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USRE30943E - Stabilized mixture - Google Patents

Stabilized mixture Download PDF

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Publication number
USRE30943E
USRE30943E US06/068,412 US6841279A USRE30943E US RE30943 E USRE30943 E US RE30943E US 6841279 A US6841279 A US 6841279A US RE30943 E USRE30943 E US RE30943E
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fly ash
kiln dust
cement kiln
per
cement
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US06/068,412
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John P. Nicholson
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Nicholson Realty Ltd
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Nicholson Realty Ltd
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Priority claimed from US05/654,211 external-priority patent/US4018617A/en
Priority claimed from US05/765,837 external-priority patent/US4101332A/en
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Priority to US06/068,412 priority Critical patent/USRE30943E/en
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04Portland cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
    • C04B18/16Waste materials; Refuse from building or ceramic industry
    • C04B18/162Cement kiln dust; Lime kiln dust
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates to materials which are capable of supporting surfacing such as pavement bases.
  • the base for the surfacing material should comprise a granular or gravel base.
  • cement-aggregate or bituminous (asphalt)-aggregate bases As reported in the Highway Research Board Special Report 61E, titled The AASHO Road Test, Report 5, Pavement Research, publication 954 of National Academy of Sciences-National Research Council, there is a clear superiority of such treated bases over untreated bases. In recent years, treated bases have become commonly known as stabilized bases.
  • Asphalt stabilized bases have become the most dominant stabilized base utilized to support a flexible surfacing such as asphalt concrete.
  • asphalt concrete has found extensive use as a resurfacing material for concrete pavement.
  • a lime-fly ash-aggregate stabilized base be used in road paving.
  • Such a base consists of a mixture of proper quantities of lime, fly ash, and graded aggregate at optimum moisture content, in which the stability is greatly enhanced by the cementing action which results from complex chemical reactions between the lime and the fly ash in the presence of water.
  • Stabilized bases are usually employed as base courses under wearing surfaces such as hot mixed, hot laid asphaltic concrete. A wearing surface is necessary to resist the high shearing stresses which are caused by traction, but the stabilized base provides the required stability to support wheel loads.
  • a serious obstacle to the expanded use of stabilized bases is the high energy costs for making the materials.
  • portland cement which is used in stabilizing bases requires substantial quantities of coal in manufacture.
  • United States Department of Transportation has suggested that fly ash be substituted for a portion of the portland cement utilized in concrete or cement-aggregate bases, Federal Highway Administration Notice N5080.4, Jan. 17, 1974.
  • asphalt-aggregate bases which is derived from petroleum processing not only utilizes petroleum which is in short supply but also requires high energy to produce them.
  • the lime, fly ash and graded aggregate stabilized bases utilize lime which requires coal in production.
  • Such bases have been used in limited geographical areas of the United States where they can compete economically because of availability of lime and fly ash.
  • the predominantly used stabilized bases utilize materials that are in short supply and require substantial quantities of energy to produce them.
  • the materials may be termed energy intensive. There is a need to avoid or minimize the use of such energy intensive materials in road paving.
  • the objects of the invention are to provide a mixture of materials for producing a stabilized base comprising a hard, strong, durable mass capable of supporting surfacing which avoids or minimizes the use of materials which are energy intensive and, moreover, utilizes materials that normally are waste materials that are readily available.
  • the mixture consists essentially of fly ash and cement kiln dust which reacts at ambient temperature with water to produce a durable mass.
  • FIGS. 1-3 are curves of compressive strength versus age at test for various compositions.
  • FIG. 4 is curves of energy requirements for various pavement materials.
  • the pozzolanic load supporting composition utilizes cement kiln dust.
  • the solid waste generated by cement manufacture is primarily kiln dust.
  • This dust contains a mixture of raw kiln feed, partly calcined material, finely divided cement klinker and alkali sulfates (usually sulfates).
  • alkali sulfates usually sulfates.
  • typical cement kiln dust may have the following analyses:
  • finely ash as used in connection with stabilized bases is well known and as used herein is intended to indicate the finely divided ash residue produced by the combustion of pulverized coal or lignite, which ash is carried off with the gases exhausted from the furnace in which the coal is burned and which is collected from these gases usually by means of suitable precipitation apparatus such as electrical precipitators.
  • suitable precipitation apparatus such as electrical precipitators.
  • Those finely pulverized ashes resulting from combustion of oil and from combustion of waste materials in a large incinerator or natural pozzolans can also be utilized in the methods described herein providing their chemical compositions are reasonably similar to pulverized coal fly ashes.
  • fly ash so obtained is in a finely divided state such that usually at least 70% by weight passes through a 200-mesh sieve, although incinerator ashes may be considerably coarser. Fly ash may be considered an "artificial pozzolan", as distinguished from a "natural pozzolan”.
  • aggregate as used in connection with load supporting compositions is also well known and refers to natural or artificial inorganic materials most of which are substantially chemically inert with respect to fly ash and lime, and substantially insoluble in water.
  • aggregate may comprise limestone, sand, blast furnace slag, gravel, synthetic aggregate and other similar material.
  • Aggregates can comprise a wide range of types and gradations, including sands, gravels, crushed stones, and several types of slag. Aggregates should be of such gradation that, when mixed with cement kiln dust, fly ash and water, the resulting mixture is mechanically stable under compaction equipment and capable of being compacted in the field to high density.
  • the aggregate should be free from deleterious organic or chemical substances which may interfere with the desired chemical reaction between the cement kiln dust, fly ash and water. Further, the aggregate should preferably consist of hard, durable particles, free from soft or disintegrated pieces.
  • a preferable mixture comprises:
  • mixture for use in road stabilizer bases may preferably vary as follows:
  • test specimens were molded using a mechanical compactor, having a 10 pound hammer with an 18 inch drop.
  • the material was placed in the molds in three equal layers, and compacted by 25 blows per layer.
  • the machine has a revolving turntable to evenly distribute the blows over the surface of the layer being compacted.
  • the samples were carefully removed from the molds, weighed, and sealed in plastic bag, labeled for identification, and placed in a constant temperature oven at 100° F. to cure until tested. Two cylinders of each mix were marked for testing at 7, 14 and 28 days of curing. After removal from the oven, the samples are submerged in water for four hours, removed, and allowed to drain on a non-absorbant surface, capped, and tested within one hour after removal from the water.
  • the capping compound used is "Hydro-Stone" a lime based, quick-hardening compound. Plate glass was used to obtain even, parallel caps on the test specimens.
  • mixtures containing cement kiln dust vary but in each instant produce a base that is stabilized.
  • additives or admixtures generally do not affect the strength except that a retarder tends to prevent the early development of strength as might be expected.
  • the strength of mixtures including cement kiln dust compare favorably with a lime, fly ash, aggregate mixture.
  • even a mixture of cement kiln dust and fly ash produces a stabilized base.
  • the mixtures of the present invention result in a stabilized base that is comparable in strength and required performance characteristics to cement-aggregate or lime-fly ash-aggregate stabilized bases and yet are not energy intensive.
  • the mixtures of the present invention cost less than the predominantly used asphalt-aggregate bases.
  • the use of mixtures of the invention releases asphalt for use in resurfacing or as a heavy industrial fuel.
