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SYNTHETIC AGGREGATES TECHNOLOGIES - Products and Markets

Feb, 23 2005

SYNTHETIC AGGREGATES TECHNOLOGIES - Products and Markets (Elite Aggregates) -- In previous articles we discussed the wide range of synthetic aggregates technologies, the economy of the growing synthetic aggregate market, and the future. There are synthetic aggregates designed and tested now that concrete producers could make current products lighter (or ultra light), stronger, and more profitable now? While early synthetics were initially designed for inclusion in roadbed, there are new synthetic aggregate formulations that are applicable to the rest of the concrete product industry. These formulas could be manufactured today to make lighter and stronger concrete products profitably, using ‘green' technology. It is possible today to make a lightweight synthetic aggregate concrete block that weighs 22 pounds per block, compared to a standard concrete block weighing 40 pounds, or 55% of the standard block with the same compressive strength of 2000psi. The value added would be a 3 times standard r-value and the capability of being cut with standard tools. The bricklayer can also lay more blocks per day, saving labor costs or completing projects sooner. In the spring and summer of 2000, lightweight test blocks were produced by this author at Northfield Block Company and Southwest Building Blocks with the results listed above. To view entire PDF document click here In the 1990's, tests were conducted on these lightweight concrete roofing shingles using synthetic aggregate as a replacement for mineral lightweight aggregate at two plants: Eagle Roofing and WESTILE manufacturing. Produced for testing was a 10.5 pound lightweight concrete roofing shingle made from synthetic aggregate instead of mineral aggregate, and it met all ASTM standards. Replacing the lightweight mineral aggregate with synthetic aggregate, a manufacturer could produce the same shingle and cut the cost of manufacturing by 20 - 40 %. These shingles also had the capability of being cut and nailed with standard tools, had a Class A Burning Brand certification, and were made from 80% recycled material ingredients. Why not make a desirable ‘green' product, and reduce landfill waste at the same time? In 1998 tests were conducted using the same synthetic aggregate technology in the making of cultured (cast) stones at Sunset Stone Company and Environmental Materials. This test produce a cast stone that looked just like a mineral stone, used commonly in decorative rock walls and fencing. (pictures below) In 1999 David Shulman coined the phrase “Ultra Lightweight concrete”, referring to concrete that today can be manufactured by formula weighing from 20 to 99 pounds per cubic foot. Tests were conducted on his synthetic aggregate at Commercial Testing Laboratories and at the United States Bureau of Reclamation in Colorado. For example, synthetic aggregate-based concrete weighing 98 pounds had a compressive strength of 8000 psi, and a tensile strength of 880 psi (11% of compressive strength). Another formulation weighed 35 pounds and had with a compressive strength of 1000 psi with a tensile strength of 110 psi (11% of compressive strength). What does this mean to the concrete industry and the concrete manufacturer? They could produce a concrete that is lighter and stronger with the new synthetic aggregates, utilize tax benefits, and be able to offer more cost effective alternative products. Concrete trucks could haul up to 40% more concrete per truck, at a savings of an additional 20 to 40 %. Synthetic aggregates can be produced year-round, stockpiled, used to offset aggregate shortages, and/or be manufactured where mineral aggregates are scarce or for specialized products. There are various plant options. A producing block plant can be readily modified to produce synthetic aggregate full time, or by just adding a shift. A new plant could be built specifically to manufacture only synthetic aggregate at coal burning power plants or near ingredient sources. One of the more exciting technologies using synthetic aggregate is a new concrete wall system developed by DMS Limited of Colorado Corporation that has an r-value of r-30 to r-40, and a roof system with r-50. This is 3 to 4 times the r-value of current existing walls and roofs in standard housing construction. The labor savings is estimated at 30 to 40 %, compared to conventional wood framing technology used in the United States today. The system uses 80% less dimensional lumber in construction, is 2 to 3 times more energy efficient than standard framing, and has a labor saving of approximately 30% to build the new home. The wall system is made of 80% recycled, non-hazardous, solid waste material. Yes, with synthetic aggregate. Construction advantages include insect, wind, earthquake, fire, and freeze-thaw resistance. Use of synthetic aggregates in the housing industry would contribute to significant reduction of solid waste currently sent to landfills, such as plastics, fly and bottom ash, and polystyrene. Other industries that would also benefit most from new synthetic technology are companies and manufacturers needing Lightweight Aggregate meeting ASTM C-330, or C-331 specifications, or Lightweight Concrete (Ready Mix). Synthetic aggregates can be used as part of the concrete mix in Insulated Concrete Forms (ICFs), and in Prestress/Tilt-up Concrete, Concrete Roof Shingles, Concrete Wall Board, Stucco, Concrete Block, Concrete Pavers, Concrete Wall Stone (Cultured Stone), Concrete Dry Mix (Bags), Well Cementing and Grouting, Culvert Pipe, Concrete Underground Vessels, Foundations, Pan Floors/Decking, Geo-technical Fill. Landscape Fill (rock), Architectural panels, and Horticulture. It was recently reported in the ARI News (11/02/04) that India alone has “85 million tonnes ending up on ash mounds covering 65,000 acres of arable land” from power plants, and it is expected to “increase to almost 200 million tonnes per year by 2012”. About 56% of the electricity in the U.S comes from coal-fired plants, producing 128,000 tons of ash waste per day (71M metric tons per year (USGS).) China alone has 3,000 coal-fired power plants (1/2 government owned), which generate about 75% of their country's power, producing ash dumps, acid rain, and severe air pollution affecting 1/3 of China's landmass, as well as world air quality. These are eco-disasters in the making. Imagine the sum total of ash and waste plastic, dumped in every country around the world, that instead could be made into profitable products, and ultra lightweight synthetic aggregates. The production of this new synthetic technology would enhance current product markets, develop whole new economically beneficial industries, and be a boon to any county's construction industry. The world's economic health is a reflection of the health of their collective aggregate industries. Whether you are an aggregate producer, a building products manufacturer, a concrete producer, an environmentalist, or a government official, there are profitable ways right now to produce and utilize these new technologies and products. The technology has already been developed and tested. While building for tomorrow, we can utilize these profitable new technologies, and reap the bonus of recycling, while saving our environment for our children and future generations. Contacts: Yvonne Smith and David Schulman yvonne.smith@eliteaggregates.com www.ELITEaggregates.com View entire PDF document click here