Nu-Rock Technology converting every tonne of ash to a new cement

(Australia) – Nu-Rock Technology is a significant new development for the conversion of readily available Fly Ash and Bottom Ash into low cost products for a diversity of building and construction, civil engineering, by-product recycling and waste disposal applications.

The Nu-Rock process binds ash that up to now have not been an acceptable feedstock due to the inability of Portland cement, epoxies, monomers and polymers to bind together such waste materials inexpensively. The chief characteristic of the Nu-Rock process is its ability to transform the pozzolanic properties inherent in the materials into cement through a chemical conversion and have a compressive strength of 5 to 50 MPa depending on the feed stock.

The properties of materials produced and the nature of the process indicate a broad range of application potential although commercial development of the Nu-Rock process is currently being focused in two main areas:

1. Building and Construction Products;
2. Agglomeration of Fines for Raw Material Optimisation and/or Recycle;

The technology has undergone extensive pre-production testing with a diversity of formulations and trial products. Developments to date include:

1. producing an Australian Standard and International Standards for Masonry Codes;
2. the production of aggregates and sand for use as road base;
3. production of spherical sand for additives and cracking sands

Depending on the application and properties required, feedstock from various sources might be combined to produce products with variable weights, density and strengths.

The Nu-Rock process has been used for the agglomeration of Fly Ash dust of every sizing and from super fine if it cannot be used in Cement applications through to cause Fly ash and Bottom Ash and aggregates these ashes to make sand and aggregate for any application to make any building product.

Any of these materials may be used in the Nu-Rock process to produce high strength/high durability building materials, or in combination with fly ash to produce a variety of high quality products, depending on the ratio of feedstock’s used in the mix. The ash uses between 1.5% to 5 % depending on the product and the desired strength.

The ash product can be made from mine back fill applications of 3 Mpa to 75 Mpa depending on the application. The Ash products can be made using Salt water and once fully cured which is in 3 minutes to eight hours depending on the product the product is totally Acid resistant and completely Salt Attack resistant. The sand and aggregate used in a standard Portland concrete mix of 32 Mpa will produce Concrete of up to 50 Mpa and 30 to 35% lighter. The Portland Cement can be replaced with Fly Ash and Nu-Rock Binder to achieve the same results as Portland Cement Concrete but again 35% lighter and 10 % stronger and using 95 % fly ash and 5% Binder to make 50 Mpa Concrete.

This Nu-Rock Concrete will be GREEN because it absorbs CO2 and the Fly Ash is chemically altered to become the cement. The new cement kilns of the 21st Century are Power Stations which we look to share the Carbon Credits with and make them completely environmentally friendly.

The Sand and aggregate can be used in many applications including mine and building shotcrete.

Drainage back fill, under parks to make recycling of water easier from irrigation.

Lining of concrete pipes to stop sewer attaching the pipes and this application is 25% the cost of most other lining methods and totally acid resistant and Salt Attack resistant.

Using these aggregate and sands make the Concrete with a lot more elasticity and achieve higher strengths because it does not fracture itself under load like normal quarried sands and aggregates.

Should this information document interest you to the point that you would like to become a licensee of the Nu-Rock technology, or benefit from the waste management solution that this technology has to offer, please do not hesitate to contact us:

Nu-Rock Corporation SARL
Tel.: (+61) (2) 9327 1896
Fax: (+61) (2) 9362 3431
Cell.: (+61) 438 500 826


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