a function of the moisture content of the starting materials. Apparatus for performing the process in a continuous or batch operation is also set forth.

Abstract: A process for making asphalt concrete comprises mixing starting materials including aggregate and binder material and optionally, other additives, to a final temperature of about 60.degree. C. to about 150.degree. C. in an indirectly heated mixing chamber which is sealed. The moisture content of the asphalt concrete mixture is controlled as a function of the moisture content of the starting materials. Apparatus for performing the process in a continuous or batch operation is also set forth.

Abstract: A process for making asphalt concrete comprises mixing starting materials including aggregate and binder material and optionally, other additives, to a final temperature of about 60.degree. C. to about 150.degree. C. in an indirectly heated mixing chamber which is sealed. The moisture content of the asphalt concrete mixture is controlled as a function of the moisture content of the starting materials. Apparatus for performing the process in a continuous or batch operation is also set forth.