NATIONAL SCIENCE FOUNDATION GEOPOLYMER GRANT PROPOSAL
Principal Investigator Paul F Pugh Jr.
Preparer Paula T Bushman
Submitted June 15, 2016 TABLE OF CONTENTS
COVER SHEET FOR PROSPOSAL ...... 1
TABLE OF CONTENTS ...... 5 KEYWORDS ...... 6 REZTECH LETTER OF INTEREST ...... 7 AIRPLANE CONSTRUCTION AND FIRE PROTECTION ...... 8 2012 COAL COMBUSTION PRODUCT (CCP) PRODUCTION & USE SURVEY REPORT ...... 9
PROJECT SUMMARY ...... 10 GEOPOLYMER CLAY MINERAL PRODUCTS ...... 11
GEOPOLYMER SYNTHESIS ...... 12 Covalent Bonding ...... 12 Environmental Benefits ...... 14 Characteristics ...... 14 HIGHWAY APPLICATIONS ...... 15 POLYMER-CLAY NANOCOMPOSITES ...... 16 WIDESPREAD COMMERCIAL TRANSPORTATION MARKET ...... 18 COVALENT BONDED INORGANIC POLYMER COATINGS ...... 19 HISTORY OF MARKET ...... 20 CIP POWDER MANUFACTURING PROCESS ...... 20 COATING APPLICATION PROCESS ...... 21 HEATING OF CIP POWDER FOR INCREASED REACTION ...... 21 NEED FOR NEW SUPPLEMENTARY CEMENTITIOUS MATERIAL ...... 22 KEY INVESTIGATION GOALS ...... 23 CONCLUSION ...... 23 Supply Limitation ...... 24 Coal Fly Ash ...... 24 Ground Granulated Blast Furnace Slag (“GGBFS”) ...... 25 REFERENCES CITED ...... 26 TEAM MEMBERS ...... 29 SUMMARY PROPOSAL BUDGET ...... 38
BUDGET JUSTIFICATION ...... 40 CURRENT AND PENDING SUPPORT ...... 42 FACILITY AND EQUIPMENT ...... 43 DATA MANAGEMENT PLAN ...... 44 LETTER OF SUPPORT ...... 46 MATERIAL DATA SHEET ...... 47 APPENDIX ...... 54
GEOPOLYMER OVERVIEW ...... 54 INVESTIGATING 21ST CENTURY CEMENT PRODUCTION ...... 71 GEOPOLYMERS IN ALASKA ...... 88 GEOPOLYMER CEMENT FEASIBILITY IN ALASKA ...... 159 USIBELLI COAL PRODUCES MORE THAN POWER, POLLUTION, AND PROFIT ...... 181 OPPORTUNITIES FOR ENERGY EFFICIENCY & DEMAND RESPONSE IN CALIFORNIA CEMENT INDUSTRY ..... 189 GREEN AND NATURAL POLYMERS IN TULARE COUNTY ...... 220 ADDRESSING PREVIOUS SUMMARY REVIEW ...... 224 Not for distribution
COVER SHEET FOR PROPOSAL TO THE NATIONAL SCIENCE FOUNDATION
PROGRAM ANNOUNCEMENT/SOLICITATION NO./DUE DATE Special Exception to Deadline Date Policy FOR NSF USE ONLY NSF 16-554 06/16/16 NSF PROPOSAL NUMBER FOR CONSIDERATION BY NSF ORGANIZATION UNIT(S) (Indicate the most specific unit known, i.e. program, division, etc.) IIP - SMALL BUSINESS PHASE I 1648130 DATE RECEIVED NUMBER OF COPIES DIVISION ASSIGNED FUND CODE DUNS# (Data Universal Numbering System) FILE LOCATION
06/16/2016 1 07070000 IIP 5371 079087979 06/16/2016 3:55pm EMPLOYER IDENTIFICATION NUMBER (EIN) OR SHOW PREVIOUS AWARD NO. IF THIS IS IS THIS PROPOSAL BEING SUBMITTED TO ANOTHER FEDERAL TAXPAYER IDENTIFICATION NUMBER (TIN) A RENEWAL AGENCY? YES NO IF YES, LIST ACRONYM(S) AN ACCOMPLISHMENT-BASED RENEWAL 563887327 NAME OF ORGANIZATION TO WHICH AWARD SHOULD BE MADE ADDRESS OF AWARDEE ORGANIZATION, INCLUDING 9 DIGIT ZIP CODE 23538 Avenue 80 Paul Pugh Terra Bella, CA 93270 AWARDEE ORGANIZATION CODE (IF KNOWN) 6250035079 NAME OF PRIMARY PLACE OF PERF ADDRESS OF PRIMARY PLACE OF PERF, INCLUDING 9 DIGIT ZIP CODE Paul F. Pugh Dba Rio Blanco Development Paul F. Pugh Dba Rio Blanco Development 23538 Ave 80 Terra Bella ,CA ,932709530 ,US.
IS AWARDEE ORGANIZATION (Check All That Apply) SMALL BUSINESS MINORITY BUSINESS IF THIS IS A PRELIMINARY PROPOSAL (See GPG II.C For Definitions) FOR-PROFIT ORGANIZATION WOMAN-OWNED BUSINESS THEN CHECK HERE TITLE OF PROPOSED PROJECT SBIR Phase I:Low Embeded Carbon Geopolymer Cement From Indigenous Clay Mineral
REQUESTED AMOUNT PROPOSED DURATION (1-60 MONTHS) REQUESTED STARTING DATE SHOW RELATED PRELIMINARY PROPOSAL NO. IF APPLICABLE $ 225,000 12months 08/01/16 THIS PROPOSAL INCLUDES ANY OF THE ITEMS LISTED BELOW BEGINNING INVESTIGATOR (GPG I.G.2) HUMAN SUBJECTS (GPG II.D.7) Human Subjects Assurance Number DISCLOSURE OF LOBBYING ACTIVITIES (GPG II.C.1.e) Exemption Subsection or IRB App. Date PROPRIETARY & PRIVILEGED INFORMATION (GPG I.D, II.C.1.d) INTERNATIONAL ACTIVITIES: COUNTRY/COUNTRIES INVOLVED (GPG II.C.2.j) HISTORIC PLACES (GPG II.C.2.j) VERTEBRATE ANIMALS (GPG II.D.6) IACUC App. Date COLLABORATIVE STATUS PHS Animal Welfare Assurance Number FUNDING MECHANISM RAPID Not a collaborative proposal PI/PD DEPARTMENT PI/PD POSTAL ADDRESS 23538 Avenue 80 PI/PD FAX NUMBER Terra Bella, CA 93270 United States NAMES (TYPED) High Degree Yr of Degree Telephone Number Email Address PI/PD NAME Paul F Pugh BA 1975 559-359-0240 [email protected] CO-PI/PD
CO-PI/PD
CO-PI/PD
CO-PI/PD
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CERTIFICATION PAGE
Certification for Authorized Organizational Representative (or Equivalent) or Individual Applicant By electronically signing and submitting this proposal, the Authorized Organizational Representative (AOR) or Individual Applicant is: (1) certifying that statements made herein are true and complete to the best of his/her knowledge; and (2) agreeing to accept the obligation to comply with NSF award terms and conditions if an award is made as a result of this application. Further, the applicant is hereby providing certifications regarding conflict of interest (when applicable), drug-free workplace, debarment and suspension, lobbying activities (see below), nondiscrimination, flood hazard insurance (when applicable), responsible conduct of research, organizational support, Federal tax obligations, unpaid Federal tax liability, and criminal convictions as set forth in the NSF Proposal & Award Policies & Procedures Guide,Part I: the Grant Proposal Guide (GPG). Willful provision of false information in this application and its supporting documents or in reports required under an ensuing award is a criminal offense (U.S. Code, Title 18, Section 1001).
Certification Regarding Conflict of Interest The AOR is required to complete certifications stating that the organization has implemented and is enforcing a written policy on conflicts of interest (COI), consistent with the provisions of AAG Chapter IV.A.; that, to the best of his/her knowledge, all financial disclosures required by the conflict of interest policy were made; and that conflicts of interest, if any, were, or prior to the organization’s expenditure of any funds under the award, will be, satisfactorily managed, reduced or eliminated in accordance with the organization’s conflict of interest policy. Conflicts that cannot be satisfactorily managed, reduced or eliminated and research that proceeds without the imposition of conditions or restrictions when a conflict of interest exists, must be disclosed to NSF via use of the Notifications and Requests Module in FastLane. Drug Free Work Place Certification By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent), is providing the Drug Free Work Place Certification contained in Exhibit II-3 of the Grant Proposal Guide.
Debarment and Suspension Certification (If answer "yes", please provide explanation.) Is the organization or its principals presently debarred, suspended, proposed for debarment, declared ineligible, or voluntarily excluded from covered transactions by any Federal department or agency? Yes No By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent) or Individual Applicant is providing the Debarment and Suspension Certification contained in Exhibit II-4 of the Grant Proposal Guide. Certification Regarding Lobbying This certification is required for an award of a Federal contract, grant, or cooperative agreement exceeding $100,000 and for an award of a Federal loan or a commitment providing for the United States to insure or guarantee a loan exceeding $150,000. Certification for Contracts, Grants, Loans and Cooperative Agreements The undersigned certifies, to the best of his or her knowledge and belief, that: (1) No Federal appropriated funds have been paid or will be paid, by or on behalf of the undersigned, to any person for influencing or attempting to influence an officer or employee of any agency, a Member of Congress, an officer or employee of Congress, or an employee of a Member of Congress in connection with the awarding of any Federal contract, the making of any Federal grant, the making of any Federal loan, the entering into of any cooperative agreement, and the extension, continuation, renewal, amendment, or modification of any Federal contract, grant, loan, or cooperative agreement. (2) If any funds other than Federal appropriated funds have been paid or will be paid to any person for influencing or attempting to influence an officer or employee of any agency, a Member of Congress, an officer or employee of Congress, or an employee of a Member of Congress in connection with this Federal contract, grant, loan, or cooperative agreement, the undersigned shall complete and submit Standard Form-LLL, ‘‘Disclosure of Lobbying Activities,’’ in accordance with its instructions. (3) The undersigned shall require that the language of this certification be included in the award documents for all subawards at all tiers including subcontracts, subgrants, and contracts under grants, loans, and cooperative agreements and that all subrecipients shall certify and disclose accordingly. This certification is a material representation of fact upon which reliance was placed when this transaction was made or entered into. Submission of this certification is a prerequisite for making or entering into this transaction imposed by section 1352, Title 31, U.S. Code. Any person who fails to file the required certification shall be subject to a civil penalty of not less than $10,000 and not more than $100,000 for each such failure. Certification Regarding Nondiscrimination By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent) is providing the Certification Regarding Nondiscrimination contained in Exhibit II-6 of the Grant Proposal Guide. Certification Regarding Flood Hazard Insurance Two sections of the National Flood Insurance Act of 1968 (42 USC §4012a and §4106) bar Federal agencies from giving financial assistance for acquisition or construction purposes in any area identified by the Federal Emergency Management Agency (FEMA) as having special flood hazards unless the: (1) community in which that area is located participates in the national flood insurance program; and (2) building (and any related equipment) is covered by adequate flood insurance.