  • FIG. 4 is a curve showing the BTU's per mile versus thickness for various road paving materials taken from Highway Research Circular titled "Fuel Usage Factors for Highway Construction", Number 158, July, 1974. It ca be seen that asphalt concrete and cement type mixtures require substantial energy and only granular base or sub-base of aggregate has minimal energy requirements in hauling, spreading, compacting and finishing. Since the mixtures of the present invention utilize waste materials, namely, cement kiln dust and fly ash, the energy requirements for making a stabilized base are only in hauling, spreading, compacting and finishing.
  • the mixtures of the present invention have minimal energy requirements and thereby obviate the energy intensive materials or prior stabilized bases.
  • the mixtures of the present invention utilize cement kiln dust which is a waste product that is relatively available from cement plants and fly ash which is readily available from power plants.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Civil Engineering (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Treating Waste Gases (AREA)
  • Developing Agents For Electrophotography (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)

Abstract

A mixture consisting essentially of fly ash and cement kiln dust which reacts at ambient temperature with water to produce a durable mass.

Description

This application is a division of application Ser. No. 654,211, filed Feb. 2, 1976, now U.S. Pat. No. 4,018,617.
This invention relates to materials which are capable of supporting surfacing such as pavement bases.
BACKGROUND OF THE INVENTION
In road paving, at one time it was thought that the base for the surfacing material should comprise a granular or gravel base. However, more recently, it has been concluded that there was a considerable difference in the performance between such bases and cement-aggregate or bituminous (asphalt)-aggregate bases. As reported in the Highway Research Board Special Report 61E, titled The AASHO Road Test, Report 5, Pavement Research, publication 954 of National Academy of Sciences-National Research Council, there is a clear superiority of such treated bases over untreated bases. In recent years, treated bases have become commonly known as stabilized bases.
In subsequent work, for example, use of asphalt mixtures in all courses of pavement above the subgrade has been proposed, The Asphalt Institute, Information Series No. 146, June 1968. Asphalt stabilized bases have become the most dominant stabilized base utilized to support a flexible surfacing such as asphalt concrete. In addition, asphalt concrete has found extensive use as a resurfacing material for concrete pavement.
It has also been proposed that a lime-fly ash-aggregate stabilized base be used in road paving. Such a base consists of a mixture of proper quantities of lime, fly ash, and graded aggregate at optimum moisture content, in which the stability is greatly enhanced by the cementing action which results from complex chemical reactions between the lime and the fly ash in the presence of water.
Stabilized bases are usually employed as base courses under wearing surfaces such as hot mixed, hot laid asphaltic concrete. A wearing surface is necessary to resist the high shearing stresses which are caused by traction, but the stabilized base provides the required stability to support wheel loads.
A serious obstacle to the expanded use of stabilized bases is the high energy costs for making the materials.
For example, it is well known that the production of portland cement which is used in stabilizing bases requires substantial quantities of coal in manufacture. In fact, the United States Department of Transportation has suggested that fly ash be substituted for a portion of the portland cement utilized in concrete or cement-aggregate bases, Federal Highway Administration Notice N5080.4, Jan. 17, 1974.
The use of asphalt in asphalt-aggregate bases which is derived from petroleum processing not only utilizes petroleum which is in short supply but also requires high energy to produce them.
Similarly, the lime, fly ash and graded aggregate stabilized bases utilize lime which requires coal in production. Such bases have been used in limited geographical areas of the United States where they can compete economically because of availability of lime and fly ash.
Thus, the predominantly used stabilized bases utilize materials that are in short supply and require substantial quantities of energy to produce them. The materials may be termed energy intensive. There is a need to avoid or minimize the use of such energy intensive materials in road paving.
Accordingly, among the objects of the invention are to provide a mixture of materials for producing a stabilized base comprising a hard, strong, durable mass capable of supporting surfacing which avoids or minimizes the use of materials which are energy intensive and, moreover, utilizes materials that normally are waste materials that are readily available.
SUMMARY OF THE INVENTION
In accordance with the invention, the mixture consists essentially of fly ash and cement kiln dust which reacts at ambient temperature with water to produce a durable mass.
DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 are curves of compressive strength versus age at test for various compositions.
FIG. 4 is curves of energy requirements for various pavement materials.
DESCRIPTION
In accordance with the invention, the pozzolanic load supporting composition utilizes cement kiln dust.
The solid waste generated by cement manufacture is primarily kiln dust. This dust contains a mixture of raw kiln feed, partly calcined material, finely divided cement klinker and alkali sulfates (usually sulfates). There is economic value in returning the dust to the kiln, but when the alkali content of the returned dust is too high for the product klinker to meet specifications, the dust must be discarded. Up to about 15% of the raw materials processed may be collected as dust and of this about half may be low enough in alkalis to be returned to the kiln. The rest is usually stockpiled as a waste material which must be disposed and may be a nuisance and possibly a hazard.
Although the chemical reactions occurring in the resultant cement kiln dust are not well known, typical cement kiln dust has a chemical analysis as follows:
SiO2
Al2 O3
Fe2 O3
CaO
MgO
SO3
Na2 O
K2 O
Loss Ignition
More specifically, typical cement kiln dust may have the following analyses:
__________________________________________________________________________
      Source                                                              
          Source                                                          
              Source                                                      
                  Source                                                  
                      Source                                              
                          Source                                          
                              Source                                      
                                  Source                                  
                                      Source                              
                                          Mid-                            
Ingredient                                                                
      A   B   C   D   E   F   G   H   I   Range                           
__________________________________________________________________________
SiO.sub.2                                                                 
      28.5%                                                               
          6.0%                                                            
              22.4%                                                       
                  11.2%                                                   
                      13.0%                                               
                          23.5%                                           
                              14.8%                                       
                                  14.6%                                   
                                      14.7%                               
                                          17.2%                           
Al.sub.2 O.sub.3                                                          
      9.6 3.4 4.71                                                        
                  3.2 4.0 3.77                                            
                              3.4 3.4 3.7 6.4                             
Fe.sub.2 O.sub.3                                                          
      5.9 0.8 1.77                                                        
                  1.4 5.0 1.71                                            
                              2.2 2.2 3.0 3.4                             
CaO   50.1                                                                
          16.0                                                            
              65.0                                                        
                  48.8                                                    
                      47.2                                                
                          61.3                                            
                              47.3                                        
                                  46.3                                    
                                      46.5                                
                                          40.5                            
MgO   3.4 0.8 2.60                                                        
                  2.1 1.2 4.83                                            
                              2.1 2.0 2.0 2.8                             
SO.sub.3                                                                  
      26.3                                                                
          0.7 1.12                                                        
                  2.4 13.6                                                
                          1.48                                            
                              4.8 5.0 8.2 13.5                            
Na.sub.2 O                                                                
      3.18                                                                
          0.08                                                            
              0.24                                                        
                  0.2 0.45                                                
                          0.24                                            
                              0.9 0.9 0.8 1.6                             
K.sub.2 O                                                                 
      26.23                                                               
          1.08                                                            
              1.3 4.2 2.9 1.85                                            
                              4.1 5.1 3.0 13.7                            
Loss on                                                                   
Ignition                                                                  
      32.0%                                                               
          7.7%                                                            
              2.50%                                                       
                  26.6%                                                   
                      12.9%                                               
                          1.84%                                           
                              21.1%                                       
                                  21.4%                                   
                                      18.2%                               
                                          17.2%                           
__________________________________________________________________________
______________________________________                                    
RANGE                                                                     
Ingredient                                                                
        Low %       High %      Average %                                 
______________________________________                                    
SiO.sub.2                                                                 
        6.0         28.5        16.5                                      
Al.sub.2 O.sub.3                                                          
        3.2         9.6         4.35                                      
Fe.sub.2 O.sub.3                                                          
        0.8         5.9         2.66                                      
CaO     16.0        65.0        47.6                                      
MgO     0.8         4.83        2.34                                      
SO.sub.3                                                                  
        0.7         26.3        7.07                                      
Na.sub.2 O                                                                
        0.08        3.18        0.78                                      
K.sub.2 O                                                                 
        1.08        26.23       5.52                                      
Loss on                                                                   
Ignition                                                                  
        2.50        32.0        16.0                                      
______________________________________                                    
When mixtures made in accordance with the invention and mixed with water to produce a pozzolanic reaction have been tested in accordance with the specifications given in ASTM C-593 for fly ash and other pozzolans for use with lime, it has been found that the compositions meet or exceed the specifications.
