PMET's process for the conversion of coal combustion residues into construction brick, block, pavers, and shaped building products is a cost effective, environmentally sound alternative to landfill disposal. This process, the subject of U. S. Patent No. 6,068,803, involves combining fly ash, bottom ash, and a reactive mineral binder, compacting the mixture into the desired shape, and hydrothermally curing the shaped product under conditions that result in the growth of Tobomorite mineral crystals which tightly bond with the ash particles to create strong, weather-resistant products. The process produces no secondary liquid, solid or gaseous wastes and requires considerably less energy than that required for producing conventional bricks. This technology is available from PMET under license with full-service customer support provided by PMET's Materials Analysis Laboratory and Structural Products Pilot Plant staffs.

PMET shaped construction products:

  • contain up to 90% ash

  • are produced using conventional forming and curing equipment

  • can be produced from ash with carbon contents above 6% L.O.I.

  • have strength equivalent to that of fired clay brick and superior to that of concrete block

  • resist weathering and absorption

  • have precise dimensions and may be produced in a variety of permanent mineralogical colors

  • may be solid, hollow, or shaped to interlock for better structural integrity

  • can be easily shaped and sized to optimize weight and cost, reduce construction costs, and vary product mix to optimize profitability