Waste Ash from Coal Could Save Billions in Repairing US Bridges and Roads

Study leader Charles Carraher, Ph.D., explained that the more than 450 coal-burning electric power plants in the United States produce about 130 million tons of "flyash" each year. Before air pollution laws, those fine particles of soot and dust flew up smokestacks and into the air. Power plants now collect the ash.

"Flyash poses enormous waste disposal problems," Carraher said. "Some of it does get recycled and reused. But almost 70 percent winds up in landfills every year, where space is increasingly scarce and expensive. Our research indicates that this waste could become a valuable resource as a shield-like coating to keep concrete from deteriorating and crumbling as it ages."

Carraher, who is with Florida Atlantic University, said that the new material can be used to coat and protect from corrosion steel reinforcing bar, or "rebar," rods embedded in concrete to reinforce and strengthen it. The coating also is suitable for repairing damaged concrete. This is part of a joint project between industry (Felix Achille, of Blue World Crete) and academia (Charles E. Carraher, Ph.D., Dept. of Chemistry and Biochemistry; Madasamy Arockiasamy, Ph.D., Dept. of Civil Engineering; and Perambur Neelakantaswamy, Ph.D., Dept. Electrical Engineering and Computer Science).

Laboratory tests have shown that the coating has excellent strength and durability when exposed to heat, cold, rain, and other simulated environmental conditions harsher than any that would occur in the real world, Carraher said. The coating protected concrete from deterioration, for instance, that involved exposure to the acids in air pollution that were 100,000 times more concentrated than typical outdoor levels environment. Coated concrete remained strong and intact for more than a year of observation, while ordinary concrete often began to crumble within days, he said.