The term "fly ash" as used in connection with stabilized bases is well known and as used herein is intended to indicate the finely divided ash residue produced by the combustion of pulverized coal or lignite, which ash is carried off with the gases exhausted from the furnace in which the coal is burned and which is collected from these gases usually by means of suitable precipitation apparatus such as electrical precipitators. Those finely pulverized ashes resulting from combustion of oil and from combustion of waste materials in a large incinerator or natural pozzolans can also be utilized in the methods described herein providing their chemical compositions are reasonably similar to pulverized coal fly ashes. The fly ash so obtained is in a finely divided state such that usually at least 70% by weight passes through a 200-mesh sieve, although incinerator ashes may be considerably coarser. Fly ash may be considered an "artificial pozzolan", as distinguished from a "natural pozzolan".
The term "aggregate" as used in connection with load supporting compositions is also well known and refers to natural or artificial inorganic materials most of which are substantially chemically inert with respect to fly ash and lime, and substantially insoluble in water. Typically, aggregate may comprise limestone, sand, blast furnace slag, gravel, synthetic aggregate and other similar material.
Aggregates can comprise a wide range of types and gradations, including sands, gravels, crushed stones, and several types of slag. Aggregates should be of such gradation that, when mixed with cement kiln dust, fly ash and water, the resulting mixture is mechanically stable under compaction equipment and capable of being compacted in the field to high density. The aggregate should be free from deleterious organic or chemical substances which may interfere with the desired chemical reaction between the cement kiln dust, fly ash and water. Further, the aggregate should preferably consist of hard, durable particles, free from soft or disintegrated pieces.
It has been found that a preferable mixture comprises:
______________________________________                                    
              Percent by                                                  
              Dry Weight                                                  
______________________________________                                    
Cement Kiln Dust                                                          
                8.0%                                                      
Fly Ash         12.0%                                                     
Aggregate       80.0%                                                     
Total           100.0%                                                    
______________________________________                                    
However, the mixture for use in road stabilizer bases may preferably vary as follows:
______________________________________                                    
              Percent By                                                  
              Dry Weight                                                  
______________________________________                                    
Cement Kiln Dust                                                          
                 4-16%                                                    
Fly Ash         6-24%                                                     
Aggregate       60-90%                                                    
______________________________________                                    
As indicated above, tests were conducted in accordance with ASTM C-593. More specifically, the test specimens were molded using a mechanical compactor, having a 10 pound hammer with an 18 inch drop. The material was placed in the molds in three equal layers, and compacted by 25 blows per layer. The machine has a revolving turntable to evenly distribute the blows over the surface of the layer being compacted.
After molding, the samples were carefully removed from the molds, weighed, and sealed in plastic bag, labeled for identification, and placed in a constant temperature oven at 100° F. to cure until tested. Two cylinders of each mix were marked for testing at 7, 14 and 28 days of curing. After removal from the oven, the samples are submerged in water for four hours, removed, and allowed to drain on a non-absorbant surface, capped, and tested within one hour after removal from the water. The capping compound used is "Hydro-Stone" a lime based, quick-hardening compound. Plate glass was used to obtain even, parallel caps on the test specimens.
Examples of various tests and compositions are as follows:
                                  EXAMPLE I                               
__________________________________________________________________________
                                        Weight of                         
                         Percent        Batch                             
__________________________________________________________________________
          Cement Kiln Dust                                                
                         8.0%            2.4#                             
          Fly Ash        12.0%           3.6#                             
          Limestone      80.0%          24.0#                             
          Total          100.0%         30.0#                             
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As   Wet Wt.                                                
                         Dry Wt.                                          
                               Area Date                                  
                                        Mach.                             
No.  Water                                                                
          Molded (Lbs.)                                                   
                   Per Cu. Ft.                                            
                         Per Cu. Ft.                                      
                               (Sq. In.)                                  
                                    Tested                                
                                        Load                              
                                            P.S.I.                        
__________________________________________________________________________
A    10.8 4.73     141.9 128.1 12.57                                      
                                    10-16                                 
                                        13,140                            
                                            1050                          
B    10.8 4.72     141.6 127.8 12.57                                      
                                    10-16                                 
                                        14,370                            
                                            1140                          
C    10.8 4.73     141.9 128.1 12.57                                      
                                    10-23                                 
                                        15,780                            
                                            1260                          
D    10.8 4.73     141.9 128.1 12.57                                      
                                    10-23                                 
                                        15,530                            
                                            1240                          
E    10.8 4.73     141.9 128.1 12.57                                      
                                    11-06                                 
                                        17,800                            
                                            1420                          
F    10.8 4.73     141.9 128.1 12.57                                      
                                    11-06                                 
                                        17,800                            
                                            1420                          
__________________________________________________________________________
 Remarks:                                                                 
 Slight bleeding at bottom of mold.                                       
                                  EXAMPLE II                              
__________________________________________________________________________
                                        Weight of                         
                         Percent        Batch                             
__________________________________________________________________________
          Cement Kiln Dust                                                
                          8.0%          2.4#                              
          Fly Ash        12.0%          3.6#                              
          Limestone      80.0%          24.0#                             
          Retarder       --             0.96 oz                           
          Total          100.0%         30.0#                             
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As   Wet Wt.                                                
                         Dry Wt.                                          
                               Area Date                                  
                                        Mach.                             
No.  Water                                                                
          Molded (Lbs.)                                                   
                   Per Cu. Ft.                                            
                         Per Cu. Ft.                                      
                               (Sq. In.)                                  
                                    Tested                                
                                        Load                              
                                            P.S.I.                        
