Abstract: This invention discloses a system for cold bond processing of combustion ash which enhances various characteristics of the resulting cured consolidated combustion ash materials. Specifically, the invention relates to processing techniques which enhances both density and strength of the of the consolidated combustion ash materials. The invention also relates to processing techniques which control various chemical reactions which assure that certain types of minerals are formed in the proper amounts which results in a cured consolidated combustion ash material which has greater dimensional stability and enhanced resistance to degradation. Embodiments for both normal weight and light weight combustion ash aggregates are disclosed which meet various ASTM and AASHTO specifications.

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 pretreating a carrier component for a cementitious composition. A quantity of any component of a cementitious composition is analyzed to determine its adsorption potential in the composition. The quantity of the component is treated with an effective amount of a treatment agent to control the adsorption potential.

Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention relates to hardenable mixtures comprising cement and fly ash which can achieve greater compressive strength than hardenable mixtures containing only concrete over the time period relevant for construction. In a specific example, processing fly ash by grinding to the desired size distribution range gives a 100% yield of fly ash for utilization in high quality concrete and mortar. Such materials can thus significantly reduce construction costs, as well as provide a useful outlet for material that is generally regarded as a pollutant and a nuisance.

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: Cementitious compositions comprising pozzolonic materials, alkaline earth metals, and a catalysts to catalyze the reaction between the pozzolonic materials and the alkaline earth metals.

Abstract: Disclosed is an improved alpha calcium sulfate hemihydrate. Methods of producing an improved powdered calcium sulfate hemihydrate (CaSO4.½H2O) [alpha-type] compound are disclosed, at least one method including forming calcium sulfate dihydrate (CaSO4.2H2O) into a briquette under high pressure, calcining the briquette to transform the calcium sulfate dihydrate to calcium sulfate hemihydrate [alpha-type], drying the calcium sulfate hemihydrate [alpha-type] briquette, and optionally grinding the briquette. Also disclosed are methods of producing an improved gypsum plaster including producing the disclosed powdered calcium sulfate hemihydrate [alpha-type] and mixing the powdered calcium sulfate hemihydrate [alpha-type] with water.

Abstract: The present invention relates to a pozzolanic admixture containing ammonia-laden fly ash, method for making the pozzolanic admixture and method for controlling ammonia gas (NH3) emission from cementitious slurries using the pozzolanic admixture. The associated hypochlorite and ammonia reaction produces monochloramine and chloride salts at relatively low concentration levels harmless to concrete and concrete applications. The resulting monochloramine and chloride salt products are stable and do not dissipate into the air, thereby, eliminating odorous emission that is produced from cementitious slurry containing untreated ammonia laden fly ash.

Abstract: A dry pulverulent ash composition is described which comprises a dry pulverulent fly ash to be used as a portland cement substitute for improving the physical properties of a finished concrete product. The ash composition includes fly ash together with an oxidizer present in a dry pulverulent form that is unreacted with the ash and is maintained in an unreacted state during shipment and storage but is capable of reacting with the fly ash upon an addition of water to convert virtually all and preferably over 95% of the sulfur compounds present in the ash to the sulfite form. The oxidizer is present in minor amount from about 0.5% to about 10% by weight of the composition. An aggregate comprising pellets can also be added to the composition together with a minor amount of portland cement and a conditioner e.g., accelerator to form a concrete block product that is up to 10% lighter than a standard concrete block that does not use the present composition and at the same time exhibits improved crushing strength.

Abstract: Concrete's durability to freeze-thaw cycles is dependent on its level of air entrainment, the appropriate level of which is achieved with the aid of surface active or air entraining agents. These agents promote the fragmentation of large air voids into smaller ones and stabilize air voids in the concrete. The carbon matter found in fly ash when used as a pozzolanic component of concrete, adsorbs the air entraining agents, reduces the air voids and concrete's ability to withstand many freeze-thaw cycles. This invention teaches a process for a partial removal of the carbon from the coal ash, used in concrete, through a partial combustion of only a fine carbon fraction of the carbon residue of the coal ash responsible for adsorbing the air entraining agents, in a reactor with a controlled ignition system. The process of the invention thus limits the adsorption of the air entraining agents and improves the freeze-thaw properties of the concrete produced.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and sodium chloride (NaCl) as a substantial replacement for Portland cement conventionally used in such compositions. The sodium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: A cementitious composition is provided that comprises an effective amount of bottom ash and an effective amount of cement. In one embodiment, a structural product formed from mixing the composition with an effective amount of water has a seven-day compressive strength of at least about 2,500 psi and, more preferably, a seven-day compressive strength of at least about 4,000 psi. In another embodiment, a structural product formed from mixing the composition with an effective amount of water has a twenty-eight-day compressive strength of at least about 4,000 psi and, more preferably, a twenty-eight-day compressive strength of at least about 5,000 psi.

