Construction Products

Resonant Shock Compaction (RSC) technology is particularly applicable to converting coal ash and other industrial wastes into construction blocks, panels and other high-valued products for the construction industry.

The technology has already been licensed in the US, Japan and India for this purpose.

The technology can also be used used to compact and stabilize contaminated soils. Some these compacted materials may also be used as construction products but others must be disposed.

The following table present a summary of many applications we have considered.

	Large Blocks & Panels	Pavers & Tiles	Aggregate	DOE Nuclear Waste	Nuclear Power Waste	Mine Tailings	Industrial Waste
Electric Utilities	X	X	X		X
Ash Brokers	X	X	X
Concrete Block	X	X	X			X	X
Construction	X	X	X			X	X
Waste Disposal	X			X	X	X	X
Mining Industry	X	X				X	X

RSC Ash-based Product Characteristics

Over one hundred mixes of Public Service of Colorado Cherokee Station bottom ash and fly ash have been compacted into RSC test blocks (4 in. x 4 in. x 12 in. and weighing about 10 pounds). Results are presented in the following figures. The goal is to make strong and durable products composed of 50 to 100% ash.

Densities of the blocks range from 75 to 120 lbs. per cubic ft., with corresponding compressive strength ranging from 2500 to 6500 psi. Density and compressive strength are controlled by mix design, e.g., the ratio of bottom ash to fly ash, and machine operating parameters. These properties are varied to achieve product design, e.g., interior walls or more durable exterior walls. Conclusion: Resonant Shock Compaction can form this bottom ash and fly ash into a wide variety of products meet product design goals.

Click here to see Figure 1-Density / Strength Properties

RSC product durability was determined by the ASTM C216-97 Maximum Saturation Coefficient (the ratio of water absorption by 24-hour submersion in cold water to that after 5-hour submersion in hot water) and Minimum Compressive Strength. A maximum saturation coefficient of 0.8 and corresponding compressive strength of 3000-5000 psi is the standard for fired masonry facing bricks. Alternatively, durability is measured by the ASTM C67 50 cycle freeze-thaw cycle test or the ASTM C666 300+ freeze-thaw cycle
test.

Durability RSC compacted ash mixes have been fabricated that pass the Maximum Saturation Coefficient test, with densities in the 80-140 lbs. per cubic ft. range, and compressive strength in the range of 2500-6500 psi; some samples have even passed a 1000 freeze-thaw cycle test. Conclusion: RSC ash-based products can be fabricated to meet masonry and concrete compressive strength and durability standards.

Click here to see Figure 2-Durability Ratio

Several RSC ash-based test blocks were subjected to extended ASTM C-666 freeze thaw cycle testing to measure physical failure or until the ASTM C-215 relative dynamic modules of elasticity reaches 60% of the initial modules. All specimens passed 400 cycles, some 700 cycles and later 1000 cycles; some concrete durability standard are only required to pass 300 cycles. Additives can increase durability by decreasing water absorption. Conclusion: RSC ash-based products can exceed freeze-thaw durability standards of some standard concrete durability standards

Click here to see Figure 3-Freeze / Thaw Tests

Click here to see Figure 4-Freeze / Thaw Tests

Typical products that may be manufactured by RSC include:

Blocks and panels for building walls.
Light-weight aggregate (Blocks are crushed to make aggregate)
Highway sound barrier walls, privacy walls and security walls.
Earth retaining walls and pond liners.
paving blocks and roofing tiles,

Many different material compositions, shapes and sizes may be manufactured. Colors and textures may be added. One licensee has manufactured refractories for 10 years; they use 400 different shaped and sized molds. Typical construction materials to be manufactured from coal ash are blocks and panels for structural load-bearing walls. A wall panel, 4 ft. by 8 ft. and 4 in. thick, weighs about 1000 lbs. The plants will be located near the electric utilities.

RSC transforms costly waste into high valued construction products. Disposal transportation and landfill costs are reduced; landfill life is extended. RSC products are similar to conventional masonry and concrete products; many test specimens have passed ASTM masonry and concrete standards for compressive strength and durability (low water absorption and up to 1000 freeze-thaw cycles).

RSC also provides low cost and high capacity (100 tons per day) waste disposal compaction, volume reduction and stabilization. Volume reduction is about 50%. The blocks meet environmental regulations.

Development of these new RSC applications has been supported by the U.S. Department of Energy Entrepreneur's Technical Assistance Program, the Public Service Company of Colorado and the University of Denver, Environmental. Materials Laboratory. See Our Technology.

Services include the design, manufacture and operation or RSC plants to meet your needs. RSC, LLC licenses the technology and will partner with other companies to design, build and operate RSC plants. Please Contact Us for more information.

techapps@ix.netcom.com

Telephone 303-413-1671