Mechanical, Fire and electrical Insulation Properties of Fly Ash-Composite

This paper demonstrates that ash-composites made from polyurethane and fly ash are able to reduce leaching of coal ash inorganics to less than one-third of the EPA MCL even after being exposed to an accelerated water circulation system for 14 months. Even if these ash blocks are broken, the composite is safe. The concept of encapsulation of fly ash into ash-composites using a polar polymer to bind the fine inorganic particles, is as nature has done in the original unburned coal, makes the ash-composite safe. The ash-composites can be formulated to have designed mechanical, fire and electrical properties by controlling the formulation and the density. Properties of typical density composites were produced, measured and compared with commercial materials. This paper also demonstrates that ash-composite technology can be extended to coal ash stored in ponds. Finally, a typical electric utility box cover was designed, fabricated, and test validated. The box cover has the less than one-half the weight of the original box cover for the same design limits. Finally, the benefits of this ash-composite technology for society, ash producers, and product manufacturers are summarized.