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: A method of cement clinker manufacture comprises feeding a clinker feed material containing a source of calcium carbonate into a feed end of a cement kiln, the feed material is heat processed in the kiln to produce cement clinker with emission of carbon dioxide from thermal decomposition of said source of calcium carbonate and discharge of the carbon dioxide from the kiln, and cement clinker is discharged from a discharge end of the kiln; a coal ash derived from burning pulverized lignite or sub-bituminous coal is included in the feed material fed into the feed end to replace a portion of the source of calcium carbonate, and provides a source of calcium as well as other components notably silicon and aluminum, in the formation of the cement clinker, with a lowering of the emission of carbon dioxide in the kiln, per unit weight of cement clinker produced.

Abstract: A method for pretreatment of a quantity of fly ash for use in a cementitious composition containing an air entrainment agent. An effective amount of an aromatic carboxylic acid or its salts is added to the fly ash to satiate unburned carbon in the ash. The treatment with the aromatic carboxylic acid (or hydroxy substituted aromatic carboxylic acid or its salts) does not significantly promote or retard the air entrainment functions of the air entrainment agent.

Abstract: A synthetic slag is produced by a high temperature combustion reaction between coal ash having a high carbon content, and a source of lime such as cement kiln dust. The carbon content of the coal ash is oxidized by oxygen gas, which typically is derived from air or an air/oxygen combination in an exothermic reaction and the heat generated is exploited in the melting process. In this way the gaseous products will typically comprise nitrogen, unreacted oxygen and carbon dioxide, and heat energy can be readily recovered from the hot off gas products evolving during the combustion reaction. The synthetic slag may be pelletized and employed as lightweight mineral aggregate or milled to cement fineness to provide slag cement.

Abstract: A method of cement clinker manufacture comprises feeding a clinker feed material containing a source of calcium carbonate into a feed end of a cement kiln, the feed material is heat processed in the kiln to produce cement clinker with emission of carbon dioxide from thermal decomposition of said source of calcium carbonate and discharge of the carbon dioxide from the kiln, and cement clinker is discharged from a discharge end of the kiln; a coal ash derived from burning pulverized lignite or sub-bituminous coal is included in the feed material fed into the feed end to replace a portion of the source of calcium carbonate, and provides a source of calcium as well as other components notably silicon and aluminium, in the formation of the cement clinker, with a lowering of the emission of carbon dioxide in the kiln, per unit weight of cement clinker produced.

Abstract: A cement composition for use in acidic environment containing liquid alkali silicate, vitreous silicate setting agent, lime containing material and inert filler and building materials made therefrom as well as the method of making such building materials. The liquid alkali silicate may include sodium silicate or potassium silicate. The vitreous silicate setting agent may include soda-lime glass powder or coal fly ash. The lime containing material refers to the materials containing more than 20% lime and may include quicklime, hydrated lime, Portland cement, blast furnace slag or steel slag. The inert fillers include ground quartz, ground ceramic, and/or clay.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and calcium chloride (CaCl2) as a substantial replacement for Portland cement conventionally used in such compositions. The calcium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: A method for removing ammonia from fly ash employs water mist (a water fog) or a flowing warm humid air stream to rid the fly ash of ammonia. Ozone alone or with other co-oxidants such as hydrogen peroxide are also used to rid fly ash of ammonia.

Abstract: A concrete in which the aggregate of sand and stones in at least partially replaced by crushed glass. The sand fraction may be replaced by a glass of grain size 0-5 mm, a non-alkali reactive mineral with grain size 0-5 mm or a combination thereof. The stone fraction may be replaced by glass of grain size 5-20 mm. The concrete further may further comprise silica dust, fly ash or crushed slag.