__________________________________________________________________________
A    10.1 4.73     141.9 128.9 12.57                                      
                                    10-16                                 
                                        --  --                            
B    10.1 4.73     141.9 128.9 12.57                                      
                                    10-16                                 
                                        --  --                            
C    10.2 4.73     141.9 128.8 12.57                                      
                                    10-23                                 
                                        1,650                             
                                            130                           
D    10.2 4.73     141.9 128.8 12.57                                      
                                    10-23                                 
                                        1,930                             
                                            150                           
E    10.3 4.73     141.9 128.6 12.57                                      
                                    11-06                                 
                                        2,300                             
                                            180                           
F    10.3 4.73     141.9 128.6 12.57                                      
                                    11-06                                 
                                        2,100                             
                                            170                           
__________________________________________________________________________
 Remarks:                                                                 
 Slight bleeding.                                                         
 Samples 2A and 2B fell apart during the four (4) hour soaking. There was 
 no intact sample to subject to the compression test.                     
 Samples C, D, E, and F were not subjected to the four (4) hour soaking,  
 prior to testing.                                                        
                                  EXAMPLE III                             
__________________________________________________________________________
                                        Weight of                         
                         Percent        Batch                             
__________________________________________________________________________
       Cement Kiln Dust   8.0%          2.4#                              
       Fly Ash           12.0%          3.6#                              
       Limestone         80.0%          24.0#                             
       Calcium Chloride Solution                                          
                         --             (0.24#)                           
       Total             100.0%         30.0#                             
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As   Wet Wt.                                                
                         Dry Wt.                                          
                               Area Date                                  
                                        Mach.                             
No.  Water                                                                
          Molded (Lbs.)                                                   
                   Per Cu. Ft.                                            
                         Per Cu. Ft.                                      
                               (Sq. in.)                                  
                                    Tested                                
                                        Load                              
                                            P.S.I.                        
__________________________________________________________________________
A    10.4 4.77     143.1 129.6 12.57                                      
                                    10-16                                 
                                        15,160                            
                                            1210                          
B    10.4 4.77     143.1 129.6 12.57                                      
                                    10-16                                 
                                        15,750                            
                                            1250                          
C    10.0 4.73     141.9 129.0 12.57                                      
                                    10-23                                 
                                        17,250                            
                                            1370                          
D     9.9 4.73     141.9 129.1 12.57                                      
                                    10-23                                 
                                        18,950                            
                                            1510                          
E     9.8 4.73     141.9 129.2 12.57                                      
                                    11-06                                 
                                        20,600                            
                                            1640                          
F     9.7 4.72     141.6 129.1 12.57                                      
                                    11-06                                 
                                        20,700                            
                                            1650                          
__________________________________________________________________________
 Remarks:                                                                 
 Slight bleeding                                                          
                                  EXAMPLE IV                              
__________________________________________________________________________
                                        Weight of                         
                         Percent        Batch                             
__________________________________________________________________________
          Cement Kiln Dust                                                
                         8.0%           2.4#                              
          Stack Dust     3.0%           0.9#                              
          Fly Ash        12.0%          3.6#                              
          Limestone      77.0%          23.1#                             
          Total          100.0%         30.0#                             
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As   Wet Wt.                                                
                         Dry Wt.                                          
                               Area Date                                  
                                        Mach.                             
No.  Water                                                                
          Molded (Lbs.)                                                   
                   Per Cu. Ft.                                            
                         Per Cu. Ft.                                      
                               (Sq. In.)                                  
                                    Tested                                
                                        Load                              
                                            P.S.I.                        
__________________________________________________________________________
A    8.5  4.53     135.9 125.3 12.57                                      
                                    10-17                                 
                                         8,200                            
                                            652                           
B    8.5  4.54     136.2 125.5 12.57                                      
                                    10-17                                 
                                         8,900                            
                                            708                           
C    8.7  4.58     137.4 126.4 12.57                                      
                                    10-24                                 
                                        10,950                            
                                            871                           
D    8.8  4.56     136.8 125.7 12.57                                      
                                    10-24                                 
                                        11,775                            
                                            937                           
E    9.0  4.58     137.4 126.1 12.57                                      
                                    11-07                                 
                                        16,050                            
                                            1280                          
F    9.0  4.56     136.8 125.5 12.57                                      
                                    11-07                                 
                                        14,850                            
                                            1180                          
__________________________________________________________________________
 Remarks:                                                                 
 No bleeding.                                                             
                                  EXAMPLE V                               
__________________________________________________________________________
                                        Weight of                         
                         Percent        Batch                             
__________________________________________________________________________
          Cement Kiln Dust                                                
                         12.0%          3.6#                              
          Fly Ash        88.0%          26.4#                             
          Total          100.0%         30.0#                             
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As   Wet Wt.                                                
                         Dry Wt.                                          
                               Area Date                                  
                                        Mach.                             
No.  Water                                                                
          Molded (Lbs.)                                                   
                   Per Cu. Ft.                                            
                         Per Cu. Ft.                                      
                               (Sq. In.)                                  
                                    Tested                                
                                        Load                              
                                            P.S.I.                        
__________________________________________________________________________
A    9.5  2.87     86.1  78.6  12.57                                      
                                    10-17                                 
                                        2,350                             
                                            187                           
B    9.7  2.90     87.0  79.3  12.57                                      
                                    10-17                                 
                                        2,300                             
                                            183                           
C    9.7  2.90     87.0  79.3  12.57                                      
                                    10-24                                 
                                        2,075                             
                                            165                           
D    9.7  2.90     87.0  79.3  12.57                                      
                                    10-24                                 
                                        1,900                             
                                            151                           
E    9.7  2.90     87.0  79.3  12.57                                      
                                    11-07                                 
                                        3,040                             
                                            240                           
F    10.0 2.96     88.8  80.7  12.57                                      
                                    11-07                                 
                                        3,230                             
                                            260                           
__________________________________________________________________________
 Remarks:                                                                 
 Had difficulty in reaching the desired moisture content because of the   
 dust's extremely dry condition. Extremely "fluffy" material.             
                                  EXAMPLE VI                              
__________________________________________________________________________
                                        Weight of                         
                         Percent        Batch                             
__________________________________________________________________________
Cement Kiln Dust         8.0%           2.4#                              
Fly Ash                  8.0%           2.4#                              
Limestone                79.0%          23.7#                             
Limestone Fines          5.0%           1.5#                              
Total                    100.0%         30.0#                             
Water added: 1158 + 136 = 1294                                            
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As   Wet Wt.                                                
                         Dry Wt.                                          
                               Area Date                                  
                                        Mach.                             
No.  Water                                                                
          Molded (Lbs.)                                                   
                   Per Cu. Ft.                                            
                         Per Cu. Ft.                                      
                               (Sq. In.)                                  
                                    Tested                                
                                        Load                              
                                            P.S.I.                        
__________________________________________________________________________
A    9.8  4.85     145.5 132.5 12.57                                      
                                    10-20                                 
                                        13,900                            
                                            1110                          
B    9.8  4.81     144.3 131.4 12.57                                      
                                    10-20                                 
                                        15,000                            
                                            1190                          
C    9.8  4.79     143.7 130.9 12.57                                      
                                    10-27                                 
                                        17,350                            
                                            1380                          
D    9.9  4.81     144.3 131.3 12.57                                      
                                    10-27                                 
                                        18,200                            
                                            1448                          
E    9.9  4.81     144.3 131.3 12.57                                      
                                    11-10                                 
                                        17,050                            
                                            1356                          
F    9.9  4.78     143.4 130.5 12.57                                      
                                    11-10                                 
                                        16,600                            
                                            1321                          
__________________________________________________________________________
 Remarks:                                                                 
 Good compactability. Material was relatively easy to work with.          
