Abstract: The present invention provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: A lime pellet for use in asphalt applications can include lime fines and an asphalt-compatible binder. The pellet is characterized as having a rigid structure with a dimension greater than about 1.5 mm and being compatible with a hot mix asphalt so as to dissolve in liquid asphalt. Optionally, the binder is characterized by having less than about 50% by weight of total binder being sulfur, or the pellet is characterized by having lime in an amount of at least 31% by weight, or being storage-stable and agglomeration resistant. The pellet is manufactured by mixing the lime fines with the asphalt-compatible binder and forming pellets therefrom. The pellets are useful for conditioning an end product of hot mix asphalt during the manufacture of such an asphalt. The method of conditioning includes providing the lime pellet, and mixing the lime pellet with a hot mix asphalt ingredient, wherein the ingredient is at least one of an aggregate or asphalt cement.

Abstract: Cement compositions for use in subterranean formations are provided. An example of a cement composition is a cement composition comprising: water, a cementitious component consisting essentially of: hydrated lime, and silica; and a dispersant. Another example of a cement composition is a cement composition comprising: water, a cementitious component consisting essentially of: hydrated lime, and silica; and a set retarder. Another example of a cement composition is a cement composition comprising: water, a cementitious component consisting essentially of: hydrated lime, and silica; and a fluid loss control additive.

Abstract: A dry mix particulate composition of a calcined oxide of Mg and/or Ca, an acid phosphate, and fly ash or equivalent, wherein the calcined oxide is present in the range of from about 17% to about 40% by weight and the acid phosphate is present in the range of from about 29% to about 52% by weight and the fly ash or equivalent is present in the range of from about 24% to about 39% by weight when sand is added to the dry mix, it is present in the range of from about 39% to about 61% by weight of the combined dry mix and sand. A method of forming a structural member is also disclosed wherein an aqueous slurry of about 8–12 pounds of water is added to dry mix and sand.

Abstract: A coating, method of coating and substrates coated thereby, wherein the coating contains an inorganic adhesive such as an alkali/alkaline earth metal silicate such as sodium silicate, potassium silicate, calcium silicate, and magnesium silicate; a filler such as a metal oxide for example silicon dioxide, aluminum oxide, titanium dioxide, magnesium oxide, calcium oxide and boron oxide; and one or more emissivity agents such as silicon hexaboride, carbon tetraboride, silicon tetraboride, silicon carbide, molybdenum disilicide, tungsten disilicide, zirconium diboride, cupric chromite, or metallic oxides such as iron oxides, magnesium oxides, manganese oxides, chromium oxides and copper chromium oxides, and derivatives thereof. In a coating solution, an admixture of the coating contains water. A stabilizer such as bentonite, kaolin, magnesium alumina silicon clay, tabular alumina and stabilized zirconium oxide may be added.

Abstract: A biocidal film-forming composition, preferably a paint, is disclosed, comprising hydrated lime, alkaline potassium salt, and a non-ionic polyolefinic latex resistant to hydrated-lime induced coagulation and phase separation. Also disclosed is the method of making certain such composition wherein hydrated lime is admixed with a non-ionic polyolefinic ester latex with agitation and continuing such agitation until hydrolysis of the ester is substantially completed and rheology of the composition is stabilized and the incidence of gelation is eliminated.

Abstract: The present invention relates to a composite of consolidation-hardening pile for soft ground and in which a composition ratio of an aggregate:a quicklime:an additive is 50–60 wt %:20–25 wt %:20–25 wt %, and the additive is an admixture made by mixing a powder of furnace slag, a fly ash or a mixture of the powder of furnace slag and the fly ash in a cement, the ratio of the cement, and the powder of furnace slag, the fly ash or the mixture of the powder of furnace slag aggregate and the fly ash is 65–85 wt %:15–35 wt %. As the pile is formed in the soft ground vertically, a composite has a strength of 50 kgf/cm2 or over to act as a supporting pile for sinking, and a reinforcing pile.

Abstract: A bone replacement material and therapy comprises the combination of calcium phosphate compounds and two or more soluble fillers in the form of fibers, mesh or other materials which have the dual functions of reinforcing an in vivo implant while dissolving at a programmed rate to form macropores capable of receiving natural bone ingrowth.

