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The Natural Builder P.O. Box 855 Montrose, CO 81402 Phone/Fax: 970-249-8821 The Natural Builder offers on-site construction help, consulting and workshops related to natural plasters, earthen floors, monolithic adobe (cob), straw-bale and other green building projects. We also authored The Natural Builder book series on Earthen Construction, Monolithic Adobe, and Earth and Mineral Plasters. These books are available at our web site: www.naturalbuilder.com. |
Two classifications of flyash are produced, according to the type of coal used. Anthracite and bituminous coal produces flyash classified as Class F. Class C flyash is produced by burning lignite or subbituminous coal. Class C flyash is preferable for the applications presented in the Green Building Guide and is the main type offered for residential applications from ready-mix suppliers.
CONSIDERATIONS:
Flyash is one of three general types of coal combustion byproducts (CCBP's). The use of these byproducts offers environmental advantages by diverting the material from the wastestream, reducing the energy investment in processing virgin materials, conserving virgin materials, and allaying pollution.
Thirteen million tons of coal ash are produced in Texas each year. Eleven percent of this ash is used which is below the national average of 30 %. About 60 - 70% of central Texas suppliers offer flyash in ready-mix products. They will substitute flyash for 20 - 35% of the portland cement used to make their products.
Although flyash offers environmental advantages, it also improves the performance and quality of concrete. Flyash affects the plastic properties of concrete by improving workability, reducing water demand, reducing segregation and bleeding, and lowering heat of hydration. Flyash increases strength, reduces permeability, reduces corrosion of reinforcing steel, increases sulphate resistance, and reduces alkali-aggregate reaction. Flyash reaches its maximum strength more slowly than concrete made with only portland cement. The techniques for working with this type of concrete are standard for the industry and will not impact the budget of a job.
This section also addresses wall-form products. Most of these products have hollow interiors and are stacked or set in place and then filled with steel-reinforced concrete creating a concrete structure for a house.
Some wall-form materials are made from EPS (expanded polystyrene) which is a lightweight non-CFC foam material. There are also fiber-cement wall-form products that can contain wood waste. The EPS/concrete systems offer high insulating qualities and easy installation. The fiber-cement blocks offer insulating qualities as well. Some EPS products also have recycled content.
Commercial Status |
Implementation Issues |
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Cementitous Structure | |||||||
Flyash Concrete | |||||||
Recycled Content Block | |||||||
Concrete Finish Floor | |||||||
Concrete Interior Wall |
Legend | |
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Satisfactory |
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Satisfactory in most conditions |
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Satisfactory in Limited Conditions |
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Unsatisfactory or Difficult |
A concrete finish floor may sound less desirable aesthetically to some persons. However, coloring, scoring, and texturing techniques can be very attractive.
Wall-form products should be well-received.
GUIDELINES
Flyash for use in portland cement concrete shall conform to the requirements of ASTM C 618, Standard Specification for Flyash and Raw or Calcined Natural Pozzolan Class C Flyash for use as a Mineral Admixture in Portland Cement. Specifically, it shall conform to all requirements of Table 1 and Table 2 as outlined therein.
The concrete supplier shall furnish a notarized certificate from the flyash marketer at the time of submittal of concrete mix designs for approval indicating conformance with these requirements. Also, a copy of the most recent chemical analysis shall be provided.
At no time during the course of the project will a change of flyash source (plant) be permitted without the prior written consent of the Engineer or Architect. For sulfate environments, only Class F flyash will be permitted and under no circumstances will Class C flyash be used.
Class F flyash will typically require an air entraining agent to be added. Class C flyash will not.
Standard concrete procedures can be employed.
The use of these systems eliminates the need for conventional framing on exterior walls.
Some feature interlocking features and stack like blocks. Some are in rigid panels on interior and exterior connected by metal or steel ties.
EPS blocks are typically stacked as exterior walls. Rebar is placed in the cores vertically and horizontally. The cores are poured full of concrete from the top.
Manufacturers claim R-values of R-30 or greater.
Specify that the foam is protected from insects. Insects will not eat the foam but will nest in it. Borate treatment is preferable.
Urethane block wall-form products are also available. These contain CFC's/HCFC's.
Can use waste wood; will not burn; insect resistant; will not support condensation.
Approximately R-12 ratings in 9 inch block.
Hollow cores are filled with steel reinforced concrete.
RESOURCES
PROFESSIONAL ASSISTANCE
Ramone L. Carrasquillo, Ph.D, P.E.