                                  EXAMPLE VII                             
__________________________________________________________________________
                             Weight of                                    
                       Percent                                            
                             Batch                                        
__________________________________________________________________________
          Fly Ash      8.0%  2.40#                                        
          Kiln Dust    10.0% 3.00#                                        
          No. 304 Limestone                                               
                       82.0% 24.60#                                       
          (Screened over 3/4" screen)                                     
          Total        100.0%                                             
                             30.00#                                       
__________________________________________________________________________
Cyl.                                                                      
   Percent                                                                
        Wt. As Wet Wt.                                                    
                     Dry Wt.                                              
                           Area Date                                      
                                    Mach.                                 
No.                                                                       
   Water                                                                  
        Molded(Lbs.)                                                      
               Per Cu. Ft.                                                
                     Per Cu. Ft.                                          
                           (Sq. In.)                                      
                                Tested                                    
                                    Load                                  
                                        P.S.I.                            
__________________________________________________________________________
1  11.5 4.73   141.9 127.3 12.57                                          
                                4-01                                      
                                     9350                                 
                                         745                              
2  11.1 4.71   141.3 127.2 12.57                                          
                                4-01                                      
                                     8610                                 
                                         685                              
3  11.1 4.73   141.9 127.7 12.57                                          
                                4-01                                      
                                     9290                                 
                                         740                              
4  11.1 4.74   142.2 128.1 12.57                                          
                                4-22                                      
                                    14050                                 
                                        1120                              
5  11.0 4.75   142.5 128.4 12.57                                          
                                4-22                                      
                                    13500                                 
                                        1075                              
6  10.7 4.74   142.2 128.5 12.57                                          
                                4-22                                      
                                    13620                                 
                                        1085                              
__________________________________________________________________________
 A. Slight bleeding at bottom of mold during compaction.                  
 B. Material appeared deficient in limestone fines (#4 material).         
 C. Some free moisture noted, giving slight "glossy" appearance.          
 D. Samples slumped, following extraction from molds.                     
                                  EXAMPLE VIII                            
__________________________________________________________________________
                             Weight of                                    
                       Percent                                            
                             Batch                                        
__________________________________________________________________________
          Fly Ash      10.0% 3.00#                                        
          Kiln Dust    8.0%  2.40#                                        
          No. 304 Limestone                                               
                       82.0% 24.60#                                       
          (Screened over 3/4" screen)                                     
          Total        100.0 30.00#                                       
__________________________________________________________________________
Cyl.                                                                      
   Percent                                                                
        Wt. As Wet Wt.                                                    
                     Dry Wt.                                              
                           Area Date                                      
                                    Mach.                                 
No.                                                                       
   Water                                                                  
        Molded (Lbs.)                                                     
               Per Cu. Ft.                                                
                     Per Cu. Ft.                                          
                           (Sq. In.)                                      
                                Tested                                    
                                    Load                                  
                                        P.S.I.                            
__________________________________________________________________________
1  9.3  4.72   141.6 129.6 12.57                                          
                                4-01                                      
                                    8060                                  
                                        640                               
2  9.4  4.71   141.3 129.2 12.57                                          
                                4-01                                      
                                    7750                                  
                                        615                               
3  9.4  4.71   141.3 129.2 12.57                                          
                                4-01                                      
                                    8000                                  
                                        635                               
4  9.5  4.69   140.7 128.5 12.57                                          
                                4-22                                      
                                    9730                                  
                                        775                               
5  9.6  4.68   140.4 128.1 12.57                                          
                                4-22                                      
                                    10450                                 
                                        830                               
6  9.5  4.69   140.7 128.5 12.57                                          
                                4-22                                      
                                    11490                                 
                                        915                               
__________________________________________________________________________
 A. Samples retained shape following extraction from molds.               
 B. No free water noticed bleeding during compaction.                     
                                  EXAMPLE IX                              
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Fly Ash      8.0%       2.40#                                     
        Kiln Dust    10.0%      3.00#                                     
        Fill Sand    82.0%      24.60#                                    
        Total        100.0%     30.00#                                    
__________________________________________________________________________
Cyl.                                                                      
   Percent                                                                
        Wt. As Wet Wt.                                                    
                     Dry Wt.                                              
                           Area Date                                      
                                    Mach.                                 
No.                                                                       
   Water                                                                  
        Molded (Lbs.)                                                     
               Per Cu. Ft.                                                
                     Per Cu. Ft.                                          
                           (Sq. In.)                                      
                                Tested                                    
                                    Load                                  
                                        P.S.I.                            
__________________________________________________________________________
1  9.8  4.09   122.7 111.7 12.57                                          
                                3-31                                      
                                    1800                                  
                                        145                               
2  10.0 4.12   123.6 112.4 12.57                                          
                                3-31                                      
                                    1700                                  
                                        135                               
3  9.9  4.10   123.0 111.9 12.57                                          
                                3-31                                      
                                    1690                                  
                                        135                               
4  9.9  4.11   123.3 112.2 12.57                                          
                                4-21                                      
                                    2810                                  
                                        225                               
5  10.0 4.10   123.0 111.8 12.57                                          
                                4-21                                      
                                    2880                                  
                                        230                               
6  9.8  4.09   122.7 111.7 12.57                                          
                                4-21                                      
                                    2670                                  
                                        210                               
__________________________________________________________________________
 A. No bleeding of sample during compaction.                              
 B. Material stayed in a ball when packed by hand.                        
 C. Slight bulking noticed.                                               
 D. Easily compacted.                                                     
                                  EXAMPLE X                               
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Fly Ash      8.0%       2.40#                                     
        Kiln Dust    10.0%      3.00#                                     
        Glass (Crushed to approx.                                         
        1/2" size)   32.0%      9.60#                                     
        Fill Sand    50.0%      15.00#                                    
        Total        100.0%     30.00#                                    
__________________________________________________________________________
Cyl.                                                                      
   Percent                                                                
        Wt. As Wet Wt.                                                    
                     Dry Wt.                                              
                           Area Date                                      
                                    Mach.                                 
No.                                                                       
   Water                                                                  
        Molded (Lbs.)                                                     
               Per Cu. Ft.                                                
                     Per Cu. Ft.                                          
                           (Sq. In.)                                      
                                Tested                                    
                                    Load                                  
                                        P.S.I.                            