Abstract: A coating admixture, method of coating and substrates coated thereby, wherein the coating contains colloidal silica, colloidal alumina, or combinations thereof; a filler such as silicon dioxide, aluminum oxide, titanium dioxide, magnesium oxide, calcium oxide and boron oxide; and one or more emissivity agents such as silicon hexaboride, carbon tetraboride, silicon tetraboride, silicon carbide, molybdenum disilicide, tungsten disilicide, zirconium diboride, cupric chromite, or metallic oxides such as iron oxides, magnesium oxides, manganese oxides, chromium oxides, copper chromium oxides, cerium oxides, terbium oxides, and derivatives thereof. In a coating solution, an admixture of the coating contains water. A stabilizer such as bentonite, kaolin, magnesium alumina silicon clay, tabular alumina and stabilized zirconium oxide is also added.

Abstract: An asbestos free, calcium silicate insulating material suitable for use in the casting of molten non-ferrous metals, and suitable for use in applications where a fire resistant, heat insulating, electrical insulating, and corrosion resistant material is desirable. The calcium silicate insulating material is peoduced by combining lime, a siliceous component, alumina silica microspheres, wollastonite and organic fibrous material in the presence of water to form a slurry. The slurry is then placed under steam pressure, to react the lime, siliceous component and water, dried, and heat treated if necessary.

Abstract: A plaster formulation for forming a non-shinny, slow-drying plaster, in which color may be blended and multiple color coats applied to form a colored surface with the appearance of depth, age, and texture.

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: 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: Composition for treating and stabilizing soils, in particular wet soils, comprising, in the form of a powder having a particle size less than 5 mm, quicklime and/or calcium-based hydraulic binders, as well as a non-aqueous fluid additive capable of agglomerating the finer particles of the composition together.

Abstract: A shaped thermal insulation body comprises inorganic material. The shaped body has the following, weight-related composition: approx. 20 wt. % inorganic filling material: approx. 40 wt. % opacifier; approx. 10 wt. % fibrous material; and approx. 15 wt. % hardening agent as well as approx. 15 wt. % water. The shaped body only contains a small amount of fumed silica with a comparatively small BET surface. Water glass is excluded during its manufacture. It can be used as a spacer for radiant heaters.

Abstract: A synthetic aggregate having a multiplicity of uses such as for mixing with a cementing material to form concrete, mortar or plaster is disclosed. The aggregate includes crushed fragments of a size which are capable of passing through mesh screen having sieve openings ranging from between about 19 mm and 75 microns. The aggregate fragments are made by curing and then crushing a compressed product. The compressed product is made by compressing an aqueous cementitious mixture comprising cement and at least one member selected from the group consisting of bottom ash and non-cementitious fly ash. The compressed product is cured so that it has a compressive strength of at least 600 psi.

Abstract: The present invention refers to a hydraulic binder made from Portland clinker containing calcium fluoroaluminate 11CaO.7Al2O3.CaF2, to which sodium aluminate, lime, and optionally, sodium bicarbonate are added. The added lime has not undergone the formation process of clinker. The cement mix that can be obtained with this binder has a very short hardening time, scarcely influenced by temperature variations during laying operations.

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.

Abstract: A synthetic aggregate having a multiplicity of uses such as for mixing with a cementing material to form concrete, mortar or plaster is disclosed. The aggregate includes crushed fragments of a size which are capable of passing through mesh screen having sieve openings ranging from between about 19 mm and 75 microns. The aggregate fragments are made by curing and then crushing a compressed product. The compressed product is made by compressing an aqueous cementitious mixture comprising cement and at least one member selected from the group consisting of bottom ash and non-cementitious fly ash. The compressed product is cured so that it has a compressive strength of at least 600 psi.

Abstract: Oil-based settable spotting fluid compositions and methods of using the compositions are provided. The oil-based settable spotting fluid compositions are basically comprised of oil, an emulsifying surfactant for emulsifying the oil with water whereby an oil-external emulsion is formed, a de-emulsifying surfactant which in time de-emulsifies said oil-external emulsion when the emulsion is contacted with external water, a hydraulic settable component selected from the group consisting of ASTM Class C or the equivalent fly ash and ASTM Class F or the equivalent fly ash together with a source of calcium and water selected from the group consisting of fresh water and salt water.

