A foamed lightweight monolithic refractory castable is provided. The castable includes one or more refractory aggregates as a main constituent, one or more foaming additives in a range of 0.1 wt % to 3.0 wt %, one or more cellulosic powder air-entraining additives in a range of 0.005 wt % to 2.0 wt %, one or more binders in a range of 1 wt % to 40 wt %, and one or more superplasticizers in a range of 0.05 wt % to 0.5 wt %. The refractory aggregates include at least one of alumina and silica. The foaming additives include at least one of alkylbenzene sulfonates, alkene sulfonates, and hydroxylalkane sulfates. The superplasticizers include at least one of sodium polyacrylates, naphthalene sulfonates, polyethylene glycols, polycarboxylates, polyacrylates, and polycarboxylate ethers.

It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec coal ash significantly improves the properties of the non-spec coal ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C coal ash. The natural pozzolan may be a volcanic ejecta, such as pumice or perlite. Other pozzolans may also be used for this beneficiation process. Many pozzolans are experimentally tested and may be used to beneficiate non-spec coal ash into certifiable Class F coal ash. Additionally, this disclosure provides a method of converting a Class C coal ash to a more valuable Class F coal ash. This discovery will extend diminishing Class F coal ash supplies and turn non-spec coal ash waste streams into valuable, certified coal ash pozzolan which will protect and enhance concrete, mortars and grouts.

It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec coal ash significantly improves the properties of the non-spec coal ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C coal ash. The natural pozzolan may be a volcanic ejecta, such as pumice or perlite. Other pozzolans may also be used for this beneficiation process. Many pozzolans are experimentally tested and may be used to beneficiate non-spec coal ash into certifiable Class F coal ash. Additionally, this disclosure provides a method of converting a Class C coal ash to a more valuable Class F coal ash. This discovery will extend diminishing Class F coal ash supplies and turn non-spec coal ash waste streams into valuable, certified coal ash pozzolan which will protect and enhance concrete, mortars and grouts.

A composition for a cementitious roofing tile, the composition includes a cement binder making up 10% to 20% of a total composition weight; a fine aggregate sand making up 20% to 25% of the total composition weight; an aggregate making up 12% to 20% of the total composition weight; a crushed glass making up 15% to 60% of the total composition weight; an alkali-silica reaction (ASR) suppressant; and a predetermined volume of water; the aggregate is selected from one of perlite, vermiculite, hemp, expanded clay, coco coir, shale and slate; and the fine aggregate sand has an average particle size from a minimum of 1 micron to a maximum size of 2 mm; and the crushed glass has an average particle size that ranges from 1 micron to a maximum of 5 mm.

A composition for a cementitious roofing tile, the composition includes a cement binder making up 10% to 20% of a total composition weight; a fine aggregate sand making up 20% to 25% of the total composition weight; an aggregate making up 12% to 20% of the total composition weight; a crushed glass making up 15% to 60% of the total composition weight; an alkali-silica reaction (ASR) suppressant; and a predetermined volume of water; the aggregate is selected from one of perlite, vermiculite, hemp, expanded clay, coco coir, shale and slate; and the fine aggregate sand has an average particle size from a minimum of 1 micron to a maximum size of 2 mm; and the crushed glass has an average particle size that ranges from 1 micron to a maximum of 5 mm.

A cementitious composite for in-situ hydration includes a first layer, a second layer, a cementitious mixture including cementitious material positioned between the first layer and the second layer, and a structure layer positioned between the first layer and the second layer. The cementitious mixture comprises a majority of a volume between the first layer and the second layer.

A cementitious composite for in-situ hydration includes a first layer, a second layer, a cementitious mixture including cementitious material positioned between the first layer and the second layer, and a structure layer positioned between the first layer and the second layer. The cementitious mixture comprises a majority of a volume between the first layer and the second layer.

A cementitious composite for in-situ hydration includes a structure layer having a first side and an opposing second side, a cementitious material disposed within the structure layer, a sealing layer disposed along and coupled to the first side of the structure layer, and a containment layer disposed along the opposing second side of the structure layer. The structure layer has an intersection at the sealing layer and the containment layer that is at least partially fiberless. The cementitious material includes a plurality of cementitious particles. The containment layer is configured to prevent the plurality of cementitious particles from migrating out of the structure layer.

A cementitious composite for in-situ hydration includes a structure layer having a first side and an opposing second side, a cementitious material disposed within the structure layer, a sealing layer disposed along and coupled to the first side of the structure layer, and a containment layer disposed along the opposing second side of the structure layer. The structure layer has an intersection at the sealing layer and the containment layer that is at least partially fiberless. The cementitious material includes a plurality of cementitious particles. The containment layer is configured to prevent the plurality of cementitious particles from migrating out of the structure layer.

Disclosed are a lightweight conductive mortar material, a preparation method therefor and use thereof. The lightweight conductive mortar material includes the following components in parts by weight: 100 parts of cement, 25 parts to 60 parts of a conductive porous lightweight aggregate loaded with a modified agar gel, and 30 parts to 45 parts of water.