Center for

By-Products

Utilization

CPI Ash as a Potential Source for Construction Materials

By Tarun R. Naik and Rudolph N. Kraus

Report No. CBU-2000-22

Rep-399

August 2000

Submitted to Consolidated Papers, Inc., Wisconsin Rapids, WI

Department of Civil Engineering and Mechanics

College of Engineering and Applied Science

THE UNIVERSITY OF WISCONSIN - MILWAUKEE

CPI

Ash as a Potential Source for

Construction Materials

A Report Submitted to Dr. F. Andrew Gilbert

Consolidated Papers, Inc.

August 2000

REP -399

CPI Ash as a Potential Source for Construction Materials

by

Tarun R. Naik, Ph.D., P.E.

and

Rudolph N. Kraus

UWM Center for By-Products Utilization

Department of Civil Engineering and Mechanics

College of Engineering and Applied Science

The University of Wisconsin - Milwaukee

P.O. Box 784

Milwaukee WI 53201

ii

Ph: (414) 229-6696

Fax: (414) 229-6958

Executive Summary

TITLE: CPI Ash as a Potential Source for Construction Materials

SOURCE: UWM-CBU Report No. CBU-2000-22, REP-399, August 2000

BACKGROUND/PURPOSE: To conduct physical, chemical, mineralogical, and microstructural tests

for determining properties of typical Consolidated Papers, Inc. (CPI) wood ashes (Biron #4 precipitator

ash, Biron #4 bottom ash, Biron #4 boiler slag, Biron #5 boiler precipitator ash, Biron #5 mechanical

hopper ash, Kraft P1-P2 "fine" ash, Kraft P1-P2 bottom ash, Niagara B21-B23 fly ash, and Niagara B24

bottom ash) for evaluating their potential options for beneficial reuse. The nine ash sources were selected

based upon their diverse character (such as color, texture, and type of collection system/process etc.) in

consultation with Dr. F. Andrew Gilbert, Consolidated Papers, Inc..

OBJECTIVE: The primary objective of this project was to recommend alternatives to the normal

practice of landfilling by evaluating potential reuse/recycle applications for these materials, especially in

cement-based construction materials.

CONCLUSIONS: CPI’s wood ashes have considerable potential for many applications. However, the

performance of these ashes needs to be established for individual applications. The following are some of

the high-volume applications that would require further evaluation. These applications would consume all

of the wood ashes produced at Consolidated Papers. Flowable Materials have up to 1200 psi compressive

strength, have flowing mud-type of consistency and fluidity, contain very little portland cement and a lot of

water, and consist mostly of ash or similar materials. It is believed that concrete Bricks, Blocks, and

Paving Stones could also be made with the wood ashes tested. Additionally the fly ash and precipitator

ash should be useful for replacement of clay in clay bricks manufacturing. The test data collected also

indicate that these wood ashes can be used as a partial replacement of aggregates and/or cement in

Medium-Strength Concrete. It is also concluded that there is a potential for high-value use of the fly ash

and precipitator ash in manufacturing Blended Cements. Soil stabilization or site remediation is another

significant potential use of the ashes. For example, for log-yard paving (Roller Compacted Concrete

Pavement) these wood ashes can function as a soil stabilizing or strengthening medium as well as

significantly improving the performance of log-yards and reducing cost of handling logs and minimizing

waste of logs. The Biron #4 slag has a very significant potential to be utilized as an Architectural

Aggregate in Concrete or as a Roofing Shingle Grit. Based upon the limited testing performed for the

project, these applications have the potential to be a significant source of revenue. A further evaluation is

very strongly recommended. Probability of success is excellent.

RECOMMENDATIONS: Further evaluation is recommended, starting with lab-scale production and

testing of wood ash use in the above applications. Cost/benefit analysis and marketing studies should be

iv

undertaken; and a long-term evaluation program for these products should be started. This includes the

development of wood ash specifications for high-potential, high-value, applications.

v

Table of Contents

Item Page

Executive Summary ................................................................................................................. iii

List of Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

List of Figures .......................................................................................................................... vi

Section 1: Introduction ................................................................................................................ 1

Section 2: Tests of CPI Wood Fly Ashes ...............................................................................5 EXPERIMENTAL PROGRAM ......................................................................................... 5

PHYSICAL PROPERTIES ................................................................................................. 5

As-Received Moisture Content .................................................................................... 5

Particle Size Analysis .................................................................................................... 6

Unit Weight .................................................................................................................. 8

Specific Gravity ............................................................................................................. 9

SSD Absorption ......................................................................................................... 10

ASTM C 618 TESTS .......................................................................................................... 11

Physical Properties per ASTM C 618 ....................................................................... 11

Cement Activity Index ............................................................................................... 11

Water Requirement ................................................................................................... 13

Autoclave Expansion .................................................................................................. 14

Chemical Properties per ASTM C 618 ..................................................................... 15

CHEMICAL COMPOSITION ........................................................................................ 17

ELEMENTAL ANALYSIS ............................................................................................... 18

SCANNING ELECTRON MICROSCOPY (SEM) ........................................................ 18

Section 3: Constructive Use Options for CPI Ashes ..........................................................20 INTRODUCTION ............................................................................................................ 20

USES OF CPI WOOD FLY ASHES ............................................................................... 20

Section 4: Suggestions for Further Evaluations .................................................................22 FLOWABLE MATERIALS .............................................................................................. 22

BRICKS, BLOCKS, AND PAVING STONES ............................................................... 23

MEDIUM-STRENGTH CONCRETE ............................................................................ 23

DECORATIVE AGGREGATE - ROOFING SHINGLE GRIT .................................. 23

BLENDED CEMENT ....................................................................................................... 24

ROLLER-COMPACTED CONCRETE PAVEMENT .................................................. 24

SOIL AMENDMENT WITH OR WITHOUT DREDGED MATERIALS ....................24

Section 5: References ............................................................................................................96

APPENDIX 1: Modified ASTM C 422 for Particle Size Analysis ....................................97

vi

List of Tables

Item Page

Table 1: As-Received CPI Ash Moisture Content...................................................................... 27

Table 2: Sieve Analysis of CPI Ash ............................................................................................. 29

Table 3: Material Finer Than No. 200 Sieve by Washing ......................................................... 34

Table 4: Materials Retained on No. 325 Sieve ........................................................................... 35

Table 5: Unit Weight and Voids ................................................................................................. 46

Table 6 Specific Gravity ............................................................................................................... 47

Table 7: Specific Gravity ............................................................................................................... 48

Table 8: Absorption ...................................................................................................................... 49

Table 9: Mortar Cube Compressive Strength ............................................................................. 51

Table 10: Strength Activity Index with Cement .......................................................................... 52

Table 11: Water Requirement .................................................................................................... 53

Table 12: Autoclave Expansion or Contraction ......................................................................... 54

Table 13: Physical Tests Requirements of Coal Fly Ash per ASTM C 618 ............................. 55

Table 14: Chemical Analysis ....................................................................................................... 57

Table 15: Mineralogy of CPI Ash ............................................................................................... 61

Table 16: Elemental Analysis ...................................................................................................... 66

Table 17: Potential Uses of the Biron #4 Wood Ashes ............................................................. 74

Table 18: Potential Uses of the Biron #5 Wood Ashes ............................................................. 77

Table 19: Potential Uses of the Kraft Wood Ashes ................................................................... 80

Table 20: Potential Uses of the Niagara Wood Ashes ............................................................... 83

vii

List of Figures

Item Page

Fig. 1: Particle Size Distribution of Biron #4 Precipitator Ash .................................................. 36

Fig. 2: Particle Size Distribution of Biron #4 Bottom Ash ......................................................... 37

Fig. 3: Particle Size Distribution of Biron #4 Slag ...................................................................... 38

Fig. 4: Particle Size Distribution of Biron #5 Precipitator Ash .................................................. 39

Fig. 5: Particle Size Distribution of Biron #5 Mechanical Hopper Ash .................................... 40

Fig. 6: Particle Size Distribution of Kraft P1-P2 "Fine" Ash ....................................................... 41

Fig. 7: Particle Size Distribution of Kraft P1-P2 Bottom Ash .................................................... 42

Fig. 8: Particle Size Distribution of Niagara B21-B23 Fly Ash ................................................... 43

Fig. 9: Particle Size Distribution of Niagara B24 Bottom Ash ................................................... 44

Fig. 10 – 13: SEM Photomicrographs of Biron #4 Precipitator Ash ......................................... 87

Figure 14 – 17: SEM Photomicrographs of Biron #4 Bottom Ash ........................................... 88

Figure 18 – 21: SEM Photomicrographs of Biron #4 Slag ......................................................... 89

Figure 22 – 25: SEM Photomicrographs of Biron #5 Precipitator Ash..................................... 90

Figure 26 – 29: SEM Photomicrographs of Biron #5 Mechanical Hopper Ash....................... 91

Figure 30 – 33: SEM Photomicrographs of Kraft P1-P2 "Fine" Ash .......................................... 92

Figure 34 – 37: SEM Photomicrographs of Kraft P1-P2 Bottom Ash ...................................... 93

Figure 38 – 41: SEM Photomicrographs of Niagara B21-B23 Fly Ash ..................................... 94

Figure 42 – 45: SEM Photomicrographs of Niagara B24 Bottom Ash ..................................... 95

-1-

Section 1

INTRODUCTION

The scope of this project was to determine physical, chemical, mineralogical, and microscopical

properties of the Consolidated Papers, Inc. (CPI) wood and/or coal combustion products from

daily operations. The main objective of this project is to recommend alternatives to the normal

practice of landfilling by recommending potential reuse/recycling applications for these materials.

Nine different types of wood and/or coal combustion products were used in this project: Biron #4

precipitator ash, Biron #4 bottom ash, Biron #4 slag, Biron #5 precipitator ash, Biron #5

mechanical hopper ash, Kraft P1-P2 "fine" ash (combined from P1 and P2 boilers), Kraft P1-P2

bottom ash (combined from P1 and P2 boilers), Niagara fly ash (combined from Boilers B21-

B23), and Niagara bottom ash (Boiler B24).

It has been established by previous projects at the UWM Center for By-Products Utilization

(UWM-CBU) that properties of wood and/or coal combustion products (i.e. different types of

ashes) can vary greatly from mill to mill depending upon the type and source of fuel, how the ash is

collected, design and operation of the boiler, etc. Therefore, it is important to determine physical,

chemical, and morphological properties of the ash for determining their appropriate use options.

Before beginning any quantitative testing, the general physical appearance of the CPI materials

were evaluated. The Biron #4 precipitator ash sample is dark-brown to black in color, had a fine

gradation, and was dry. The Biron #4 bottom ash is light-brown in color, appeared to be a typical

coal bottom ash type of material with gradation varying from a sand-like material with larger pieces

up to 1-1/2". Biron #4 slag is a black glassy material with a coarse sand consistency (up to

-2-

maximum size of 3/8-inch). Biron #5 precipitator ash is a very fine, dry, dark-gray ash. Biron #5

mechanical hopper ash is dry with a fine to coarse gradation, and color varies from gray to black.

The Kraft P1-P2 "fine" ash is a black dry ash with a sand-like consistency, some agglomeration is

present due to the fine material, and some large gray colored pieces are present. Kraft P1-P2

bottom ash is moist, light-brown to brown in color, has a typical coal bottom ash type of

appearance, gradation varies from a fine sand to larger coarse pieces. The larger pieces of the

Kraft P1-P2 bottom ash are heavy and agglomerated. The Niagara B21-B23 fly ash is a very fine,

black, dry ash (appears to have a high carbon content). Niagara B24 bottom ash is black to dark-

gray in color, dry, and has some fine sand-like particles but has generally coarse gradation.

The following background information on the source of the ash materials was obtained from

Consolidated Papers, Inc.

-3-

Background Information on the Biron Ash

Source

Biron Boiler #4

Biron Boiler #5

Make of Boiler B&W

Combustion Engineering

Type of Boiler Cyclone

Stoker Traveling Grate

Age of Boiler 43 yrs.

14 yrs.

Type of Fuel

Eastern coal, and #6 Oil

Aspen-Spruce-Balsam bark, Misc.

wood waste (pallets), Aspen saw

dust, Western coal Maximum Size of Wood Fuel

None

None

Amount of Fuel Used Per Year

86,850 tons coal

23.8 x 106

BTU/ton

132,840 tons coal

17.7 x 106

BTU ton

49,370 tons wood waste

8.4 x 106

BTU/ton Burning Temperature, Deg.F

Not measured

1250

Type of Energy

Steam

1450 psi, 950F

Steam

1450 psi, 950F Amount of Energy

1.76 x 10

12

BTU/yr 2.32 x 10

12

BTU/yr

Wet or Dry Ash Collection

Dry - Fly Ash

Wet - Slag

Dry - Fly Ash

Dry - Mechanical Collector Ash Amount of Slag/Bottom Ash

4,500 tons/yr - Slag

100,000 tons/yr - Bottom Ash

Amount of Fly Ash

(1)

(2)

(1) #4 Boiler Precipitator Ash = 4,000 tons/yr, #4 Boiler Hopper Fly Ash = 1,200 tons/yr

(2) #5 Boiler Precipitator Ash = 3,000 tons/yr, #5 Boiler Mechanical Hopper Ash = 2,500 tons/yr

Background Information on the Kraft Division Ash

Source

Kraft P-1

Kraft P-2

Make of Boiler

Combustion

Engineering

Combustion

Engineering

Type of Boiler

Stoker Traveling

Grate

Stoker Traveling

Grate

Age of Boiler 34 yrs.

