GREEN CAST is a foamed material made exclusively of alkali activated fly ash, without Portland cement at all. It has been thought to be a green alternative to AAC for non-structural applications. This initiative aims at helping the environment by reducing the amount of fly ash that is landfilled and at the same time promoting a competitive material for the building industry.

Sustainability

GREEN CAST is made of fly ash obtained as by-product in thermal power plants, therefore its carbon footprint is considered null. The GREEN CAST material is manufactured in a low energy consuming process.

Time(h)T(ºC)P(atm)
GREEN CAST16801
ACC1019011

Performance

Due to its high porosity GREEN CAST offers superior thermal and acoustic insulation performance compared to conventional AAC maintaining low density and good mechanical resistance.

ð (kg/m3)MF (MPa)MC (MPa)λ (W/mK)Ra
GREEN CAST660-7800.54.80.1436
AAC5500.664.50.1641

Two pilots were built with GREEN CAST and conventional AAC respectively (16 m3), and their thermal inertia was compared over a period of 33 days in a summer regime in Madrid. In order to keep both pilots at the same temperature,GREEN CAST building required less energy.

Costs analysis

A production plant has been ideated by converting a conventional AAC plant into a GREEN CAST production plant, considering raw materials, personnel, production costs, investment, 10 years depreciation and a yearly production of 50,000 m3.

According to a preliminary business model GREEN CAST should cost around 90€/m3 against 100€/m3 of conventional AAC. Please note that all operative costs are related to Western European Countries.