By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent) or Individual Applicant located in FEMA-designated special flood hazard areas is certifying that adequate flood insurance has been or will be obtained in the following situations: (1) for NSF grants for the construction of a building or facility, regardless of the dollar amount of the grant; and (2) for other NSF grants when more than $25,000 has been budgeted in the proposal for repair, alteration or improvement (construction) of a building or facility. Certification Regarding Responsible Conduct of Research (RCR) (This certification is not applicable to proposals for conferences, symposia, and workshops.) By electronically signing the Certification Pages, the Authorized Organizational Representative is certifying that, in accordance with the NSF Proposal & Award Policies & Procedures Guide, Part II, Award & Administration Guide (AAG) Chapter IV.B., the institution has a plan in place to provide appropriate training and oversight in the responsible and ethical conduct of research to undergraduates, graduate students and postdoctoral researchers who will be supported by NSF to conduct research. The AOR shall require that the language of this certification be included in any award documents for all subawards at all tiers.
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CERTIFICATION PAGE - CONTINUED
Certification Regarding Organizational Support By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent) is certifying that there is organizational support for the proposal as required by Section 526 of the America COMPETES Reauthorization Act of 2010. This support extends to the portion of the proposal developed to satisfy the Broader Impacts Review Criterion as well as the Intellectual Merit Review Criterion, and any additional review criteria specified in the solicitation. Organizational support will be made available, as described in the proposal, in order to address the broader impacts and intellectual merit activities to be undertaken. Certification Regarding Federal Tax Obligations When the proposal exceeds $5,000,000, the Authorized Organizational Representative (or equivalent) is required to complete the following certification regarding Federal tax obligations. By electronically signing the Certification pages, the Authorized Organizational Representative is certifying that, to the best of their knowledge and belief, the proposing organization: (1) has filed all Federal tax returns required during the three years preceding this certification; (2) has not been convicted of a criminal offense under the Internal Revenue Code of 1986; and (3) has not, more than 90 days prior to this certification, been notified of any unpaid Federal tax assessment for which the liability remains unsatisfied, unless the assessment is the subject of an installment agreement or offer in compromise that has been approved by the Internal Revenue Service and is not in default, or the assessment is the subject of a non-frivolous administrative or judicial proceeding. Certification Regarding Unpaid Federal Tax Liability When the proposing organization is a corporation, the Authorized Organizational Representative (or equivalent) is required to complete the following certification regarding Federal Tax Liability:
By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent) is certifying that the corporation has no unpaid Federal tax liability that has been assessed, for which all judicial and administrative remedies have been exhausted or lapsed, and that is not being paid in a timely manner pursuant to an agreement with the authority responsible for collecting the tax liability. Certification Regarding Criminal Convictions When the proposing organization is a corporation, the Authorized Organizational Representative (or equivalent) is required to complete the following certification regarding Criminal Convictions:
By electronically signing the Certification Pages, the Authorized Organizational Representative (or equivalent) is certifying that the corporation has not been convicted of a felony criminal violation under any Federal law within the 24 months preceding the date on which the certification is signed. Certification Dual Use Research of Concern By electronically signing the certification pages, the Authorized Organizational Representative is certifying that the organization will be or is in compliance with all aspects of the United States Government Policy for Institutional Oversight of Life Sciences Dual Use Research of Concern.
AUTHORIZED ORGANIZATIONAL REPRESENTATIVE SIGNATURE DATE NAME Paul F Pugh Electronic Signature Jun 16 2016 3:48PM TELEPHONE NUMBER EMAIL ADDRESS FAX NUMBER 559-359-0240 [email protected] fm1207rrs-07
Page 3 of 3 Not for distribution NATIONAL SCIENCE FOUNDATION Program Solicitation/Instruction Guide Number NSF 16-554
SBIR PHASE I - PROPOSAL COVER PAGE TOPIC SUBTOPIC LETTER (if any) TOPIC TITLE MI A1a Advanced Materials and Instrumentation PROPOSAL TITLE SBIR Phase I:Low Embeded Carbon Geopolymer Cement From Indigenous Clay Mineral
COMPANY NAME EMPLOYER IDENTIFICATION NUMBER (EIN) OR TAXPAYER IDENTIFICATION NUMBER (TIN) Paul Pugh 563887327 NAME OF ANY AFFILIATED COMPANIES (Parent, Subsidiary, Predecessor)
ADDRESS (Including address of Company Headquarters and zip code plus four digit extension) 23538 Avenue 80 Terra Bella, CA 93270
REQUESTED AMOUNT PROPOSED DURATION PERIOD OF PERFORMANCE $225000 12 THE SMALL BUSINESS CERTIFIES THAT: Y/N 1. It is a small business as defined in the solicitation. Y 2. It qualifies as a socially and economically disadvantaged business as defined in the solicitation. (FOR STATISTICAL PURPOSES ONLY.) Y 3. It qualifies as a women-owned business as defined in the solicitation. (FOR STATISTICAL PURPOSES ONLY) N 4. NSF is the only Federal agency that has received this proposal (or overlapping or equivalent proposal) from the small business concern. If No, you must disclose overlapping or equivalent proposals and awards as required by this solicitation. Y 5.SBIR: A minimum of two-thirds of the research will be performed by this firm in Phase I. STTR: It will perform at least 40 percent of the work and the collaborating research institution will perform at least 30 percent of the work as described in the proposal. Y 6. The primary employment of the Principal Investigator will be with this firm at the time of the award and during the conduct of the research. Y 7. It will permit the government to disclose the title and technical abstact page, plus the name, address and telephone number of a corporate official if the proposal does not result in an award to parties that may be interested in contacting the small business for further information or possible investment. Y 8. It will comply with the provisions of the Civil Rights Act of 1964 (P.L. 88-352) and the regulations pursuant thereto. Y 9. It has previously submitted proposals to NSF. Y 10. It previously submitted this proposal (which was declined) and significant modifications have been made as described in the solicitation. Y 11. It has received Phase II awards from the Federal Government. If "yes" provide a company commercialization history in the supplementary documents module. N PRINCIPAL INVESTIGATOR / PROJECT DIRECTOR NAME Paul F Pugh SOCIAL SECURITY NO. HIGHEST DEGREE / YEAR E-MAIL ADDRESS not displayed intentionally BA/1975 [email protected] TELEPHONE NO. FAX NO. WEB ADDRESS 559-359-0240 COMPANY OFFICER (FOR BUSINESS AND FINANCIAL MATTERS) NAME TITLE TELEPHONE NO. Paula T. Bushman Research, Grants and Finance 954-793-6720 OTHER INFORMATION PRESIDENTS NAME Paul F. Pugh, Jr. YEAR FIRM FOUNDED 1988 NUMBER OF EMPLOYEES (including Parent, Subsidiary, Predecessor) AVERAGE PREVIOUS 12 MO.: 1 CURRENTLY: 1 RESEARCH INSTITUTION NAME Paul F. Pugh Dba Rio Blanco Development RESEARCH INVESTIGATOR NAME Paul F. Pugh, Jr. RESEARCH INVESTIGATOR TELEPHONE NO. 559-359-0240 PROPRIETARY NOTICE: See instructions concerning proprietary information. Check Here if proposal contains proprietary information. TABLE OF CONTENTS
For font size and page formatting specifications, see GPG section II.B.2.
Total No. of Page No.* Pages (Optional)*
Cover Sheet for Proposal to the National Science Foundation
Project Summary (not to exceed 1 page) 1
Table of Contents 1
Project Description (Including Results from Prior 15 NSF Support) (not to exceed 15 pages) (Exceed only if allowed by a specific program announcement/solicitation or if approved in advance by the appropriate NSF Assistant Director or designee)
References Cited 3
Biographical Sketches (Not to exceed 2 pages each) 9
Budget 4 (Plus up to 3 pages of budget justification)
Current and Pending Support 1
Facilities, Equipment and Other Resources 1
Special Information/Supplementary Documents 2 (Data Management Plan, Mentoring Plan and Other Supplementary Documents)
Appendix (List below. ) (Include only if allowed by a specific program announcement/ solicitation or if approved in advance by the appropriate NSF Assistant Director or designee)
Appendix Items:
*Proposers may select any numbering mechanism for the proposal. The entire proposal however, must be paginated. Complete both columns only if the proposal is numbered consecutively.