34 yrs.

Type of Fuel

Bark, wood, saw

dust, and coal

Bark, wood, saw

dust, and coal Maximum Size of Wood Fuel

~1" x 1"

~1" x 1"

Amount of Fuel Used

Per Year

89,000 t/yr coal

88,000 t/yr wood

waste

97,000 t/yr coal

89,000 t/yr wood

waste Burning Temperature, Deg.F

1800-2000

1800-2000

Type of Energy

Steam

Steam

Amount of Energy

~240 k#/hr

~250 k#/hr

Wet or Dry Ash Collection

Dry - Fly Ash

Wet - Bottom

Ash

Dry - FlyAsh

Wet - Bottom

Ash

Amount of Bottom Ash

800 tons/yr

900 tons/yr

Amount of Fly Ash

7,400 tons/yr

7,800 tons/yr

-4-

Background Information on the Niagara Ash

Source

Niagara

Boiler B21

Niagara Boiler

B22

Niagara

Boiler B23

Niagara Boiler

B24 Make of Boiler

Combustion

Engineering

Combustion

Engineering

Combustion

Engineering Babcock & Wilcox

Type of Boiler

Pulverized

General, Dry

Bottom

Pulverized

General, Dry

Bottom

Pulverized

General, Dry

Bottom Spreader Stoker

Age of Boiler 61 yrs.

61 yrs.

61 yrs.

39 yrs.

Type of Fuel Coal, wood waste

Coal, wood waste

Coal

Coal

Maximum Size of Wood

Fuel Not Available

Not Available

Not Available

Not Available

Amount of Fuel Used

Per Year

13,170 tons

coal

19,790 tons

wood waste

21,760 tons coal

19,790 tons

wood waste

27,360 tons

coal 16,980 tons coal

Burning Temperature,

Deg.F Not Available

Not Available

Not Available

Not Available

Type of Energy

Steam

Steam

Steam

Steam

Amount of Energy

360,324,000 lb

steam

515,110,000 lb

steam

536,887,000 lb

steam

329,031,000 lb

steam Wet or Dry Ash

Collection

Dry-Fly Ash

Dry-Fly Ash

Dry-Fly Ash

Dry-Fly Ash Amount of Bottom Ash

Not Available

Not Available

Not Available

(1)

Amount of Fly Ash

(1)

(1)

(1)

Not Available

(1) Total Fly Ash from Boiler B21, B22 and B23 = 7120 tons/yr, Total Bottom Ash from Boiler B24 =

2380 tons/yr

-5-

Section 2

Tests of CPI Wood and/or Coal Combustion Products

EXPERIMENTAL PROGRAM

A test program was designed to measure physical, chemical, mineralogical, and microscopical

properties of the ashes from CPI boilers. Wood and/or coal combustion products were received

from the following CPI mills: Biron, Kraft Division, and Niagra. Five types of ash were received

from the Biron mill: Boiler #4 precipitator ash, Boiler #4 bottom ash, Boiler #4 Slag, Boiler #5

precipitator ash, and Boiler #5 mechanical hopper ash. Two types of ash were received from the

Kraft Division: "fine ash" and bottom ash. These ash materials were obtained from a combination

of units P1 and P2. Finally, two types of ash were obtained from the Niagara mill: fly ash

combined from boilers B21-B23 and bottom ash from boiler B24. In order to measure properties

of these ash products, the following experiments were carried out.

PHYSICAL PROPERTIES

As-Received Moisture Content

As-received moisture content (MC) of the ashes was determined in accordance with the ASTM

Test Designation C 311. Table 1 provides the test data. The results show that the Kraft P1-P2

"fine" ash had a very high (78.9% ) MC, while the Biron #4 bottom ash, Kraft P1-P2 bottom ash,

Niagara B21-B23 fly ash, and Niagara B24 bottom ash had a mid-range MC (20.0%, 17.7%, 27.9%,

and 12.2%, respectively). The remaining materials, Biron #4 precipitator ash, Biron #4 slag, Biron

#5 precipitator ash, and Biron #5 mechanical hopper ash had low moisture contents (0.1%, 3.3%,

-6-

0.3%, and 0.2%, respectively). There are some significant negative attributes of these ashes with

very high end to mid-range MC:

(1) moisture/water content leads to cost of shipping water along with the ash to the potential user of

the ash. This, of course, increases the cost to the user in obtaining the ash for beneficial reuse.

(2) If the moisture content is not within control, then the variation leads to quality control

problems for the user.

(3) The water content is a critical parameter for manufacturing cement-based products. Therefore,

if the user is planning to use the ash in cement-based materials, then the water content must be

controlled in a narrow range to control the quality of such products.

(4) Wetting the ash with or soaking it in water destroys any cementitious ability of the ash. (5) A

typical manufacturer of cement-based materials is equipped very well to handle dry or relatively

dry materials. Therefore, wet or variable moisture content ash would make it harder for CPI to

market these ashes for reuse/recycle purposes to such manufacturers.

Particle Size Analysis

Ash samples were first oven-dried at 210F ± 10F and then were tested for gradation using

standard sieve sizes (3/4" through #100), as reported in Table 2, in accordance with ASTM Test

Designation C 136. Ash samples were also tested in accordance with ASTM Test Designation

C117 to determine the amount of material finer than No. 200 sieve by washing as reported in

Table 3. Three ash samples, Biron #4 precipitator ash, Biron #5 precipitator ash, and Niagara

B21-23 fly ash were not evaluated using ASTM C 136 and C 117 due to the fact that these sources

of the ash were too fine to conduct these tests. Ash samples were further tested for materials

passing No. 325 sieve by washing under pressure in accordance with ASTM Test Designation

C 430. Bottom ash and slag samples were too coarse for this test. Results are reported in Table 4.

-7-

The size distributions of samples having a significant percentage of particles passing #100 sieve

(Biron #4 precipitator ash, Biron #5 precipitator ash, Biron #5 mechanical hopper ash, Niagara

B21-B23 fly ash, and Niagara B24 bottom ash) were also analyzed in accordance with ASTM C

422 (hydrometer analysis). The complete size distribution of all of the ashes are shown in Fig. 1 to

Fig. 9.

Table 2 particle size analysis data show that the Biron #4 bottom ash, Biron #4 slag and Kraft P1-

P2 bottom ash generally were coarse materials with only 16% to 21% passing through the No. 16

sieve. Furthermore, these materials had less than 4% of the total materials passing No. 200 sieve

when washed with water (Table 3). These test data indicate that these three sources of ash may be

acceptable as a substitute for sand replacement in ready-mixed concrete and/or as both coarse and

fine aggregates replacements in dry-cast concrete products such as bricks, blocks, and paving stones

because of its generally coarse gradation. Furthermore, these materials are not fine enough; i.e.,

too coarse, to be used for cement replacement in concrete.

Table 4 data show that the Biron #4 precipitator ash, Biron #5 mechanical hopper ash, and Kraft

P1-P2 "fine" ash had a considerable amount of material retained on the No. 325 sieve (53%, 76%,

and 93%, respectively). The Biron #5 precipitator ash and Niagara B21-B23 fly ash were

considerably finer with about 10% and 31%, respectively, retained on the No. 325 sieve. ASTM

C 618 for coal fly ash classifies a value of maximum 34% retained on the No. 325 sieve as

satisfactory for use in concrete. Based upon this criterion for pulverized coal fly ash, the CPI

Biron #5 precipitator ash and Niagara B21-B23 fly ash met this requirement of ASTM C 618.

These results indicate that the Biron #5 precipitator ash and Niagara B21-B23 fly ash may be quite

suitable as a cement replacement in concrete and also for CLSM-type of flowable slurry products.

-8-

The coarser materials (Biron #4 precipitator fly ash, Biron #5 mechanical hopper ash, and Kraft

P1-P2 "fine" ash) maybe more suitable for use in CLSM, but may be too coarse as produced to be

used as a cement replacement in concrete.

Test data for particle size analysis in accordance with the modified ASTM C 422 are presented in

Figs. 1, 4, 5, 8, and 9. Appendix 1 provides the details of this modified ASTM test. These figures

show that the gradation of the Biron #4 precipitator ash, Biron #5 mechanical hopper ash, and

Niagara B21-B23 fly ash (Figs. 1, 5, and 8, respectively) is reasonably uniform while over 80% of

the particles of Biron #5 precipitator ash (Fig. 4) fall between 8-15 microns.

Unit Weight

Unit weight (i.e., bulk density) of the ash was determined in accordance with the ASTM Test

Designation C 29. Table 5 provides the test results. The results show that the fine ash materials

(Biron #4 precipitator ash, Biron #5 precipitator ash, Kraft P1-P2 "fine" ash, and Niagara B21-B23

fly ash) had similar density values, approximately 15-29 lb/ft³.

Bulk density of Biron #4 bottom

ash, Biron #4 slag, Biron #5 mechanical hopper ash, Kraft P1-P2 bottom ash, and Niagara B24

bottom ash was 60, 93, 48, 61, and 44 lb/ft³, respectively. This is consistent with the gradation of

the slag and bottom ash, which showed a significant amount of coarser fractions of the ash

materials. These data indicate that these materials (except the Biron #4 slag) may be suitable for

replacing regular, normal-weight, sand and/or coarse aggregates in making semi-lightweight or

lightweight CLSM and/or concrete. Such lightweight construction materials are well suited for

insulating fill for roofs and walls, as well as sound and/or ground vibration barriers. Typical

manufactured lightweight sand costs over $50 per ton and light weight coarse aggregates costs about

$45 per ton. Bulk density value is also necessary for calculations for establishing and modifying

-9-

cement-based construction materials mixture proportioning. Percentage of voids in Table 5

indicate amount of free space available for packing of other materials in making cement-based

materials. The higher the percent voids, the higher the amount of other materials necessary for

making cement-based materials.

Specific Gravity

Specific gravity tests for the fine ash materials (Biron #4 precipitator ash, Biron #5 precipitator ash,

Biron #5 mechanical hopper ash (passing No. 100 sieve), and Niagara B21-B23 fly ash were

conducted in accordance with the ASTM Test Designation C 188, Table 6. Results show that the

specific gravity values for the Biron #4 precipitator ash and Niagara B21-B23 fly ash are similar,

approximately 2.15 (ranges between 2.13 and 2.21). This is a similar order of magnitude as a

typical coal fly ash, though these two ashes have a lower specific gravity value than typical Class F

coal fly ash (specific gravity approximately 2.50), and significantly lower than typical Class C fly ash

(specific gravity approximately 2.60). The value of specific gravity for the Biron #5 precipitator ash

is 2.50. This is consistent with specific gravity of typical Class F coal ash. It is also noted from

Table 6 that the specific gravity for samples passing #100 sieve is slightly higher than that tested for

as received samples. This may be due to the fact that the coarse fractions of the ashes contain

higher amounts of carbon than the finer fractions. Specific gravity value is necessary for

determining relative substitution rate for fly ash versus amount of cement or sand replaced in a

mixture; and, also for calculations for establishing and modifying cement-based construction

materials mixture proportions.

Specific gravity tests for the Biron #4 bottom ash, Biron #4 slag, Biron #5 mechanical hopper ash

(as received), Kraft P1-P2 "fine" ash, Kraft P1-P2 bottom ash, and Niagara B24 bottom ash were

-10-

carried out in accordance with ASTM Test Designation C 128. Test results are shown in Table 7.

The Biron #5 mechanical hopper ash, Kraft P1-P2 "fine" ash and Niagara B24 bottom ash had an

average apparent specific gravity of 1.84, 1.85 and 2.03, respectively. This is considerably lower

than that for typical aggregates used in concrete, which is around 2.65. Therefore, these sources of

ash should be useful as semi-lightweight and/or lightweight aggregates. Specific gravity of Biron #4

slag, 2.67, is consistent with that of a typical concrete aggregate and may have applications as a

decorative aggregate in concrete. The remaining materials, Biron #4 bottom ash and Kraft P1-P2

bottom ash have specific gravities slightly lower than a typical aggregate (2.37 - 2.38). These may

be useful for reducing the weight of the construction materials made from these ash materials.

SSD Absorption

For the coarser ashes (Biron #4 bottom ash, Biron #4 slag, Biron #5 mechanical hopper ash, Kraft

P1-P2 "fine" ash, Kraft P1-P2 bottom ash, and Niagara B24 bottom ash) saturated surface dry

(SSD) moisture absorption tests in accordance with the ASTM Test Designation C 128 were

conducted. Results are shown in Table 8. These ash materials, with the exception of Biron #4

slag, had SSD absorption values that were considerably higher than that for typical sand or coarse

aggregate used in concrete, which is typically less than 2%. The Kraft P1-P2 bottom ash had an

absorption of over 50%. The SSD absorption value is an indication of the porosity of the

aggregates. Typical lightweight aggregates used in concrete generally have very high absorption

values and must be pre-soaked in order to manufacture consistent quality workable concrete. SSD

moisture absorption value is also required for calculations for establishing and modifying cement-

based construction materials mixture proportioning. Higher absorption materials may lead to

better curing of the cement-based materials after they are cast; and, therefore, better quality for

such materials.

-11-

ASTM C 618 TESTS

Physical Properties per ASTM C 618

ASTM C 618 provides standard specifications for coal fly ash for use in concrete. There is no

other similar test standards available for wood ashes. Therefore, to judge the suitability of the CPI

wood ash resource for potential use as a mineral admixture in cement-based materials, physical

tests were performed as described below in accordance with the ASTM Test Designation C 618.

