Light-weight aggregate
AssigneeResource Technology, Inc.
InventorRobert W. Styron
Life of this patent
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Abstract
A light-weight aggregate, for use in production of light-weight structural products, composed of a self-hardening fly ash, a surfactant foam, and optionally an accelerator and additives. The self-hardening fly ash is preferably class C fly ash formed by the combustion of sub-bituminous coal from the Power River Basin. The surfactant foam is preferably an anionic sulfate surfactant foam. The accelerator is preferably an extract of silica fume dust. The additives may include magnesium and boron compounds, other fly ashes, light-weight fillers, polymers, cement and magnesium silicate and like materials.
Claims16
A light-weight aggregate comprising a pellitized agglomerated mixture of by weight 50 to 86 parts self-hardening fly ash formed in the combustion of sub-bituminous coal from the Powder River Basin 1 to 14 parts sulfate surfactant foam, 0 to 6 parts accelerator which is extract of silica fume dust, and 0-30 parts additive selected from the group consisting of magnesium and boron compounds, class F fly ash, incinerated sewage sludge, diatomaceous earth, fullers earth, kaolin, kiln dust, perlite, pyrophyllite, talc, ground vermiculite, ground polyethylene, cement, and magnesium silicate.
A light-weight structural composition comprising a pozzolanic material, water, and a light-weight aggregate consisting of a pellitized agglomerated mixture of by wegiht to 50 to 86 parts self-hardening fly ash formed in the combustion of sub-bituminous coal from the Powder River Basin, 1 to 14 parts sulfate surfactant foam, 0 to 6 parts accelerator which is an extract of silica fume dust, and 0 to 30 parts additive selected from the group consisting of magnesium and boron compounds, class F fly ash, incinerated sewage sludge, diatomaceous earth, fullers earth, kaolin, kiln dust, perlite, pyrophyllite, talc, ground vermiculite, ground polyethylene, cement, and magnesium silicate.
A method for producing light-weight aggregate particles comprising the steps of:
- preparing a sulfate surfactant foam,
- mixing said surfactant foam, and a self-hardening fly ash to form a pelletized agglomerated mixture, and
- hardening said pelletized agglomerated mixture.
An accelerator for use in accelerating the hardening of pozzolanic materials comprising an extract of silica fume dust prepared by mixing silica fume dust with water, raising the pH to between 10-12, settling and collecting the resulting supernatant.
Dependencies are inferred from the claim text.