A Novel Approach To Manufacture Recycled Composite Timbers for Structural

Engineering Mechanics Corporation of Columbus¿ (Emc2) approach is to convert both municipal and industrial solid waste products into large dimensional composite timbers for structural and waterfront applications through a novel and efficient manufacturing process. The environmental benefits include: (1) diversion of solid waste plastics and reinforcements from landfills; (2) pollution prevention as a substitute for copper-, chromium-, and arsenic-treated timbers; and (3) conservation of natural resources and rainforests. This feasibility study will investigate methods for joining structural-grade recycled plastic lumber (SG-RPL) that will result in a high production rate for laminated recycled composite timbers (RCTs). The specific target markets for RCTs are marine and waterfront structural components such as fender piling, bearing piles, and other large dimensional components. This market is estimated to be in excess of $40 billion, and the need for alternate, durable, and environmentally friendly materials with long service life is particularly acute due to premature failure of traditional material systems. A novel, patentable formulation with postindustrial and postconsumer waste stream already has been developed by the Principal Investigator along with a private-sector client for manufacturing smaller dimension, cost-competitive, high-performance SG-RPL. A pilot plant for this product also has been installed. Emc2¿s approach is to demonstrate that the use of plastics welding technology to convert the SG-RPL from existing production to large dimensional RCTs at extremely high production rates is technically feasible and commercially viable. Thus, a commercialization partner for the technology to be developed during Phases I and II already has been identified and will work cooperatively from project inception to the marketing of end products. The anticipated results from Phase I are to prove the feasibility of the appropriate welding technology that results in a high-performance RCT as well as its scalabilitv for commercial manufacture. During Phase II, prototype equipment will be fabricated for manufacturing RCTs from SG-RPL, and field trials in a variety of applications will be conducted.