The following physical properties of the CPI ash were determined: (1) Cement Activity Index;

(2) Water Requirement; and, (3) Autoclave Expansion.

Cement Activity Index

Cement activity index tests for four fine ash materials (Biron #4 precipitator ash, Biron #5

precipitator ash, Biron #5 mechanical hopper ash, and Niagara B21-B23 fly ash) were performed

in accordance with the ASTM Test Designation C 311/C 109. Two-inch mortar cubes were made

in a prescribed manner using a mixture of cement, sand, and water, without any wood ash (Control

Mixture). Compressive strength tests were conducted at the age of 3, 7, and 28 days. Actual

strength test results, in psi, are reported in Table 9 for these test specimens made from the Control

Mixture. Additional test mixtures were prepared using 80% cement and 20% CPI ash, by weight

(instead of cement only without CPI ashes as in the Control Mixture). Four different mixtures

were made with the four fine CPI ashes

being evaluated in this study. Cube compressive strength test results, in psi, for these CPI ashes are

also reported in Table 9.

-12-

Comparison of the four CPI ash mixtures cube compressive strengths, with the Control Mixture, is

reported in Table 10. These results are designated as Strength Activity Index with Cement. In this

comparison, the Control Mixture was assigned a value of 100, at each age, and all other cube

compressive strength values were scaled from this reference datum.

The Biron #5 precipitator ash and Niagara B21-B23 fly ash samples pass the ASTM C 618

requirement for Cement Activity Index of Class N, C, and F fly ash (75% at either 7- or 28-day test

age). Overall, the Activity Index with Cement test results of these two CPI ashes show that they

are suitable for making medium strength (say up to 5,000 psi compressive strength) concrete and

CLSM (which by the ACI Committee 229 Definition has up to 1,200 psi compressive strength).

The cube compressive strength test results, Table 9, for the Biron #4 precipitator ash and Biron #5

mechanical hopper ash mixtures were lower than that for the Control Mixture without fly ash. The

Activity Index with Cement data, Table 10, for these ashes were 54% to 58% (lower than 75%

required for coal ash by ASTM C 618) for the compressive strength, compared with the Control

Mixture without the CPI ash. However, the actual test data, Table 9, show that sufficient

compressive strength can be achieved with the Biron #4 precipitator ash and Biron #5 mechanical

hopper ash even though these ash mixtures did not perform as well as the no ash Control Mixture.

Based upon the cube compressive strength data, overall, it can be concluded that the Biron #4

precipitator ash and Biron #5 mechanical hopper ash are suitable for making CLSM, including

making slightly lower strength (say up to 4,000 psi compressive strength) concrete for base course

and/or sub-base course for pavement of highways, roadways, and airfields; driveways; parking lots;

and other similar construction applications. These ash sources can also be considered quite

satisfactory for housing construction where typically a compressive strength of 3,000 psi concrete at

the age of 28 days, is used. These two ash resources can also be used for in-house concrete

-13-

construction needs of the CPI mills.

In summary, ASTM C 618 classifies a value at 7-day or 28-day age of 75 or above for the Activity

Index with Cement for coal fly ash as passing. Based upon this criterion only, the Biron #5

precipitator ash and Niagara B21-B23 fly ash pass and the Biron #4 precipitator ash and Biron #5

mechanical hopper ash do not pass either the 7 or 28 day requirement.

Water Requirement

Water requirement tests for the Biron #4 precipitator ash, Biron #5 precipitator ash, Biron #5

mechanical hopper ash, and Niagara B21-B23 fly ash were performed in accordance with the

ASTM Test Designation C 311. This test determines the relative amount of water that may be

required for mixture proportioning of cement-based construction materials. It is well established

that the lower the water required for a desired value of workability for the cement-based material,

the higher the overall quality of the product. Test data for water requirement for the CPI ashes are

reported in Table 11. The results show that the average value for water requirement for the four

CPI ashes tested were higher than the maximum desirable value for water requirement. ASTM

C 618 specifies a maximum value of 105 or 115, depending upon the type of ash, as an acceptable

value for water requirement. For coal fly ash the acceptable value is 105, while that for volcanic

ash it is 115. It is concluded that these CPI ashes may perform satisfactorily in cement-based

construction materials, even though the water required for a desired amount of workability

probably would be somewhat higher. This would lead to a slightly higher amount of cement to

compensate for the potential negative effects of the higher water content in the mixture. This

negative effect of higher water required could also be overcome by judicious use of chemical

admixtures which would be more cost-effective.

-14-

Autoclave Expansion

Autoclave expansion tests for the Biron #4 precipitator ash, Biron #5 precipitator ash, Niagara

B21-B23 fly ash, and Niagara B24 bottom ash (material passing No. 20 sieve) were performed in

accordance with the ASTM Test Designation C 311/C 151. Test specimens in the shape of bars

were cast using cement paste containing these CPI ashes. The test specimens were then subjected

to a high-temperature steam bath at approximately 295 psi pressure in a boiler (a pressure cooker

meeting the requirements of the ASTM). The test results, given in Table 12, show that the

expansion was negligible. The range of expansion values recorded for the CPI ash samples tested

were well below the acceptable maximum limit of expansion/contraction of 0.8%, as specified by

ASTM C 618 for coal fly ash. Therefore, all CPI ashes tested are acceptable in terms of long-term

soundness/durability from the viewpoint of undesirable autoclave expansion.

Table 13 shows physical properties requirements for coal fly ash per ASTM Test C 618.

Chemical Properties per ASTM C 618

Chemical analysis tests were conducted to determine oxides present in the nine sources of the CPI

ash. X-ray fluorescence (XRF) technique was used to detect the presence of silicon dioxide

(SiO2), aluminum oxide (Al2O3), iron oxide (Fe2O3), calcium oxide (CaO), magnesium oxide

(MgO), titanium oxide (TiO2), potassium oxide (K2O), and sodium oxide (Na2O). In this method,

ignited samples were fused in a 4:1 ratio with lithium carbonate-lithium tetraborate flux and cast

into pellets in platinum molds. The XRF technique for measuring sulfate (SO3) involves grinding

the ash sample and manufacturing a compressed pellet with boric acid. A double dilution method

using a 4:1 and a 10:1 ratio with boric acid was used to correct for matrix effects. These buttons

-15-

were used to measure x-ray fluorescence intensities for the desired element, in accordance with

standard practice for cementitious materials, by using an automated Philips PW1410 x-ray

spectrometer. The percentages of each element were derived from the measured intensities

through a standardized computer program based on a procedure outlined for low-dilution fusion.

This is a “standard practice” for detecting oxides in cementitious compounds, including coal fly

ash. Tests are reported in Table 14. Loss on ignition (LOI), moisture content, and available alkali

(Na2O equivalent) for the pre-dried CPI ashes were also determined. These test results are also

reported in Table 14.

According to the oxide analysis data, the Biron #4 precipitator ash, Biron #5 precipitator ash,

Biron #5 mechanical hopper ash, Kraft P1-P2 "fine" ash, and Niagara B21-B23 fly ash do not meet

Class C or F coal fly ash requirements due to one or more of the following: high LOI, high

available alkali content, and high sulfate contents. The calcium oxide content for the Biron #4

bottom ash, Biron #5 precipitator ash, Biron #5 mechanical hopper ash, Kraft P1-P2 "fine" ash,

and Kraft P1-P2 bottom ash is judged to be very good because the calcium oxide values are above

10 percent. Furthermore, the magnesium oxide values are judged to be quite low enough for all

CPI ash samples to minimize the soundness/durability related problems created due to a high

MgO value, which is accepted to be greater than five percent. In general all oxides present, except

the available alkali (Na2O equivalent, LOI, and the sulfate content), were within limits specified in

the ASTM C 618 for coal fly ash.

Available alkali was higher than that specified in ASTM for the Biron #5 precipitator ash and Kraft

P1-P2 "fine" ash. Maximum amount of available alkali for coal fly ash is limited to 1.5% in

accordance with the ASTM C 618. The actual values were 7.2 and 1.9% for the Biron #5

-16-

precipitator ash and the Kraft P1-P2 "fine" ash, respectively. Available alkali of the remaining CPI

ashes tested were less than 1.5 percent. Bottom ash and slag samples typically had the lowest

available alkali values, approximately 0.1 - 0.3 percent. The presence of high amount of alkali may

lead to desirable early hydration reaction products in coal fly ash, natural pozzolans, ground

granulated blast-furnace slag, silica fume, and/or metakaoline types of reactive-powder additives

used in making cement-based construction materials. Available alkali may also impact cement-

based construction materials negatively (developing “ASR”, alkali silica reaction) if it contains free-

silica-based compounds in coarse or fine aggregates used for making such construction materials.

Furthermore, higher amounts of available alkali may also lead to chemical combination with

sulfates and leaching of such sulfate-based white compounds (“precipitates”) on the surface of

concrete (called efflorescence) creating undesirable, randomly distributed, white coloring on the

concrete surface.

Loss on ignition (LOI) for many CPI ashes is higher (approximately 20 to 40%) than that

permitted (maximum 6%) by ASTM C 618 for coal fly ash, with the exception of Biron #4 bottom

ash, Biron #4 slag, and Kraft P1-P2 bottom ash. Under certain circumstances, up to 12%

maximum LOI is permitted by ASTM C 618. Recent research at the UWM Center for By-

Products Utilization show that high-LOI coal ash can be effectively used for CLSM as well as roller

compacted concrete pavements. Currents practice in Wisconsin and elsewhere also show that

high-LOI coal fly ash should generally perform satisfactorily for CLSM. High-LOI ashes affect the

use of air-entering agent used in concrete to make the concrete resistant to a freezing and thawing

environment. In general, therefore, the CPI ashes may be used for CLSM and concrete, no-fines

concrete, roller compacted concrete pavements, dry-cast concrete products, etc. These types of

construction materials do not require the use of air-entraining agent for freezing and thawing

-17-

resistance of concrete.

CHEMICAL COMPOSITION

The mineral analysis, (i.e., chemical composition) for the CPI ashes were conducted by using the

X-ray diffraction (XRD) method. The results are shown in Table 15. A typical coal fly ash

contains approximately 80% glass (amorphous) phase. Since the glass contents of fly ash

contributes to its potential pozzolanic reactivity, a higher amount of glass phase is preferred when a

fly ash is used as cementitious materials. As can be expected, the Biron #4 slag contained the

highest amounts of glass phase (100%). Biron #4 precipitator ash, Biron #5 mechanical hopper

ash, Kraft P1-P2 "fine" ash, and Niagara B24 bottom ash had glass phases that range from 72-79%

while glass phases of the Biron #4 bottom ash, Biron #5 precipitator ash, Kraft P1-P2 bottom ash,

and Niagara B21-B23 fly ash ranged from 54-63 percent.

ELEMENTAL ANALYSIS

All CPI ash samples were analyzed for total chemical make-up by the Instrumental Neutron

Activation Analysis (INAA). Knowledge of total elemental concentration is necessary because it

provides an insight into the possibility of leaching potential characteristics of the material tested.

Leaching of trace metals is known to be highly dependent upon the temperature of the combustion

in the boiler and how these trace elements are converted to chemical compounds. A high

concentration of undesirable elements does not necessarily mean that these undesirable elements

will leach. Tests for leachate characteristics of construction materials, such as TCLP, must be

performed in order to conduct the environmental assessment of the materials proposed to be used

and the product (e.g., cement-based materials) to be made from it. The results for the elemental

analysis performed are reported in Table 16.

-18-

SCANNING ELECTRON MICROSCOPY (SEM)

A scanning electron microscope available at the University of Wisconsin-Milwaukee was employed

for this part of the investigation. SEM pictures (photomicrographs) for the nine CPI ashes were

obtained, Figures 10 through 45. These SEM pictures are an important part of understanding the

character and morphology of the particles of the product being evaluated for considering their

constructive use options. For example, studying the morphology allows judgment to be made

regarding the physical and/or mechanical bond that might be possible for the wood ash in creating

new cement-based construction materials. Also, it allows an opportunity to study the contours of

the particles and how they may help in mixing and manufacturing these cement-based materials.

The particle morphology helps in understanding the level of completeness of combustion and

microstructure of burned, partially burned, or unburned particles. This evaluation of level of

combustion, and particle size and distribution, also help in judging the water demand that may be

placed upon for making cement-based materials.

All nine CPI ash SEM micrographs can be observed to be composed of heterogeneous mixture of

particles of varying size. Some glass-type material is present, particularly in the Biron #4 slag and

other Biron #4 ashes. Partially hydrated, unhydrated, and hydrated compounds of calcium are

also present. Unlike coal fly ash particles, these CPI ash particles are not all spherical in shape.

Also, all of these CPI ash particles are not observed to be solid but some of them are cellular in

form. These cellular particles are mostly unburned or partially burned wood or bark particles.

-19-

Section 3

Constructive Use Options for CPI Ashes

INTRODUCTION

A number of uses of coal combustion products (CCP) in construction materials already exist [1].

However, these applications depend upon physical, chemical, mineralogical, and surface

properties of such by-products. The same is true for the CPI ashes. The following sections deal

with potential uses of the CPI ashes analyzed in this investigation.

USES OF CPI WOOD ASHES

The size distribution of some CPI ash products is similar to that of conventional coal ash products.

In general, however, CPI fly ashes are not as fine as typical coal fly ash. Furthermore, the CPI

ashes are irregular in shape versus spherical shape for coal fly ash. This means that when CPI

ashes are added in mortar or concrete then workability of fresh mortar or concrete may not be

helped as much as that typical with the use of coal fly ash. In fact, some porous particles of

unburned or partially burned wood or coal (charcoal) may absorb the water added in mortar or

concrete and further reduce the workability of the mixture. Some of the CPI ashes have high LOI

(i.e., unburned or partially burned wood).