Abstract: The invention pertains to a method of delaying the set time of cement and to compositions produced therefrom. The set time of hydraulic cement mixtures of fly ash pozzolans, specifically Class C and Class F, and Portland cement can be delayed by controlling the pH of a retarder slurry that is mixed with the dry components of the composition. The pH of the retarder slurry is controlled by balancing the salts therein such that the retarder slurry is acidic, or having a pH less than 7. The slurry activator of the present invention generally includes a pH balancing agent, an acid component, and water. The pH balancing agent can include any basic alkali and alkaline earth metal hydroxide, or a salt of the acid component. The acid component may include a hydroxycarboxylic acid, preferably citric acid. Slower setting mortar and concrete compositions having high strength can be prepared with this hydraulic cement.

Abstract: The present invention provides a method of producing a blended cement capable of meeting ASTM C-595 and C-1157 standards. The blended cement of the present invention contains portland cement clinker, calcium sulfate and volcanic ash. The volcanic ash utilized by the present invention has been subjected to heat in the range of between 800° F. and 1300° F. and contains between 40% and 45% hollow spheres unable to pass #325 sieve. The portland cement clinker, calcium sulfate and volcanic ash are interground to an ultimate blaine fineness of between 350 m2/kg and 500 m2/kg to produce a blended cement capable of subsequent admixing with class C fly ash to produce synergistic effects.

Abstract: A finely ground powder comprising a mixture of fly ash and a compound selected from the group consisting of alkali and alkaline earth metal salts, alkali and alkaline earth metal oxides, and metakaolinite. Preferably, the amount of said compound is 0.4 to 1% by weight of the powder. A composition comprising Portland cement and finely ground powder, said finely ground powder being a mixture of fly ash and a compound selected from the group consisting of alkali and alkaline earth metal salts, alkali and alkaline earth metal oxides, and metakaolinite. A method for the treatment of fly ash comprising the step of subjecting a mixture of fly ash and a compound selected from the group consisting of alkali and alkaline earth metal salts, alkali and alkaline earth metal oxides, and metakaolinite, preferably in which the fly ash has been treated for removal of carbon and in particular to increase the amount of crystalline phase.

Abstract: Concrete's durability to freeze-thaw cycles is dependent on its level of air entrainment, the appropriate level of which is achieved with the aid of surface active or air entraining agents. These agents promote the fragmentation of large air voids into smaller ones and stabilize air voids in the concrete. The carbon matter found in fly ash when used as a pozzolanic component of concrete, adsorbs the air entraining agents, reduces the air voids and concrete's ability to withstand many freeze-thaw cycles. This invention teaches a process for a partial removal of the carbon from the coal ash, used in concrete, through a partial combustion of only a fine carbon fraction of the carbon residue of the coal ash responsible for adsorbing the air entraining agents, in a reactor with a controlled ignition system. The process of the invention thus limits the adsorption of the air entraining agents and improves the freeze-thaw properties of the concrete produced.

Abstract: Oil-based settable spotting fluid compositions for cementing in wells and subterranean formations are provided. The oil-based settable spotting fluid compositions basically comprise an oil external emulsion comprising oil, water and an emulsifying surfactant, a hydraulically settable component and a de-emulsifying surfactant for de-emulsifying the oil-external emulsion when the emulsion is cured.

Abstract: A composition used in making wallboard is provided. The composition requires at least fly ash, water and a first binder. The composition is located between two members that together form the wallboard. In one embodiment, at least the first binder is part of a foamable solution and part of a binder solution. In this embodiment, the fly ash, foamable solution and binder solution are combined in a mixer. The output of the mixer can be regulated based on detection of a magnitude related to viscosity of the composition. During the process for making the wallboard, the composition is sandwiched between the two members and subject to both preheating and subsequent heating stages. During the preheating, a sufficient number of bubbles associated with the binder are maintained in order to achieve a predetermined density based on the closed cells that are formed after the water evaporates.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and sodium chloride (NaCl) as a substantial replacement for Portland cement conventionally used in such compositions. The sodium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: A method for pretreating a carrier component for a cementitious composition. A quantity of any component of a cementitious composition is analyzed to determine its adsorption potential in the composition. The quantity of the component is treated with an effective amount of a treatment agent to control the adsorption potential.

Abstract: A concrete composition contain glass, including ordinary recycled glass is provided. The invention also relates to methods of producing the concrete compositions of the invention. A concrete composition containing glass particles, including recycled glass, a substance to mitigate alkali-silica reaction such as E-glass particles, and or pozzolans and/or lithium-containing substances, and cement is provided as well. Compositions containing E-glass (also known as electric glass) and processes for producing E-glass-containing compositions are also provided.

