Beneficial Use
Eco Material’s products are routinely specified in the construction of large-scale infrastructure projects and manufacturing facilities not only to lower the carbon footprint of these structures, but to reduce material costs while providing a stronger, more durable concrete. Eco has supplied sustainable cement alternatives for projects including:
- Bridges, roads, dams, and airport runways
- Manufacturing, chip, and datacenter facilities
- Energy infrastructure projects, including LNG plants
- Federal, state, and municipal buildings
Case Study: Lake Williams Dam Rehabilitation
Lake Williams Dam has operated for over a century to provide water and recreational opportunities for 200,000 residents of York and Adams County, Pa. The original dam was built with a soil face on its back that, it was feared, could wash away during an extreme flood. To comply with Pennsylvania Department of Environmental Protection Division of Dam Safety requirements, the dam underwent an overhaul in 2022-23 to give it adequate spillway capacity to safely pass a Spillway Design Flood equivalent to 100 percent of the Probable Maximum Flood.
Given the requirement for high-strength concrete, and the potential for excessive heat of hydration in the mass placement, specifiers opted for a concrete mix with fly ash sourced from Eco Material’s Montour County, Pa., monofill. Placement of the 46,000 CY of roller compacted concrete utilized 5,200 tons fly ash at 50 percent substitution for cement. The dam received the Association of State Dam Safety Officials’ 2024 National Rehabilitation Project of the Year award. To learn more, please click here.
Case Study: Near-Zero-Carbon, 3D-Printed Houses
In 2023, Eco Material Technologies partnered with Hive 3D to supply PozzoCEM Vite®, a near-zero-carbon, longer-lasting and more durable cement alternative, for the 3D printing of affordable houses at The Casitas @ The Halles, in Round Top, Texas.
Eco Material’s PozzoCEM Vite® replaced 100 percent of the ordinary portland cement (OPC) that would commonly be used in the concrete mix, decreasing emissions by 92 percent, and at a setting time of just 2-3 minutes – significantly faster than OPC. In addition to the environmental advantages of the material, Hive 3D worked with technology partner CyBe Construction to develop a mobile, small-footprint, next-generation construction printer and mixing system to use Eco Material’s unique low-cost sustainable cement replacement products at industry-leading speeds and quality. This allowed Hive 3D to produce printable material at a fraction of the cost of other commercially available 3D printing mortars – and subsequently build houses for significantly less than they could be built by traditional means. To learn more, please click here.
Harvesting Projects
As the coal-fueled utility industry adjusts to evolving energy markets, Eco Material is increasing the availability of fly ash and near-zero-carbon products by harvesting previously disposed ash, which is dried and beneficiated into a quality pozzolan for commercial use in concrete. Eco Material offers a range of beneficiation technologies, including its patented ES Efficient Carbon Offloading™ (ECO) System, which improves the quality of harvested fly ash, making it suitable for use in concrete and other applications.
- Eco Material is harvesting 100,000 tons annually from its Montour, Pa., monofill, which has the capacity to produce 2 million tons of fly ash over the life of the project. Over 1.5 million tons of CO2e emissions will be avoided through the use of this material in concrete production over the project’s life. To learn more, please click here.
- Eco Material has entered a partnership with Georgia Power to harvest landfilled ash from Plant Bowen in Cartersville, Ga. It is estimated that Eco will remove and beneficially use 600,000 tons of landfilled ash per year once operations are running at full capacity – and over 9 million tons over the life of the project. To learn more, please click here.
- In October 2023, Eco Material announced an agreement with Georgia Power to harvest landfilled ash from Plant Branch, a coal-fueled power plant retired in 2015. Eco will harvest approximately 600,000 tons of landfilled ash per year from the Putnam County, Ga., plant and remove and beneficially use more than 8 million tons of fly ash over a 15-year term. To learn more, please click here.
- In November 2023, Eco Material announced an expanded partnership with Rainbow Energy Center to jointly harvest and beneficiate 400,000 tons annually of SCMs from Coal Creek Station over the next 25 years to service rapidly growing markets in North Dakota, Minnesota, and Wisconsin. The project will also beneficiate Coal Creek’s annual production of 150,000 tons of calcium sulfite into marketable synthetic gypsum for the wallboard industry. To learn more, please click here.
- In 2024, Eco announced a collaboration with Alabama Power to harvest and beneficially use more than 700,000 tons of stored ash per year from Plant Barry, a coal- and natural gas-fueled electrical generation facility in Bucks, Ala. To learn more, please click here.