This investigation revealed that the CPI ash samples generally did not conform to all parts of the

-20-

ASTM C 618 Class F or C requirements for coal fly ash for applications in cement-based

composites. ASTM C 618 also gives standard specifications for natural pozzolans, which is a

volcanic ash. There are no wood ash ASTM standards available. Therefore, the CPI ashes

cannot be compared to such standard specifications. However, the CPI fly ashes are still expected

to be suitable for use in normal strength (up to 5,000 psi) concrete. The CPI ashes are also very

suitable for CLSM and grouting applications.

In some applications in which conventional coal fly ashes are used, the CPI ash cannot be used.

However, the CPI ashes probably can be used effectively for many more applications after it is

beneficiated; for example, after sieving coarser fractions and/or removing undesirable charcoal

particles and thus reducing LOI. For more useful applications, with or without beneficiating CPI

ashes, further study would be needed to develop optimum use options. A list of potential uses of

the CPI ashes presented in Tables 17 - 20.

-21-

Section 4

Suggestions for Further Evaluations

As indicated in Section 3, the CPI ashes have considerable potential for many applications.

However, the performance of these CPI ashes needs to be proven for individual applications.

The following are some of the potential high-volume applications that would require further proof

for various uses.. It is anticipated that these applications can consume most of the ash products

produced by CPI.

FLOWABLE MATERIALS

Large amounts of CPI ashes can be utilized in manufacture of flowable fill (a.k.a. manufactured

dirt) material. This is defined by ACI Committee 229 as Controlled Low-Strength Material

(CLSM). The compressive strength of CLSM can be very little (10 psi) up to 1200 psi. This

material can be used for foundations, bridge abutments, buildings, retaining walls, utility trenches,

etc. as backfill; as embankment, grouts, abandoned tunnel and mine filling for stabilization of such

cavities, etc. See Tables 17 - 20 for more details.

CLSM can be manufactured with large amounts of CPI ash, low amount of cement and/or lime,

and high water-to-cementitious materials ratio to produce the flowable fill. An evaluation study is

highly (very strongly) recommended in order to produce CLSM for various applications with this

material for approval by local environmental agencies, such as Wisconsin Department of Natural

Resources. Probability of success is excellent.

-22-

BRICKS, BLOCKS, AND PAVING STONES

The CPI ashes have potential for applications in numerous masonry products such as bricks,

blocks, and paving stones. Additionally, these ashes can be utilized as a replacement of clay in

manufacture of clay bricks. However, in order to meet the ASTM requirements for strength and

durability, testing and evaluation work is necessary. The results of such testing would be used in

developing specifications for the CPI ash in the manufacture of masonry products. Lab evaluation

is strongly recommended. Probability of success is very high.

MEDIUM-STRENGTH CONCRETE

The CPI ashes can be used as a partial replacement of sand and/or cement in concrete. This is a

very broad conclusion from the work conducted as a part of this test evaluation. Test results show

that these wood ashes did not meet all ASTM C 618 coal ash requirements for concrete products

applications. However, the ASTM C 618 is written exclusively for coal fly ash (and

natural/volcanic ash) materials. Future ASTM standards, therefore, may evolve which could be

satisfied by the CPI ashes. In order to determine the effects of optimum inclusion of the these

ashes on concrete strength and durability properties, lab study is very strongly recommended.

Probability of success is very high.

DECORATIVE AGGREGATE - ROOFING SHINGLE GRIT

The CPI Biron #4 slag has a very significant potential to be utilized as an architectural aggregate in

concrete or as a roofing shingle grit. Based upon the limited testing performed for the project,

these applications have the potential to be a significant source of revenue. A further evaluation is

very strongly recommended. Probability of success is excellent.

-23-

BLENDED CEMENT

The highest market value use of the CPI ashes is in the production of blended cements. Blended

cement material is typically composed of portland cement, coal fly ash, and/or other cementitious

or pozzolonic materials, and chemicals. The CPI ashes have significant available alkali content

(above the maximum allowed by ASTM C 618, Table 14). The high alkali content, however,

would be a desirable characteristic for activating chemical reactions for cementing-ability of

blended cements for various applications. Further evaluation is very strongly recommended.

Probability of success is very high.

ROLLER-COMPACTED CONCRETE PAVEMENT

The CPI ashes can be used for Roller-Compacted Concrete Pavement (RCCP) for improving the

performance and use of log-yards in all types of Wisconsin weather. Log-yards pavings using CPI

ashes would be a very important application. RCCP popularity is increasing in Wisconsin. Lab

evaluation is very strongly recommended for future applications. Probability of success is very

high.

SOIL AMENDMENT WITH OR WITHOUT DREDGED MATERIALS

Wisconsin dredges a significant tonnage of dredged materials from the Great Lakes and the

Mississippi River to keep the navigation channels open. The CPI ashes would be an excellent

additive to dredged materials to make manufactured topsoil for use in tree farms, sod farms,

potting soil, pulp-mill new growth woods/plantations, etc. These ashes will act as a desiccant,

deodorizer, and chemical activators for dredged materials. The resulting manufactured topsoil can

be used as a fertilizer, and to decrease subsurface porosity and

-24-

improve infiltration characteristics of soils. Further lab study is very strongly recommended.

Probability of success is very high.

-25-

CONSOLIDATED PAPERS, INC.

ASH CHARACTERIZATION

Biron #4 Precipitator Ash, Bottom Ash and Slag.

Biron #5 Precipitator Ash and Mechanical Hopper Ash.

Kraft P1 and P2 "Fine" Ash and Bottom Ash.

Niagara B21-B23 Fly Ash.

Niagara B24 Bottom Ash.

-26-

Table 1: As-Received CPI Ash Moisture Content

Ash Source*

Moisture Content, %

Actual**

Average

Biron #4

Precipitator Ash

0.1

0.1

0.1

Biron #4 Bottom

Ash

20.3

20.0

19.7

Biron #4

Slag

3.3

3.3

3.3

Biron #5

Precipitator Ash

0.3

0.3

0.4

Biron #5

Mechanical Hopper

Ash

0.1

0.2

0.2

Kraft P1-P2

"Fine" Ash

77.1

78.9

80.8

Kraft P1-P2 Bottom

Ash

17.4

17.7

18.0

Niagara B21-B23

Fly Ash

28.2

27.9

27.7

Niagara B24

Bottom Ash

11.4

12.2

13.0

* All samples were received in August 1999.

** Moisture content, as-received, % = (as-received sample wt. - dry sample wt.) * 100

dry sample weight

-27-

CONSOLIDATED PAPERS, INC.

ASH PARTICLE SIZE ANALYSIS

-28-

Table 2: Sieve Analysis of CPI Ash (As-Received Samples)

(Tests conducted per ASTM C 136)

Biron #4 Precipitator Ash

Sieve Size % Passing*

3/4" (19.1-mm)

NA***

1/2" (12.7-mm)

NA***

3/8" (9.5-mm)

NA***

#4 (4.75-mm)

NA***

#8 (2.36 mm)

NA***

#16 (1.18 mm)

NA***

#30 (600 μm**)

NA***

#50 (300 μm**)

NA***

#100 (150 μm**)

NA***

Biron #4 Bottom Ash

Sieve Size % Passing*

ASTM C 33

% Passing

for sand

3/8" (9.5-mm)

89.7

100

#4 (4.75-mm)

67.1

95 to 100

#8 (2.36 mm)

40.5

80 to 100

#16 (1.18 mm)

20.7

50 to 85

#30 (600 μm**)

10.6

25 to 60

#50 (300 μm**)

5.1

10 to 30 #100 (150 μm**)

2.0

2 to 10

* Values reported for % passing are the average of two tests.

** 1.0 μm = 10-6

m = 0.001 mm

*** NA = Test is not applicable, material very fine, see Fig. 1

-29-

Table 2 (Continued): Sieve Analysis of CPI Ash (As-Received Samples)

(Tests conducted per ASTM C 136)

Biron #4 Slag

Sieve Size % Passing*

ASTM C 33

% Passing

for sand

3/8" (9.5-mm)

97.5

100

#4 (4.75-mm)

88.8

95 to 100

#8 (2.36 mm)

59.7

80 to 100

#16 (1.18 mm)

21.1

50 to 85

#30 (600 μm**)

6.1

25 to 60

#50 (300 μm**)

2.2

10 to 30 #100 (150 μm**)

0.9

2 to 10

Biron #5 Precipitator Ash

Sieve Size % Passing*

3/8" (9.5-mm)

NA***

#4 (4.75-mm)

NA***

#8 (2.36 mm)

NA***

#16 (1.18 mm)

NA***

#30 (600 μm**)

NA***

#50 (300 μm**)

NA***

#100 (150 μm**)

NA***

* Values reported for % passing are the average of two tests.

** 1.0 μm = 10-6

m = 0.001 mm

***NA = Test not applicable, material very fine, see Fig. 4

-30-

Table 2 (Continued): Sieve Analysis of CPI Ash (As-Received Samples)

(Tests conducted per ASTM C 136)

Biron #5 Mechanical Hopper Ash

Sieve Size % Passing*

ASTM C 33

% Passing

for sand

3/8" (9.5-mm)

100.0

100

#4 (4.75-mm)

100.0

95 to 100

#8 (2.36 mm)

100.0

80 to 100

#16 (1.18 mm)

98.3

50 to 85

#30 (600 μm**)

83.5

25 to 60

#50 (300 μm**)

60.9

10 to 30 #100 (150 μm**)

44.0

2 to 10

Kraft P1-P2 "Fine" Ash

Sieve Size % Passing*

ASTM C 33

% Passing

for sand

3/8" (9.5-mm)

78.4

100

#4 (4.75-mm)

70.4

95 to 100

#8 (2.36 mm)

57.6

80 to 100

#16 (1.18 mm)

35.5

50 to 85

#30 (600 μm**)

19.2

25 to 60

#50 (300 μm**)

8.0

10 to 30 #100 (150 μm**)

2.9

2 to 10

* Values reported for % passing are the average of two tests.

** 1.0 μm = 10-6

m = 0.001 mm

-31-

Table 2 (Continued): Sieve Analysis of CPI Ash (As-Received Samples)

(Tests conducted per ASTM C 136)

Kraft P1-P2 Bottom Ash

Sieve Size % Passing*

ASTM C 33

% Passing

for sand

1/2" (12.7-mm)

67.9

100

3/8" (9.5-mm)

61.8

100

#4 (4.75-mm)

49.9

95 to 100

#8 (2.36 mm)

30.3

80 to 100

#16 (1.18 mm)

15.9

50 to 85

#30 (600 μm**)

7.8

25 to 60

#50 (300 μm**)

3.7

10 to 30 #100 (150 μm**)

2.1

2 to 10

Niagara B21-B23 Fly Ash

Sieve Size % Passing*

3/4" (19.1-mm)

NA***

1/2" (12.7-mm)

NA***

3/8" (9.5-mm)

NA***

#4 (4.75-mm)

NA***

#8 (2.36 mm)

NA***

#16 (1.18 mm)

NA***

#30 (600 μm**)

NA***

#50 (300 μm**)

NA***

#100 (150 μm**)

NA***

* Values reported for % passing are the average of two tests.

** 1.0 μm = 10-6

m = 0.001 mm

-32-

*** NA = Test not applicable, material very fine, see Fig. 8

-33-

Table 2 (Continued): Sieve Analysis of CPI Ash (As-Received Samples)

(Tests conducted per ASTM C 136)

Niagara B24 Bottom Ash

Sieve Size % Passing*

ASTM C 33

% Passing

for sand

1/2" (12.7-mm)

93.9

100

3/8" (9.5-mm)

90.6

100

#4 (4.75-mm)

84.2

95 to 100

#8 (2.36 mm)

76.6

80 to 100

#16 (1.18 mm)

68.3

50 to 85

#30 (600 μm**)

57.3

25 to 60

#50 (300 μm**)

45.0

10 to 30 #100 (150 μm**)

27.9

2 to 10

* Values reported for % passing are the average of two tests.

** 1.0 μm = 10-6

m = 0.001 mm

-34-

Table 3: Material Finer Than No. 200 Sieve by Washing (As-Received Samples)

(Tests conducted per ASTM C 117)

Ash Source

Material Finer than No.

200 Sieve (%)

Actual Average

Biron #4 Precipitator

Ash

NA*

NA*

NA*

Biron #4 Bottom Ash

3.8

3.9

3.9

Biron #4 Slag

0.4

0.5

0.5

Biron #5

Precipitator Ash

NA*

NA*

NA*

Biron #5 Mechanical

Hopper Ash

31.5

31.3

31.0

Kraft P1-P2

"Fine" Ash

16.0

16.0

16.0

Kraft P1-P2

Bottom Ash

1.1

1.2

1.2

Niagara B21-B23

Fly Ash

NA*

NA*

NA*

Niagara B24

Bottom Ash

18.2

18.5

18.7

* Test not applicable.

