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Old Posted May 26, 2011, 4:00 AM
amor de cosmos amor de cosmos is offline
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Steel-mill waste turned into bricks

I wonder if this thread could be for general developments in construction materials or something. Anyway, this seems pretty cool:

Quote:
Trash to treasure: Turning steel-mill waste into bricks


Scientists are reporting development and successful testing of a promising new way of using a troublesome byproduct of the global steel industry as raw materials for bricks that can be used in construction projects. Their study appears in ACS' Industrial & Engineering Chemistry Research.
http://www.eurekalert.org/pub_releas...-ttt052511.php
http://www.sciencedaily.com/releases...0525110446.htm

Quote:
The recovery of electric arc furnace (EAF) dust generates large amounts of an industrial byproduct called Waelz slag. This residue, consisting primarily of iron oxide contaminated with other metal oxides (including zinc and lead), is usually disposed of in landfill sites at a high economic and environmental cost. This paper investigates an alternative based on industrial ecology principles, which involves the incorporation of Waelz slag into clay ceramic construction bricks.....

The experimental results demonstrate that incorporation of Waelz slag does not deteriorate the physical, mechanical, and chemical properties of the resulting products. The leaching of species during its useful lives show compliance with threshold values established according to the Dutch Building Materials Decree (DBMD), and Waelz slag containing bricks fall into the category of nonhazardous waste landfill, just like conventional bricks used at this work. Emissions of CO2 and NOx were reduced versus the emissions of halogenated gases and SO2, which were favored due to the thermal decomposition of S, Cl, and F contained in the waste material.
http://pubs.acs.org/doi/abs/10.1021/ie102145h
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  #2  
Old Posted May 26, 2011, 5:55 PM
Rizzo Rizzo is offline
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A company out of Wisconsin is already producing these bricks. You cannot even tell the difference between their product and conventional bricks. They also say their product has better durability. It's also more environmentally friendly in the fact that they don't furnaces or any heat to create this product.

So recycled material, low energy production, flexible industrial space (meaning relative ease of locating near all metro areas reducing shipping distance), and long lasting durability and good material aesthetics. Seems like a win in every direction.
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Old Posted May 26, 2011, 8:17 PM
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I believe that fly ash from coal-burning processes is also being used to make bricks nowadays. Fly ash has long been used as an additive to concrete because of its pozzolanic properties, but it has only been recently that fly ash has been turned into the primary material of a structural material.
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Old Posted May 26, 2011, 8:26 PM
Nowhereman1280 Nowhereman1280 is offline
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Aren't cinder blocks already made out of foundry byproducts or is that in reference to volcanic ash or something?
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Old Posted May 28, 2011, 4:01 AM
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Quote:
Originally Posted by Nowhereman1280 View Post
Aren't cinder blocks already made out of foundry byproducts or is that in reference to volcanic ash or something?

It is a reference to volcanic ash.
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Old Posted Jun 10, 2011, 2:11 AM
amor de cosmos amor de cosmos is offline
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Quote:
A new way to make lighter, stronger steel -- in a flash

COLUMBUS, Ohio – A Detroit entrepreneur surprised university engineers here recently, when he invented a heat-treatment that makes steel 7 percent stronger than any steel on record – in less than 10 seconds.

In fact, the steel, now trademarked as Flash Bainite, has tested stronger and more shock-absorbing than the most common titanium alloys used by industry.

Now the entrepreneur is working with researchers at Ohio State University to better understand the science behind the new treatment, called flash processing.

What they've discovered may hold the key to making cars and military vehicles lighter, stronger, and more fuel-efficient.


Cola's entire process took less than 10 seconds.

He claimed that the resulting steel was 7 percent stronger than martensitic advanced high-strength steel. [Martensitic steel is so named because the internal microstructure is entirely composed of a crystal form called martensite.] Cola further claimed that his steel could be drawn – that is, thinned and lengthened – 30 percent more than martensitic steels without losing its enhanced strength.

If that were true, then Cola's steel could enable carmakers to build frames that are up to 30 percent thinner and lighter without compromising safety. Or, it could reinforce an armored vehicle without weighing it down.

"We asked for a few samples to test, and it turned out that everything he said was true," said Ohio State graduate student Tapasvi Lolla. "Then it was up to us to understand what was happening."
http://www.eurekalert.org/pub_releas...-anw060911.php
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Old Posted Jul 12, 2011, 3:44 AM
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My questions would be how much such bricks cost relative to existing products, and how much their compressive strength is affected.
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Old Posted Jul 27, 2011, 4:00 AM
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I've decided I'm turning this into a green materials thread

Quote:
Traditional cement has become a target of environmental criticism because its production releases carbon dioxide into the atmosphere. About one ton of carbon is emitted per ton of portland cement produced, constituting about 5% of the world's industrial carbon emissions.

Blue World Crete's binder forms at ambient temperatures, requiring 90% less energy than portland cement. It also can be placed with traditional methods.

Such recipes rely on geopolymers, which are ceramic-like substances formed at low temperatures, according to the Commonwealth Scientific and Industrial Research Organisation, Australia's national science agency.

Blue World Crete paddle-mixes its proprietary geopolymer with various types of ash material. This process excites a chemical reaction with the aluminosilicate in the ash to create a binding agent that can be used to manufacture concrete, block and other materials.
http://enr.construction.com/products...landcement.asp
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Old Posted Aug 2, 2011, 6:08 PM
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Quote:
Hebrew University student turns paper mill waste into ‘green’ material for industrial applications
01 August 2011 Hebrew University of Jerusalem

Shaul Lapidot, a Ph.D. student of Prof. Oded Shoseyov, along with his laboratory colleagues at the Robert H. Smith Faculty of Agriculture, Food and Environment of the Hebrew University in Rehovot, has formulated a procedure for production of nano-crystalline cellulose (NCC) from paper mill waste. NCC is further processed into composite foams for applications in the composite materials industry as bio-based replacement for synthetic foams.

The process of paper production involves loss of all fibers with dimensions lower than the forming fabric mesh. Consequently around 50% of the total fibers initially produced are washed away as sludge. In Europe alone, 11 million tons of waste are produced annually by this industry, creating an incentive for finding alternative uses and different applications for the wastes.

Lapidot has found that fibers from paper mill sludge are a perfect source for NCC production due to their small dimensions which require relatively low energy and chemical input in order to process them into NCC. He also developed the application of NCC into nano-structured foams. This is further processed into composite foams for applications in the composite materials industry to be used as bio-based replacement for synthetic foams.
http://www.alphagalileo.org/ViewItem...CultureCode=en
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Old Posted Aug 11, 2011, 4:36 AM
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Quote:
New CO2 Sand Bricks are 2.5 Times Stronger than Concrete
by Andrew Michler, 08/10/11




The bricks are created using a very simple process: high silicon content sand is put into an air tight mold that can be virtually any shape. CO2 is pumped into the mold and bonds with the silica to make a solid brick-like material in less than a minute — at this point, the brick is very strong under lateral loads, but still crumbles if stressed under tensile pressure.

The next step is to infuse the bricks with a binder such as epoxy or urethane. Bathing the blocks in the binder creates a hardened brick that has all the proper requirements for a strong building component. The strength of the brick is 2.5 times that of concrete in less than 24 hours, which is critical for emergency building.
http://inhabitat.com/new-co2-sand-br...than-concrete/
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