Keywords: Calcined clays, Pozzolans, Metakaolin, Thermal activation
OPC: Ordinary Portland Cement
SFB: Solid Fuel Block
XRD: X-Ray Diffraction
TGA: Themorgravimetric Analysis
DTG: Derivative Thermogravimetry
DTA: Differential Thermal Analysis
DSC: Differential Scanning Calorimetry
SEM-IA: Scanning Electron Microscopy – Image Analysis
EDX analysis: Energy Dispersive X-Ray analysis (or EDS)
EDS: Energy Dispersive Spectroscopy
NMR: Nuclear Magnetic Resonance
BSE: Backscattered Electron
PSD: Particle Size Distribution
BET: Brunauer Emmet Teller (theory for specific surface measurements)
MIP Mercury Intrusion Porosimetry
EPMA: Electron Probe Micro Analyser
1 Clay particles are made up of thin sheets or leaves, which is why argillaceous minerals are referred to as phyllite (“Phylon” means leaf in Greek). Thus, like micas, they form part of the phyllosilicates group.
Paula Twitty Bushman 4020 SW 54TH AVENUE Davie, Florida 33314
June 1, 2016
The following is an excerpt from my paper released at Broward College of Florida in a thesis research capacity and as such the following information was researched thoroughly. The paper in its entirety was graded at a one hundred percent and in review currently for release to engineering periodicals. It is with this research that I concluded that there will be serious needs in the future for continued research into Geopolymers to better suit safety needs as well as green technologies that can better serve our communities worldwide without releasing toxic chemicals into our environment. The excerpt as is follows:
Airplane Construction and Fire Protection The Benefits of Using Advanced Technology Construction Materials to Avoid Catastrophic Fire Hazards Justifies the Cost Incurred by Airlines
“Stronger composites, as discussed in this paper, have been mentioned such as geopolymers that could be used not only in aircrafts but also building materials and coated on steel to have reinforced strength and corrosive resistance, possibly lasting throughout time similar to the pyramids of Egypt; another example of geopolymerization at its best. Did the ancient Egyptians and Romans of past know chemistry much better than the modern age today?
In the interview with Patricia Billings she stated that “not only are the composites used in airplanes toxic, ignite rapidly and the smoke alone could kill anyone almost instantly, but the walls of the towers in New York on September 11, 2001, collapsed and the findings in the report by the NIST concluded that the drywall and the insulation failed in the buildings, due to fire and water damage”. (Billings, April 29, 2014).
New technologies such as geopolymerization and inorganic materials, which are low cost, (according to this analysis showing carbon/epoxy pricing and Paul F. Pugh’s statement on an inorganic material), have low curing temperatures and fireproof characteristics, definitely outweigh costs associated in creating better lightweight newer technologies to protect passenger safety.
All organics will burn as shown in studies; however inorganic materials do not burn. The next advancement in new technologies that will better benefit passengers on all types of aircrafts will be a lightweight geopolymerization material; however the FAA has not mandated that any manufacturer must use all inorganic materials. An interview with Mr. Lyon of the FAA was conducted on April 26, 2014 in which he states “as he knows it the geopolymer tests he performed in the mid-nineties, did not meet the weight requirements and were too heavy for airplane use, and he stated that this material to date, is not being used either structurally or in the interior of Airplanes”. (Lyon, Apr. 26, 2014).
There is a need for an overhaul to composites being used that are toxic to humans on airplanes and employees mixing these toxic materials at manufacturer plants. Improving further, fire properties in terms of flash over times on ignition, integrity of structures, smoke emitting materials and allowing for additional escape times of passengers will allow fire fighters additional time to set up, extinguish the fires and reduce loss of life.
According to T. Hull (2009), there is a need to satisfy this multibillion dollar market of polymeric materials to meet the need for fire safety, with combinations of alumina, silica, clay-phosphates combinations. Interestingly enough he discusses the nano particulate fillers, the shape of these, the use of carbon nano fibers and nanotubes, however the pricing of combinations of certain resins with fillers, and variations of clay powder can be cost effective in creating the best fire protection the airline has yet to see.” (Paula Twitty Bushman, 2014)
AmericanCoalAshAssociation Phone:720Ͳ870Ͳ7897 38800CountryClubDrive Fax:720Ͳ870Ͳ7889 FarmingtonHills,MI48331 Internet: www.ACAAͲUSA.org 2012CoalCombustionProduct(CCP)Production&UseSurveyReport Email:info@acaaͲusa.org
Beneficial Utilization versus Production Totals (Short Tons) FGD FGD Material Wet FGD Material CCP Production / 2012 CCP Categories Fly Ash** Bottom Ash** Boiler Slag* FGD Other* FBC Ash* Gypsum** Scrubbers* Dry Scrubbers* Utilization Totals
Total CCPs Produced by Category 52,100,000 14,100,000 1,720,945 24,200,000 6,803,636 655,119 326,762 9,843,922 109,750,384
Total CCPs Used by Category 23,205,204 5,474,167 1,437,556 12,102,964 546,616 205,733 0 8,914,774 51,887,014
1. Concrete/Concrete Products /Grout 11,779,021 732,260 0 63,607 0 5,372 0 0 12,580,260
2. Blended Cement/ Feed for Clinker 2,281,211 1,287,343 0 1,755,891 0 0 0 0 5,324,445
3. Flowable Fill 141,081 9,435 0 0 0 28 0 0 150,544
4. Structural Fills/Embankments 3,083,441 1,716,196 210,000 6,738 321,676 65,065 0 0 5,403,116
5. Road Base/Sub-base 193,711 352,469 1,300 31 0 0 0 0 547,511
6. Soil Modification/Stabilization 303,354 140,092 0 1,425 0 821 0 64,562 510,254
7. Snow and Ice Control 0 198,153 57,975 0 0 0 0 0 256,128
8. Blasting Grit/Roofing Granules 11,678 15,930 1,156,246 0 0 0 0 0 1,183,854
9. Mining Applications 2,086,074 437,986 0 1,181,799 224,940 118,868 0 8,762,464 12,812,131
10. Gypsum Panel Products 0 0 0 7,641,625 0 0 0 0 7,641,625
11. Waste Stabilization/Solidification 2,187,514 333 0 777,479 0 227 0 87,748 3,053,301
12. Agriculture 26,312 1,698 0 655,600 0 0 0 0 683,610
13. Aggregate 0 381,657 12,035 0 0 0 0 0 393,692
14. Oil Field Services 568,772 18,215 0 0 0 15,352 0 0 602,339
15. Miscellaneous/Other 543,035 182,400 0 18,769 0 0 0 0 744,204
Summary Utilization to Production Rate FGD FGD Material Wet FGD Material CCP Categories Fly Ash Bottom Ash Boiler Slag FGD Other FBC Ash CCP Utilization Total** Gypsum Scrubbers Dry Scrubbers
Totals by CCP Type/Application 23,205,204 5,474,167 1,437,556 12,102,964 546,616 205,733 0 8,914,774 51,887,014
Category Use to Production Rate (%)*** 44.53% 38.82% 83.53% 50.00% 8.03% 31.40% 0.00% 90.56% 47.27%
2012 Cenospheres Sold (Pounds) 23,104,970 This data represents 209, 598 MWs Name Plate rating of the total industry wide approximate 329,483 MW capacity (coal fueled) based on Ventyx data
The data received this year represents approximately 59 % of the coal consumed in 2012 by electric utilities and IPPs (approximately 821,400,000 tons) * These are actual tonnages reported by utilities responding and do not reflect estimates for utilities that did not respond this year. **These numbers are derived from previous, current and applicable industry-wide available data, including Energy Information Administration (EIA) Reports 923 and 860 and other outside sources. ***Utilization estimates are based on actual tons reported and on extrapolated estimates only for fly ash, bottom ash, and FGD gypsum;
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PROJECT SUMMARY
Overview:
Portland Cement and its products: poured concrete, blocks and pavers are the backbone of America’s building and developed infrastructure. A world is seeking solutions to Global Warming caused by the production and the emission of greenhouse gases (GHG). Experts believe the production of Ordinary Portland cement (OPC) contributes between 5% to 10% of the Global atmospheric GHG’s. With continued growth of just the CleanTech sector across all areas of the Globe coupled with government mandates directed to reduce GHG’s new technology needs deployment and ancient proven technology needs to be revisited. A good place to start in construction materials is with the still standing 4,500 yr. old Great Pyramids of GIZA. NSF findings published in 2007 concluded that when viewed at the sub- micron level that casing stones "were indeed consistent with a reconstituted limestone". With this grant the PI and the team will demonstrate what the future holds for a non- fossil fueled energy source used to synthesize inorganic soft rock polymers that will take shape and form the Brick and Mortar of the 21st Century and the 4th Industrial Revolution. . Intellectual Merit:
This Small Business Innovation Research Phase I project will reveal systems & methods for inorganic polymerization falling under a myriad of names, backed by hundreds of patents and a thousand scientific review articles. Emerging names in the applied material sciences are: Geopolymers, HydroCeramics, Soil Cements, and Alkali Activated Cement. All of these perspectives have in common as an alternative to OPC little market share at under 5%, high cost and a lack of recognized and approved standards. At present only one commercial Australian entity has been able to obtain and satisfy market share with a geopolymer concrete. To give specifying engineers, architects and owner/ builders a product they can work with and compare function requires requisite composites constructed with these emerging methods to have some kind of verifiable evidence at the electron level of just what the synthesized composite consists. Over the last 20 years the technical apparatus to observe at the nano molecular scale has become more readily available and affordable thus giving names and hypotheses to what previously could not be seen and therefore not easily understood. When it comes to polymers, "green" and natural are not the same. As their name implies, natural polymers (biopolymers) are polymers that occur naturally or are produced by living organisms. By a wider definition natural polymers can be man-made out of inorganic raw materials found in nature. Since we are a product of the earth upon which we live it stands to reason we should want to manage our resources well and to our advantage. Applied science has been used successfully to guide the incorporation of coal ash; a waste product of energy generation into a substantive replacement for Portland cement. Presently C-Trans and many DOT’s allow 25% substitution of OPC in a concrete mix with fly ash. This is allowed by codes and standards and while noteworthy it really has only scratched the surface of possibility and is hardly source sustainable long term if coal burning is curtailed in favor of another energy source.