-35-

Table 4: Materials Retained on No. 325 Sieve

(Tests conducted per ASTM C 311/C 430)

Ash Source

% Retained on

No. 325 Sieve

(As-Received Sample)

Actual Average

Biron #4 Precipitator Fly Ash

53.0

53.0

53.0

Biron #4 Bottom Ash

NA

NA

NA

Biron #4 Boiler Slag

NA

NA

NA

Biron #5 Boiler Precipitator

Ash

10.0

9.5

9.0

Biron #5 Mechanical Hopper

Ash

76.0

76.0

76.0

Kraft P1-P2

"Fine" Ash

93.0

93.0

93.0

Kraft P1-P2

Bottom Ash

NA

NA

NA

Niagara B21-B23

Fly Ash

31.0

31.0

31.0

Niagara B24

Bottom Ash

NA

NA

NA

-36-

Fig. 1 Biron #4 Precipitator Ash - GEN-1003.8

-37-

Fig. 2 Biron # 4 Bottom Ash - GEN-1003.1

-38-

Fig. 3 Biron #4 Slag - GEN-1003.3

-39-

Fig. 4 Biron #5 Precipitator Ash - GEN-1003.9

-40-

Fig. 5 Biron #5 Mechanical Hopper Ash - GEN-1003.10

-41-

Fig. 6 Kraft "Fine" Ash - Gen-1003.7

-42-

Fig. 7 Kraft Bottom Ash - GEN-1003.2

-43-

Fig. 8 Niagara Fly Ash - GEN-1003.12

-44-

Fig. 9 Niagara Bottom Ash - GEN-1003.11

-45-

CPI ASH

UNIT WEIGHT, VOIDS, SPECIFIC GRAVITY,

AND SSD MOISTURE CONTENT

-46-

Table 5: Unit Weight and Voids

(Tests conducted on as-received samples per modified ASTM C 29,

utilizing 400 ml measure)

Ash Source

Unit Weight

(lbs/ft3)

Voids

(%) Actual

Average

Actual

Average

Biron #4

Precipitator Ash

26*

26

80

81

25**

81

Biron #4 Bottom

Ash

60**

60

47

48

59**

49

Biron #4

Slag

92**

93

44

43

93**

43

Biron #5

Precipitator Ash

15*

15

90

90

15*

90

Biron #5

Mechanical Hopper

Ash

48**

48

66

66

48**

66

Kraft P1-P2

"Fine" Ash

28**

28

39

38

28**

37

Kraft P1-P2

Bottom Ash

61**

61

47

47

61**

47

Niagara B21-B23

Fly Ash

29*

29

79

79

29*

79

Niagara B24

Bottom Ash

44**

44

35

35

44**

35

* Tested using a 400 ml volume container

** Tested using a 1/10 ft3 volume container

-47-

Table 6: Specific Gravity

(Tests Conducted per ASTM C 311/C 188)

Ash Source

Specific Gravity

Actual

Average

Biron #4

Precipitator Ash

2.12

2.13

2.14

Biron #4 Bottom

Ash

NA

NA**

NA

Biron #4 Slag

NA

NA**

NA

Biron #5

Precipitator Ash

2.54

2.50

2.47

Biron #5 Mech.

Hopper Ash

(As received)

NA

NA**

NA

Biron #5

Mechanical Hopper

Ash*

2.72

2.72

2.72

Kraft P1-P2 "Fine"

Ash

NA

NA**

NA

Kraft P1-P2

Bottom Ash

NA

NA**

NA

Niagara B21-B23

Fly Ash

2.21

2.20 2.21

2.21

Niagara B24

Bottom Ash*

NA

NA

NA

*Samples were first sieved over No. 100 sieve. The specific gravity of this P100 size

fraction is required for the particle size distribution obtained from ASTM D 422

Hydrometer Analysis, Fig. 5.

**NA indicates test not applicable due to the sample gradation being too course.

-48-

Table 7: Specific Gravity

(Tests Conducted per ASTM C 128)

Ash Source

Bulk Specific

Gravity

Bulk Specific

Gravity

(SSD Basis)

Apparent Specific

Gravity Actual

Average

Actual

Average

Actual

Average

Biron #4

Precipitator Ash

NA

NA

NA

NA

NA

NA

NA

NA

NA

Biron #4 Bottom

Ash*

1.84

1.83

2.06

2.05

2.38

2.37

1.81

2.03

2.35

Biron #4 Boiler

Slag*

2.62

2.62

2.63

2.63

2.66

2.67

2.61

2.63

2.67

Biron #5 Boiler

Precipitator Ash

NA

NA

NA

NA

NA

NA

NA

NA

NA

Biron #5

Mechanical

Hopper Ash*

1.47

1.45

1.68

1.66

1.87

1.84

1.42

1.63

1.80

Kraft P1-P2

"Fine" Ash*

0.99

1.00

1.48

1.50

2.00

2.03

1.00

1.51

2.05

Kraft P1-P2

Bottom Ash*

1.98

1.99

2.14

2.15

2.37

2.38

1.99

2.15

2.38

Niagara B21-B23

Fly Ash

NA

NA

NA

NA

NA

NA

NA

NA

NA

Niagara B24

Bottom Ash*

1.74

1.75

1.79

1.80

1.83

1.85

1.75

1.80

1.87

*Samples were first sieved over No. 8 sieve. Tests were conducted on the ash

that passed through this No. 8 sieve since the procedure of ASTM C 128 is for

specific gravity for fine aggregates. Other ash sources were not tested because

they were not coarse enough (NA).

-49-

Table 8: Absorption

(Tests Conducted per ASTM C 128)

Ash Source

SSD Absorption, %

Actual

Average

Biron #4

Precipitator Ash

NA

NA

NA

Biron #4 Bottom

Ash*

12.7

12.6

12.4

Biron #4 Boiler

Slag*

0.8

0.7

0.6

Biron #5 Boiler

Precipitator Ash

NA

NA

NA

Biron #5

Mechanical

Hopper Ash*

14.4

14.8

15.2

Kraft P1-P2

"Fine" Ash*

50.2

50.3

50.4

Kraft P1-P2

Bottom Ash*

8.5

8.5

8.4

Niagara B21-B23

Fly Ash

NA

NA

NA

Niagara B24

Bottom Ash*

3.1

3.4

3.6

* Samples were first sieved over No. 8 sieve. Tests were conducted on the ash

that passed through this No. 8 sieve since the procedure of ASTM C 128 is

for fine aggregates. Other ash sources were not tested because they were

not coarse enough (NA).

-50-

CPI ASH

ASTM C 618 PHYSICAL PROPERTIES

-51-

Table 9: Mortar Cube Compressive Strength*

(Tests conducted per ASTM C 311/C 109)

Ash Source

Compressive Strength (psi)

3-Day

7-Day

28-Day

Control

3430

4460

5420

Biron #4

Precipitator Ash

1620

2090

3150

Biron #5

Precipitator Ash

3300

3660

4320

Biron #5

Mechanical

Hopper Ash

1670

1990

2930 Niagara B21-B23

Fly Ash

2070

3200

4220

*ASTM C 311 is used in conjunction with ASTM C 618 for evaluation of

strength development of mineral admixtures with portland cement. A

mineral admixture is added as replacement of cement for the test mixture. For

this reason, the finer fraction of the fly and precipitator ashes were v utilized

to better reflect the potential reactivity of the ashes. The finer material has

increased surface area and, therefore, would have increased potential for

reactivity. Each result is an average of three compression tests. Other ash

sources were not tested for strength because they were not fine enough.

-52-

Table 10: Strength Activity Index with Cement*

(Tests conducted per ASTM C 311/C 109)

Ash Source

3-day Test

%

7-Day Test

%

28-Day Test

%

Control

100.0

100.0

100.0

Biron #4

Precipitator Ash

47.2

46.9

58.1

Biron #5

Precipitator Ash

96.2

82.1

79.7

Biron #5

Mechanical

Hopper Ash

48.7

44.6

54.0 Niagara B21-B23

Fly Ash

60.3

71.7

77.8

* Results obtained from the mortar cube compressive strength results, Table 9.

-53-

Table 11: Water Requirement*

(Tests conducted per ASTM C 311)

Ash Source

Water

Requirement

(% of Control)

ASTM C 618

Specifications

Class N

Class C

Class F

Biron #4

Precipitator Ash

115.7

115

max

105

max

105

max

Biron #5

Precipitator Ash

128.0

Biron #5

Mechanical

Hopper Ash

128.0 Niagara B21-B23

Fly Ash

123.9

* Results obtained for the mortar cube mixtures, Table 9.

-54-

Table 12: Autoclave Expansion or Contraction

(Tests conducted per ASTM C 311/C 151)

Ash Source

Autoclave Expansion (%)

Actual

Average

Biron #4 Precipitator

Ash

0.01

-0.02

-0.04

Biron #5 Precipitator

Ash

-0.03

-0.03

-0.02

Biron #5 Mechanical

Hopper Ash

-0.06

-0.07

-0.07

Niagara B21-B23 Fly

Ash

0.01

0.00

-0.01

Niagara B24

Bottom Ash*

0.04

0.02

-0.01

* Samples were first sieved over No. 20 sieve. Tests were conducted on the

ash that passed through the No. 20 sieve.

-55-

Table 13: Physical Test Requirements of Coal Fly Ash per ASTM C 618

TEST

ASTM C 618 SPECIFICATIONS CLASS N

CLASS C

CLASS F

Retained on No.325 sieve, (%)

34 max

34 max

34 max

Strength Activity Index with Cement at 7 or

28 days, (% of Control)

75 min

75 min

75 min

Water Requirement (% of Control)

115 max

105 max

105 max

Autoclave Expansion, (%)

±0.8

±0.8

±0.8

Specific Gravity

-

-

-

Variation from Mean, (%)

Fineness

Specific Gravity

5 max

5 max

5 max

5 max

5 max

5 max

-56-

CPI ASH ASTM C 618 CHEMICAL

PROPERTIES

-57-

Table 14: Chemical Analysis (oxides, LOI, moisture content, available alkali)

(Tests conducted on as-received samples)

OXIDES, SO3, AND LOSS ON IGNITION ANALYSIS, (%)

Analysis Parameter

Ash Source

ASTM C 618

Requirements Biron #4

Precipitator

Ash

Biron #4

Bottom

Ash

Biron

#4 Slag

Class

C

Class

F Silicon Dioxide, SiO2

26.6

45.8

50.7

--

--

Aluminum Oxide,

Al2O3

10.8

20.3

19.4

--

--

Iron Oxide, Fe2O3

12.4

4.7

23.3

--

--

SiO2 + Al2O3 +

Fe2O3

49.8

70.8

93.4

50.0,

Min.

70.0,

Min. Calcium Oxide, CaO

3.5

20.7

4.2

--

--

Magnesium Oxide,

MgO

0.7

4.7

0.9

--

-- Titanium Oxide, TiO2

0.7

1.5

0.7

--

--

Potassium Oxide, K2O

1.8

0.5

2.2

--

--

Sodium Oxide, Na2O

0.4

1.3

0.4

--

--

Sulfate, SO3

2.9

0.1

0.3

5.0,

Max.

5.0,

Max. Loss on Ignition, LOI

(@ 750 C)

41.1

1.4

1.5

6.0,

Max.

6.0,

Max.*

Moisture Content 0.5

0.7

0.5

3.0,

Max.

3.0,

Max.

Available Alkali,

Na2O Equivalent

(ASTM C-311)

1.2

0.1

0.3

1.5,

Max.*

*

1.5,

Max.

**

* Under certain circumstances, up to 12.0% max. LOI may be allowed.

** Optional. Required for ASR Minimization.

-58-

Table 14 (Continued): Chemical Analysis (oxides, LOI, moisture content, available alkali)

(Tests conducted on as-received samples)

OXIDES, SO3, AND LOSS ON IGNITION ANALYSIS, (%) Analysis Parameter

Biron #5

Precipitator

Ash

Biron #5

Mechanical

Hopper Ash

Kraft

P1-P2

"Fine"

Ash

ASTM C 618

Requirements Class

C

Class

F

Silicon Dioxide,

SiO2

6.1

18.8

15.4

--

--

Aluminum Oxide,

Al2O3

6.0

11.0

7.0

--

--

Iron Oxide, Fe2O3

2.5

3.9

2.6

--

--

SiO2 + Al2O3 +

Fe2O3

14.6

33.7

25.0

50.0,

Min.

70.0,

Min.

Calcium Oxide,

CaO

25.1

20.3

24.5

--

-- Magnesium Oxide,

MgO

4.0

4.1

3.0

--

--

Titanium Oxide,

TiO2

0.2

0.6

0.4

--

--

Potassium Oxide,

K2O

4.2

0.4

1.8

--

--

Sodium Oxide,

Na2O

3.4

0.8

1.3

--

--

Sulfate, SO3 15.9

1.5

4.4

5.0,

Max.

5.0,

Max.

Loss on Ignition,

LOI (@ 750 C)

20.2

37.2

35.1

6.0,

Max.

6.0,

Max.*

Moisture Content 1.3

1.0

2.9

3.0,

Max.

3.0,

Max.

Available Alkali,

Na2O Equivalent

(ASTM C-311)

7.2

0.6

1.9

1.5,

Max.*

*

1.5,

Max.

**

* Under certain circumstances, up to 12.0% max. LOI may be allowed.

** Optional. Required for ASR Minimization.

-59-

Table 14 (Continued): Chemical Analysis (oxides, LOI, moisture content, available alkali)

(Tests conducted on as-received samples)

OXIDES, SO3, AND LOSS ON IGNITION ANALYSIS, (%) Analysis Parameter

Ash Source

ASTM C 618

Requirements

Kraft

P1-P2

Bottom Ash

Niagara

B21-B23

Fly Ash

Niagara

B24

Bottom Ash

Class

C

Class

F

Silicon Dioxide,

SiO2

45.0

32.4

32.2

--

--

Aluminum Oxide,

Al2O3

17.6

17.0

15.5

--

--

Iron Oxide, Fe2O3

5.1

9.6

9.2

--

--

SiO2 + Al2O3 +

Fe2O3

67.7

59.0

56.9

50.0,

Min.

