초록 ▼

The present invention describes an improved building material composition, useful for example as a fire door core and to improved methods of making this composition. The building material of the present invention consists essentially of expanded perlite, a fireproof binder, clay or vermiculite, and

The present invention describes an improved building material composition, useful for example as a fire door core and to improved methods of making this composition. The building material of the present invention consists essentially of expanded perlite, a fireproof binder, clay or vermiculite, and optionally diatomaceous earth, one or more viscosity-enhancing components, reinforcement fibers, and a plasticizer or mixtures thereof. The method of making this improved composition is a semi-continuous batch press method wherein at least the expanded perlite, fireproof binder, and clay or vermiculite are mixed; the mixture compressed in a mold, and the compressed mixture dried.

대표청구항 ▼

The present invention describes an improved building material composition, useful for example as a fire door core and to improved methods of making this composition. The building material of the present invention consists essentially of expanded perlite, a fireproof binder, clay or vermiculite, and

The present invention describes an improved building material composition, useful for example as a fire door core and to improved methods of making this composition. The building material of the present invention consists essentially of expanded perlite, a fireproof binder, clay or vermiculite, and optionally diatomaceous earth, one or more viscosity-enhancing components, reinforcement fibers, and a plasticizer or mixtures thereof. The method of making this improved composition is a semi-continuous batch press method wherein at least the expanded perlite, fireproof binder, and clay or vermiculite are mixed; the mixture compressed in a mold, and the compressed mixture dried. al of claim 6, wherein the mix comprises, by weight, from about 30% to about 40% coal processing waste and from about 60% to about 70% of a coal combustion by-product selected from the group consisting of Class F-fly ash, Class C-fly ash, ponded fly ash, fluidized bed combustion ash, wet scrubber sludge, and mixtures thereof. 9. The fill material of claim 1, wherein the fill material comprises, by weight, from about 30% to about 40% coal processing waste; from about 20% to about 25% lime waste; and from about 35% to about 55% of a coal combustion by-product selected from the group consisting of Class F-fly ash, Class C-fly ash, ponded fly ash, fluidized bed combustion ash, wet scrubber sludge, and mixtures thereof. 10. The fill material mix of claim 6, wherein the acid/base potential is lower than about 1/2. 11. The fill material mix of claim 10, wherein the acid/base potential is lower than about 1/4. 12. The fill material mix of claim 11, wherein the acid/base potential is lower than about 1/7. 13. The fill material mix of claim 12, wherein the acid/base potential is lower than about 1/10. 14. The fill material of claim 1, wherein the fill material is a mortar and further comprises water in an amount sufficient to permit curing of the mixture. 15. The fill material of claim 14, wherein the amount of by-product composition in the mortar is sufficient to provide that the mortar has an acid/base potential of 1/1 or less. 16. The fill material of claim 15, wherein the mortar comprises from about 25% to about 60% coal processing waste and about 40% to about 75% of the by-product composition, in percent by weight of solids, and from about 30% to about 50% of water, in percent by weight of the mortar. 17. The fill material of claim 16, wherein the mortar comprises from about 30% to about 45% coal processing waste and about 55% to about 70% of the by-product composition, in percent by weight of solids, and from about 32% to about 42% of water, in percent by weight of the mortar. 18. The fill material of claim 17, wherein the mortar comprises from about 30% to about 40% coal processing waste and from about 60% to about 70% of a coal combustion by-product selected from the group consisting of Class F-fly ash, Class C-fly ash, ponded fly ash, fluidized bed combustion ash, wet scrubber sludge, and mixtures thereof, in percent by weight of solids, and from about 32% to about 42% of water, in percent by weight of the mortars. 19. The fill material of claim 18, wherein the mortar comprises from about 30% to about 40% coal processing waste; from about 20% to about 25% lime waste; and from about 35% to about 55% of a coal combustion by-product selected from the group consisting of Class F-fly ash, Class C-fly ash, ponded fly ash, fluidized bed combustion ash, wet scrubber sludge, and mixtures thereof, in percent by weight of solids, and from about 34% to about 42% of water, in percent by weight of the mortar. 20. A cured fill material comprising a cured product of the fill material of claim 14. 21. The cured fill material of claim 20, wherein the cured product has an acid/base potential of 1/1, or lower. 22. The cured fill material of claim 21, wherein the cured fill material comprises a cured product of a mixture of from about 30% to about 40% coal processing waste; from about 20% to about 25% lime waste; and from about 35% to about 55% of a coal combustion by-product selected from the group consisting of Class F-fly ash, Class C-fly ash, ponded fly ash, fluidized bed combustion ash, wet scrubber sludge, and mixtures thereof, in percent by weight of the solids, and from about 34% to about 42% of water, in percent by weight of the mixture. 23. The fill material of claim 22, wherein the fill material develops a strength of at least about 20 psi, as measured by a pocket penetrometer, within three days. 24. The fill material of claim 23, wherein the fill material develops a strength of at least about 60 psi, as measured by a pocket penetrometer