Broader Impacts :
With recent advancements in material science, land use planning and a mandate Globally for carbon reduction to the atmosphere, (see Research Report attached, Investigating 21st Century Production in Interior Alaska using Alaskan Resources) no other branch of science offers more promise for a sustainable naturally occurring building material than geopolymers. Imagine a future where Oil dependence is replaced by the ground we walk on. This project proposes a direct response to a call throughout the engineering and standards community for a universal body of knowledge on the relationships between mix design, field performance, microstructure, and chemistry of inorganic polymers. [IP] Developing rural communities to undeveloped world nations can benefit from a rapid reliance on locally available "green" materials to build out, maintain, or improve their roads, dams, water delivery systems and commercial and domestic structures. The core objective of this project is to demonstrate a commercially ready inorganic polymer mix design with properties measured according to ordinary Portland cement standards or better of the practice. Less Energy overall in this project, compared to traditional manufacturing plants will meet the demands of the 4th industrial revolution and will be powered by green energy technologies. Over the last 20 years the technical apparatus to observe at the nano molecular scale have become more readily available and affordable thus giving names and hypotheses to what previously could not be seen and therefore not easily understood.
This small business will demonstrate that its innovative technologies and those of its founder can deploy to widespread commercial use a production concept using innovative nano particle sizing to create low embodied carbon reactive ingredients for use in high impact markets such as a replacement for Portland cement in construction. The testing and research will provide other products that are called out in the Project Description of 15 pages, which include no less than green technology for grout, paints, resins, wall boards, fencing and other products that could provide a forever long lasting weather resistance to the elements of natural destruction (wind, fire, water), also noted by Rezcast a company that produces slip resistant flooring. Imagine the future where lives are saved due to this type of green technology whereby fire does not spread, and roads do not disintegrate. GEOPOLYMER CLAY MINERALS
. GEOPOLYMER CLAY MINERAL PRODUCTS
Since its invention in the 19th century, ordinary Portland cement (OPC) and its products (i.e., poured concrete, blocks, and pavers) have grown to become the backbone of societal infrastructure. The only substance used more widely today is water. In the 21st century, however, OPC faces many challenges. The world is seeking a solution to the negative environmental effects stemming from the production of greenhouse gases (GHG), and OPC is responsible for ~ 5 -10 % of global production of GHGs. At the same time, other challenges are also growing, including the storage, use or re-use of industrial waste. The lack of options for appropriate, sustainable, and affordable building materials in many developing municipalities, and problems associated with our ageing concrete infrastructure present untold threats to future generations.
To reduce the threat that atmospheric carbon dioxide brings a single emerging technology could be a partial solution to many problems: Inorganic Geopolymer Cement (IPC). Made primarily from ubiquitous industrial by-products (waste), IPC can be competitive with OPC in performance, but with significantly lower CO2 emissions. Side benefits include projections for lower cost, improved durability. Today, a variety of systems are being promoted under several names such as Inorganic Polymer Cement [IPC] geopolymer cement [GC], Hydro Ceramics, Soil Cements, or just Alkali Activated Cements, realize though OPC still commands a 95% market share with billions of dollars in sunken capital.
Numerous scientific review articles and comprehensive books on the state-of-the-art lay claims for several varieties of Geopolymer based cement and concrete. Advantages over OPC include: (i) dramatically less CO2 production; (ii) longer life and better durability; (iii) better defense against chemical attacks (i.e., chloride, sulfate); (iv) rapid strength gain; (v) better performance in marine environments; (vi) repurposing of unclaimed industrial/agricultural waste; (vii) composites containing steel like properties with the light weight and flexibility found in plastics or wood; and (viii) uncompromising resistance to high temperature. IPC still has several design challenges to overcome, including, (i) rapid setting; (ii) leaching and salt efflorescence formation; (iii) variation in raw materials, and; (iv)temperature effected curing. The design advantages, and challenges, for IPC vary by type (magnesia, slag, geopolymer, sulfoaluminate, etc.), but the preceding list is fairly typical of alkaline based GC.
The core objective of this project is to correlate mix design and cement component properties by experiment (i.e. chemistry, particle size) to bulk performance, of a light weight, low embodied carbon, and inorganic composite compound.
This project represents a direct response to a call throughout the engineering, scientific and standards community for an improved body of knowledge for a one on one comparison using established Portland cement mix designs. Recent developments in Portland cement mixes have made use of widely available by- products of energy generation, agriculture and industry. Short term, this has made use of many slags and fly ashes to achieve carbon dioxide reductions by extending OPC.
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The critical link between otherwise waste component chemistry and Portland concrete performance has meant a conservative approach in an already snail paced environment. Standards are just know trickling down to the masses involving the use of slag, fly ash, as well as natural Pozzolans. Standards are important in overcoming a major stumbling block created for the design engineer: the field variation in cementitious by-product streams. Since the 1990’s slags and fly ashes have evolved from being by-products to becoming co-products, further promoting the recycling and reuse of billions of tons of “waste” into essential building materials.
Geopolymer synthesis
Covalent bonding
The fundamental unit within a geopolymer structure is a tetrahedral complex consisting of Si or Al coordinated through covalent bonds to four oxygens. The geopolymer framework results from the cross-linking between these tetrahedral, which leads to a 3-dimensional aluminosilicate network, where the negative charge associated with tetrahedral aluminum is balanced by a small cationic species, most commonly an alkali metal cation. These alkali metal cations are often ion- exchangeable, as they are associated with, but only loosely bonded to, the main covalent network, similarly to the non-framework cations present in zeolites.
The mainstream development in the field of concrete and other cement products focuses on the modification of mortar, concrete, and other mixtures using OPC containing flyash. For the long term this may prove unsatisfactory, as recent government regulations are poised to mandate long term decommissioning of coal fired combustion in order to turn back the negative effect of climate change. Within this proposed project, the cement itself, the resin or binder that makes all concrete products possible, would be the focus, opening the doors to revolutionary rather than evolutionary expectations.
The PI proposes this is best accomplished on advice from the scientific and engineering design community within California to take existing OPC codes, standards, and test methods and use them as the control sample and benchmark. From there mix and record the outcomes of the new mix designs using the sub-micron (nano meter measure) component which is an innovation that the PI and his company brings to the market. When proven successful this project would serve as a model for sustainable growth using green materials in the 4th Industrial revolution. A revolution that will demand that materials be inexpensively available that can construct such a structure as a 3D printed house.
A mainstream introduction of alternative cements [IP & GC] test results at the conclusion of this project to the California Department of Transportation [Caltrans] new products review would create job opportunities and be unlikely to impact established cement producers who could adapt to the emerging technology.
Inorganic polymerization (IP) is designed to function as a direct replacement for OPC, so production of, and construction with (IP) would be performed using existing methods, minimizing the need for additional training or equipment.
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Progress has been made in the development and understanding of a fine mineral powder based aluminosilicate aggregate concrete/mortar comprising ground energetically modified cement, activated by water. This system was chosen for several reasons, including literature support for the success of using ubiquitous and accessible kaolin clays as a precursor and the fact that of common activators, H20 is the most inexpensive, available, and environmentally benign agent. Activator is used here loosely to designate a point in time from which plasticity of a dry powder precursor is manipulated (mixed) into a liquid including water to agglomerate the mineral powders over a prescribed time into a solid composite.
The production of 100% [IP or GC] cement developed through this project is projected to produce approximately 50 kg of CO2 per ton as opposed to 900+ kg per ton for OPC, a ~95% reduction. If all global slag and fly ash supplies were utilized for geopolymerization as an OPC alternative, global CO2 production would be reduced by 10% or ~ 3 billion tons annually. This project can reveal a pathway for significantly reducing global CO2 production, demonstrate sustainable extractive mining, and continue to reuse and recycle agricultural/industrial waste. Because the raw minerals used are ubiquitous, and the approach, in principle, is flexible to accommodate varying local conditions; the potential impacts are broadly applicable and transferable around the world.
If all industrial/agricultural wastes were to become exhausted, the solar calcination of native clay soils for cement could as a result of this project be considered as a highly reactive synthetic precursor to geopolymer cement with zero contribution to atmospheric CO2 for the life of the soft rock soil resource.
The team members are established contacts of the PI and represent Materials, Business of Applied Science, Chemical, Power, Civil Engineering, Geology and Soils, and Entrepreneurship. Their tools, techniques, experience and perspectives from all seven disciplines will be leveraged, including respectively: characterization and chemistry, systems design, and cement/concrete expertise. A direct and positive impact for the people at the epicenter of this project will be to improve their lives by making high-quality building materials more available and affordable. The local mineral source under development, Sears White River Clay (SWRC) has an inherent natural ceramic benefit of high fire resistance and insulating properties.
Collectively all Californian’s benefit using locally sourced inorganic polymer cement.(i) The introduction of alternative “green”cements create job opportunities, and are unlikely to negatively impact established cement producers, especially in this instance as currently there are none planned within a 200 mile radius of the proposed business location due to clean air restraints and the high cost of energy (ii) Production of and construction with “green” concrete would be performed using off the shelf methods, minimizing the need for additional training or equipment.
Why White River Clay (WRC)? WRC is the finely divided powder that results from the pulverization of clay the mineral. Therefore, WRC the powder is an aluminosilicate that is free from any hazardous contents and is able to pass stringent tests that allow it to be used in foods.
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How does clay compare to fly ash? Currently, over (22 million tons) of mineral fillers are used annually in a variety of engineering applications.
Typical highway engineering applications include: Portland cement concrete (PCC), soil and road base stabilization, flowable fills, grouts, structural fill and asphalt filler. What makes WRC useful? Its species is most commonly used as a pozzolan in PCC applications. Pozzolans are defined as siliceous or siliceous and aluminous materials, which in a finely divided form and in the presence of water, react with calcium hydroxide (lime) at ordinary temperatures to produce cementitious compounds.