70.0,

Min.

Calcium Oxide,

CaO

22.2

3.5

5.7

--

-- Magnesium Oxide,

MgO

4.8

0.7

0.9

--

--

Titanium Oxide,

TiO2

1.5

0.7

0.7

--

--

Potassium Oxide,

K2O

0.7

1.0

1.1

--

--

Sodium Oxide,

Na2O

1.3

1.0

0.8

--

--

Sulfate, SO3 0.4

2.1

0.7

5.0,

Max.

5.0,

Max.

Loss on Ignition,

LOI (@ 750 C)

2.9

31.5

33.2

6.0,

Max.

6.0,

Max.*

Moisture Content 0.8

1.2

0.9

3.0,

Max.

3.0,

Max.

Available Alkali,

Na2O Equivalent

(ASTM C-311)

0.3

1.0

0.3

1.5,

Max.*

*

1.5,

Max.

**

-60-

* Under certain circumstances, up to 12.0% max. LOI may be allowed.

** Optional. Required for ASR Minimization.

-61-

CPI ASH

CHEMICAL COMPOSITION

-62-

Table 15: Mineralogy of CPI Ash

MINERALOGY (% by Weight) Analysis Parameter

Biron #4

Precipitato

r Ash

Biron #4

Bottom Ash

Biron #4

Slag Amorphous

78.9

53.5

100

Anhydrite, CaSO4

*

Aphthitalite, (K,Na) 2SO4

*

Bassanite, CaSO4 ½H20

*

*

*

Calcite, CaCO3

*

*

*

C3A

*

1.4

*

C4AF

*

*

Diopside, CaMgSi2O6

*

11.2

*

Gypsum, CaSO4.H20

*

*

*

Hematite, Fe2O3

4.8

*

*

Lime, CaO

*

*

*

Magnetite, Fe3O4

10.8

*

*

Mellite,

Ca2(Mg,Al)Al,Si)2O7

*

13.6

* Merwinite, Ca3Mg(SiO4)2

*

Mullite, Al2O3.SiO2

*

*

*

Periclase, MgO

*

*

*

Plagioclase,

(Na,Ca)(Al,Si)4O8

*

9.7

* Portlandite, Ca(OH)2

*

*

*

Quartz, SiO2

5.4

10.6

*

Rutile TiO2

*

*

*

* Not Detectable

-63-

Table 15 (Continued): Mineralogy of CPI Ash

MINERALOGY (% by Weight) Analysis Parameter

Biron #5

Precipitator

Ash

Biron #5

Mechanical

Hopper Ash Amorphous

58.8

76.6

Anhydrite, CaSO4

8.2

1.6

Aphthitalite, (K,Na) 2SO4

11.3

*

Bassanite, CaSO4 ½H20

*

*

Calcite, CaCO3

6.9

*

C3A

*

*

C4AF

6.2

*

Diopside, CaMgSi2O6

*

*

Gypsum, CaSO4.H20

*

*

Hematite, Fe2O3

*

*

Lime, CaO

3.3

1.2

Magnetite, Fe3O4

*

*

Mellite,

Ca2(Mg,Al)Al,Si)2O7

*

2.7 Merwinite, Ca3Mg(SiO4)2

*

7.1

Mullite, Al2O3.SiO2

*

*

Periclase, MgO

*

1.9

Plagioclase,

(Na,Ca)(Al,Si)4O8

*

* Portlandite, Ca(OH)2

3.4

*

Quartz, SiO2

1.8

4.2

Rutile TiO2

6.9

*

* Not Detectable

-64-

Table 15 (Continued): Mineralogy of CPI Ash

MINERALOGY (% by Weight) Analysis Parameter

Kraft

P1-P2

"Fine" Ash

Kraft

P1-P2

Bottom Ash Amorphous

75.6

53.8

Anhydrite, CaSO4

*

*

Aphthitalite, (K,Na)2SO4

*

*

Bassanite, CaSO4 ½H2O

*

*

Calcite, CaCO3

9.6

*

C3A

*

4.1

C4AF

*

*

Diopside, CaMgSi2O6

*

4.7

Gypsum, CaSO4.H2O

1.2

*

Hematite, Fe2O3

*

*

Lime, CaO

*

*

Magnetite, Fe3O4

*

*

Melilite

*

14.1

Merwinite, Ca3Mg(SiO4)2

*

*

Mullite, Al2O3.SiO2

*

*

Periclase, MgO

1.6

*

Plagioclase,

(Na,Ca)(Al,Si)4O8

*

7.4 Portlandite, Ca(OH)2

*

*

Quartz, SiO2

11.9

15.8

Rutile TiO2

*

*

* Not Detectable

-65-

Table 15 (Continued): Mineralogy of CPI Ash

MINERALOGY (% by Weight) Analysis Parameter

Niagara B21-

B23

Fly Ash

Niagara

B24

Bottom Ash Amorphous

63.2

71.6

Anhydrite, CaSO4

*

*

Aphthitalite, (K,Na)2SO4

*

*

Bassanite, CaSO4 ½H2O

5.4

*

Calcite, CaCO3

*

0.6

C3A

*

*

C4AF

*

*

Diopside, CaMgSi2O6

*

*

Gypsum, CaSO4.H2O

*

*

Hematite, Fe2O3

5.8

5.4

Lime, CaO

*

*

Magnetite, Fe3O4

5.4

8.6

Melilite

*

*

Merwinite, Ca3Mg(SiO4)2

*

*

Mullite, Al2O3.SiO2

11.7

11.7

Periclase, MgO

*

*

Plagioclase,

(Na,Ca)(Al,Si)4O8

*

* Portlandite, Ca(OH)2

*

*

Quartz, SiO2

8.5

2.1

Rutile TiO2

*

*

* Not Detectable

-66-

CPI ASH ELEMENTAL ANALYSIS

-67-

Table 16: Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Biron #4

Precipitator

Ash (ppm)*

Biron #4

Bottom Ash

(ppm)*

Biron #4

Slag (ppm)*

Biron #5

Precipitator Ash

(ppm)*

Biron #5

Mechanical

Hopper Ash

(ppm)*

Aluminum (Al)

43365.7

83576.5

82140.6

30984.6

43706.6

Antimony (Sb)

20.8

< 6.9

< 1.5

15.0

1.9

Arsenic (As)

3425.8

1237.8

< 13.8

737.9

117.1

Barium (Ba)

< 183.3

1315.5

137.8

2094.0

1396.4

Bromine (Br)

1.1

< 1.1

< 0.7

50.2

3.7

Cadmium (Cd)

< 3824.5

< 3566.0

< 2368.9

< 5295.8

< 2522.9

Calcium (Ca)

4270.1

21538.5

5133.1

41321.3

24932.7

Cerium (Ce)

27.4

51.8

104.2

47.4

54.3

Cesium (Cs)

8.6

10.8

7.8

1.9

0.4

Chlorine (Cl)

< 220.0

< 128.6

< 136.0

859.7

< 172.0

Chromium (Cr)

86.0

91.2

71.5

32.9

23.4

Cobalt (Co)

16.3

19.4

19.2

12.4

7.9

Copper (Cu)

< 586.0

< 358.1

< 300.0

< 1543.2

< 412.3

Dysprosium (Dy)

< 6.8

< 3.4

< 3.8

< 22.5

< 5.5

* Detection Limit Indicated by "<"

-68-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Biron #4

Precipitator

Ash (ppm)*

Biron #4

Bottom Ash

(ppm)*

Biron #4

Slag (ppm)*

Biron #5

Precipitator

Ash (ppm)*

Biron #5

Mechanical

Hopper Ash

(ppm)*

Europium (Eu)

0.8

0.9

0.9

0.7

0.9

Gallium (Ga)

< 566.5

< 266.7

< 322.0

< 1923.5

< 441.3

Gold (Au)

0.0

0.0

0.0

0.1

0.0

Hafnium (Hf)

1.7

2.3

0.6

0.7

10.5

Holmium (Ho)

< 8.8

< 11.5

< 7.2

< 17.3

< 9.4

Indium (In)

< 0.6

< 0.3

< 0.3

< 2.0

< 0.5

Iodine (I)

< 17.4

< 9.0

< 9.8

< 57.9

< 14.0

Iridium (Ir)

< 0.0

< 0.0

< 0.0

< 0.0

< 0.0

Iron (Fe)

75816.4

67191.7

123910.0

22637.7

25042.7

Lanthanum (La)

26.9

91.1

50.1

40.3

47.4

Lutetium (Lu)

2.6

2.8

1.8

0.8

1.2

Magnesium (Mg)

4045.9

12777.2

6003.8

13699.8

10680.3

Manganese (Mn)

2999.2

1272.2

3384.2

23715.5

3652.0

Mercury (Hg)

82.3

45.7

< 0.7

19.4

< 0.9

* Detection Limit Indicated by "<"

-69-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Biron #4

Precipitator

Ash (ppm)*

Biron #4

Bottom Ash

(ppm)*

Biron #4

Slag (ppm)*

Biron #5

Precipitator Ash

(ppm)*

Biron #5

Mechanical

Hopper Ash

(ppm)* Molybdenum (Mo)

218.9

< 173.8

< 107.2

< 266.2

< 127.8

Neodymium (Nd)

20.0

92.5

49.3

< 29.8

37.5

Nickel (Ni)

< 4426.0

< 3993.9

< 3023.7

< 5960.4

< 2532.9

Palladium (Pd)

< 936.6

< 459.3

< 553.0

< 3184.2

< 781.3

Potassium (K)

22436.5

20909.4

26915.4

71373.4

< 4899.4

Praseodymium (Pr)

< 32.8

< 42.7

< 26.1

< 83.1

< 37.8

Rubidium (Rb)

< 139.8

< 131.3

< 78.1

< 199.4

< 122.3

Rhenium (Re)

188.8

258.6

213.0

159.1

15.4

Ruthenium (Ru)

8.9

114.1

10.7

141.3

110.5

Samarium (Sm)

7.2

22.1

11.4

8.1

9.8

Scandium (Sc)

15.5

11.8

13.8

5.8

7.8

Selenium (Se)

753.1

< 265.6

< 171.7

1286.4

< 138.3

Silver (Ag)

< 27.4

< 20.5

< 18.2

< 36.7

< 15.7

Sodium (Na)

1704.9

406.5

1776.8

19874.1

4211.3

* Detection Limit Indicated by "<"

-70-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Biron #4

Precipitator

Ash (ppm)*

Biron #4

Bottom Ash

(ppm)*

Biron #4

Slag (ppm)*

Biron #5

Precipitator

Ash (ppm)*

Biron #5

Mechanical

Hopper Ash

(ppm)*

Strontium (Sr)

< 68.9

123.2

35.7

252.2

1361.7

Tantalum (Ta)

1.0

4.5

1.8

< 1.9

1.8

Tellurium (Te)

2.6

1.2

0.5

< 1.3

0.5

Terbidium (Tb)

< 0.9

1.1

< 0.7

< 1.9

< 0.7

Thorium (Th)

6.5

5.1

8.2

6.8

9.9

Thulium (Tm)

25.0

< 1.1

20.8

26.4

20.2

Tin (Sn)

< 767.5

< 687.4

< 451.3

< 1019.0

< 416.6

Titanium (Ti)

3063.7

6349.6

3476.5

< 5143.0

2931.0

Tungsten (W)

19.9

11.7

7.8

12.5

5.7

Uranium (U)

79.9

43.5

27.8

16.2

21.5

Vanadium (V)

269.1

167.6

204.1

86.4

101.7

Ytterbium (Yb)

9.2

14.9

9.0

3.3

5.9

Zinc (Zn)

< 40.1

< 32.1

< 24.8

1433.3

19.8

Zirconium (Zr)

219.5

274.8

172.0

< 388.6

152.7

* Detection Limit Indicated by "<"

-71-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Kraft

P1-P2

"Fine" Ash

(ppm)*

Kraft

P1-P2

Bottom Ash

(ppm)*

Niagara

B21-B23

Fly Ash

(ppm)*

Niagara

B24

Bottom Ash

(ppm)*

Aluminum (Al)

31216.2

74788.9

68620.7

61959.2

Antimony (Sb)

3.9

< 4.0

3.5

< 1.5

Arsenic (As)

102.5

71.8

570.3

74.5

Barium (Ba)

1251.9

1305.3

298.7

329.6

Bromine (Br)

13.3

< 1.1

23.7

3.1

Cadmium (Cd)

< 2648.2

< 3691.2

< 3940.0

< 2498.8

Calcium (Ca)

32198.7

22249.9

4836.9

7033.3

Cerium (Ce)

36.9

51.8

66.3

78.9

Cesium (Cs)

0.6

2.6

4.7

3.4

Chlorine (Cl)

743.5

< 170.3

240.8

< 172.2

Chromium (Cr)

25.7

56.0

70.2

45.9

Cobalt (Co)

7.1

16.0

12.4

9.5

Copper (Cu)

< 887.1

< 425.2

< 574.5

< 370.6

Dysprosium (Dy)

< 16.1

< 4.8

< 6.7

< 5.1

* Detection Limit Indicated by "<"

-72-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Kraft

P1-P2

"Fine" Ash

(ppm)*

Kraft

P1-P2

Bottom Ash

(ppm)*

Niagara

B21-B23

Fly Ash

(ppm)*

Niagara

B24

Bottom Ash

(ppm)*

Europium (Eu)

0.6

0.9

0.9

0.8

Gallium (Ga)