Abstract: The present invention is directed at a synthetic lightweight aggregate composition comprising fly ash and a mixture of two or more polymer components. More specifically, the present invention is also directed at a lightweight concrete which cures to a hardened cementious composite comprising Portland cement, water in a weight ratio of between about 0.2 and 0.7 of the water to the Portland cement, synthetic lightweight aggregate in a weight ratio of between about 0.1 and 0.5 of the synthetic lightweight aggregate to the cement, wherein the synthetic lightweight aggregate comprises fly ash and two or more polymer components.

Abstract: A pozzolan admixture composition suitable for use in portland cement mixtures and mix designs that, when combined with; portland cement, sand and/or aggregate, and water, are used to prepare cementitious products. The admixture contains ultra-fine fly ash, calcined kaolin, fused silica, and cellulose ether derivative. A pozzolan-modified portland cement composition containing the present invention's composition inter-ground or inter-blended with a portland cement. The pozzolan-modified portland cement contains portland cement, ultra-fine fly ash, calcined kaolin, fused silica, and a cellulose ether derivative. An admixture, additive, or addition, based on the present invention's composition, inter-ground or inter-blended into portland cement to create such pozzolan-modified portland cements.

Abstract: Producing both colored and noncolored lightweight aggregates. The processes involve mixing a lightweight fine material such as ash with cement, and optionally pigment, then agglomerating the mixture, curing, and sizing the lightweight aggregate. Calcium stearate is added to the lightweight aggregate for reducing the moisture permeability of the lightweight aggregate end product. The colored and noncolored lightweight aggregate may be used in a variety of ways such as to provide a lightweight concrete mix with the same exterior and interior color, and for other asphalt pavement, geotechnical, horticulture, and specialty uses.

Abstract: The present invention provides methods, lightweight well cement compositions and additives for the well cement compositions. The methods of the invention for sealing pipe in a well bore penetrating a zone or formation which readily fractures at low hydrostatic pressure is basically comprised of the steps of providing a lightweight cement composition comprised of a hydraulic cement, water and an additive comprising a suspension of microspheres in water gelled with sodium bentonite, placing the cement composition in the annulus between the pipe and the well bore and allowing the cement composition to set.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and potassium chloride (KCl) as a substantial replacement for Portland cement conventionally used in such compositions. The potassium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: A process for binding porous-rock particles with cement, wherein the rock is saturated in water prior to mixing with the cement. The saturation step causes water to fill the voids in the porous structure of the rock such that, during mixing of the wet rock with cement, cement particles adhere to the surface of the rock but are mostly precluded from reaching void spaces in the rock. As a result of this procedure, the interstitial water is available from within the rock for the cement hydration process, thereby providing a more uniform curing step than otherwise available, and a greater proportion of the cement is appropriately placed on the outer surface of the particles for bonding. The resulting aggregate is stronger than obtained by conventional mixing processes. In addition, because of the voids left in the composite after the cement has cured and the interstitial water has been either used by the hydration process or has evaporated, the material also exhibits improved insulating properties.

Abstract: The present invention provides a cementing composition for an oil well or the like with porosity of less than 50%, and with a solid phase constituted by 35% to 65% (by volume) hollow microspheres, 20% to 45% Class G Portland cement, and 5% to 25% of Class G Portland micro-cement. The invention is used to cement conductor pipes in arctic zones or in deep water holes.

Abstract: The present invention provides methods, lightweight well cement compositions and additives for the well cement compositions. The methods of the invention for sealing pipe in a well bore penetrating a zone or formation which readily fractures at low hydrostatic pressure is basically comprised of the steps of providing a lightweight cement composition comprised of a hydraulic cement, water and an additive comprising a suspension of microspheres in water gelled with sodium bentonite, placing the cement composition in the annulus between the pipe and the well bore and allowing the cement composition to set.