The unique shape and particle size distribution of WRC also makes it a great mineral filler in hot mix asphalt (HMA) applications and it improves the fluidity of flowable fill and grout. It was marketed for a number of years as a pumping aide for OPC in Southern California. The consistency and abundance of mineral pozzolan in Central California foothills present unique opportunities for use in structural fills and other highway applications including the developing California High Speed Rail Project which is estimated to use 3 cubic yards of OPC concrete per lineal foot.
Environmental Benefits. Natural mineral powder utilization, especially in concrete, has significant environmental benefits including: (1) increasing the life of concrete roads and structures by improving concrete durability, (2) net reduction in energy use and greenhouse gas and other adverse air emissions when mineral powder is used to replace or extend manufactured OPC, (3) conservation of other natural resources and materials.
Characteristics as to Size and Shape. Mineral powders are typically finer than Portland cement and lime. California clay aluminosilicates consist of fine-sized particles which are generally flat or sheet-like, typically ranging in size between 10 and 100 micron. These small particles improve the fluidity and workability of fresh concrete. The PI believes fineness is one of the most important properties contributing to the pozzolanic reactivity of clay mineral powders. Chemistry Clay such as those from White River consist primarily of amorphous oxides of silicon, aluminum and iron. Magnesium, potassium, sodium, and titanium are also present to a trace degree.
When used as an Engineering Material for a mineral admixture in concrete, it would typically be classified as either Class C or Class F fly ash based on its chemical composition. The state of California shy away from calcium based admixtures due to concerns with Alkali Silica reactivity [ASR] American Association of State Highway Transportation Officials (AASHTO) M 295 [American Society for Testing and Materials (ASTM) Specification C 618] defines the chemical composition of Class C and Class F fly ash. Class C ashes are generally derived from sub- bituminous coals and consist primarily of calcium alumino-sulfate glass, as well as quartz, tricalcium aluminate, and free lime (CaO).
Class C ash is also referred to as high calcium fly ash because it typically contains more than 20 percent CaO. Class F ashes are typically derived from bituminous and anthracite coals and consist primarily as do most West Coast clays of an alumino-silicate glass, with quartz, mullite, and magnetite also present. Class F, or low calcium fly ash has less than 10 percent CaO.
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Therefore under today’s standards California Clays are within a Class F, fly ash as relates to chemistry- but that is only half the story when it comes to high performance cement. Color: Clay can be white to light gray, depending on its chemical and mineral constituents. Beige and light colors are typically associated with high kaolinite content. A heavy beige color is typically associated with the iron content. Uniformity of a clay body’s characteristics will vary so it is imperative to classify to maintain a consistent product. Clay chemistry and characteristics are typically known in advance so concrete mixes are designed and tested for performance. Quality Assurance and Quality Control criteria vary for each use of the mineral powder within the various markets and specifications.
Some agencies or owners require certified samples from the silo on a specified basis for testing and approval before use. Others maintain lists of approved sources and accept project suppliers' certifications of quality. The degree of quality control requirements depends on the intended use, the particular deposit location by drill verification, and its variability. Testing requirements are typically established by the individual specifying agencies.
Highway Applications
Using Mineral additives in Portland Cement Concrete. Clay is used in concrete admixtures to enhance the performance of concrete. Portland cement contains about 65 percent lime. Some of this lime becomes free and available during the hydration process. When the right clay is present with free lime, it reacts chemically to form additional cementitious materials, improving many of the properties of the concrete. Benefits- The many benefits of incorporating clay pozzolan as an SCM similar to Class F- Fly Ash into PCC have been demonstrated through extensive research and countless highway and bridge construction projects.
Benefits to concrete vary depending on the type of specification, proportion used, other mix ingredients, mixing procedure, field conditions and placement. Some of the benefits of Clay in concrete: Higher ultimate strength ; Improved workability ; Reduced bleeding ; Reduced heat of hydration; Reduced permeability ; Increased resistance to sulfate attack; Increased resistance to alkali-silica reactivity (ASR) ; Reduced shrinkage; Increased Durability; and Lowered costs.
Samples of clay will be calcined at temperatures based on laboratory findings of their thermogravimetric performance. The characterization of the raw and calcined clays will be analyzed subject to budget limitations and availability using XRD, TGA, DTA, NMR, PSD, BET and SEM. The study of the pozzolanic activity in the cement pastes will be done by replacing 10% to 50% of cement by the clays at a water/binder ratio at a baseline of 0.4. Curing will follow in water at 30°C to simulate the California climate. CH depletion will be monitored using XRD and TGA up to 90 days. The degree of hydration of the clinker component will be assessed by BSE-image analysis. The identification of the hydrated phases in pastes will be at optimum using XRD, NMR and SEM. To measure the different reactivity’s of the clays from a mechanical properties perspective, standard mortar bars (w/b 0.5) are suggested and will be cured under the same conditions as the pastes for testing in compressive strength at 1, 7, 28 and 90 days.
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Another NSF Study by researcher Leslie J. Struble, University of Illinois, DMR 1008102 published the following finding:
“The research group has successfully identified geopolymer gel and calcium silicate hydrate using MAS-NMR in geopolymers prepared using metakaolin with added calcium oxide. This result represents an important advancement in the characterization of geopolymers. With this achievement, it is now possible to determine the composition and amount of each phase in a geopolymer. Only with this achievement will it be possible to relate geopolymer composition to engineering properties”.
Polymer-Clay Nanocomposites
One of the desirable end-goals of materials science research is the development of multi- functional materials. These materials are defined as compositions that bring more than one property enhancement to a particular application, thus allowing the material to replace more than one other material in an engineered object, or to replace an entire class of materials which alone, are only capable of addressing one end-use need.
The polymer nanocomposite field has been earnestly studied since the early 1990’s, spawning dozens if not hundreds of conferences, books, and journal articles. To some extent, it became a major field of study due to key papers from Gianellis and Vaia in the mid-90s and to the release of a commercial polyamide-6 clay nanocomposite by Ube/Toyota of Japan. From the broad discipline approach it can be said that polymer nanocomposite technology has been around for quite some time in the form of latex paints, carbon-black filled tires, and other polymer systems filled with nanoscale particles. However, the nanoscale interface nature of these materials was not truly understood and elucidated until late last century. Today, there are dedicated review papers and books that cover the entire field of polymer nanocomposite research, including applications, with a wide range of nanofillers such as layered silicates (clays), carbon nanotubes/nanofibers, colloidal oxides, double-layered hydroxides, quantum dots, nanocrystalline metals, and amorphous mineral resins. The majority of the research conducted to date has been with organically-treated, layered silicates, or organoclays, for purposes of this NSF Grant Proposal the focus is on untreated geopolymer nanocomposites made with alumina-silicate minerals.
Before describing organoclay structure and chemistry, a rudimentary understanding of the polymer nanocomposite itself is required. A traditional composite containing micron or larger particles/fibers/reinforcement can best be thought of as containing two major components, the bulk polymer and the filler/reinforcement, and a third, very minor component, or interfacial polymer. Poor interfacial bonding between the bulk polymer and filler can result in an undesirable balance of properties, or at worst, material failure under mechanical, thermal, or
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GEOPOLYMER CLAY MINERALS electrical load. In a polymer nanocomposite, since the reinforcing particle is at the nanometer scale, it is actually a minor component in terms of total weight or volume percent in the final material. If the nanoparticle is fully dispersed in the polymer matrix, the bulk polymer also becomes a minor, and in some cases, a non-existent part of the final material. With the nanofiller homogenously dispersed in the polymer matrix, the entire polymer becomes an interfacial polymer, and the properties of the material begin to change. Changes in properties of the interfacial polymer become magnified in the final material, and great improvements in properties are seen.
Therefore, a polymer nanocomposite is a composite where filler and bulk polymer are minor components, and the interfacial polymer is the component that dictates material properties. With this in mind, the design of the nanoparticle is critical to nanocomposite structure, and careful understanding of nanoparticle chemistry and structure are needed. The only exception would be where the clay also becomes the finish matrix or where the clay becomes integral to a new compound as in the case of MetaCrete ™as an alternative or compliment to ordinary Portland cement Concrete. Under this circumstance the composite would be referred to as an inorganic geopolymer. [PI]
Organoclay Chemistry and Structure Clays are a broad class of inorganic layered structures. They can occur naturally or be made via synthetic techniques. While many different clay structures have been used in the synthesis of organoclays and polymer-organoclay nanocomposites, the majority of the research has been accomplished with montmorillonite. Montmorillonite is a 2:1 aluminosilicate, meaning it is composed of an octahedral aluminum oxide layer sandwiched between two tetrahedral silicon oxide layers. In the octahedral layer, aluminum atoms are replaced with other cations (e.g., magnesium, iron), which creates some charge defects in the structure (Figure 1). This means that montmorillonite has cations associated with its structure to balance this charge in the octahedral layer, and these cations sit atop the silicate tetrahedral layer.
Without this organic treatment, the montmorillonite would never disperse into the polymer and remain as micron-sized particles, serving as traditional filler. The PI for this project believes that Akl Awwad stating in his book “Nano-structured kaolin clay and its Industrial Applications” provides sufficient evidence that kaolin clay and or non-expansive montmorillonite clay can disperse into organic polymers without the organic treatment referenced above or certainly with a less complicated and lower cost process. Such a process would rely on increased mechanical particle size reduction. Polymer clay nanocomposites show great promise for materials science applications, but the synthesis and successful development of these materials is not simple. Organoclays are not a “drop-in” solution; careful selection and consideration of the entire nanocomposite system must be undertaken before a successful polymer-clay nanocomposite (or any nanocomposite for that matter) can be prepared and utilized for a new materials science application.
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The most common use of polymer-clay nanocomposites has been in mechanical reinforcement of thermoplastics, especially polyamide-6 and polypropylene. The aforementioned polyamide-6 clay nanocomposite produced by Ube/Toyota was used to replace a metal component near the engine block that yielded some weight savings. The clay in this application improved the heat distortion temperature of the material, allowing it to be used in this higher temperature application. GM/Blackhawk has also announced polypropylene-clay nanocomposites for automotive applications, and the clay brought an increase in flexural/tensile modulus while maintaining impact performance. The use of polymer-clay nanocomposites for flame retardant applications is becoming more common, especially as it is realized that the clay nanocomposite can replace part of the flame retardant package while maintaining fire safety ratings at a lower flame retardant loading.