__________________________________________________________________________
1  9.4  4.50   135.0 123.4 12.57                                          
                                4-02                                      
                                    4390                                  
                                        350                               
2  9.4  4.50   135.0 123.4 12.57                                          
                                4-02                                      
                                    4590                                  
                                        365                               
3  9.3  4.51   135.3 123.8 12.57                                          
                                4-02                                      
                                    4200                                  
                                        335                               
4  9.2  4.52   135.6 124.2 12.57                                          
                                4-23                                      
                                    6750                                  
                                        535                               
5  9.1  4.51   135.3 124.0 12.57                                          
                                4-23                                      
                                    6870                                  
                                        545                               
6  9.1  4.47   134.1 122.9 12.57                                          
                                4-23                                      
                                    6280                                  
                                        500                               
__________________________________________________________________________
 A. Material originally mixed to 10.3% moisture, looked wet, probably     
 because nonabsorbancy of glass.                                          
 B. Air dried the mix out to approximately 9.4% moisture, did not bulk at 
 this moisture content.                                                   
 C. Surprisingly good cohesion of mix, even with the smooth faces of glass
 particles.                                                               
 D. Strength of cylinders higher than expected, thought the mix would slip
 off the smooth glass faces, when put under compression.                  
                                  EXAMPLE XI                              
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Cement Kiln Dust                                                  
                     16.0       3.2#                                      
        Fly Ash      24.0       4.8#                                      
        No. 304 Crushed Limestone                                         
                     60.0       12.0#                                     
        Total        100.0      20.0#                                     
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As Wet Wt.                                                  
                       Dry Wt.                                            
                             Area Date                                    
                                      Mach.                               
No.  Water                                                                
          Molded (Lbs.)                                                   
                 Per Cu. Ft.                                              
                       Per Cu. Ft.                                        
                             (Sq. In.)                                    
                                  Tested                                  
                                      Load                                
                                          P.S.I.                          
__________________________________________________________________________
A    16.6 4.50   135.0 115.8 12.57                                        
                                  12/22                                   
                                      5890                                
                                          470                             
B    15.1 4.46   133.8 116.2 12.57                                        
                                  12/22                                   
                                      6000                                
                                          480                             
C    15.0 4.46   133.8 116.3 12.57                                        
                                  12/22                                   
                                      6150                                
                                          490                             
__________________________________________________________________________
                                  EXAMPLE XII                             
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Cement Kiln Dust                                                  
                     4.0        0.8#                                      
        Fly Ash      6.0        1.2#                                      
        No. 304 Crushed Limestone                                         
                     90.0       18.0#                                     
        Total        100.0      20.0#                                     
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As Wet Wt.                                                  
                       Dry Wt.                                            
                             Area Date                                    
                                      Mach.                               
No.  Water                                                                
          Molded (Lbs.)                                                   
                 Per Cu. Ft.                                              
                       Per Cu. Ft.                                        
                             (Sq. In.)                                    
                                  Tested                                  
                                      Load                                
                                          P.S.I.                          
__________________________________________________________________________
A    11.1 4.94   148.2 133.4 12.57                                        
                                  12/22                                   
                                      2950                                
                                          230                             
B    11.2 4.93   147.9 133.0 12.57                                        
                                  12/22                                   
                                      3570                                
                                          280                             
C    11.2 4.93   147.9 133.0 12.57                                        
                                  12/22                                   
                                      3250                                
                                          260                             
__________________________________________________________________________
                                  EXAMPLE XIII                            
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Cement Kiln Dust                                                  
                     6.9%       140#                                      
        Fly Ash      11.8%      240#                                      
        Limestone Screenings                                              
                     39.4%      800#                                      
        No. 57 Crushed Limestone                                          
                     39.4%      800#                                      
        Water        2.5%        50#                                      
        Total        100.0%     2030#                                     
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As Wet Wt.                                                  
                       Dry Wt.                                            
                             Area Date      Mach.                         
No.  Water                                                                
          Molded (Lbs.)                                                   
                 Per Cu. Ft.                                              
                       Per Cu. Ft.                                        
                             (Sq. In.)                                    
                                  Tested    Load                          
                                                P.S.I.                    
__________________________________________________________________________
A    5.6  4.49   134.7 127.6 12.57                                        
                                  11-22     8,950                         
                                                712                       
B    5.1  4.51   135.3 128.7 12.57                                        
                                  11-22     8,225                         
                                                654                       
C    5.5  4.51   135.3 128.2 12.57                                        
                                  11-22     9,050                         
                                                720                       
D    5.4  4.50   135.0 128.1 12.57                                        
                                  11-29     9,610                         
                                                760                       
E    5.5  4.49   134.7 127.7 12.57                                        
                                  11-29     8,080                         
                                                640                       
F    4.9  4.50   135.0 128.7 12.57                                        
                                  11-29     9,630                         
                                                770                       
G    5.1  4.46   133.8 127.3 12.57                                        
                                  12-13     8,820                         
                                                700                       
H    5.3  4.51   135.3 128.5 12.57                                        
                                  12-13     9,380                         
                                                750                       
I    5.4  4.50   135.0 128.1 12.57                                        
                                  12-13     9,400                         
                                                750                       
J    5.3  4.46   133.8 127.1 12.57                                        
                                  02-03                                   
K    5.1  4.51   135.3 128.7 12.57                                        
                                  02-03                                   
L    4.9  4.48   134.4 128.1 12.57                                        
                                  02-03                                   
M    5.0  4.54   136.2 129.7 12.57                                        
                                  For Durablilty Test                     
N    4.9  4.54   136.2 129.8 12.57                                        
                                  For Durability Test                     
O    4.8  4.47   134.1 128.0 12.57                                        
                                  For Durability Test                     
__________________________________________________________________________
                                  EXAMPLE XIV                             
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Cement Type I                                                     
                     1.0%        20#                                      
        Cement Kiln Dust                                                  
                     6.8%       140#                                      
        Fly Ash      11.7%      240#                                      
        Limestone Screenings                                              
                     39.0%      800#                                      
        No. 57 Crushed Limestone                                          
                     39.0%      800#                                      
        Water        2.5%        50#                                      
        Total        100.0%     1050#                                     
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As Wet Wt.                                                  
                       Dry Wt.                                            
                             Area Date      Mach.                         
No.  Water                                                                
          Molded (Lbs.)                                                   
                 Per Cu. Ft.                                              
                       Per Cu. Ft.                                        
                             (Sq. In.)                                    
                                  Tested    Load                          
                                                P.S.I.                    
__________________________________________________________________________
A    5.4  4.58   137.4 130.4 12.57                                        
                                  11-21     10,030                        
                                                 800                      
B    5.4  4.58   137.4 130.4 12.57                                        
                                  11-21     11,780                        
                                                 940                      
C    5.4  4.58   137.4 130.4 12.57                                        
                                  11-21     14,120                        
                                                1120                      
D    5.3  4.58   137.4 130.5 12.57                                        
                                  11-28     15,500                        
                                                1230                      
E    5.0  4.58   137.4 130.9 12.57                                        
                                  11-28     18,500                        
                                                1470                      
F    5.8  4.46   133.8 126.5 12.57                                        
                                  11-29     14,910                        
                                                1190                      
G    5.8  4.46   133.8 126.5 12.57                                        
                                  12-13     17,900                        
                                                1420                      
H    5.7  4.46   133.8 126.6 12.57                                        
                                  12-13     20,010                        
                                                1590                      
I    5.7  4.46   133.8 126.6 12.57                                        
                                  12-13     14,980                        
                                                1190                      
J    5.7  4.46   133.8 126.6 12.57                                        
                                  02-13                                   
K    5.6  4.46   133.8 126.7 12.57                                        
                                  02-13                                   
L    5.6  4.46   133.8 126.7 12.57                                        
                                  02-13                                   
M    5.4  4.49   134.7 127.8 12.57                                        
                                  For Durability Test                     
N    5.4  4.49   134.7 127.8 12.57                                        
                                  For Durability Test                     
O    5.4  4.49   134.7 127.8 12.57                                        
                                  For Durability Test                     
__________________________________________________________________________
                                  EXAMPLE XV                              
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Cement Kiln Dust                                                  
                     7.8%       160#                                      
        Fly Ash      11.7%      240#                                      
        Limestone Screenings                                              
                     39.0%      800#                                      
        No. 57 Crushed Limestone                                          
                     39.0%      800#                                      
        Water        2.5%        50#                                      
        Total        100.0%     2050#                                     
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As Wet Wt.                                                  
                       Dry Wt.                                            
                             Area Date      Mach.                         
