Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO.sub.2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.

The present invention relates to fabricating lightweight ceramic sand as a building and construction material. More specifically it relates to a novel process of manufacturing sintered synthetic lightweight ceramic sand particulates directly from pond ash and fly ash as a secondary raw material. The said synthetic lightweight ceramic sand can be used as a building material. The novel feature of the invention is to manufacture low cost lightweight sand at high throughput to compete against the fast depleting natural sand and crushed stones.

The present invention relates to fabricating lightweight ceramic sand as a building and construction material. More specifically it relates to a novel process of manufacturing sintered synthetic lightweight ceramic sand particulates directly from pond ash and fly ash as a secondary raw material. The said synthetic lightweight ceramic sand can be used as a building material. The novel feature of the invention is to manufacture low cost lightweight sand at high throughput to compete against the fast depleting natural sand and crushed stones.

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 synergistic disposal method of hazardous waste incineration residues and solid wastes, ceramsite and an application thereof, all belonging to the field of resources and environment. The disposal method includes the following steps: mixing of the hazardous waste incineration residues and solid wastes, granulation and dehydration of the resulting mixture and calcination to obtain ceramsite. In the preparation of ceramsite by the synergistic disposal of hazardous waste incineration residues and solid wastes as the raw materials, dioxin and organic matters in the hazardous waste incineration residues and solid wastes are decomposed, meanwhile the contained heavy metals are reduced and solidified, solving the disposal problem of hazardous waste incineration residues and solid wastes, saving a lot of land for landfills, decreasing the cost for comprehensive disposal, not producing new hazardous wastes, and reducing the burden of ecological environment.

A synergistic disposal method of hazardous waste incineration residues and solid wastes, ceramsite and an application thereof, all belonging to the field of resources and environment. The disposal method includes the following steps: mixing of the hazardous waste incineration residues and solid wastes, granulation and dehydration of the resulting mixture and calcination to obtain ceramsite. In the preparation of ceramsite by the synergistic disposal of hazardous waste incineration residues and solid wastes as the raw materials, dioxin and organic matters in the hazardous waste incineration residues and solid wastes are decomposed, meanwhile the contained heavy metals are reduced and solidified, solving the disposal problem of hazardous waste incineration residues and solid wastes, saving a lot of land for landfills, decreasing the cost for comprehensive disposal, not producing new hazardous wastes, and reducing the burden of ecological environment.

A cement-based material is formed from a mixture that includes cement in the range of about 40 to 90% by wet weight percent, a lightweight expanded aggregate in the range of about 10 to 60% by wet weight percent, a secondary material in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 1 to 20% by wet weight percent, a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent, a retarder in the range of about 0.1 to 8% by wet weight percent, and water in the range of 10 to 60% of a total wet material weight.

An energy-saving building system using a porous silicate material for thermal insulation, comprises a foundation, a retaining wall body, and a roof system. The foundation comprises a ground ring beam and columns, and a porous silicate thermal insulation material is cast around the ground ring beam and the columns; the porous silicate thermal insulation material is composed of an organic lightweight aggregate and a lightweight inorganic matrix, and the lightweight inorganic matrix is provided thereon with a plurality of micropores; the retaining wall body comprises an outer wall disposed on the ground ring beam, the outer wall comprises an outer side support body, an inner side support body, and the porous silicate thermal insulation material cast between the inner and outer side support bodies, and the outer side support body and the inner side support body are connected therebetween by means of a heat insulating connection member.