Before describing organoclay structure and chemistry, a rudimentary understanding of the polymer nanocomposite itself is required. A traditional composite containing micron or larger particles/fibers/reinforcement can best be thought of as containing two major components, the bulk polymer and the filler/reinforcement, and a third, very minor component, or interfacial polymer. If the nanoparticle is fully dispersed in the polymer matrix, the bulk polymer also becomes a minor, and in some cases, a non-existent part of the final material. With the nanofiller homogenously dispersed in the polymer matrix, the entire polymer becomes an interfacial polymer, and the properties of the material begin to change. Changes in properties of the interfacial polymer become magnified in the final material, and great improvements in properties are seen. Therefore, a polymer nanocomposite is a composite where filler and bulk polymer are minor components, and the interfacial polymer is the component that dictates material properties.
With NSF Phase 1 successfully completed key objectives would be satisfied allowing the following product launch during construction of a first phase micronizing module capable of ~10,000 tons per year with a capital cost of ~$1.5 million.
Widespread Commercial Transportation Market
Include Surfaces for Airports, Bridge Decks, Roadways and more, MetaCrete Systems ™ a family of advanced polymer cement slurry surfacing (PCSS) products that provide a durable barrier over asphalt and concrete pavements. By addressing specific pavement needs before the onset of serious damage, these Systems can extend service life and defer more expensive remedies. New products, which include: MetaCrete ™ Friction Surface, MetaCrete Crack fill, and MetaCrete Coating Preserve, have been formulated to engage common surfacing problems experienced by roadway, airport and bridge deck pavements, not to mention industrial, institutional and food processing surfaces. Per American Road and Transportation Builders Association, “Industry consensus finds that every dollar invested in pavement & surface preservation yields as much as 10 times that value in extended service life.” This concept rings true for maintenance and rehabilitation using new MetaCrete Geopolymer products. Pavement surfacing solutions like MetaCrete Systems ™ minimize traffic disruption, and optimize surface pavement performance at the lowest possible life-cycle cost. MetaCrete ™
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GEOPOLYMER CLAY MINERALS applied as a micro surface provides a safe, green and quick installation and is also viscosity adjustable to ensure ease of penetration into cracks, voids and surface irregularities. The surfacing offers abrasion resistance to traffic, protecting the substrate from exposure to liquid intrusion due to its low air voids, it is effectively resistant to freeze/thaw cycles and resistant to de-icing salts and its geopolymer ceramic like properties resist exposure to heat and flame to thousands of degrees unlike any other product in this market today.
A single 1/8th inch (125mil) to 2 inch application is thermally compatible with asphalt and concrete, ensuring short and long-term bond strength with the substrate in the event of extreme thermal activity – unlike some epoxies or thermal plastics. MetaCrete ™ offers safety colors for surface application, which can be customized to match specific requirements or blend with an existing pavement. Because pigments can be integrated within the dry product prior to mixing at the job site, surface color treatments are more uniform across the job, wear better and last longer. Light colors make a big difference to surface temperatures and the surrounding air temperature. With this in mind, Natural MetaCrete ™ is an off-white color that can create ‘cool pavements’ when applied over asphalt that delivers significant environmental benefits.
The MetaCrete System ™ begins by offering a 1/8th inch (125mil) thick product that provides surface durability, adds minimal weight to the structure, looks similar to the existing concrete surface and provides a fast installation and return to use. Contracted services include site evaluation, conceptual engineering, design, value engineering and turnkey installation through Rezcast Industrial Services of Fresno, California.
Covalent bonded inorganic polymer coatings [CIP’s]
Covalent bonded inorganic polymer, also known as geopolymer powder coating and is to be commonly referred to as CIP coating, is a mineral-based powder coating that will be disruptive to current petroleum based products used in construction. CIP coatings are inorganic thermoset- polymer coatings. They come under the category of protective coatings in paints and coating nomenclature. The name Covalent bonded polymer is based upon resin cross-linking and the application method, which is different from a conventional paint. The resin and hardener components in the dry powder CIP stock remain unreacted at normal storage conditions. At typical coating application temperatures, usually in the range of 25 -100°C the contents of the powder begins to polymerize in the presence of water. The liquid film wets and flows onto the surface on which it is applied, and soon becomes a solid coating by chemical cross-linking, expedited and assisted by heat. This process is known as “fusion (covalent) bonding”. The chemical cross-linking reaction taking place in this case is irreversible. Once the curing takes place, the coating cannot be returned to its original form by any means. Application of further heating will not “melt” the coating and thus it is known as a “thermoset” coating. The world's leading petroleum based Fusion Bonded Epoxy [FBE] manufacturers are Valspar, SolEpoxy (former Henkel/Dexter), KCC Corporation, Jotun Powder Coatings, Sherwin-Williams, 3M, Axalta, Akzo Nobel, BASF, Rohm & Haas, and Dow- Corning.
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History of Market
Since their introduction as a protective coating in the early 1960s, FBE coating formulations have gone through vast improvements and developments. Today, various types of FBE coatings, which are tailor made to meet various requirements are available. FBEs are available as stand- alone coatings as well as a part in multi-layers. FBE coatings with different properties are available to suit coating application on the main body of pipe, internal surfaces and linear surfaces.
Essential components of a powder coating are Organic or Inorganic Based resin, Hardener or curing agent/s, fillers and extenders, and color pigments. The resin and hardener part together is known as the "Binder". As the name indicates, in Fusion bonded epoxy coatings the resin part is an "epoxy" type resin. “Epoxy” or “Oxirane” structure contains a three membered cyclic ring — one oxygen atom connected to two carbon atoms - in the resin molecule. This part is the most reactive group in the epoxy resins. Most commonly used FBE resins are derivatives of bisphenol A and epichlorohydrin.
The second most important part of FBE coatings is the curing agent or hardener. Curing agents react either with the epoxy ring or with the hydroxyl groups, along the epoxy molecular chain. Various types of curing agents, used in FBE manufacture, include dicyandiamide, aromatic amines, aliphatic diamines, etc. The selected curing agent determines the nature of the final FBE product — its cross linking density, chemical resistance, brittleness, flexibility etc.
In addition to these two major components, FBE coatings include fillers, pigments, extenders and various additives, to provide specific desired properties. These components control characteristics such as permeability, viscosity, hardness, color, thickness, abrasion resistance etc. All of these components are normally dry solids, even though small quantities of liquid additives may be used in some FBE formulations. If used, these liquid components are sprayed into the formulation mix during pre-blending in the manufacturing process.
The standard for FBE coating of pipelines is ISO 21809 Part 2. This NSF Grant is proposing to develop a trial standard similar to ISO 21809 for the company’s inorganic formulations as used in the organic petroleum based market (testing standards) that can be cross referenced for use on existing concrete structures so as to provide an inorganic polymeric cementitious veneer to enhance and prolong existing concrete surfaces. Note paragraphs above are written from an organic chemistry perspective because no standards currently exist for inorganic polymerization. Polymerization as a procedure doesn’t change only the terminology perspective would differentiate, inorganic being at least an order of magnitude less hazardous and more environmentally friendly.
CIP powder manufacturing process
Essential parts of a powder coating manufacturing plant are, weighting station, pre-blending station, an extruder and a classifier or grinding unit.
The components of the CIP formulation are weighed and pre-blended in high speed mixers. The mix is then transferred to a high-shear extruder. CIP extruders incorporate a single or dual screw
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GEOPOLYMER CLAY MINERALS setup, rotating within a fixed clamshell barrel. A temperature range from 25 °C to 100 °C is used within the extruder barrel. This setup compresses the CIP blend. During this process, the ingredients of the ambient mix are dispersed thoroughly. Because of the fast operation of the extruder and relatively low temperature within the barrel, the powder and hardener components will not undergo a significant chemical reaction.
The plastic then passes between cold-rollers and becomes a solid sheet or shape. Note: After the extraction stage (mining) of the mineral precursor as chips, they are pulverized, using high speed grinders (classifiers) to a particle size of less than 150 micrometers (standard specifications requires 100% pass through in 250 micrometer sieves and maximum 3% retains in 150 micrometer sieve). To create the reactive mineral precursor a process similar to that used in the Portland cement industry called Energetically Modified Cement [EMC] is used to activate the mineral molecules; during this process the precursor product is packaged in closed containers, with particular care given to avoid moisture contamination. Normal storage of powder coatings are in temperature/humidity warehouses or portable frac tanks as found in the petroleum industry may be used.
Coating application process Regardless of the shape and type of surface to be coated, the CIP powder coating application has three essential stages first, the surface is thoroughly cleaned, then the cleaned surface may be damp dried, and finally the coating may be box screed applied or spray like using a gunite or shotcrete nozzle.
Surface preparation - blast cleaning is the most commonly used method for preparation of steel or concrete surfaces. This effectively removes rust, scale, loose concrete, etc., from the surface and produces an industrial grade cleaning and a rough surface finish. The roughness of the steel achieved after blasting is referred to as profile, which is measured in micrometers or mils. Profile increases the effective surface area of the steel. The cleanliness achieved is assessed to ISO 8501-1 grades: these originated from a set of photographic slides in a Swedish standard (SIS) showing exemplars of the common terminology of white-metal, near white-metal, etc. It is important to remove grease or oil contamination prior to blast cleaning. Solvent cleaning, burn-off, etc., are commonly used for this purpose. In the blast cleaning process, compressed air (90 to 110 psi) is used to force an abrasive onto the surface to be cleaned. Aluminum oxide, steel grit, steel shot, garnet, coal slag, etc., are the frequently used abrasives. In this method, abrasive is thrown to the surface, using a specially designed wheel, which is rotated at high speed, while the abrasive is fed from the center of the wheel. The company owns a ride on Blastrac capable of surface preparation on concrete at 2000 square feet per hour.