Abstract: The present invention relates to admixtures production and to a method of application of the admixtures in cement and concrete technology. The method allows production of high-strength and high durable cement based systems, as well as cement systems with specially designed properties of cheap high-volume mineral admixture cements.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and cement kiln dust (CKD) as a substantial replacement for Portland cement conventionally used in such compositions. The compositions of the present invention provide high early strength thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: The present invention relates to a pozzolanic admixture containing ammonia-laden fly ash, method for making the pozzolanic admixture and method for controlling ammonia gas (NH3) emission from cementitious slurries using the pozzolanic admixture. The associated hypochlorite and ammonia reaction produces monochloramine and chloride salts at relatively low concentration levels harmless to concrete and concrete applications. The resulting monochloramine and chloride salt products are stable and do not dissipate into the air, thereby, eliminating odorous emission that is produced from cementitious slurry containing untreated ammonia laden fly ash.

Abstract: A rapid setting cementitious composition useful for making cement boards employs an insoluble form of anhydrous calcium sulfate (anhydrite) to accelerate setting and to permit reducing the amount of high alumina cement usage.

Abstract: The invention concerns silica sol mixture comprising a first silica sol having a broad particle size distribution, the relative standard deviation being at least about 30% by numbers, and a second silica sol having a narrow particle size distribution having a relative standard deviation lower than about 15% by numbers. The invention also concerns a method for preparing a silica sol mixture and use thereof. The invention further concerns a concrete composition comprising a silica sol mixture and a method for preparing such composition.

Abstract: The invention relates to a product for the internal coating of a pipeline component (1), in particular a metal pipeline component, comprising an internal wall (4) of high curvature. This product comprises a solid charge and a liquid. The liquid is a solution of an alkali metal silicate and the solid charge comprises sand, between 20 and 30% by mass of a binder which sets chemically by reaction with the liquid, and between 4 and 10% by mass of plasticizing adjuvants. The solid charge and the liquid are intended to be mixed (in 5) with a liquid/binder ratio by mass of between approximately 0.3 and 0.45. Application to pipelines for discharge of waste water made of spheroidal graphite cast iron.

Abstract: This invention discloses a system for cold bond processing of combustion ash which enhances various characteristics of the resulting cured consolidated combustion ash materials. Specifically, the invention relates to processing techniques which enhances both density and strength of the of the consolidated combustion ash materials. The invention also relates to processing techniques which control various chemical reactions which assure that certain types of minerals are formed in the proper amounts which results in a cured consolidated combustion ash material which has greater dimensional stability and enhanced resistance to degradation. Embodiments for both normal weight and light weight combustion ash aggregates are disclosed which meet various ASTM and AASHTO specifications.

Abstract: Methods and compositions for sealing subterranean zones penetrated by well bores are provided. The methods basically comprise the steps of introducing a sealing composition into the subterranean zone comprised of a hydraulic cement, sufficient water to form a slurry and a rapidly acting thixotropy providing gelling agent, and allowing the sealing composition to remain at rest in the zone whereby the sealing composition rapidly gels and then sets into a hard impermeable mass therein.

Abstract: A cementitious slurry comprising fly ash having a predominant particle size of up to about 10 microns, and/or aluminous material having a predominant particle size of up to about 150 microns. The additive acts as a water reduction agent and can replace either wholly or partially a conventional plasticiser.

Abstract: A method for pretreatment of a quantity of fly ash for use in a cementitious composition containing an air entrainment agent. An effective amount of an aromatic carboxylic acid or its salts is added to the fly ash to satiate unburned carbon in the ash. The treatment with the aromatic carboxylic acid (or hydroxy substituted aromatic carboxylic acid or its salts) does not significantly promote or retard the air entrainment functions of the air entrainment agent.

Abstract: Construction material from granular material reclaimed from the ash of a municipal waste combustor wherein the ash is subjected to sorting and separating recovered metals, the granular material including particles having a maximum particle diameter of 5 to 40 mm, a U-coefficient of 10 or more, and ignition loss of 10% or less in weight and being subjected to at least one heavy metal immobilization agent, preferably phosphoric acid; and a second heavy metal immobilization agent consisting of ferrous sulfate. The ash is further subjected to drying before subjecting the ash to the at least one heavy metal immobilization agent. The ash is further subjected to mulling the material after subjecting the ash to the at least one heavy metal immobilization agent.

Abstract: Methods for drilling well bores and cementing a pipe string in the well bores using oil-based settable drilling fluids are provided. The oil-based settable drilling fluid compositions basically comprise an oil external emulsion comprising oil, water and an emulsifying surfactant; a hydraulically settable component; and a de-emulsifying surfactant for de-emulsifying the oil-external emulsion when the emulsion is cured.