Volcanic ashes used in building materials
The Kansas State Geological Society (KSGS) has opened new market potential for the use of volcanic ash in building materials. Pearl-Lite Inc., now constructing a new plant in Mankato, will use volcanic ash to manufacture building panels and doors. Although the mineral has been plentiful, it had limited commercial uses until now.
Ronald G. Hardy, geologist for the KSGS, said the new material, "expanded" volcanic ash mixed with polyurethane foam, had a high potential for construction of low cost, prefabricated housing, simulated wood paneling and other uses.
After the rubber has hardened, he said, it is stripped from the form and, because of the molding quality of the rubber, retains even the smallest crevice or the grain of the wood.
When a particular wood decorative panel is needed in quantity, he said, a mold of silicone fiber is first made from an exact wooden model of the panel.
Finally, the volcanic ash-polyurethane mixture is poured into the mold and left to harden. Later, the mold is stripped off and a perfect replica of the panel is left, Hardy said.
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The finished panel itself, he said, is highly insulative, waterproof, airtight, gasproof, flame resistant and is unaffected by weather aside from retaining the natural appearance and texture of the wood.
Also, when a natural wood color is desired, he said, the manufacturer sprays the inside of the mold with the desired shade prior to pouring. After the mixture is poured in and hardens, it keeps the thin paint film as the mold is pulled off.
Besides these advantages, Hardy said, the volcanic ash panels can be made either lighter than the original wood panel, as heavy or heavier, depending on the customer's wish. The advantage of this quality, he said, is that natural, life-like wood paneling can replace artificial plastic
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Looks like wood; feels like wood, but it isn't.
This "wood" panel is the product of a new material developed by the Kansas Geological Survey and currently under manufacture by Pearl-Lite Inc. The wood-like panels are made of a volcanic ash-polyurethane mixture.
panels now being used by department stores and businesses.
Also, he said, the panels are less expensive than wood.
The Pearl-Lite Corporation's second plant being built in Mankato will primarily be in operation to manufacture the new material. The first plant was the Mankato Division of Interpace Inc., which processes volcanic ash into the expanded form called "Coreel", another result of the KSGS's research.
Pearl-Lite's Research and Development Division is seeking
further uses for Pearl-Foam in low-cost housing applications such as one piece interior and exterior walls, ceilings and roofs complete with prehung windows and doors.
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