Heating of CIP Powder for Increased Reaction The CIP powder at the factory is placed on a “fluidization bed”. In a fluidization bed, the powder particles are suspended in a stream of air, in which the powder will “behave” like a fluid The fluidized powder is subjected to a flash exposure of plasma at a predetermined rate to thermodynamically change the properties of the mineral. The company believes they can run commercial quantity (4 tons per hour) of the mineral precursor through this process powered by
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GEOPOLYMER CLAY MINERALS an array of PV Panels. This would be the first commercial scale demonstration of this renewable energy method in this industry.
Standard coating thickness range of stand-alone CIP without aggregate filler is between 250 to 500 mils, even though lower or higher thickness ranges might be specified, depending on service conditions. The slurry powder ‘flows’ into the profile and bonds with the substrate. The slurry powder will become a solid coating, when the ‘set- time’ is over, which usually occurs within few seconds after coating application. The resin part of the coating will undergo cross-linking, which is known as “curing” under the hot condition. Complete curing is achieved either by the residual heat on the substrate, or by the help of additional heating sources. Depending on the CIP coating system, full cure can be achieved in less than one day to a day or two. The PI proposes to partner with Bruce Roeder as an evaluator of our Laboratory findings for use in Civil Works Applications, such as Friction surface coatings for highway pavements.
Need for New Supplementary Cementitious Materials
In spite of its often negative image based on the California Legislature’s AB 32 the Greenhouse Gas Initiative, concrete is the building material best suited to meet the demand – it is flexible, gives good performance in use, the basic raw materials are widely available and it has a relatively low energy and environmental impact compared to alternatives. Nevertheless, cement, the central ingredient is often disproportionately expensive in developing regions due partly to the significant energy consumption associated with its manufacture.
The most promising option to lower costs (and environmental impact) is to blend conventional Portland cement with pozzolanic materials. Pozzolans occur in natural deposits or can be obtained as by products in the form of waste from the agricultural-industrial sectors. They have drawn the attention of cement manufacturers for their good performance as cement replacement materials. Fly ash and slag, derived from the coal fired power stations and steel industries respectively, are good examples of industrial by-products that are being extensively used to substitute cement.
However, it is important to realize that in the long term, these existing by-products cannot fulfil the growing demand for supplementary cementitious materials (SCM’s). Moreover, the availability of these by-products in California is scarce. Thus, there is growing concern to find new alternative SCM’s from local sources that are affordable and yet contribute to providing sustainable solutions. With these considerations in mind, there is growing interest in this project to focus on calcined clayey soils. First, because it is a widely accessible material, and second because it has already been shown that under exposure to specific temperature conditions, the materials could reveal excellent pozzolanic properties. This has emphasized the need for a scientific approach in order to understand the influence the type of clay has on the activation potential of these materials by thermal treatment.
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A major part of this project the PI is dedicated to investigating:
• Study the decomposition mechanisms leading to clay activation. Although many works report on phase changes of clays with temperature, the decomposition sequence of these materials is still unknown and the structure of metastable phases is still unresolved.
• Identify parameters controlling the pozzolanic reactivity of a calcined clay. These parameters are chemical or physical and will depend on the raw material and the thermal treatment.
• Understand the effect of calcined clays on the microstructure of cementitious materials. Little work has been done to explain the mechanical properties of cement-calcined clays blends based on the interaction of these materials at the microstructural level.
• Predict the pozzolanic activity of any clay according to its mineralogy
• Provide local communities with simple techniques derived from these fundamental studies to evaluate the activation potential of any given clay.
• Identify new or already existing technologies where the activation process can be justified by a commercial green energy source.
It should be mentioned that other types of clay exist, based on oxides other than silica and alumina such as silica and magnesia or silica and iron oxide. Nevertheless, the ubiquitous alumino-silicates minerals represent 74% of the earth’s crust and that is why clays based on alumino-silicates structures as found in Tulare County’s Sears Clay Deposit will be considered exclusively in this Project. Different clay mineral groups are characterized by the stacking arrangements of sheets and the manner in which two, successive two or three-sheet layers are held together • The 1:1 layer group (Kaolinite, Halloysite) • The 2:1 layer group Pyrophyllite, Smectite (Montmorillonite), Vermiculite, Illite) • The 2:1:1 layer group (Chlorite) Note: that more than one type of clay mineral is usually found in most soils. Also, irregular or random interstratification of two or more layer types often occurs within a single particle.
Conclusion
Generally SCM (supplementary cementitious material) used for concrete construction in California are not originated in the State. Research of the supply and demand of SCMs demonstrates that; (i) the future supply of fly ash is uncertain; (ii) the supply of granulated blast furnace slag is limited to sources in Pacific Asia and is also uncertain; and (iii) the long-term alternative to the referenced industrial by-products are processed natural pozzolans that are widely available in California.
Natural pozzolans have many similarities with fly ash Class F, the most commonly used SCM in California and the United States. In contrast to fly ash, which is a by-product of coal combustion at power plants, EMC’s natural pozzolan-based SCM is a manufactured product having
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GEOPOLYMER CLAY MINERALS controlled and consistent chemical and mineral compositions. EMC Technology is a low-energy process consisting of mechanical grinding and activation. The end-product has a high degree of amorphization, optimized particle-size distribution and improved surface morphology, all enhancing its concrete making properties.
Supply Limitation
None of the SCMs intended for use in concrete originate or are produced in California. Our analysis indicates that, upon complete recovery to the level of 2005, the annual demand for SCMs in California may reach; -3 million tons, if the average replacement rate of Portland Cement in concrete would be increased to 15% -4 million tons; if the average replacement rate of Portland Cement in concrete would be increased to 20% -10 million tons; if the average replacement rate of Portland Cement in concrete would be increased to 50%.
Coal Fly Ash
According to the “Corrected 2009 Coal Combustion Product Production & Use Survey by ACAA” [4], the total volume of fly ash produced in the U.S. was 63 million tons, volume of fly ash for concrete and grouts was 9.8 million tons and volume of fly ash used for production of blended cements and Portland cement clinker was 2.4 million tons. Other significant applications of fly ash included: -Structural fills and embankment: 4.6 million tons -Waste stabilization/solidification: 3.5 million tons-Mining application: 2.1 million tons. Total industrial usage of fly ash reached 24.7 million tons or 39% of the volume originated. Approximately 61% of fly ash was disposed of in landfills, most of which would not otherwise be usable in concrete. Coal fly ash is mostly originated in the Mid-West, North-East and South-East (from Texas eastwards)
California Building Code (DSA/OSHPD), Caltrans Stand Specification and some other governing specifications limit the use of fly ash to Class F only. Class C fly ash is not considered efficient in mitigating deleterious expansion caused by reaction of siliceous aggregate with alkali and sulfate problems due to its high calcium oxide (CaO) content. Considering the abundance of potentially reactive sources of aggregates in California, in our vision, Class F fly ash with low to moderate content of calcium oxide (CaO) will remain the only permitted fly ash.
Analysis performed by Keybridge Research and CTL Group for Coalition of Cement Manufacturers of California demonstrates that future supply of concrete quality fly ash is highly uncertain.
Some of the factors contributing to the uncertainty of fly ash Class F supply to California noted in the referenced research and further justification for this project are:
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GEOPOLYMER CLAY MINERALS
-Recovery of the construction industry with a projected increase in consumption of cement in the U.S. of more than 117% between 2010 and 2030 leading to an increase in fly ash consumption in the areas of its origin;
-Environmental regulations that may, in general, limit use of fly ash
-Projected increase of the usage of subbituminous coal resulting in the decrease volume of outcome of fly ash Class F
-Decreasing use of coal in favor of natural gas;
-Cost driven by, among other, (i) long transportation distances, (ii) dwindling supply as power plants switch coal supply leading to Class C ash, (iii) potential environmental regulation where heavy metals are present that classifies fly ash as a “special waste” subject to regulation, (iv) possible processing of fly ash to remove substances making some fly ash unsuitable for concrete, and (v) increasing demand in markets where the fly ash originates.
Ground Granulated Blast Furnace Slag (“GGBFS”)
GGBFS is a by-product of steel refining processes. It belongs to the group of hydraulic CMT (as opposed to fly ash Class F which is pozzolanic in nature). The U.S. blast furnace mills are concentrated in the eastern United States. It is therefore more cost efficient to import slag to the Southwest United States from Asia. GGBFS supplied to Northern California and Oregon was mostly shipped from China and Japan.
In 2010 GGBFS was available only in Northern California. A total estimated amount of imported GGBFS was approximately 100,000 tons. The implementation of new Caltrans Standard Specifications will increase the demand for GGBFS.
The foreseen limitations to importing GGBFS to California are due to:
-Capacity of steel and iron mills in coastal areas of China, India, and Japan;
-Capacity of quenching facilities needed for producing granulated slag consisting of active glass phase;
-Increasing consumption of GGBFS by local Asian cement and concrete industries;
-Decreased production of GGBFS by steel and iron mills in China due to the current economic slowdown and increased environmental regulations.
-Limited availability of port terminals equipped for powder products in California; - Cost. Within the next decade supply of GGBFS to California may increase to approximately 400,000 tons, still not covering the potential increase in demand. [4] ACAA Corrected 2009 Coal Combustion Product (CCP) Production & Use Survey.
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1. M. Fr as, M. SÆnchez de Rojas Microstructural alterations in fly ash mortar: study on phenomena affecting particle and pore size Cement. Concrete. Res., 27 (1997), pp. 50-57
2. J.G. Cabrera, S.O. Nwaubani The microstructure and chloride ion diffusion characteristic of cements containing metakaolin and fly ash V.M. Malhotra (Ed.), 6th International Conference on Fly Ash, Silica Fume, Slag and Natural Pozzolans in Concrete, vol. 1CANMET/ACI SP-178, Bangkok (1998), pp. 385-400
3. M.D.A. Thomasa, M.H. Shehataa, S.G. Shashiprakasha, D.S. Hopkinsb, K. Cailb Use of ternary cementitious systems containing silica fume and fly ash in concrete Cem. Concr. Res., 29 (1999), pp. 1207-1214
4. R.W.M. Chan, P.N.L. Ho, E.P.W. Chan, Concrete admixture for waterproofing construction,structural engineering branch, Architectural Services Department, Technical Report, Structural Materials Group, 1999, p. 41.
