Abstract: The invention relates to concrete compositions with improved characteristics which contain glass, including ordinary recycled glass. The invention also relates to methods of producing the concrete compositions of the invention. In particular, the invention relates to a cement composition containing glass particles, including recycled glass, a substance to mitigate alkali-silica reaction such as lithium-containing glass, and cement. The compositions provided exhibiting improved characteristics and are particularly useful for applications such as forming surfaces adjacent to swimming pools. The present invention also relates to compositions containing E-glass (also known as electric glass). Such compositions are particularly useful as pool plasters for finishing surfaces associated with swimming pool construction. The present invention also relates to processes for producing E-glass-containing compositions.

Abstract: This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.

Abstract: The invention concerns cementing compositions, particularly for squeeze cementing, comprising a liquid phase and a solid phase constituted by particulate materials which are insoluble in said liquid phase, in particular a microcement. The compositions of the invention comprise additives of a nature and composition such that variations in viscosity of the composition due to fluid loss are minimized. Preferably, the compositions comprise at least one “very fine” additive formed from particles which are smaller than the cement, with a ratio of the average grain sizes of the particles of said additive and those of the cement in the range 5 to 100, preferably about 10, the respective proportions of the solid particles corresponding to a packing volume fraction close to the maximum, and the porosity of the solid mixture being such that the mixture is in a state of hindered settling.

Abstract: This invention relates to enhancing the compressive strength of cements after 1, 3, 7 and 28 days following hydration and to improving porosity and finished surfaces of the hardened cements and concretes made therefrom. The improved cements are prepared using certain hydroxylamine additives in amounts of up to 0.1% which preferably are added during grinding of the cement in which case the amines further act as grinding aids.

Abstract: Mortar mixes comprising as a major part, Class F fly ash and fluidized bed combustion ash in amounts and proportions sufficient to reduce the negative effects of the presence of unburned carbon in the Class F fly ash and the presence of sulfate in the fluidized bed combustion ash and which mortar mixes also include, as a minor part, a cementitious material. The mortar produced by mixing the mortar mix with water can include a density reduction material and can be formed into support members for use in mines.

Abstract: A fly ash composition is provided which includes an amount of lithium carbonate to reduce alkali silica reactivity when the fly ash composition is used in concrete applications. The fly ash composition includes from about 0.5 wt.% to about 98% wt.% subbituminous fly ash and from about 0.5 wt.% to about 3 wt.% lithium carbonate.

Abstract: A composition for use in construction materials, which may be substituted for high performance concrete, patching materials, joint compounds, and the like, such as backer boards or panels, which includes a settable calcium sulfate, preferably a hemihydrate, Portland cement, a finely divided pozzolanic material, lime, and an aggregate, optionally including other additives. The volume ratio of the aggregate to the combined calcium sulfate, Portland cement, pozzolanic material, and lime (a cementitious binder) is equal to or greater than 2/1. Panels made from this composition are useful, particularly when exposed to water since they have good dimensional stability.

Abstract: An ultra-high performance composite concrete, with low cement and fiber content and having good mechanical properties as well as good impacts, shocks and projectile protection properties, includes hydraulic binder, aggregates, an admixture of metal fibers. Particularly, the composite concrete includes 70% to 85% of particles (A) having a particle size distribution which ranges from 0.01 to 3 mm up to particle size distribution which ranges from 0.01 to 0.50 mm; 2% to 10% of particles (B) having particle size of between 0.01 and 1 .mu.m; 3% to 20% of hydraulic binder; 0.1 to 3% of a dispersant or plasticizer; 0.05% to 8.5% of fibers; and, mixing water, wherein the percentages being weight percentages based on the sum of the weights of constituents a) to d).

Abstract: A method and a mixture for chemically stabilizing electric arc furnace dust (EAFD) containing thallium by entrapping the metals inherent in EAFD within a cementitiously hardened product from the mixture. The method includes using the pozzolanic characteristics of EAFD by forming a mixture of EAFD with sufficient water, ferrous sulfate, and Portland cement, then permitting the mixture to react to form a product having a decreased concentration of thallium in its leachate. The method may also include permitting the mixture to form a cementitiously hardened product. The composition of the present invention is the mixture of EAFD, water, ferrous sulfate, and Portland cement. Even immediately after forming the mixture and before hardening, the composition has acceptable leachate characteristics. The hardened product also has acceptable leachate concentrations.

Abstract: This invention relates to enhancing the compressive strength of cements after 1, 3, 7 and 28 days following hydration and to improving porosity and finished surfaces of the hardened cements and concretes made therefrom. The improved cements are prepared using certain hydroxylamine additives in amounts of up to 0.1% which preferably are added during grinding of the cement in which case the amines further act as grinding aids.