No.  Water                                                                
          Molded(Lbs.)                                                    
                 Per Cu. Ft.                                              
                       Per Cu. Ft.                                        
                             (Sq. In.)                                    
                                  Tested    Load                          
                                                P.S.I.                    
__________________________________________________________________________
A    8.1  4.24   127.2 117.7 12.57                                        
                                  11-22     4,650                         
                                                370*                      
B    7.9  4.24   127.2 117.9 12.57                                        
                                  11-22     5,700                         
                                                450                       
C    8.3  4.29   128.7 118.8 12.57                                        
                                  11-22     6,030                         
D    7.8  4.25   127.5 118.3 12.57                                        
                                  11-29     7,200                         
                                                570                       
E    7.7  4.24   127.2 118.1 12.57                                        
                                  11-29     6,850                         
                                                540                       
F    7.6  4.26   127.8 118.8 12.57                                        
                                  11-29     8,080                         
                                                640                       
G    7.6  4.30   129.0 119.9 12.57                                        
                                  12-13     10,000                        
                                                800                       
H    7.6  4.27   128.1 119.0 12.57                                        
                                  12-13     9,500                         
                                                760                       
I    7.6  4.27   128.1 119.0 12.57                                        
                                  12-13     8,980                         
                                                710                       
J    7.5  4.27   128.1 119.2 12.57                                        
                                  02-13                                   
K    7.3  4.28   128.4 119.7 12.57                                        
                                  02-13                                   
L    7.2  4.26   127.8 119.2 12.57                                        
                                  02-13                                   
M    7.2  4.27   128.1 119.5 12.57                                        
                                  For Durability Test                     
N    7.1  4.24   127.2 118.8 12.57                                        
                                  For Durability Test                     
O    7.2  4.25   127.5 118.9 12.57                                        
                                  For Durability Test                     
__________________________________________________________________________
  *Sample fractured horizontally during capping                           
 Remarks:                                                                 
 This product was produced on November 6, and sampled on November 13.     
 Materials are the same as in Example XIII  This example is a check to see
 if the age of the product, before use, has any effect on the strength    
 results.                                                                 
                                  EXAMPLE XVI                             
__________________________________________________________________________
                                Weight of                                 
                     Percent    Batch                                     
__________________________________________________________________________
        Fly Ash      11.6%       232#                                     
        Lime          3.4%       68#                                      
        No. 304 Crushed Limestone                                         
                     85.0%      1700#                                     
        Water        --         --                                        
        Total        100.0%     2000#                                     
__________________________________________________________________________
Specimen                                                                  
     Percent                                                              
          Wt. As Wet Wt.                                                  
                       Dry Wt.                                            
                             Area Date      Mach.                         
No.  Water                                                                
          Molded(Lbs.)                                                    
                 Per Cu. Ft.                                              
                       Per Cu. Ft.                                        
                             (Sq. In.)                                    
                                  Tested    Load                          
                                                P.S.I.                    
__________________________________________________________________________
A    10.4 4.60   138.0 125.0 12.57                                        
                                  11-28     10,325                        
                                                 820                      
B    10.4 4.70   141.0 127.7 12.57                                        
                                  11-28     11,950                        
                                                 950                      
C    10.2 4.62   138.6 125.8 12.57                                        
                                  11-28     10,650                        
                                                 850                      
D    10.2 4.67   140.1 127.1 12.57                                        
                                  12-05     19,600                        
                                                1559                      
E    10.2 4.66   139.8 126.9 12.57                                        
                                  12-05     18,950                        
                                                1508                      
F    11.1 4.65   139.5 125.6 12.57                                        
                                  12-05     19,825                        
                                                1577                      
G    10.8 4.66   139.8 126.2 12.57                                        
                                  12-19     21,860                        
                                                1740                      
H    10.8 4.66   139.8 126.2 12.57                                        
                                  12-19     20,790                        
                                                1650                      
I    10.8 4.64   139.2 125.6 12.57                                        
                                  12-19     21,000                        
                                                1670                      
J    10.8 4.70   141.0 127.3 12.57                                        
                                  02-19                                   
K    10.9 4.65   139.5 125.8 12.57                                        
                                  02-19                                   
L    10.9 4.68   140.4 126.6 12.57                                        
                                  02-19                                   
M    10.9 4.66   139.8 126.1 12.57                                        
                                  For Durability Test                     
N    10.9 4.68   140.4 126.6 12.57                                        
                                  For Durability Test                     
O     9.6 4.63   138.9 126.7 12.57                                        
                                  For Durability Test                     
__________________________________________________________________________
The results of the tests are summarized in FIGS. 1-3.
As shown in FIG. 1, mixtures containing cement kiln dust vary but in each instant produce a base that is stabilized.
As shown in FIG. 2, the addition of additives or admixtures generally do not affect the strength except that a retarder tends to prevent the early development of strength as might be expected.
As shown in FIG. 3, the strength of mixtures including cement kiln dust compare favorably with a lime, fly ash, aggregate mixture. In addition, even a mixture of cement kiln dust and fly ash produces a stabilized base.
Thus, the mixtures of the present invention result in a stabilized base that is comparable in strength and required performance characteristics to cement-aggregate or lime-fly ash-aggregate stabilized bases and yet are not energy intensive. The mixtures of the present invention cost less than the predominantly used asphalt-aggregate bases. Also, the use of mixtures of the invention releases asphalt for use in resurfacing or as a heavy industrial fuel.
FIG. 4 is a curve showing the BTU's per mile versus thickness for various road paving materials taken from Highway Research Circular titled "Fuel Usage Factors for Highway Construction", Number 158, July, 1974. It ca be seen that asphalt concrete and cement type mixtures require substantial energy and only granular base or sub-base of aggregate has minimal energy requirements in hauling, spreading, compacting and finishing. Since the mixtures of the present invention utilize waste materials, namely, cement kiln dust and fly ash, the energy requirements for making a stabilized base are only in hauling, spreading, compacting and finishing.
As a result, the mixtures of the present invention have minimal energy requirements and thereby obviate the energy intensive materials or prior stabilized bases.
The mixtures of the present invention utilize cement kiln dust which is a waste product that is relatively available from cement plants and fly ash which is readily available from power plants.