Abstract: A method is provided for manufacturing cement from a raw material mixture which includes finely ground steel slag. Selected quantities of steel slag and other raw materials are mixed with each other and supplied to a raw mill. The steel slag and other raw materials are preferably ground to a fine, dry powder. For some applications, the dry powder is preferably supplied to a blend tank for further mixing to ensure more uniform commingling of the finely ground steel slag with other finely ground raw materials. The fine dry powder may be supplied to a preheat system and then to the feed end of a kiln. Alternatively, the dry powder may be supplied directly to the feed end of a kiln.

Abstract: Composition for treating and stabilizing soils, in particular wet soils, comprising, in the form of a powder having a particle size less than 2 mm, quicklime and/or calcium-based hydraulic binders, as well as a non-aqueous fluid additive capable of agglomerating the finer particles of the composition together.

Abstract: A binder for mine tailings and aggregate used as a backfill for an underground void comprises ferrous slag, and cement kiln dust, optionally with lime kiln dust; the binder displays strength characteristics better than or comparable to those achieved with conventional binders based on Portland cement and slag.

Abstract: A method for manufacturing an aerated autoclaved concrete material. A quick-stiffening mixture is prepared by combining a silica containing material, quicklime, a rising agent, gypsum, cement and water. The mixture is deposited into a mold and is allowed to form a stiffened body. The stiffened body is removed from the mold and placed in an autoclave station in which it is steam cured at elevated temperature and pressure. The quicklime which is used to form the quick-stiffening mixture is modified with a chemical modifier to provide a desired degree of chemical reactivity in the quick-stiffening mixture.

Abstract: A joint compound includes water, calcium carbonate, and a water-soluble polymeric set retarder formed from a monomer having two or more carboxyl groups. The joint compound is useful in various applications and in a hybrid joint compound made with a calcium sulfate hemihydrate setting-type joint compound.

Abstract: A method is disclosed for rapidly carbonating large cement structures, by forming and hardening cement in a mold under high carbon dioxide density, such as supercritical or near-supercritical conditions. The method is more reliable, efficient, and effective than are post-molding treatments with high-pressure CO2. Cements molded in the presence of high-pressure CO2 are significantly denser than otherwise comparable cements having no CO2 treatment, and are also significantly denser than otherwise comparable cements treated with CO2 after hardening. Bulk carbonation of cementitious materials produces several beneficial effects, including reducing permeability of the cement, increasing its compressive strength, and reducing its pH. These effects are produced rapidly, and extend throughout the bulk of the cement—they are not limited to a surface layer, as are prior methods of post-hardening CO2 treatment.

Abstract: A biocidal film-forming composition, preferably a paint, is disclosed, comprising hydrated lime and a non-ionic polyolefinic latex resistant to hydrated-lime induced coagulation and phase separation. Also disclosed is the method of making certain such composition wherein hydrated lime is admixed with a non-ionic polyolefinic ester latex with agitation and continuing such agitation until hydrolysis of the ester is substantially completed and rheology of the composition is stabilized.

Abstract: A method of producing a new type of cement, hereafter called Conch-krete. Conch-krete is created by adding sodium carbonate (also known as soda ash, natron, etc.) and one or more minerals from the calcium carbonate group (including aragonite, limestone, calcite, marble, dolomite, etc.) and the addition of water to the mix that will harden into a cement-like material. The combination of sodium carbonate and calcium carbonate can be either layered or in a mixed state. An exothermic reaction starts after the addition of water. The composition of Conch-krete can vary between 20% sodium carbonate and 80% calcium carbonate to 80% sodium carbonate and 20% calcium carbonate. Conch-Icrete can be used in a variety of applications not inclusive of forming bricks, interior architecture, table or counter tops, ornaments, repairing damaged cement products, casting and other applications not mentioned above.

Abstract: A method of reducing the curing time of drywall joint compound, and thereby reducing the time required to finish drywall joints or to repair plaster walls, includes adding a predetermined amount of a drying agent to a conventional ready-mixed drywall joint compound. The drying agent preferably comprises at least one compound selected from the group of compounds consisting of plaster of Paris, calcium carbonate, gypsum, crystallized silicon dioxide (quartz), Portland cement, perlite, lime, hydroxy ethyl ether of cellulose, polyvinyl alcohol, starch, wood fiber, potassium naphthalene sulfon, aluminum sulfate, sodium citrate, ammonium tartrate, hydrolyzed protein, monosodium phosphate, sodium naphthalene sulfonate, potassium sulfate and various trace materials, or mixtures thereof A sufficient amount of water is added to the drying agent to facilitate mixing the drying agent with the drywall joint compound to form a joint compound mixture.

