It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec fly ash significantly improves the properties of the non-spec fly ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C fly 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 fly ash into certifiable Class F fly ash. Additionally, this disclosure provides a method of converting a Class C fly ash to a more valuable Class F fly ash. This discovery will extend diminishing Class F fly ash supplies and turn non-spec fly ash waste streams into valuable, certified fly ash pozzolan which will protect and enhance concrete, mortars and grouts.

Methods and systems for efficiently manufacturing particulate blending materials for use in making particle size optimized cements, SCMs, blended cements and cement-SCM blends. An initial hydraulic cement or SCM having an initial particle size distribution (PSD), an initial d10, and an initial d90 is processed using one or more air classifiers, and optionally one or more mills, to yield a plurality of hydraulic cement or SCM fractions having desired particle size distributions (PSDs). The hydraulic cement fractions can be blended with SCMs to form binary and ternary cement-SCM blends. The SCM fractions can also be used to make binary and ternary blends. A surplus fine cement fraction can be used to raise the fineness and/or reactivity of a less fine and/or less reactive hydraulic cement. A surplus fine SCM can be used as a silica fume substitute.

Methods and systems for efficiently manufacturing particulate blending materials for use in making particle size optimized cements, SCMs, blended cements and cement-SCM blends. An initial hydraulic cement or SCM having an initial particle size distribution (PSD), an initial d10, and an initial d90 is processed using one or more air classifiers, and optionally one or more mills, to yield a plurality of hydraulic cement or SCM fractions having desired particle size distributions (PSDs). The hydraulic cement fractions can be blended with SCMs to form binary and ternary cement-SCM blends. The SCM fractions can also be used to make binary and ternary blends. A surplus fine cement fraction can be used to raise the fineness and/or reactivity of a less fine and/or less reactive hydraulic cement. A surplus fine SCM can be used as a silica fume substitute.

The described systems, methods, and compositions relate to systems, methods, and compositions for forming one or more cementitious materials that cure into one or more mortars and/or concretes. More particularly, some embodiments relate to systems, methods, and compositions for forming cured mortars and/or concretes that tend to have an increased strength over time due to the use of one or more reactive aggregates, activator materials, and/or alkaline compounds for conditioning the aggregate. In some cases, a cementitious mixture that is configured to form a mortar that can receive one or more filler aggregates (e.g., reactive filler aggregates) to make a concrete. Additionally, in some cases, the reactive aggregate is conditioned with an aqueous solution comprising one or more alkaline compounds having a concentration in the aqueous solution of between about 0.001 mol/L and about 10 mol/L, or within any subrange thereof (e.g., between about 0.25 molar and about 5 molar).

The described systems, methods, and compositions relate to systems, methods, and compositions for forming one or more cementitious materials that cure into one or more mortars and/or concretes. More particularly, some embodiments relate to systems, methods, and compositions for forming cured mortars and/or concretes that tend to have an increased strength over time due to the use of one or more reactive aggregates, activator materials, and/or alkaline compounds for conditioning the aggregate. In some cases, a cementitious mixture that is configured to form a mortar that can receive one or more filler aggregates (e.g., reactive filler aggregates) to make a concrete. Additionally, in some cases, the reactive aggregate is conditioned with an aqueous solution comprising one or more alkaline compounds having a concentration in the aqueous solution of between about 0.001 mol/L and about 10 mol/L, or within any subrange thereof (e.g., between about 0.25 molar and about 5 molar).

The described systems, methods, and compositions relate to systems, methods, and compositions for forming one or more cementitious mixtures that cure into one or more mortars and/or concretes. More particularly, some embodiments relate to systems, methods, and compositions for producing cementitious materials (or cured mortar and/or concrete compositions) that tend to increase in strength over time due to the use of saltwater (e.g., instead of freshwater) and/or due to the use of one or more reactive aggregates that interact with an activator material that is primarily comprised of lime. In some cases, the described cementitious material can (before being cured to form mortar or concrete) include one or more reactive aggregates; hydrating solutions comprising water with a salt content greater than 0.5 ppt; and/or activator materials comprising at least 40% calcium oxide by mass (e.g., when the activator is dry).

The described systems, methods, and compositions relate to systems, methods, and compositions for forming one or more cementitious mixtures that cure into one or more mortars and/or concretes. More particularly, some embodiments relate to systems, methods, and compositions for producing cementitious materials (or cured mortar and/or concrete compositions) that tend to increase in strength over time due to the use of saltwater (e.g., instead of freshwater) and/or due to the use of one or more reactive aggregates that interact with an activator material that is primarily comprised of lime. In some cases, the described cementitious material can (before being cured to form mortar or concrete) include one or more reactive aggregates; hydrating solutions comprising water with a salt content greater than 0.5 ppt; and/or activator materials comprising at least 40% calcium oxide by mass (e.g., when the activator is dry).

The described systems, methods, and compositions relate to systems, methods, and compositions for forming one or more cementitious materials that cure into one or more mortars or concretes. More particularly, some embodiments relate to systems, methods, and compositions for producing cured cementitious materials that tend to increase in strength over time due to the use of one or more reactive aggregates that interact with one or more activating materials (lime components). In some cases, a mortar or a concrete includes a reactive aggregate with an oven-dried bulk density between about 0.25 and 3.0 gm/cc and a porous structure, wherein at least 5% of a total mass of the reactive aggregate is comprised of particles less than (or equal to) 1 mm. In some such embodiments, the cementitious mixture further comprises a hydrating solution including water and an activating material, wherein the activator comprises at least 40% calcium oxide, by mass.

The invention comprises a cementitious material comprising a natural pozzolan selected from hyaloclastite, sideromelane or tachylite, wherein the natural pozzolan has a volume-based mean particle size of less than or equal to 40 μm. The cementitious material also comprising an aqueous alkaline activating solution suitable for forming a geopolymer. A method making a cementitious material is also disclosed.

The invention comprises a cementitious material comprising a natural pozzolan selected from hyaloclastite, sideromelane or tachylite, wherein the natural pozzolan has a volume-based mean particle size of less than or equal to 40 μm. The cementitious material also comprising an aqueous alkaline activating solution suitable for forming a geopolymer. A method making a cementitious material is also disclosed.