Abstract: The cement composition of this invention includes 10 to 35% by weight of portland cement, 65 to 90% by weight of a synthetic pozzolan, and an activator for reducing the positive surface potential of the synthetic pozzolan. The synthetic pozzolan is obtained by an at least partial reduction from combustion residues having a SiO.sub.2 /CaO ratio of greater than 1:1 and containing Na.sub.2 O and K.sub.2 O as alkali oxides in an amount exceeding 1.5% by weight. The activator includes anionically active or anionic tensides.

Abstract: A cementitious composition for the molding of ultra-lightweight, durable, large structural units comprising Portland cement, coal combustion byproducts, expanded or extruded polystyrene and water, and a modified block machine used in the manufacture of such structural units.

Abstract: A wood-cement board is manufactured by a method comprising mixing 30 to 40% by weight of cement material, 20 to 27% by weight of wood flake, and 30 to 40% by weight of fly ash to prepare a raw material mixture, strewing said raw material mixture on a mold panel to form a mat, pressing and pre-curing said mat with moisture, and main-curing said pre-cured mat in an autoclave. Preferably the particle size of said fly ash is selected so that less than 10% by weight of fly ash may remain on the sieve whose opening size is 150 .mu.m and said main-curing process is carried out at a temperature of the saturated aqueous vapor in a range between 140 to 165.degree. C. for 7 to 10 hours.

Abstract: The present invention is directed to blended hydraulic cement compositions which are formed with subbituminous fly ash. In one embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt. % of a retarding agent; from about 0.1 wt. % to about 4 wt. % potassium carbonate; from about 0.1 wt. % to about 4 wt. % citric acid; from about 0.1 wt. % to about 5 wt. % lithium carbonate; and from about 85 wt. % to about 99.7 wt. % of a subbituminous fly ash. In another embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt % of a retarding agent; from about 0.1 wt. % to about 6 wt. % of an alkali source selected from the group consisting of potassium carbonate, potassium hydroxide and blends thereof; from about 0.1 wt. % to about 4 wt. % citric acid; from about 0.1 wt. % to about 5 wt. % lithium carbonate; from about 25 wt. % to about 91.7 wt. % of a first subbituminous fly ash having a lime content; and from about 8 wt. % to about 60 wt.

Abstract: A composition for manufacturing concrete containing cement, coal ash, and organic plant ash, and a process of making such composition.

Abstract: A combination of a class C fly ash having a high analytical content of CaO, and a silica fume, with a hydraulic cement, such as Portland cement, produces concrete with alkali-silica reactive aggregate having acceptable low expansion such as by ASTM C 1260; and also produces sulphate resistance with mineral aggregates generally.

Abstract: Cementitious binders include calcium sulfate beta-hemihydrate, a cement component comprising Portland cement, and either silica fume or rice-husk ash. The silica fume or rice-husk ash component is at least about 92 wt % amorphous silica and has an alumina content of about 0.6 wt % or less.

Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention includes a method for predicting the compressive strength of such a hardenable mixture, which is very important for planning a project. The invention also 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 embodiment, a formula is provided that accurately predicts compressive strength of concrete containing fly ash out to 180 days. In other specific examples, concrete and mortar containing about 15% to 25% fly ash as a replacement for cement, which are capable of meeting design specification required for building and highway construction, are provided. Such materials can thus significantly reduce construction costs.

Abstract: A lightweight, cementitious composition and method which includes a noncementitious filler, Portland cement, bentonite, diatamaceous earth and lime. The noncementitious filler may be sawdust, rubber chips, flyash or combinations of two or more of these ingredients. Once mixed with water and air, the composition can be molded to form a variety of structures, including electrically nonconductive posts, and can be used to absorb and contain liquid contaminants in a vessel.

Abstract: A Portland cement clinker free of C.sub.4 A.sub.3 S having the following proportions of clinker phases, in % by wt.:--C.sub.3 S: 40 to 80--C.sub.4 AF: <20--C.sub.2 S: <30--C.sub.3 A: <20and a SO.sub.3 content from 1.0 to 3.0% by wt., based on the clinker, obtained by burning a mixture of raw materials containing CaO, SiO.sub.2, Al.sub.2 O.sub.3, Fe.sub.2 O.sub.3 and an additive containing SO.sub.3 at temperatures from 1200.degree. to 1350.degree. C. centigrade, the use thereof and a Portland cement.

Abstract: An aqueous composition for coloring cement based compositions comprising water, pigment, a suspension enhancing agent and latex polymer solids.