Abstract: The present invention prolongs the biocidal activity of hydrated lime in a paint or coating by using a sufficient amount of a binder in the paint or coating to block carbon dioxide from reacting with the hydrated lime while still producing a coating that is durable and adhesive upon drying and not unduly friable due to the amount of hydrated lime in said coating.

Abstract: Composite materials having fly ash as a constituent is manufactured into a sulfur-less gypsum-like material, a portland cement-like material and a lightweight aggregate. Methods for making such composite materials include combining precipitated calcium carbonate and either Class C-fly ash, Class F-fly ash and/or bottom ash in particular ratios by adding water to dry material and subsequently allowing the material to dry to create the above-described products. Methods for forming and using such composites include the use of a single piece gatefold form for casting manifold surfaces, a panel system for forming concrete walls and a system for creating retaining walls.

Abstract: A method for making aggregate includes the following steps: (a) preparing a wet mixture by mixing water with a combination of ingredients in a mixer, the combination of ingredients including by weight about, 68% to 95% fly-ash and 2% to 10% lime; (b) dropping the wet mixture into at least one pile on a base surface; (c) allowing the wet mixture in the pile to substantially completely hydrolyze into a hard product; and (d) crushing the product to form the aggregate. Preferably, step (b) further includes forming an arcuate stack having multiple overlapping conical piles of the dropped wet mixture such that the stack extends a circular distance over the surface. The wet mixture may be transported from the mixer to a height above the surface and dropped to the surface by a radial stacker. The combination of ingredients, preferably, further includes by weight 0.5% to 12% alkali hydroxide and, more particularly, sodium hydroxide.

Abstract: Calcium carbonate sludge from sugar beet refining is recycled for use as a blast cleaning medium; and contaminate blast cleaning media is employed in the manufacture of cement. Also disclosed herein is the use of pumice as an additive to enhance the efficiency of blast cleaning media.

Abstract: A mortar cement composition is composed of a cement or ground portland cement clinker, ground limestone and/or lime, sand, a sufficient amount of water to render the composition flowable, and at least one water-soluble polymer present in the amount having a lower limit of about 0.001 wt % and an upper limit of about 0.04 wt % based on total dry weight of the ingredients, with the proviso that the extent of adsorption of the polymer onto the cement is less than 50%, and wherein the resulting mortar has 8-16% air content and greater than 70 psi flexural bond strength. This mortar cement composition is for use in building structures in all seismic zones.

Abstract: The present invention prolongs the biocidal activity of hydrated lime in a paint or coating by using a sufficient amount of a binder in the paint or coating to block carbon dioxide from reacting with the hydrated lime while still producing a coating that is durable and adhesive upon drying and not unduly friable due to the amount of hydrated lime in said coating

Abstract: The invention includes methods and compositions relating to calcium phosphate cements, which self-harden substantially to hydroxyapatite at ambient temperature when in contact with an aqueous medium. More specifically the cements comprise a combination of one or more sparingly soluble calcium phosphates other than tetracalcium phosphate with an aqueous solution adjusted with a base to maintain a pH of about 12.5 or above and having sufficient dissolved phosphate salt to yield a solution mixture with phosphate concentration equal to or greater than about 0.2 mol/L.

Abstract: The invention includes methods and compositions relating to calcium phosphate cements, which self-harden substantially to hydroxyapatite at ambient temperature when in contact with an aqueous medium. More specifically the cements comprise a combination of one or more sparingly soluble calcium phosphates other than tetracalcium phosphate with an aqueous solution adjusted with a base to maintain a pH of about 12.5 or above and having sufficient dissolved phosphate salt to yield a solution mixture with phosphate concentration equal to or greater than about 0.2 mol/L.

Abstract: The invention includes methods and compositions relating to calcium phosphate cements, which self-harden substantially to hydroxyapatite at ambient temperature when in contact with an aqueous medium. More specifically the cements comprise a combination of one or more sparingly soluble calcium phosphates other than tetracalcium phosphate with an aqueous solution adjusted with a base to maintain a pH of about 12.5 or above and having sufficient dissolved phosphate salt to yield a solution mixture with phosphate concentration equal to or greater than about 0.2 mol/L.

