Mineral fines reduce OPC content in concrete, mortar and other cementitious compositions, typically in combination with a pozzolanically active SCM. Mineral fines can replace and/or augment a portion of hydraulic cement and/or fine aggregate. Mineral fines can replace a portion of cement binder and fine aggregate as an intermediate that fills a size void between largest cement particles and smallest fine aggregate particles. Supplemental lime can enhance balance of calcium ions in the mix water and/or pore solution. Supplemental sulfate can address sulfate deficiencies caused by high clinker reduction, use of water reducers and/or superplasticizers, and SCMs containing aluminates. Concentrated or pure carbon dioxide (CO.sub.2) can be used to passivate alkaline values in highly alkaline materials, such as concrete washout fines, CKD, class C flyash, incinerator ash, bottom ash, or biomass ash. CO.sub.2 passivation or sequestration can be carried out before, during or after forming an initial concrete mix.

A mortar for formation of a masonry element includes a co-product from the production of steel and an alkaline solution. A masonry element is formed from the mortar, the masonry element including at least one of a brick, a block, a paver, veneer stone, exterior or interior wall panels, roof tiles, faux slate, faux wood, decorative stone, and a poured structure. A method of forming a masonry element includes providing the mortar and compressing the mortar to form the masonry element.

A mortar for formation of a masonry element includes a co-product from the production of steel and an alkaline solution. A masonry element is formed from the mortar, the masonry element including at least one of a brick, a block, a paver, veneer stone, exterior or interior wall panels, roof tiles, faux slate, faux wood, decorative stone, and a poured structure. A method of forming a masonry element includes providing the mortar and compressing the mortar to form the masonry element.

A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand at a mixing device to generate a non-Portland cement-based material. The method may also include transporting the non-Portland cement-based material from the mixing device, through a conduit to a nozzle and combining the transported non-Portland cement-based material with water at the nozzle to generate a partially liquefied non-Portland cement-based material. The method may further include pneumatically applying the partially liquefied non-Portland cement-based material to a surface.

A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand at a mixing device to generate a non-Portland cement-based material. The method may also include transporting the non-Portland cement-based material from the mixing device, through a conduit to a nozzle and combining the transported non-Portland cement-based material with water at the nozzle to generate a partially liquefied non-Portland cement-based material. The method may further include pneumatically applying the partially liquefied non-Portland cement-based material to a surface.

In the present disclosure, a cement board is disclosed. The cement board comprises a core having a first surface and a second surface opposite the first surface and a binder including a pozzolan material and a water-resistant additive, wherein the water-resistant additive is present in an amount of less than 5 wt. % based on the weight of the pozzolan material.

In the present disclosure, a cement board is disclosed. The cement board comprises a core having a first surface and a second surface opposite the first surface and a binder including a pozzolan material and a water-resistant additive, wherein the water-resistant additive is present in an amount of less than 5 wt. % based on the weight of the pozzolan material.

A method of producing a carbonated composite material includes: providing a carbonatable cementitious material in particulate form; mixing the carbonatable cementitious material with water to produce a mix; forming a predetermined shape with the mix, wherein the predetermined shape has an initial pore structure containing an initial pore solution having a first pH; pre-conditioning the predetermined shape to remove a predetermined amount of the water from the predetermined shape to produce a pre-conditioned shape; carbonating the pre-conditioned shape in an environment comprising carbon dioxide to produce a modified pore structure containing a modified pore solution having and a second pH, wherein the difference between the first pH and the second pH is represented by a ΔpH, and the ΔpH is 1.0 or less.

A method of producing a carbonated composite material includes: providing a carbonatable cementitious material in particulate form; mixing the carbonatable cementitious material with water to produce a mix; forming a predetermined shape with the mix, wherein the predetermined shape has an initial pore structure containing an initial pore solution having a first pH; pre-conditioning the predetermined shape to remove a predetermined amount of the water from the predetermined shape to produce a pre-conditioned shape; carbonating the pre-conditioned shape in an environment comprising carbon dioxide to produce a modified pore structure containing a modified pore solution having and a second pH, wherein the difference between the first pH and the second pH is represented by a ΔpH, and the ΔpH is 1.0 or less.

The present invention relates to granular composite density enhancement, and related methods and compositions. The applications where these properties are valuable include but are not limited to: 1) additive manufacturing (“3D printing”) involving metallic, ceramic, cermet, polymer, plastic, or other dry or solvent-suspended powders or gels, 2) concrete materials, 3) solid propellant materials, 4) cermet materials, 5) granular armors, 6) glass-metal and glass-plastic mixtures, and 7) ceramics comprising (or manufactured using) granular composites.