Abstract: Contaminated coal ash, for example flyash contaminated with carbon is introduced to hot clinker in a cooler downstream of a cement kiln; the carbon is combusted in the cooler to provide a cement clinker having an effective content of flyash free of carbon; this permits use of flyash contaminated with carbon without the need for separate special steps for carbon removal; volatile contaminants or contaminants having a volatile component, for example adsorbed ammonia are similarly removed in the cooler by volatilization.

Abstract: The invention relates to an improved sound absorbing cementitious composition and method of making involving a preformed foam solution made from a surfactant, such as an ammonium salt of a sulfated linear alcohol ethoxylate surfactant, preblended with water at a dilution ratio in a range of water to surfactant of from about 40:1 to 10:1. Thereafter, the preformed foam solution is combined with components including cement(s), aggregate(s), water and optional additives. The composition provides for an open cellular surface capable of absorbing sound.

Abstract: Novel cementitious systems comprised of gypsum, calcined clay, and clinker consisting essentially of hydraulic calcium silicates are disclosed which have the following properties: (1) a water demand of less than about 33% nc; (2) one-day strengths of at least about 1000 psi; and (3) low alkali functionality. By increasing the amount of calcined clay, the resulting cementitious system will sequentially gain the following properties: (1) alkali non-reactiveness; (2) alkali resistance; and (3) low chloride permeability. Novel methods of preparing the novel cementitious systems of this invention are also disclosed. The novel methods not only reduce production costs by decreasing fuel and raw material consumption, but they also allow the cement producer to proactively address significant environmental concerns related to the manufacturing process.

Abstract: A cellular drainage structure is formed of a predetermined volume of a settable, water permeable, cellular concrete product. A concrete mix is formed of a uniformly graded aggregate in the size range from 1/16 inch to two inches and in a quantity corresponding to the predetermined volume; a cementitious component in the quantity range from 141 to 658 pounds per cubic yard of product; water in quantity sufficient to create a water-to-cement ratio in the approximate range from 0.30 to 0.55 and sufficient to wet the aggregate, establishing a cementitious-component-and-water matrix of determinable volume; a pre-formed surfactant foam, generated from an aqueous surfactant mixture at a dilution of from approximately 3 to 25 grams per liter of surfactant in water, wherein the pre-formed foam is in the density range of from 2.0 to 3.0 pcf, and the foam is added in the quantity range of 5% to 30% of the volume of the cementitious-component-and-water matrix.

Abstract: A method for producing fly ash granules, which comprises mixing 100 parts by weight of fly ash, from 0.001 to 1 part by weight of a water-soluble polymer having from 2 to 80 mol %, based on the total repeating units, of repeating units having carboxyl groups, and from 40 to 100 parts by weight of water, for granulation.

Abstract: The present invention is directed to an imidized polycarboxylic acid polymer useful as a cement admixture, to improved cement compositions containing said polymer and to a process of forming the same.

Abstract: An improved lightweight cementitious product made up of an aqueous cementious mixture using cement and expanded shale, clay and slate mix, that can incorporate fly ash, lime, and the weight saving component, which is micronized polystyrene particles having particle sizes in the range of 50 to 2000 microns, and characterized by having water contents in the range of from about 0.5% to 50% v/v. The ultra low water compositions can be extruded and can be molded under high pressure.

Abstract: The present invention is directed to blended hydraulic cement compositions which are formed with subbituminous fly ash. In a first embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt. % of a retarding agent; from about 0.1 wt. % to about 4 wt. % of the total composition of potassium carbonate; from about 0.1 wt. % to about 4 wt. % of the total composition of citric acid; and from about 85 wt. % to about 99.7 wt. % of the total composition of a subbituminous fly ash. In a second embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt % of the total composition of a retarding agent; from about 0.1 wt. % to about 6 wt. % of the total composition of an alkali source selected from the group consisting of potassium carbonate, potassium hydroxide and blends thereof; from about 0.1 wt. % to about 4 wt. % of the total composition of citric acid; from about 25 wt. % to about 91.7 wt.

Abstract: The present invention is directed to processes for making blended hydraulic cement compositions. In one embodiment, the process includes the steps of: providing from about 85 wt. % to about 99.7 wt. % of the total composition of a subbituminous fly ash; separating out about a 10% portion of the fly ash; adding from about 0.1 wt. % to about 7 wt. % of the total composition of a retarding agent, from about 0.1 wt. % to about 4 wt. % of the total composition of citric acid, and from about 0.1 wt. % to about 4 wt. % of the total composition of potassium carbonate to the 10% portion; and blending the remainder of the ash with the 10% portion to create a blended hydraulic cement composition.