Abstract: The present invention regards a particularly quick-setting Portland cement clinker containing calcium fluoro-aluminate (11CaO.7Al.sub.2 O.sub.3.CaF.sub.2) mixed with lime that has not undergone the burning process of the clinker.

Abstract: A building and construction material and method of making the material utilizes water with cement which are mixed together and followed by mixing with a mineral filler material such as sand or gravel to produce concrete having micropores of about 0.01 to about 5.mu. in diameter. By eliminating from the mineral filler material all fine grains of less than 0.2 mm, it has been found that the strength of the concrete is improved and the amount of shrinkage is reduced.

Abstract: A patching composition in the form of a putty composition for application to concrete surfaces. The composition comprises a substantial portion of a conventional cement, such as a Portland cement, and a silica sand selected to have the right consistency and density along with calcium oxide. The composition is then mixed in water and applied to voids or holes in a concrete wall. The composition, when applied as a single coating and fully cured, results in an appearance similar to that of the concrete and provides strength characteristics substantially equivalent to that of the original concrete.

Abstract: A process in which the conventional sulfate components in an aerated concrete mixture, such as gypsum, semihydrate or anhydrite, are replaced at least in part by calcium aluminum sulfates and/or calcium aluminate sulfate hydrates. As a result, agglomeration of the lime, retardation of the lime hydration, and aftergrowth of the cut aerated concrete cakes are reduced or even ruled out. In addition, the number of molds used can be reduced with the process in accordance with the invention, whereby the use of one single mold is achievable.

Abstract: A method of forming a repository for radioactive waste comprises locating the waste in a subterranean vault and backfilling the vault with a filling material which is water permeable and provides a substantial reservoir of available alkalinity such that any ground water permeating through the filling material to the waste has a pH of at least 10.5.

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: A fire resistant article comprising at least about 65 wt. % gypsum dihydrate, reinforcing fibers disposed substantially homogeneously throughout said set gypsum dihydrate, inorganic binder, and optionally refractive filler. This composition provides superior resistance to damage when subjected to a stream of pressurized water as from a fire hose.

Abstract: A method and plant for heat treatment of lime sludge (CaCO.sub.3) formed by the causticizing process during the manufacture of paper pulp. The lime sludge is dried and pulverized in a first process stage and preheated in a second process stage by means of hot exhaust gas coming from a kiln. In order to ensure that the temperature in the second process stage does not exceed a predetermined temperature lying within the range from 400.degree.-600.degree. C., the relationship between the amount of energy available in the exhaust gas for preheating in the second process stage and the amount of accumulated energy in the material which is to be preheated is regulated.

Abstract: The present invention provides a method and mixture for use in forming strong light-weight aggregate and includes by weight about; 68% to 95% fly-ash, 2% to 10% hydrated lime, and 3% to 12% alkali hydroxide such as Sodium Hydroxide. While many types of fly-ash may be used, Type F or Type C fly-ash are preferred. The admix is mixed with water to form a slurry including water in a range of 10% to 25% by weight of the dry mixture and the slurry is then compacted. The compacted slurry is then cured such as by using a rotary kiln or by in situ open air curing. The cured slurry is then allowed to hydrolyzed to form a hard material which then may be crushed and optionally screened to form an aggregate having a particular size or range of sizes.

Abstract: A source of free lime is introduced into a cooling zone of a cement kiln in an amount to elevate the free lime content to a content of 0.6 to 2.0%, by weight. This addition is made without altering the normal or standard process operating parameters of the kiln for cement clinker production. The free lime content of 0.6 to 2.0%, by weight, provides advantageous characteristics in cement produced with the cement clinker.

Abstract: A method for producing quick setting concrete is provided comprising hydrng a concrete dry mixture with carbonate solution to create a slurry, and allowing the slurry to cure. The invention also provides for a quick setting concrete having a predetermined proportion of CaCO.sub.3 of between 5 and 23 weight percent of the entire concrete mixture, and whereby the concrete has a compression strength of approximately 4,000 pounds per square inch (psi) within 24 hours after pouring.

Abstract: A process for preparing high strength, rock-like, water-resistant aggregates by high intensity mixing of acidic metal chlorides and alkaline/cementitious materials in the presence of a low water ratio wherein the metal chlorides are simultaneously neutralized/stabilized and the mixture is solidified.