A man-made aggregate or a masonry unit may be made by adding impound residues and mixing the impound residues with other residues, ceramic materials and/or additives to form an admixture. The impound residues may also be mixed with synthetic or organic polymers. The impound residues may not conform to the requirements of ASTM C618-15. The admixture may be subjected to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

A man-made aggregate or a masonry unit may be made by adding impound residues and mixing the impound residues with other residues, ceramic materials and/or additives to form an admixture. The impound residues may also be mixed with synthetic or organic polymers. The impound residues may not conform to the requirements of ASTM C618-15. The admixture may be subjected to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

Synthetic aggregate that includes a plurality of agglomerations. Each of the plurality of agglomerations may include a core; and a shell material disposed on the core. According to various embodiments, the construction aggregate may be non-flammable. According to various embodiments, at least one agglomeration of the plurality of agglomerations may have a plurality of cores. The core may include coal, a coal byproduct, and combinations thereof. According to various embodiments, the coal may be a type such as lignite, sub-bituminous, bituminous, and anthracite. The coal byproduct may be fly ash, bottom ash, shale coal, or coal gob.

Synthetic aggregate that includes a plurality of agglomerations. Each of the plurality of agglomerations may include a core; and a shell material disposed on the core. According to various embodiments, the construction aggregate may be non-flammable. According to various embodiments, at least one agglomeration of the plurality of agglomerations may have a plurality of cores. The core may include coal, a coal byproduct, and combinations thereof. According to various embodiments, the coal may be a type such as lignite, sub-bituminous, bituminous, and anthracite. The coal byproduct may be fly ash, bottom ash, shale coal, or coal gob.

Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and other optional additives.

Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and other optional additives.

A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.

A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material, and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses are described, including compressed air storage facilities and a pumped hydroelectric facility, including such a facility adapted for use with a lock system of a waterway.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material, and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses are described, including compressed air storage facilities and a pumped hydroelectric facility, including such a facility adapted for use with a lock system of a waterway.