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Western Research Institute (WRI) of Laramie, Wyoming and AeRock, LLC of Eagar, Arizona (formerly of Bellevue, Washington) partnered, under sponsorship of the U.S. Department of Energy National Energy Technology Laboratory (U.S. DOE-NETL), to support the development of rapid-setting, ash-based, fiber-incorporated ''green'' building products. Green building materials are a rapidly growing trend in the building and construction industry in the US. A two phase project was implemented wherein Phase I assessed, through chemical and physical testing, ash, ash-based cement and fiber composites exhibiting superior structural performance when applied to the AeRock mixing and extrusion process and involved the conduct of pilot-scale production trials of AeRock products, and wherein Phase II involved the design, construction, and operation of a commercial-scale plant to confirm production issues and to produce panels for performance evaluations. Phase I optimized the composite ingredients including ash-based cement, Class F and Class C DFGD ash, and various fiber reinforcements. Additives, such as retardants and accelerators, were also evaluated as related to extruder performance. The optimized composite from the Phase I effort was characterized by a modulus of rupture (MOR) measured between 1,931 and 2,221 psi flexural strength, comparable to other wood and non-wood building materials. Continuous extrusion of the optimum composite in the AeRock pilot-scale facility produced an excellent product that was assembled into a demonstration for exhibit and durability purposes. Finishes, from plain to marbled, from bright reds to muted earth tones and with various textures, could easily be applied during the mixing and extrusion process. The successful pilot-scale demonstration was in turn used to design the production parameters and extruder dies for a commercial scale demonstration at Ultrapanel Pty, Ltd of Ballarat, Australia under Phase II. The initial commercial-scale production trials showed green product sagging, as a result of the die design. After the third die was acquired and fitted to the extruder, satisfactory decking and structural panels were produced. Cured decking was shipped to the US but experienced significant breakage and damage during transport. Subsequent evaluations concluded that an alternative die design was needed that would produce a more robust product resistant to damage. In summary, AeRock Decking can be a commercially-viable non-wood alternative decking product. This project has provided WRI and AeRock the knowledge and understanding to make AeRock Decking a commercial success. However, a commercial demonstration that produces quality product and the subsequent evaluation of its performance is needed before commercial acceptance of the AeRock product

Ash-Based Building Panels Production and Demonstration of Aerock Decking Building Product