Manufacture of articles from fly ash
AssigneeNewSouth Innovations Pty Limited
InventorsObada Kayali, Karl John Shaw
Life of this patent
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Abstract
Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.
Claims20
A method of forming a shaped article having a matrix containing sintered fly ash, said method comprising the steps of:
- blending fly ash together with water to produce a fly ash dough;
- forming a green article in a desired shape from the fly ash dough;
- curing the green article to at least partially solidify the article at between 30-80° C. and 20%-60% relative humidity;
- and
- firing the green article so that the shaped article is hardened by sintering its fly ash matrix;
- wherein the water is added in excess of that which is absorbed by the fly ash so that the dough contains free water so as to be in at least a partially fluid state;
- and removing at least a portion of the free water from the fly ash dough during and/or after forming of the green article.
A method of forming a shape article having a matrix containing sintered fly ash, said method comprising the steps of:
- blending fly ash together with water to produce a fly ash dough;
- forming a green article in a desired shape from the fly ash dough;
- curing the green article to at least partially solidify the article at a temperature in the range of 55° C. to 65° C. and 20%-60% relative humidity;
- and
- firing the green article so that the shaped article is hardened by sintering its fly ash matrix.
A method of forming a shaped article having a matrix containing sintered fly ash, said method comprising the steps of:
- forming a fly ash dough incorporating fly ash, water and a superplasticiser;
- forming a green article in a desired shape from the fly ash dough;
- curing the green article, wherein during curing the water reacts with the fly ash so as to at least partially solidify the article;
- and
- firing the green article so that the shaped article is hardened by sintering its fly ash matrix;
- wherein in forming the fly ash dough the water is added in excess of that which is absorbed by the fly ash so that the dough contains free water so as to be in a partially fluid state, and during curing at least a portion of the free water is removed from the fly ash dough.
A method of forming a shaped article having a matrix containing sintered fly ash, said method comprising the steps of:
- forming a fly ash dough incorporating fly ash, water and a superplasticiser;
- forming a green article in a desired shape from the fly ash dough;
- curing the green article at a temperature of between 55-65° C., wherein during curing the water reacts with the fly ash so as to at least partially solidify the article;
- and
- firing the green article so that the shaped article is hardened by sintering its fly ash matrix.
Dependencies are inferred from the claim text.