< 1351.6

< 397.3

< 494.5

< 421.6

Gold (Au)

0.0

0.0

0.0

< 0.0

Hafnium (Hf)

9.9

3.4

2.4

6.5

Holmium (Ho)

< 9.2

< 12.7

< 12.1

< 8.6

Indium (In)

< 1.4

< 0.4

< 0.6

< 0.5

Iodine (I)

< 40.1

< 12.3

< 17.0

< 13.5

Iridium (Ir)

< 0.0

< 0.0

< 0.0

< 0.0

Iron (Fe)

19992.6

52372.5

66121.7

60956.3

Lanthanum (La)

32.2

92.2

50.6

47.6

Lutetium (Lu)

0.8

2.7

1.4

1.3

Magnesium (Mg)

8733.9

13039.3

5258.1

5509.3

Manganese (Mn)

27849.6

4315.0

1848.9

4556.6

Mercury (Hg)

< 1.0

49.5

< 1.2

< 0.8

* Detection Limit Indicated by "<"

-73-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Kraft

P1-P2

"Fine" Ash

(ppm)*

Kraft

P1-P2

Bottom Ash

(ppm)*

Niagara

B21-B23

Fly Ash

(ppm)*

Niagara

B24

Bottom Ash

(ppm)* Molybdenum (Mo)

< 136.7

< 184.6

< 182.2

< 114.5

Neodymium (Nd)

20.7

92.3

41.9

38.8

Nickel (Ni)

< 2812.8

< 4133.0

< 4363.9

< 2665.4

Palladium (Pd)

< 2291.9

< 670.5

< 858.8

< 733.4

Potassium (K)

26716.4

13791.2

12274.8

13246.6

Praseodymium (Pr)

< 39.6

< 49.1

< 46.5

< 34.0

Rubidium (Rb)

< 117.7

< 137.1

< 154.9

< 112.6

Rhenium (Re)

51.5

94.0

76.0

69.5

Ruthenium (Ru)

96.4

198.1

20.9

23.2

Samarium (Sm)

6.6

19.6

12.1

10.3

Scandium (Sc)

5.4

10.7

12.0

9.8

Selenium (Se)

< 192.0

< 277.6

< 275.1

< 162.6

Silver (Ag)

< 17.4

< 25.8

< 27.1

< 16.3

Sodium (Na)

6139.9

836.4

4531.0

3565.4

* Detection Limit Indicated by "<"

-74-

Table 16 (Continued): Elemental Analysis (As-Received Sample)

ELEMENTAL (BULK CHEMICAL) ANALYSIS

(Average of two samples unless noted otherwise)

Element

Material

Kraft

P1-P2

"Fine" Ash

(ppm)*

Kraft

P1-P2

Bottom Ash

(ppm)*

Niagara

B21-B23

Fly Ash

(ppm)*

Niagara

B24

Bottom Ash

(ppm)*

Strontium (Sr)

746.8

109.3

394.3

392.2

Tantalum (Ta)

1.2

6.0

1.7

1.6

Tellurium (Te)

0.4

1.2

< 0.7

< 0.4

Terbidium (Tb)

< 0.8

< 1.1

< 1.1

< 0.6

Thorium (Th)

6.6

5.7

8.4

7.7

Thulium (Tm)

17.3

< 1.6

20.7

17.4

Tin (Sn)

< 467.0

< 708.5

< 707.3

< 416.3

Titanium (Ti)

< 3555.3

6541.4

3463.6

2761.4

Tungsten (W)

10.0

12.2

< 8.2

5.0

Uranium (U)

14.7

47.8

15.1

13.4

Vanadium (V)

74.1

147.6

123.3

87.7

Ytterbium (Yb)

3.8

13.6

7.3

6.7

Zinc (Zn)

< 55.1

< 34.2

< 34.8

< 19.9

Zirconium (Zr)

< 171.7

350.1

< 290.9

< 176.3

* Detection Limit Indicated by "<"

-75-

Table 17: Potential Uses of the Biron #4 Ashes

Type of Application

Biron #4

Precipitator

Ash

Biron #4

Bottom

Ash

Biron #4

Slag

HIGH TECHNOLOGY APPLICATIONS 1. Recovery of Materials

Low

Low

Low

2. Filler Material for Polymer Matrix (plastic)

Very Low

Very

Low

Very Low

3. Filler Material for Metal Matrix Composites

Low

Very

Low

Very Low

4. Other Filler Applications:

a. Asphaltic roofing shingles

b. Wallboard

c. Joint filler compounds

d. Carpet backing

e. Vinyl flooring

f. Industrial coatings

Low

High

Low

Low

Low

Very Low

Medium

Medium

Low

Low

Low

Very

Low

Very High

Low

Low

Low

Low

Very Low

5. Super Pozzolanic Materials (beneficiated fly ash)

Medium

Low

Low

MEDIUM TECHNOLOGY APPLICATIONS

1. Manufacture of Blended Cement

High

Low

Low 2. Manufacture of Lightweight Aggregates:

a. Fired

b. Unfired

High

Medium

Medium

Low

Low

Low 3. Manufacture of Concrete Products:

a. Low-strength concrete

b. Medium-strength concrete

c. High-strength concrete

d. Lightweight concrete

e. Prestressed/precast concrete products

f. Roller compacted concrete

g. No-fines and/or Cellular concrete

h. Manufactured decorative concrete (including

artificial marble, granite, architectural light-

colored panels, etc.)

Very High

Very High

Low

High

Medium

Very High

Very High

Medium

Very

High

Very

High

Low

High

Low

High

High

Medium

Very High

Very High

Very Low

Low

Low

Medium

Low

Very High

4. Filler in Asphalt Mix

Medium

Medium

Very High

5. Bricks:

a. Unfired bricks

High

High

High

-76-

b. Fired bricks

c. Clay bricks

Very High

Very High

High

Medium

High

High

-77-

Table 17 (Continued): Potential Uses of the Biron #4 Ashes

Type of Application

Biron #4

Precipitator

Ash

Biron #4

Bottom

Ash

Biron #4

Slag

6. Blocks:

a. Building blocks

b. Decorative blocks

High

High

High

High

Very

High

Very

High 7. Reefs for Fish Habitats

Very High

Very

High

Very

High 8. Paving Stones

Very High

Very

High

Very

High 9. Stabilization of Municipal Sewage Residual

Very High

Medium

Low

10. Waste Stabilization:

a. Inorganic wastes*

b. Organic wastes*

c. Combined complex wastes

High

Very High

Low

Medium

Medium

Low

Low

Low

Low 11. Ceramic Products

Low

Low

Low

LOW TECHNOLOGY APPLICATIONS

1. Backfills:

a. Bridge abutment, buildings, etc.

b. Trench and excavation backfills

Very High

Very High

Very High

Very High

Very High

Very High 2. Embankments

Very High

Very High

Medium

3. Site Development Fills Very High

Very High

Medium

4. Stabilization of Landslides – Grouting Very High

Very High

Medium

5. Landfill Cover (as a substitute for soil cover) Very High

High

Medium

6. Pavement Base and Sub-base Courses:

a. Combination with lime or cement and coarse

aggregate

b. Combination with cement or lime

c. Combination with on-site soils without the

addition of lime or cement

Very High

Very High

Very High

Very High

Very High

Medium

Very High

Very High

Medium

7. Subgrade Stabilization or Soil Stabilization:

a. Roadways/Highways

b. Parking areas

c. Runways

High

High

High

Medium

Medium

Medium

Medium

Medium

Medium 8. Land Reclamation:

-78-

a. Agriculture

b. Turf-grass (for example golf courses)

c. Park Land

Very High

Very High

Very High

Very High

Very High

Very High

Medium

Medium

Medium

*Or a combination of inorganic and organic dredged materials from the Great Lakes and/or the Mississippi River.

-79-

Table 17 (Continued): Potential Uses of the Biron #4 Ashes

Type of Application

Biron #4

Precipitato

r Ash

Biron #4

Bottom

Ash

Biron #4

Slag

9. Soil Amendment (agriculture and/or potting soil)*:

a. Improve infiltration characteristics

b. Decrease Subsurface porosity

c. Fertilizer/Composting

Very Low

Very High

Very High

Very

High

Medium

High

Low

Very

Low

Low 10. Slurried Flowable Fly ash

Very High

Very

High

Very

High

MISCELLANEOUS CIVIL ENGINEERING APPLICATIONS 1. Backfills:

a. Between foundations and existing soil

b. Retaining walls

c. Utility trenches

Very High

Very High

Very High

Very

High

Very

High

Very

High

Very

High

Very

High

Very

High 2. Excavation in Streets and around Foundation

Very High

Very

High

Very

High 3. Fills for Abandoned Tunnels, Sewers, and other

Underground Facilities (including mines)

Very High

Very

High

Very

High 4. Grouts

Very High

High

Medium

5. Hydraulic Fills Very High

Very

High

Medium

* With or without other products, such as dredged materials.

-80-

Table 18: Potential Uses of the Biron #5 Ashes

Type of Application

Biron #5

Precipitato

r Ash

Biron #5

Mechanical

Hopper Ash

HIGH TECHNOLOGY APPLICATIONS 1. Recovery of Materials

Low

Low

2. Filler Material for Polymer Matrix (plastic) Very Low

Very Low

3. Filler Material for Metal Matrix Composites

Low

Very Low 4. Other Filler Applications:

a. Asphaltic roofing shingles

b. Wallboard

c. Joint filler compounds

d. Carpet backing

e. Vinyl flooring

f. Industrial coatings

Low

High

Low

Low

Low

Very Low

Low

High

Low

Low

Low

Very Low 5. Super Pozzolanic Materials (beneficiated fly ash)

Medium

Medium

MEDIUM TECHNOLOGY APPLICATIONS

1. Manufacture of Blended Cement

High

Medium 2. Manufacture of Lightweight Aggregates:

a. Fired

b. Unfired

High

Medium

High

Medium 3. Manufacture of Concrete Products:

a. Low-strength concrete

b. Medium-strength concrete

c. High-strength concrete

d. Lightweight concrete

e. Prestressed/precast concrete products

f. Roller compacted concrete

g. No-fines and/or Cellular concrete

h. Manufactured decorative concrete (including

artificial marble, granite, architectural light-

colored panels, etc.)

Very High

Very High

Low

High

Medium

Very High

Very High

Medium

Very High

Very High

Low

High

Medium

Very High

Very High

Medium

4. Filler in Asphalt Mix

Medium

Medium

5. Bricks:

a. Unfired bricks

b. Fired bricks

c. Clay bricks

High

Very High

Very High

High

High

Medium

-81-

Table 18 (Continued) : Potential Uses of the Biron #5 Ashes

Type of Application

Biron #5

Precipitator

Ash

Biron #5

Mechanica

l Hopper

Ash 6. Blocks:

a. Building blocks

b. Decorative blocks

High

High

High

High 7. Reefs for Fish Habitats

Very High

Very High

8. Paving Stones Very High

Very High

9. Stabilization of Municipal Sewage Residual Very High

Medium

10. Waste Stabilization:

a. Inorganic wastes*

b. Organic wastes*

c. Combined complex wastes

High

Very High

Low

Medium

Medium

Low 11. Ceramic Products

Low

Low

LOW TECHNOLOGY APPLICATIONS

1. Backfills:

a. Bridge abutment, buildings, etc.

b. Trench and excavation backfills

Very High

Very High

Very High

Very High 2. Embankments

Very High

Very High

3. Site Development Fills Very High

Very High

4. Stabilization of Landslides – Grouting Very High

Very High

5. Landfill Cover (as a substitute for soil cover) Very High

Very High

6. Pavement Base and Sub-base Courses:

a. Combination with lime or cement and coarse

aggregate

b. Combination with cement or lime

c. Combination with on-site soils without the

addition of lime or cement

Very High

Very High

Very High

Very High

High

Medium

7. Subgrade Stabilization or Soil Stabilization:

a. Roadways/Highways

b. Parking areas

c. Runways

High

High

High

Medium

Medium

Medium

*Or a combination of inorganic and organic dredged materials from the Great Lakes

and/or the Mississippi River.

-82-

Table 18 (Continued): Potential Uses of the Biron #5 Ashes

Type of Application

Biron #5

Precipitato

r Ash

Biron #5

Mechanical

Hopper

Ash 8. Land Reclamation:

a. Agriculture

b. Turf-grass (for example golf courses)

c. Park land

Very High

Very High

Very High

High

High

High 9. Soil Amendment (agriculture and/or potting soil)*:

a. Improve infiltration characteristics

b. Decrease Subsurface porosity

c. Fertilizer/Composting

Very Low

Very High

Very High

Very Low

Medium

High 10. Slurried Flowable Fly ash

Very High

Very High

MISCELLANEOUS CIVIL ENGINEERING APPLICATIONS

1. Backfills:

a. Between foundations and existing soil

b. Retaining walls

c. Utility trenches

Very High

Very High

Very High

Very High

Very High

Very High 2. Excavation in Streets and around Foundation

Very High

Very High

3. Fills for Abandoned Tunnels, Sewers, and other

Underground Facilities (including mines)

Very High

Very High

4. Grouts

Very High

Very High

5. Hydraulic Fills Very High

Very High

* With or without other products, such as dredged materials.

