The invention relates to the use of a hydraulic binder containing calcium aluminate, obtainable by a method in which a) prepared amorphous residual material rich in aluminium oxide and/or aluminium hydroxide is heated after the addition of a b) calcium ion-containing binder component and c) water, for the production of a constructing material.

The invention relates to the use of a hydraulic binder containing calcium aluminate, obtainable by a method in which a) prepared amorphous residual material rich in aluminium oxide and/or aluminium hydroxide is heated after the addition of a b) calcium ion-containing binder component and c) water, for the production of a constructing material.

A method for processing water treatment residuals, or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals, for use in the manufacture of hydraulic binders, comprising heating the residuals to remove water and oxidise organic material contained therein, comprising controlling the temperature of the residuals during heating such that they are heated to a temperature no higher than 800° C., more preferably no higher than 650° C., to ensure that aluminium compounds in the WTR, in particular aluminium oxide and aluminium hydroxide, remain in an amorphous state. The method may comprise controlling the temperature of the water treatment residuals such that they are heated to a temperature between 350° C. and 650° C., more preferably between 400° C. and 500° C.

A method for processing water treatment residuals, or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals, for use in the manufacture of hydraulic binders, comprising heating the residuals to remove water and oxidise organic material contained therein, comprising controlling the temperature of the residuals during heating such that they are heated to a temperature no higher than 800° C., more preferably no higher than 650° C., to ensure that aluminium compounds in the WTR, in particular aluminium oxide and aluminium hydroxide, remain in an amorphous state. The method may comprise controlling the temperature of the water treatment residuals such that they are heated to a temperature between 350° C. and 650° C., more preferably between 400° C. and 500° C.

A method of forming a lightweight polished concrete and the resulting composition. Calcium sulfoaluminate (CSA) cement and specialized grout may be added to an amount of water in a mixer. The CSA cement, specialized grout, and water may be blended to a smooth consistency. Lightweight aggregates (LWA) may be added to the blended CSA cement, specialized grout, and water to form a mixture. The mixture may be poured over a fiberglass rebar, vibrated, screeded, and allowed to set. The set mixture may be smoothed with float blades. The smoothed mixture may be hardened with metal blades, such that the hardened mixture becomes reflective. A concrete densifier may be applied to the hardened mixture to form the lightweight polished concrete. Optionally, one or more saw cuts may be formed in the lightweight polished concrete and a coating to may be applied to fill the one or more saw cuts.

A method of forming a lightweight concrete block and the resulting structure. Calcium sulfoaluminate (CSA) cement and specialized grout maybe added to an amount of water in a mixer. The CSA cement, specialized grout, and water may be blended to a smooth consistency. Lightweight aggregates (LWA) maybe added to form a mixture. The mixture may be poured into a mold, allowed the mixture to cure, and removed from the mold to form the lightweight concrete block. The lightweight concrete block may have a first side and a second side joined by a plurality of interposing walls, the interposing walls defining one or more inner cavities and one or more outer cavities. The lightweight concrete block may have features that allow for the insertion of fiberglass rebar to aide in stacking and filling to form a wall.

A method of forming a lightweight concrete comprising lightweight aggregates (LWA) made from recycled materials and the resulting composition. The lightweight concrete may be formed by adding calcium sulfoaluminate (CSA) cement and a specialized grout to an amount of water in a mixer, wherein a ratio of the water to the CSA cement is 1 quart to every 10 lbs of CSA cement. The CSA cement, specialized grout, and water may be blended to a smooth consistency. LWA may be added to the blended CSA cement, specialized grout, and water, wherein a ratio of the CSA cement to LWA is 60/40 by weight. The mixture of LWA, CSA cement, specialized grout, and water may be poured over a fiberglass rebar. The mixture may be allowed to cure and before being densified with a lithium densifier.

A method of making a supplementary cementitious material is described that includes: forming a slurry comprising water and a carbonatable material powder, wherein a weight ratio of water to the carbonatable material powder is at least 1; and flowing a gas comprising carbon dioxide into the slurry for 0.5 to 24 hours while maintaining the slurry at a temperature of 1° C. to 99° C. to form a carbonated slurry comprising CaCO.sub.3 and amorphous silica. A method of forming cement or concrete using the supplemental cementitious material is also described.

A raw meal and clinker are provided based on animal by-products, such as bone ash. The resulting cement contains clinker phases such as: tricalcium phosphate (TCP), calcium sulfoaluminate (CSA), calcium aluminate phases (CA, CA.sub.2, CA.sub.6, C.sub.12A.sub.7, among others), hydroxyapatite (HA), and minor phases (anhydrite, lime, among others).

A raw meal and clinker are provided based on animal by-products, such as bone ash. The resulting cement contains clinker phases such as: tricalcium phosphate (TCP), calcium sulfoaluminate (CSA), calcium aluminate phases (CA, CA.sub.2, CA.sub.6, C.sub.12A.sub.7, among others), hydroxyapatite (HA), and minor phases (anhydrite, lime, among others).