Claims (8)

I claim:
1. A mixture consisting essentially of fly ash and cement kiln dust.
2. The mixture set forth in claim 1 including an amount of portland cement.
3. The mixture set forth in claim 1 wherein said cement kiln dust comprises about 12% by dry weight and said fly ash comprises about 88% by dry weight.
4. The method which comprises mixing fly ash, cement kiln dust and water and permitting the mixture to react at ambient temperatures to produce a durable mass.
5. The method set forth in claim 4 wherein said .[.fly ash.]. .Iadd.cement kiln dust .Iaddend.comprises about 12% by dry weight of the total of fly ash and cement kiln dust and the .[.cement kiln dust.]. .Iadd.fly ash .Iaddend.comprises about 88% by dry weight of the total of fly ash and cement kiln dust.
6. The mixture set forth in claim 1 including about 1% portland cement.
7. The mixture set forth in claim 1 wherein the fly ash comprises the major constituent.
8. The method set forth in claim 4 including mixing about 1% portland cement with said fly ash and cement kiln dust.
US06/068,412 1976-02-02 1979-08-21 Stabilized mixture Expired - Lifetime USRE30943E (en)

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US05/654,211 US4018617A (en) 1976-02-02 1976-02-02 Mixture for pavement bases and the like
US05/765,837 US4101332A (en) 1976-02-02 1977-02-04 Stabilized mixture
US06/068,412 USRE30943E (en) 1976-02-02 1979-08-21 Stabilized mixture

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Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4715896A (en) 1986-08-04 1987-12-29 Standard Slag Cement Cementitious binder for consolidated fill
US4772330A (en) 1986-02-14 1988-09-20 Ube Industries, Ltd. Process for producing low water-absorption artificial lightweight aggregate
US4917733A (en) 1988-11-14 1990-04-17 Hansen David L Pozzolanic mixture for stabilizing landfill leachate
US4997484A (en) * 1987-12-11 1991-03-05 Lone Star Industries, Inc. Hydraulic cement and composition employing the same
US5211750A (en) * 1991-06-19 1993-05-18 Conversion Systems, Inc. Synthetic aggregate and landfill method
US5256197A (en) * 1991-06-19 1993-10-26 Conversion Systems, Inc. Abrasion-resistant synthetic article and method of making
US5277826A (en) * 1991-11-01 1994-01-11 Browning Ferris Industries Lime and fly ash stabilization of wastewater treatment sludge
US5366548A (en) * 1991-07-05 1994-11-22 Riddle Mitchell S Volcanic fly ash and kiln dust compositions, and a process for making articles therefrom
US5374307A (en) * 1991-07-05 1994-12-20 Riddle; Mitchell S. Fly ash composition and process for making articles therefrom
US5383521A (en) * 1993-04-01 1995-01-24 Halliburton Company Fly ash cementing compositions and methods
US6053857A (en) 1998-05-15 2000-04-25 Conversion Systems, Inc. Immobilization of thallium during electric arc furnace dust treatment
US6200379B1 (en) 1995-09-08 2001-03-13 Midway Environmental Associates, Inc. Fly ash composites and methods for making same
US6387175B1 (en) 2000-10-05 2002-05-14 Bethlehem Steel Corporation Roadway base intermediate, roadway base, and methods of manufacture
US6645290B1 (en) * 2001-10-09 2003-11-11 Ronald Lee Barbour Settable composition containing cement kiln dust
US20080300442A1 (en) * 2007-05-31 2008-12-04 Utter Technology, Llc Method for forming products from a flue gas desulfurization by-product and products formed thereby
US20120055374A1 (en) * 2010-09-03 2012-03-08 Spence William B Fly ash used in construction application

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2564690A (en) * 1948-06-30 1951-08-21 Jules E Havelin Hydrated lime-fly ash-fine aggregate cement
US3669701A (en) * 1970-10-29 1972-06-13 Cities Service Oil Co Lightweight cements for oil wells
US3852084A (en) * 1970-03-30 1974-12-03 C Smith Cementitious composition containing activated lime-fly ash mixture

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2564690A (en) * 1948-06-30 1951-08-21 Jules E Havelin Hydrated lime-fly ash-fine aggregate cement
US3852084A (en) * 1970-03-30 1974-12-03 C Smith Cementitious composition containing activated lime-fly ash mixture
US3669701A (en) * 1970-10-29 1972-06-13 Cities Service Oil Co Lightweight cements for oil wells

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4772330A (en) 1986-02-14 1988-09-20 Ube Industries, Ltd. Process for producing low water-absorption artificial lightweight aggregate
US4715896A (en) 1986-08-04 1987-12-29 Standard Slag Cement Cementitious binder for consolidated fill
US4997484A (en) * 1987-12-11 1991-03-05 Lone Star Industries, Inc. Hydraulic cement and composition employing the same
US4917733A (en) 1988-11-14 1990-04-17 Hansen David L Pozzolanic mixture for stabilizing landfill leachate
US5211750A (en) * 1991-06-19 1993-05-18 Conversion Systems, Inc. Synthetic aggregate and landfill method
US5256197A (en) * 1991-06-19 1993-10-26 Conversion Systems, Inc. Abrasion-resistant synthetic article and method of making
US5405441A (en) * 1991-07-05 1995-04-11 Tide Company Fly ash composition and process for making articles therefrom
US5366548A (en) * 1991-07-05 1994-11-22 Riddle Mitchell S Volcanic fly ash and kiln dust compositions, and a process for making articles therefrom
US5374307A (en) * 1991-07-05 1994-12-20 Riddle; Mitchell S. Fly ash composition and process for making articles therefrom
US5425807A (en) * 1991-07-05 1995-06-20 Tide Company Volcanic fly ash and kiln dust compositions and a process for making articles therefrom
US5277826A (en) * 1991-11-01 1994-01-11 Browning Ferris Industries Lime and fly ash stabilization of wastewater treatment sludge
US5383521A (en) * 1993-04-01 1995-01-24 Halliburton Company Fly ash cementing compositions and methods
US6200379B1 (en) 1995-09-08 2001-03-13 Midway Environmental Associates, Inc. Fly ash composites and methods for making same
US6053857A (en) 1998-05-15 2000-04-25 Conversion Systems, Inc. Immobilization of thallium during electric arc furnace dust treatment
US6387175B1 (en) 2000-10-05 2002-05-14 Bethlehem Steel Corporation Roadway base intermediate, roadway base, and methods of manufacture
US6645290B1 (en) * 2001-10-09 2003-11-11 Ronald Lee Barbour Settable composition containing cement kiln dust
US20080300442A1 (en) * 2007-05-31 2008-12-04 Utter Technology, Llc Method for forming products from a flue gas desulfurization by-product and products formed thereby
US8303842B2 (en) 2007-05-31 2012-11-06 Utter Technology, Llc Method for forming products from a flue gas desulfurization by-product and products formed thereby
US8669203B2 (en) 2007-05-31 2014-03-11 Utter Technology Llc Method for forming products from a flue gas desulfurization by-product and products formed thereby
US9896387B2 (en) 2007-05-31 2018-02-20 Utter Technology, Llc Products from a flue gas desulfurization by-product
US20120055374A1 (en) * 2010-09-03 2012-03-08 Spence William B Fly ash used in construction application

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