Abstract: A composition for producing an unsaturated polyester is provided. The composition comprises an unsaturated polyester resin; cement; sand; bleaching agent; and curing agent.

Abstract: A cementitious mixture includes hydraulic cement, fly ash, and an effective amount of unfired nature finely divided material, such as a clay, containing at least about 35% alumina, to accelerate the early strength of a mix. A method of accelerating early strength in a cementitious mix comprises the adding of alumina in the form of an unfired raw material, such as clay, in an effective amount in such mix.

Abstract: A method for solidification and stabilization of soils contaminated with vy metals and organic compounds removable by activated carbon includes the steps of placing a selected weight of the contaminated soil in a vessel, adding water to the contaminated soil in the vessel, mixing the soil and the water in the vessel, adding activated carbon to the mixture of soil and water in the vessel, mixing the soil, water and carbon in the vessel, adding cement and fly ash to the mixture of soil, water and carbon in the vessel, mixing the soil, water, carbon, cement and fly ash in the vessel and pouring the mixture of soil, water, carbon, cement and fly ash into a mold and curing the mixture therein.

Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention provides a method for increasing the rate of strength gain of a hardenable mixture containing fly ash by exposing the fly ash to an aqueous slurry of calcium oxide (lime) prior to its incorporation into the hardenable mixture. The invention further relates to such hardenable mixtures, e.g., concrete and mortar, that contain fly ash pre-reacted with calcium oxide. In particular, the fly ash is added to a slurry of calcium oxide in water, prior to incorporating the fly ash in a hardenable mixture. The hardenable mixture may be concrete or mortar. In a specific embodiment, mortar containing fly ash treated by exposure to an aqueous lime slurry are prepared and tested for compressive strength at early time points.

Abstract: Novel cementitious systems comprised of gypsum, calcined clay, and clinker consisting essentially of hydraulic calcium silicates are disclosed which have the following properties: (1) a water demand of less than about 33% nc; (2) one-day strengths of at least about 1000 psi; and (3) low alkali functionality. By increasing the amount of calcined clay, the resulting cementitious system will sequentially gain the following properties: (1) alkali non-reactiveness; (2) alkali resistance; and (3) low chloride permeability. Novel methods of preparing the novel cementitious systems of this invention are also disclosed. The novel methods not only reduce production costs by decreasing fuel and raw material consumption, but they also allow the cement producer to proactively address significant environmental concerns related to the manufacturing process.

Abstract: An improved lightweight cementitious product made up of an aqueous cementious mixture that can incorporate fly ash, portland cement, sand, lime, and the weight saving component, which is micronized polystyrene particles having particle sizes in the range of 50 to 2000 microns, and characterized by having very low water contents, in the range of from about 0.5% to 5% v/v. The ultra low water compositions can be extruded and can be molded under high pressure.

Abstract: The subject invention is directed to a cement admixture composition composed of certain alkylene glycols and copolymers of alkenyl ether and maleic anhydride. The present admixture provides a means to inhibit drying shrinkage of cement compositions while enhancing the compressive strength of the set composition.

Abstract: Methods for combining Class C fly ash into cementitious mixtures for producing concretes that are resistant to sulfate-containing environments. In one method, Class C fly ash is intergound with portland cement clinker and gypsum to produce a cementitions mixture, which, when combined with water and an aggregate produces a hardened concrete that is resistant to sulfate environments. Alternatively, portland cement clinker and gypsum are first interground and the resultant mixture is admixed with Class C fly ash to produce a cementitious mixture. Thie cementitious mixture, in combination with water and an aggregage, produces a hardened concrete that has improved resistance to sulfate environments. In other aspects, a concrete that is stable in sulfate environments is produced by admixing portland cement, Class C fly ash and water containing a source of ions selected from the group consisting of sulfate and hydroxyl anions.

Abstract: Class C fly ash containing cementitious mixtures for producing concretes that are resistant to sulfate-containing environments. Class C fly ash is intergound with portland cement clinker and gypsum to produce a cementitions mixture, which, when combined with water and an aggregate produces a hardened concrete that is resistant to sulfate environments. Alternatively, portland cement clinker and gypsum are first interground and the resultant mixture is admixed with Class C fly ash to produce a cementitious mixture. This cementitious mixture, in combination with water and an aggregate, produces a hardened concrete that has improved resistance to sulfate environments. In other aspects, a concrete that is stable in sulfate environments is produced by admixing portland cement, Class C fly ash and water containing a source of ions selected from the group consisting of sulfate and hydroxyl anions.

