The present invention relates to a composite cement obtainable by grinding Portland cement clinker and latent hydraulic material together, preferably in the presence of at least one amine grinding aid, to provide a ground mixture and combining the ground mixture with a mineral filler. It further relates to a method of manufacturing the composite cement comprising the steps of grinding a latent hydraulic material and a portland cement clinker together, preferably in the presence of at least one amine, to provide a ground mixture and combining the ground mixture with one or more mineral fillers as well as to binders and to using the cement or binders as building material.

An embodiment includes a Class C fly ash (CFA) cementitious composition with a controllable setting time comprising at least one Class C fly ash; at least one alkali hydroxide; at least one source of phosphate; and water. Alternate embodiments include a Class C fly ash (CFA) cementitious composition with a solid activator comprising at least one Class C fly ash; at least one alkali carbonate; at least one source of phosphate; and water.

A non-conforming fly ash is converted into conforming fly ash by: (1) obtaining an initial fly ash with at least one non-conforming characteristic selected from excess carbon or low reactivity index as defined by ASTM C-618 and having a D10, D50 and D90; (2) classifying the initial fly ash using one or more air classifiers to produce at least two separate fly ash streams, including fine fly ash and coarse fly ash; and (3) collecting the fine fly ash and the coarse fly ash, (4) the fine fly ash having a D90 approximately equal to or less than the D50 of the initial fly ash and a conforming carbon content and a conforming reactivity index as defined by ASTM C-618.

A non-conforming fly ash is converted into conforming fly ash by: (1) obtaining an initial fly ash with at least one non-conforming characteristic selected from excess carbon or low reactivity index as defined by ASTM C-618 and having a D10, D50 and D90; (2) classifying the initial fly ash using one or more air classifiers to produce at least two separate fly ash streams, including fine fly ash and coarse fly ash; and (3) collecting the fine fly ash and the coarse fly ash, (4) the fine fly ash having a D90 approximately equal to or less than the D50 of the initial fly ash and a conforming carbon content and a conforming reactivity index as defined by ASTM C-618.

A method of manufacturing an activated pozzolan composition includes: (i) grinding a natural pozzolan, alone or with another mineral component that is not cement clinker, to form a finely ground pozzolan component having a first d90 in a range of about 10 m to about 45 m and a first d10 less than about 5 m; and (ii) blending, without intergrinding, the finely ground pozzolan component with a coarse particulate mineral component comprised of coarse mineral particles not interground with the fine interground particulate component, the coarse particulate component having a second d90 greater than the first d90 and a second d10 greater than the first d10. The natural pozzolan can be one or more of natural pozzolanic deposits, volcanic ash, metakaolin, shale dust, calcined clay, trass, and pumice.

A method of manufacturing an activated pozzolan composition includes: (i) grinding a natural pozzolan, alone or with another mineral component that is not cement clinker, to form a finely ground pozzolan component having a first d90 in a range of about 10 m to about 45 m and a first d10 less than about 5 m; and (ii) blending, without intergrinding, the finely ground pozzolan component with a coarse particulate mineral component comprised of coarse mineral particles not interground with the fine interground particulate component, the coarse particulate component having a second d90 greater than the first d90 and a second d10 greater than the first d10. The natural pozzolan can be one or more of natural pozzolanic deposits, volcanic ash, metakaolin, shale dust, calcined clay, trass, and pumice.

A low density annular grout composition for filling voids. The composition may consist of cementitious fly ash, water, set retarder and cellular foam. The composition may have a compressive strength of between 100 and 600 psi at seven days and less than 1500 psi at 28 days. The composition may have a density between 20 and 75 pcf. Also disclosed is a method of filling a void with a low density annular grout composition. The method can include determining the time necessary to fill the void, adding water and set retarder to a cementitious fly ash to make a wet mixture, adding air to the wet mixture, and adding the composition to the void.

A low density annular grout composition for filling voids. The composition may consist of cementitious fly ash, water, set retarder and cellular foam. The composition may have a compressive strength of between 100 and 600 psi at seven days and less than 1500 psi at 28 days. The composition may have a density between 20 and 75 pcf. Also disclosed is a method of filling a void with a low density annular grout composition. The method can include determining the time necessary to fill the void, adding water and set retarder to a cementitious fly ash to make a wet mixture, adding air to the wet mixture, and adding the composition to the void.

Mortar with small autogenous shrinkage strain and a method for producing the same are provided.

Mortar has binder and fine aggregate, wherein the binder includes cement and fine mineral powder, and the mortar is formed by being mixed with water. The fine aggregate is air granulated ferronickel slag, and weight ratio of water to a combination of the binder and the fine aggregate is 7.0% or more and 9.0% or less. Such mortar can be produced by mixing binder, fine aggregate and water.

Mortar with small autogenous shrinkage strain and a method for producing the same are provided.

Mortar has binder and fine aggregate, wherein the binder includes cement and fine mineral powder, and the mortar is formed by being mixed with water. The fine aggregate is air granulated ferronickel slag, and weight ratio of water to a combination of the binder and the fine aggregate is 7.0% or more and 9.0% or less. Such mortar can be produced by mixing binder, fine aggregate and water.