-83-

Table 19: Potential Uses of the Kraft Ashes

Type of Application Kraft P1-

P2 "Fine"

Ash

Kraft P1-

P2 Bottom

Ash

HIGH TECHNOLOGY APPLICATIONS 1. Recovery of Materials

Low

Low

2. Filler Material for Polymer Matrix (plastic)

Very Low

Very

Low 3. Filler Material for Metal Matrix Composites

Very Low

Very

Low 4. Other Filler Applications:

a. Asphaltic roofing shingles

b. Wallboard

c. Joint filler compounds

d. Carpet backing

e. Vinyl flooring

f. Industrial coatings

Low

High

Low

Low

Low

Very Low

Medium

Medium

Low

Low

Low

Very

Low 5. Super Pozzolanic Materials (beneficiated fly ash)

Medium

Low

MEDIUM TECHNOLOGY APPLICATIONS

1. Manufacture of Blended Cement

Medium

Low 2. Manufacture of Lightweight Aggregates:

a. Fired

b. Unfired

High

Medium

Medium

Low 3. Manufacture of Concrete Products:

a. Low-strength concrete

b. Medium-strength concrete

c. High-strength concrete

d. Lightweight concrete

e. Prestressed/precast concrete products

f. Roller compacted concrete

g. No-fines and/or Cellular concrete

h. Manufactured decorative concrete (including

artificial marble, granite, architectural light-

colored panels, etc.)

Very High

Very High

Low

High

Medium

Very High

Very High

Medium

Very

High

Very

High

Low

High

Low

High

High

Medium 4. Filler in Asphalt Mix

Medium

Medium

5. Bricks:

a. Unfired bricks

High

High

-84-

b. Fired bricks

c. Clay bricks

High

Medium

High

Medium

-85-

Table 19 (Continued): Potential Uses of the Kraft Ashes

Type of Application

Kraft P-1

"Fine" Ash

Kraft P-

2 Bottom

Ash 6. Blocks:

a. Building blocks

b. Decorative blocks

High

High

High

High 7. Reefs for Fish Habitats

Very High

Very

High 8. Paving Stones

Very High

Very

High 9. Stabilization of Municipal Sewage Residual

Medium

Medium

10. Waste Stabilization:

a. Inorganic wastes*

b. Organic wastes*

c. Combined complex wastes

Medium

Medium

Low

Medium

Medium

Low 11. Ceramic Products

Low

Low

LOW TECHNOLOGY APPLICATIONS

1. Backfills:

a. Bridge abutment, buildings, etc.

b. Trench and excavation backfills

Very High

Very High

Very

High

Very

High 2. Embankments

Very High

Very

High 3. Site Development Fills

Very High

Very

High 4. Stabilization of Landslides – Grouting

Very High

Very

High 5. Landfill Cover (as a substitute for soil cover)

Very High

High

6. Pavement Base and Sub-base Courses:

a. Combination with lime or cement and coarse

aggregate

b. Combination with cement or lime

c. Combination with on-site soils without the

addition of lime or cement

Very High

High

Medium

Very

High

Very

High

Medium 7. Subgrade Stabilization or Soil Stabilization:

a. Roadways/Highways

Medium

Medium

-86-

b. Parking areas

c. Runways

Medium

Medium

Medium

Medium

*Or a combination of inorganic and organic dredged materials from the Great Lakes

and/or the Mississippi River.

-87-

Table 19 (Continued): Potential Uses of the Kraft Ashes

Type of Application

Kraft P-1

"Fine" Ash

Kraft P-

2 Bottom

Ash 8. Land Reclamation:

a. Agriculture

b. Turf-grass (for example golf courses)

c. Park land

High

High

High

Very

High

Very

High

Very

High 9. Soil Amendment (agriculture and/or potting soil)*:

a. Improve infiltration characteristics

b. Decrease Subsurface porosity

c. Fertilizer/Composting

Very Low

Medium

High

Very

High

Medium

High 10. Slurried Flowable Fly ash

Very High

Very

High

MISCELLANEOUS CIVIL ENGINEERING APPLICATIONS 1. Backfills:

a. Between foundations and existing soil

b. Retaining walls

c. Utility trenches

Very High

Very High

Very High

Very

High

Very

High

Very

High 2. Excavation in Streets and around Foundation

Very High

Very

High 3. Fills for Abandoned Tunnels, Sewers, and other

Underground Facilities (including mines)

Very High

Very

High 4. Grouts

Very High

High

5. Hydraulic Fills Very High

Very

High

* With or without other products, such as dredged materials.

-88-

Table 20: Potential Uses of the Niagara Ashes

Type of Application

Niagara

B21-B23

Fly Ash

Niagara

B24

Bottom

Ash

HIGH TECHNOLOGY APPLICATIONS 1. Recovery of Materials

Low

Low

2. Filler Material for Polymer Matrix (plastic)

Very Low

Very

Low 3. Filler Material for Metal Matrix Composites

Low

Very

Low 4. Other Filler Applications:

a. Asphaltic roofing shingles

b. Wallboard

c. Joint filler compounds

d. Carpet backing

e. Vinyl flooring

f. Industrial coatings

Low

High

Low

Low

Low

Very Low

Medium

Medium

Low

Low

Low

Very

Low 5. Super Pozzolanic Materials (beneficiated fly ash)

Medium

Low

MEDIUM TECHNOLOGY APPLICATIONS

1. Manufacture of Blended Cement

High

Low 2. Manufacture of Lightweight Aggregates:

a. Fired

b. Unfired

High

Medium

Medium

Low 3. Manufacture of Concrete Products:

a. Low-strength concrete

b. Medium-strength concrete

c. High-strength concrete

d. Lightweight concrete

e. Prestressed/precast concrete products

f. Roller compacted concrete

g. No-fines and/or Cellular concrete

h. Manufactured decorative concrete (including

artificial marble, granite, architectural light-

colored panels, etc.)

Very High

Very High

Low

High

Medium

Very High

Very High

Medium

Very

High

Very

High

Low

High

Low

High

High

Medium 4. Filler in Asphalt Mix

Medium

Medium

5. Bricks:

-89-

a. Unfired bricks

b. Fired bricks

c. Clay bricks

High

Very High

Very High

High

High

Medium

Table 20 (Continued): Potential Uses of the Niagara Ashes

Type of Application

Niagara

B21-B23

Fly Ash

Niagara

B24

Bottom

Ash 6. Blocks:

a. Building blocks

b. Decorative blocks

High

High

High

High 7. Reefs for Fish Habitats

Very High

Very

High 8. Paving Stones

Very High

Very

High 9. Stabilization of Municipal Sewage Residual

Very High

Medium

10. Waste Stabilization:

a. Inorganic wastes*

b. Organic wastes*

c. Combined complex wastes

High

Very High

Low

Medium

Medium

Low 11. Ceramic Products

Low

Low

LOW TECHNOLOGY APPLICATIONS

1. Backfills:

a. Bridge abutment, buildings, etc.

b. Trench and excavation backfills

Very High

Very High

Very

High

Very

High 2. Embankments

Very High

Very

High 3. Site Development Fills

Very High

Very

High 4. Stabilization of Landslides – Grouting

Very High

Very

High 5. Landfill Cover (as a substitute for soil cover)

Very High

High

6. Pavement Base and Sub-base Courses:

a. Combination with lime or cement and coarse

aggregate

Very High

Very

High

-90-

b. Combination with cement or lime

c. Combination with on-site soils without the

addition of lime or cement

Very High

Very High

Very

High

Medium 7. Subgrade Stabilization or Soil Stabilization:

a. Roadways/Highways

b. Parking areas

c. Runways

High

High

High

Medium

Medium

Medium

*Or a combination of inorganic and organic dredged materials from the Great Lakes

and/or the Mississippi River.

-91-

Table 20 (Continued): Potential Uses of the Niagara Ashes

Type of Application

Niagara

B21-B23

Fly Ash

Niagara

B24

Bottom

Ash 8. Land Reclamation:

a. Agriculture

b. Turf-grass (for example golf courses)

c. Park land

Very High

Very High

Very High

Very

High

Very

High

Very

High 9. Soil Amendment (agriculture and/or potting soil)*:

a. Improve infiltration characteristics

b. Decrease Subsurface porosity

c. Fertilizer/Composting

Very Low

Very High

Very High

Very

High

Medium

High 10. Slurried Flowable Fly ash

Very High

Very

High

MISCELLANEOUS CIVIL ENGINEERING APPLICATIONS 1. Backfills:

a. Between foundations and existing soil

b. Retaining walls

c. Utility trenches

Very High

Very High

Very High

Very

High

Very

High

Very

High 2. Excavation in Streets and around Foundation

Very High

Very

High 3. Fills for Abandoned Tunnels, Sewers, and other

Underground Facilities (including mines)

Very High

Very

High 4. Grouts

Very High

High

5. Hydraulic Fills Very High

Very

High

* With or without other products, such as dredged materials.

-92-

-93-

SCANNING ELECTRON MICROGRAPHS OF

CPI ASHES

-94-

FIG. 10: Biron #4 Precipitator Ash, FIG. 11: Biron #4 Precipitator Ash,

100X Magnification 500X Magnification

FIG.12: Biron #4 Precipitator Ash, FIG.13: Biron #4 Precipitator Ash,

1000X Magnification 5000X Magnification

-95-

FIG.14: Biron #4 Bottom Ash, FIG.15: Biron #4 Bottom Ash,

100X Magnification 500X Magnification

FIG.16: Biron #4 Bottom Ash, FIG.17: Biron #4 Bottom Ash,

1000X Magnification 5000X Magnification

-96-

FIG. 18: Biron #4 Slag, FIG. 19: Biron #4 Slag,

100X Magnification 500X Magnification

FIG.20: Biron #4 Slag, FIG. 21: Biron #4 Slag,

1000X Magnification 5000X Magnification

-97-

FIG. 22: Biron #5 Precipitator Ash, FIG. 23: Biron #5 Precipitator Ash,

100X Magnification 500X Magnification

FIG. 24: Biron #5 Precipitator Ash, FIG. 25: Biron #5 Precipitator Ash,

1000X Magnification 5000X Magnification

-98-

FIG. 26: Biron #5 Mechanical Hopper Ash, FIG. 27: Biron #5 Mechanical Hopper Ash,

100X Magnification 500X Magnification

FIG. 28: Biron #5 Mechanical Hopper Ash, FIG. 29: Biron #5 Mechanical Hopper Ash,

1000X Magnification 5000X Magnification

-99-

FIG. 30: Kraft P1-P2 "Fine" Ash, FIG. 31: Kraft P1-P2 "Fine" Ash,

100X Magnification 500X Magnification

FIG. 32: Kraft P1-P2 "Fine" Ash, FIG. 33: Kraft P1-P2 "Fine" Ash,

1000X Magnification 5000X Magnification

-100-

FIG. 34: Kraft P1-P2 Bottom Ash, FIG. 35: Kraft P1-P2 Bottom Ash,

20X Magnification 100X Magnification

FIG. 36: Kraft P1-P2 Bottom Ash, FIG. 37: Kraft P1-P2 Bottom Ash,

500X Magnification 5000X Magnification

-101-

FIG. 38: Niagara B21-B23 Fly Ash, FIG. 39: Niagara B21-B23 Fly Ash,

100X Magnification 500X Magnification

FIG. 40: Niagara B21-B23 Fly Ash, FIG. 41: Niagara B21-B23 Fly Ash,

1000X Magnification 5000X Magnification

-102-

FIG. 42: Niagara B24 Bottom Ash, FIG. 43: Niagara B24 Bottom Ash,

100X Magnification 500X Magnification

FIG. 44: Niagara B24 Bottom Ash, FIG. 45: Niagara B24 Bottom Ash,

1000X Magnification 5000X Magnification

-103-

Section 5

References

[1] Naik, T. R., and Singh, S. S., “Fly Ash Generation and Utilization – An Overview,” in

Recent Trend in Fly Ash Utilization, Ministry of Environment and Forests, Government of

India, Bhopal, India, June 1993 (available from the UWM Center for By-Products

Utilization).

-104-

APPENDIX 1: Modified ASTM C 422 for Particle Size Distribution

Tests conducted at the UWM Center for By-Products Utilization (UWM-CBU) had revealed that

the standard ASTM C 422 test method is inadequate to measure particle size distribution of fly

ashes, and similar fine grained materials, especially below 10-micron size particles. This is partially

due to agglomeration caused by very fine particles of fly ash and also potentially due to chemical

reaction caused by the cementitious nature of the fly ash. A significant gel formation occurs during

the sedimentation testing of the fly ash. Therefore, in order to obtain more accurate test results, a

modified ASTM C 422 test method was developed by the UWM-CBU for measuring particle size

distribution of fly ash samples by the sedimentation technique. This UWM-CBU method differs

from the standard ASTM C 422 in respect to sample preparation, sedimentation liquid, size of the

sedimentation cylinder, and the hydrometer used. In the UWM-CBU modified ASTM C 422

procedure, the fly ash sample is not subjected to pretreatment prior to the sedimentation test. The

particle concentration in the polymeric suspending liquid used was maintained at about three

percent. This new suspending liquid had a specific gravity of about 0.8. This also necessitated the

use of a different hydrometer, which can measure the density of the liquid containing suspended

particles having specific gravity in the range of approximately 0.8 to 0.9. The size of the

sedimentation cylinder was changed to 500 ml instead of 1000 ml used in the standard ASTM

C 422 procedure. This was done to more effectively use the sedimentation liquid. In order to

measure the particle size distribution, the fly ash test sample and the liquid were added in the

sedimentation cylinder and were mixed by inverting the cylinder, with open end closed by hand,

-105-

60 times in one minute. Then the sedimentation readings were taken and calculations made in

accordance with the ASTM Test C 422 for determination of particle size distribution. Typical

results are shown in Fig. 1, 4, 5, 8, and 9.