Abstract: A method of immobilizing toxic waste material slurries is disclosed wherein aggregates are formed containing the toxic waste and the aggregates admixed with and embedded in a sulfur cement to form a concrete shape.

Abstract: A system and method for dispersing pigment in cement based compositions comprising a predetermined and prepackaged amount of a cement based component and a predetermined and prepackaged amount of an aqueous dispersion of a pigment containing component.

Abstract: A cementitious composition comprising(a) a cementitious material;(b) a fly ash which has a calcium oxide content of from 15-45% by weight;(c) a hydroxycarboxylic acid; and(d) a water-soluble source of alkali metal ions.The compositions are useful as concretes, grouts and mortars.

Abstract: A method of recovering steel plant waste revert materials including blast furnace flue dust and sludges involves mixing the revert materials with water to provide a total moisture content of about 14-20% by weight, then adding Portland cement as a sole binder, mixing, and, when the water content is limited to about 18 to 20%, casting the mixture onto the ground in the form of a slab or, when the water content is limited to about 14 to 16% and an accelerator for curing the cement is used, casting the mixture onto a conveyor in the form of preformed streams, curing the cast mixture and breaking it up to provide 1/2 inch to 5 inch agglomerate particles that can be recycled to the blast furnace.

Abstract: A cementitious composition comprising(A) 10-30 parts cementitious material;(B) 50-80 parts fly ash weight; and(C) 1.5-8 parts hydroxycarboxylic acid and/or salt thereof.

Abstract: A synthetic cover for bulk material piles and loads in transit may be formed from a mixture of liquid, binder, and fibers. These constituents may be mixed and applied to cover a waste pile. The cover will harden to minimize water infiltration, wind blown dust, odor and affinity to birds, flies and other insects. The liquid may include water; the binder may include portland cement, portland cement with flyash, cement kiln dust with or without bentonite, or stone dust. The fibers may comprise shredded paper or wood or plastic fibers.

Abstract: From about 25% to about 50% but not more than about 200 lbs of the Portland cement of a general purpose concrete mix which contains for each cubic yard of the concrete to be produced in generally homogeneous admixture about 400-750 lbs. portland cement, about 1600-2000 lbs. coarse aggregate of a size of at least about 3/8 inch, and sufficient fine aggregate of a size less than 3/8 inch and up to minor amounts of conventional additives to yield one cubic yard when the admixture is combined with water in an amount equal to about 40-70% by weight of said portland cement, is replaced with a) Class F fly ash having a calcium oxide content up to about 6% and b) cement kiln dust (CKD) in a weight ratio of fly ash to CKD of about 2:3-3:2. Preferably, 30% or more of the Portland cement is replaced.

Abstract: A blended hydraulic cement binder, is disclosed, consisting of water, fly ash, Type III portland cement, Type I portland cement, slag cement, ground silica, boric acid, borax, citric acid and an alkali metal activator. The cement binder and sequences for mixing the composition, is particularly useful because it provides: time to mix all components adequately, unrestricted transporting time that can be terminated, at will, followed by alterable placement and finishing times. The cement binder can be used as a neat cement or it can be extended with fillers, such as sand and gravel, to make mortar or concrete, that rapidly gains very high structural strengths.

Abstract: A cementitious composition for oil well cementation able to prevent fluid migration comprises water, hydraulic cement, surfactant or organic dispersant, and carbon black.

Abstract: A process is disclosed for producing a hydraulic cement binder for both general and special applications, consisting of water, cementitious materials, boric acid, borax, citric acid, an alkali metal activator, and with or without ground silica. This cement making process with sequences for mixing the composition, is particularly useful because it provides: time to mix all components adequately, unrestricted transporting time that can be terminated, at will, followed by alterable placement and finishing times. The process provides the means for creating a hydraulic cement binder that can be used as a neat cement or it can be extended with fillers, such as sand and gravel, to make mortar or concrete, that rapidly gains very high structural strengths.

Abstract: A homogeneous dry particulate cement mixture in ready-to-use form is provided, which comprises ground blast-furnace slag having a specific surface area of 500-750 m.sup.2 /kg and ground fly ash having a specific surface area of 500-750 m.sup.2 /kg, in a weight ratio in the range of 20/80-70/30, and further comprises the following components in the amounts indicated, calculated on the total mixture: at least 2% by weight of portland cement clinker and 2-12% by weight of sodium silicate (calculated as Na.sub.2 O+SiO.sub.2). When processed, the cement mixture yields a mortar or a concrete having improved strength properties as well as a good resistance against an acidic environment.