5. ACI Committee, 234. Guide for the use of silica fume in concrete. ACI 234R 2006; 2008.
6. J.L. Marriaga, L.G. L pez YØpez, Effect of silica fume addition on the chloride-related transport properties of high-performance concrete. Dyna, year 79, Medellin, February 2012, ISSN 0012-7353 No. 171:105-110.
7. M.F. Rojas, J. Cabrera
8. V.G. Papadakis Effect of fly ash on Portland cement systems, Part II. High-calcium fly ash Cem. Concr. Res., 30 (2000), pp. 1647-1654
9. S. Wild, J.M. Khatib, A. Jones Relative strength, pozzolanic activity and cement hydration in superplasticised metakaolin concrete Cem. Concr. Res., 26 (1996), pp. 1537- 1544
10. M. Fr as, M.I. SÆnchez de Rojas, M. Cabrera The effect that the pozzolanic reaction of metakaolin has on the heat evolution in MK- cement Mortar Cem. Concr. Res., 30 (2000), pp. 209-216
11. R. Boynton Chemistry and Technology of Lime and Limestone Interscience Pub, New York (1966)
12. J.J.D. Oca, J.F.M. Hernandez, L. Rodreguez, R.G. Lopez Effect of lime-zeolite binder on compression strength and durability properties of concrete Rev. Ing. Constr., 24 (2009), pp. 181-194 www.ing.puc.cl/ric . 13. S.A. Barbhuiya, J.K. Gbagbo, M.I. Russell, P.A.M. Basheer Properties of fly ash concrete modified with hydrated lime and silica fume Constr. Build. Materials., 23 (2009), pp. 3233-3239 . 14. P.K. Mehta, Role of pozzolanic and cementitious material in sustainable development of theconcrete industry, in: Proceedings of the Sixth International Conference on the Use of FlyAsh, Silica Fume, Slag, and Natural Pozzolans in Concrete, ACI SP-178, vol. 1, Bangkok, 1998.
15. N.G. Thompson, D.R. Lankard, Improved Concretes for Corrosion Resistance, Federal Highway Administration, US Department of Transportation, Georgetown Pike, McLean VA, Report No. FHWARD-96-207;1997.
16. P. Mira, V.G. Papadakis, S. Tsimas Effect of lime putty addition on structural and durability properties of concrete Cem. Concr. Res., 32 (2002), pp. 683-689
17. P.J.P. Gleize, A. Miller, H.R. Roman Microstructural investigation of a silica fume, cement and lime mortar Cement Concr. Compos., 25 (2003), pp. 171-175
18. ASTM C 187-98, American Society for Testing and Materials, Standard Test Method for Normal Consistency of Hydraulic Cement, West Conshohocken, United States, p. 2.
19. A.M. Alshamsi, A.R. Sabouni, A.H. Bushlaibi Influence of set retarding superplasticizers and microsilica on setting time of pastes at various temperatures Cem. Concr. Res., 23 (1993), pp. 592-598 | 20. Qing, Z. Zenan, K. Deyu, C. Rongshen Influence of nano-SiO2 addition on properties of hardened cement paste as compared with silica fume Constr. Build. Mater., 21 (2007), pp. 539-545
21. G.A. Rao Investigations on the performance of silica fume-incorporated cement pastes and mortars
22. Cem. Concr. Res., 33 (2003), pp. 1765-1770
23. C. Peter, Hewlett Leas Chemistry of Cement and Concrete (fourth ed.)Elsevier Butterworth-Heinemann, Linacre House, Jordan Hill, Oxford OX28DP (2005)
24. J.M.R. Dotto, A.G. De Abreu, D.C.C. Dal Molin, I.L. Muller Influence of silica fume addition on concretes physical properties and on corrosion behavior of reinforcement bars Cement Concr. Compos., 26 (2004), pp. 31-39
25. Joseph Davidovits Geopolymer Chemistry and Applications pp.1-612 2011 www.geopolymer.org
26. Akl Awwad Nano-structured Kaolin Clay and its Industrial Applications (2011) pp.3-21
27. Transportation Research Record Journal of the Transportation Research Board No. 2141 NANOTECHNOLOGY IN CEMENT AND CONCRETE Volume 1 and 2 (2010) Volume 1,pgs. 11,15,19, 28, 36,46, 47-51,68-74, Volume 2, pgs. ix, 1-4, 18,19,34,39,52- 57.
28. Clay Resources and Ceramic Industry of California- Bulletin No. 99, 1928; pgs. 19,20,51, 231-232, 237, 282, 314, 316
29. Clay Mineralogy Second Edition Ralph E. Grim, McGraw-Hill, 1968 pgs. 121,122,189- 192, 315-316, 471, 549, 555, 563, 566, 567, 569, 570, 579 Table C.
30. Applied Clay Mineralogy Ralph E. Grim, McGraw-Hill, 1962 pgs. 133,335-336. 348-359
31. Fly Ash, Silica Fume, Slag, and Natural Pozzolans in Concrete Volume 2, 2001 Editor V.M. Malhorta pg. 785
32. Sustainable Development of Cement and Concrete, 2001 V.M. Malhortra, Editor; pgs. 97, 397,403,413,432,441.
33. Fly Ash, Silica Fume, Slag and Natural Pozzolans in Concrete, 1998 Volume 1, V.M. Malhotra, Editor; pgs. 385, 391-392, 575-603.
Paul F. Pugh, Jr. 33112 Globe Drive Springville, CA 93265 [email protected] 559-359-0240 EDUCATION B.A., CSU Hayward— Major: Speech, Debate & Forensics, Political Science, Pre-Law Minor: Business Administration, Marketing & Management University of Wisconsin — Improving Public Works Construction Inspection Skills Certificate (2011)
EXPERIENCE Public Works Inspector; City of Porterville, Porterville, CA —2007-2016 ವ Determine quality of materials and workmanship, and compliance with plans, specifications, estimates and all applicable codes and regulations. ವ Check elevations and grades and check sub-grade conditions and determines soil values for paving purposes. ವ Inspect mix, placement of and finished concrete and asphalt improvements ವ Inspects various underground sub-structures, pipelines, etc. ವ Prepares memos, progress reports, notices and logs as required. Maintains accurate and up-to-date inspection records. Reviews various engineering plans for compliance with codes, regulations and other standards. ವ Coordinates inspections and related activities with contractors, utility personnel, consultants and various City staff. ವ When assigned to City contracts, works closely with assigned Project Manager in coordination of scheduling, inspection of materials and workmanship to ensure adherence to project specifications. ವ Attends division and department meetings as required. ವ Receives and responds to public inquiries and complaints regarding inspections.Keeps abreast of current codes and regulations affecting City projects. ವ Keeps abreast of current codes and regulations affecting City projects. Project Manager, Bay Area Technical Center; Fremont, CA — 1999—2007 ವ Seek out, bid and secure contracts in Western United State with state, county and local organizations. ವ Ensure all codes and regulations are met affecting company projects. ವ Source and purchase equipment, labor and other necessary materials for projects. ವ Maintain connections through presence at State & County Bridge groups, County Engineers/Public Works Directors Meetings. ವ Provide presence for mobilization & Customer support in Utah and New Mexico. Mineral Consultant/Project Manager, Lebec Sand & Gravel 1996-2000 ವ Establish 105 acre sand and gravel mining operation ವ Successfully guide company through permitting, production and safety programs ವ Coordinate with State, County and Local agencies to Ensure EPA, safety and mining standards are met ವ Develop products for Ready-Mix applications and CalTrans highway road base construction. ವ Establish and maintain contract bids for individual and multi-year contracts.
SKILLS Microsoft Office, Excel, Powerpoint, iOS, Public Works, Construction, Project Management, Civil Engineering, Electrical Engineering, Client Acquisition, Market Forecasting, Sales, Market Research, Product Creation, CalTrans Codes & Regulations
PROFESSIONAL ORGANIZATIONS
ವAmerican Shotcrete Association Specialty Areas (Admixtures, Foaming, Water Reducing, Cement/Pozzolanic Materials/Dry Metakaolin, Dry & Wet Mix, White, Colored Cement. ವStrategic Highway Safety Plan Stakeholder (SHSP) California ವMineral Producers of California — Board Member/President ವTransportation Research Board (TRB) — Alternate Industry Technical Committee ವAmerican Concrete Institute (ACI) — Fly Ash and Natural Pozzolans in Concrete (232) ವInternational Concrete Repair Institute (ICRI) ವSociety For Mining, Metallurgy, and Exploration (SME) ವWire Association International (WAI)a ವNational Electrical Manufacturers Association (NEMA) ವIndustry Delegate CalTrans ವPublished Presentation West Coast Bridge Engineers Conference (WCBE)
PAULA TWITTY BUSHMAN - 4020 SW 54th Avenue - Davie, Florida 33314 954-793-0427 - [email protected] US Marine Corps Veteran
SENIOR OPERATING & GENERAL MANAGEMENT EXECUTIVE
Entrepreneur, Created solid strategic and tactical expertise in a state wide operation, fiscal management, sales and new product development. Expert at scaling operations, planning/executing mission critical o business mission, vision, and initiatives. Revenue gains in the triple digit distinguished this accomplishment, and achieved profitability objectives despite economic downturns, and fluctuating economies. Successful at formulating effective training, and go to market strategies, in addition negotiating multinational transactions for distributorship and private label. Outstanding record of achievement coupled with the ability to build and direct a business to profitability through leadership, creativity, effective management, motivation and development of staff to maximum potential. . MANAGEMENT / ADMINISTRATION EXPERTISE