Construction Materials Research Group
Balcones Research Center
10100 Burnet Rd., Bldg. 18B
Mail Code 79100
Austin, TX 78758
(512) 471-4585
Center for Maximum Potential Building Systems
8604 FM 969
Austin, TX 78724
(512) 928-4786
Don Callaway
P.O.Box 152
La Grange, TX 78945
(409) 968-4032
callaway@fais.net
Applied Concrete Technology
P.O.Box 4015
Arlington Heights, IL 60006-4015
(800) 228-6694
manufactuer of "Protecrete" earth-friendly concrete enhancement/protection products
Insulform Building Systems
1001 E. Highway 20
Lockhart, TX 78644
(512) 376-9955
Polystyrene stackable block wall-form
RASTRA Building System
6421 Box Springs Blvd.
Riverside, CA 92507
(714) 653-3346
Polystyrene block wall-form
R - Forms
8386 Coconut Blvd.
Royal Palm Beach, FL 33410
(561) 792-6264
Polystyrene panel wall-form
Faswall Concrete Systems
1676 Nixon Rd.
Augusta, GA 30906
(706) 793-8880
Fiber-cement wall-form
Advanced Concrete Technologies
67 South Bedford St.
Burlington, MA 01803
(617) 272-0588
Wood-cement wall-forms
Lite-Form, Inc.
1210 Steuben St.
P. O. Box 774
Sioux City, IA 51102-0774
(800) 551-3313
www.liteform.com
"Fold-Form" panel wall-form
Lite-Form of San Antonio (210) 599-372
GreenBlock WorldWide Corp.
P.O.Box 749
Woodland Park, CO 80866
(800) 216-1820
www.greenblock.com
Reddi-Form, Inc.
P.O.Box 165
Oakland, NJ 07436
(800) 334-4303
"Reddi-Form" EPS block wall-form
Local: Michael Beck (512) 259-8836
American ConForm Industries
1820 S Santa Fe St.
Santa Anna, CA 92705
(800) 266-3676
www.smartblock.com
SmartBlock EPS wall-form
Fast Forms
Branch River Foam Plastics
15 Thurber Blvd.
Smithfield, RI 02917
(401) 232-0270
Polystyrene block wall-form
American Polysteel Forms
5150 Edith NE
Albuquerque, NM 87107
(505) 345-8153
"Polysteel" EPS block wall-form
Local: Gary Simmons (512) 869-1175
Therma Foam Inc.
2324 Franklin Drive
Ft. Worth, TX 76106
(800) 333-3626
foam manufacturer and supplier of "Diamond-Snap Form" ICF system
ENER-GRID
6847 South Rainbow Rd,
Buckeye, AZ 85326
(602) 386-2232
ENER-GRID recycled EPS/cement block
Local: 3E Industries (512) 264-3462
AAB Building Systems
840 Division St.
Cobourg, Ontario, Canada K9A 4J9
(800) 293-3210
www.bluemaxxaab.com
"BlueMaxx" EPS wall-form
Advanced Bldg. Systems (888) 226-8362
STYROCHEM International Inc.
3607 N. Sylvania
Ft. Worth, TX 76040
(800) 448-6232
Reward Wall Systems
4115 South 87th Street
Omaha, NE 68127-1601
(800) 468-6344
www.rewardwalls.com
reward@rewardwalls.com
Reward Insulating Concrete Forms
John Moylan (800) 468-6344
I. C. E. Block
206 South Main
Maquoketa, IA 52060
(800) ICE-BLOC
"ICE Block" EPS block wall-form
ICE Block of North Texas (214) 324-0046
RASTRA Building System
6421 Box Springs Blvd.
Riverside, CA 92507
(714) 653-3346
recycled EPS/cement block
ThermoFormed Block Corp.
P.O.Box 2454
Ft. Collins, CO 80522-2454
(800) 821-0855
"ThermoFormed" EPS block wall-form
Monex Industries
Colene M. Crain
45 N.E. Loop 410, Ste. 700
San Antonio, TX 78701
(800) 292-5354
Flyash marketing company, wholesale
Federal Register
Friday, January 28, 1983
Part IV, Environmental Protection Agency
"Cement and Concrete Containing Fly Ash; Guideline for Federal Procurement"
State Department of Highways and Public Transportation
"Department Materials Specification: D-9-8900 Fly Ash"
Joe Raska
(512) 465-7469
Portland Cement Association
5420 Old Orchard Rd.
Skokie, IL 60077-1083
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Sustainable Building Sourcebook web version copyright Sustainable Sources 1994-1999.