New Coal Char-Based Building Products: Manufacturing, Engineering Performance, and Techno-Economic Analysis for the USA Market

Suraj Prasad Pandey, Hua Yu, Chooikim Lau and Kam Ng ()
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Suraj Prasad Pandey: Department of Civil and Architectural Engineering and Construction Management, University of Wyoming, Laramie, WY 82071, USA
Hua Yu: Department of Civil and Architectural Engineering and Construction Management, University of Wyoming, Laramie, WY 82071, USA
Chooikim Lau: Department of Civil and Architectural Engineering and Construction Management, University of Wyoming, Laramie, WY 82071, USA
Kam Ng: Department of Civil and Architectural Engineering and Construction Management, University of Wyoming, Laramie, WY 82071, USA

Sustainability, 2024, vol. 16, issue 5, 1-26

Abstract: Common building products, i.e., thin brick and stone veneer, add the look of brick walls or the enduring charm of natural stones into buildings and houses without imposing a substantial increase in structural load. This study investigates the mechanical strength, durability, and economic feasibility of producing innovative char-based thin bricks and stone veneers. The char-based thin brick vacuum treated with hydrophobic liquid exhibits water absorption rates within the 4–7% range, displays durability against 50 freeze–thaw (F-T) cycles, and maintains a saturation coefficient below 0.6. In contrast, commercial thin bricks have water absorption of 9–12%. Treated char-based stone veneer has water absorption of 5.3% and an average compressive strength of 19.2 MPa, maintains its structural integrity throughout 50 F-T cycles, and exhibits a negligible linear shrinkage of approximately 0.01%. In contrast, commercial stone veneers have water absorption of 10–16%. These engineering properties meet the criteria as per ASTM standards C1088 and C1670 for thin brick and stone veneer, respectively. A techno-economic study was preliminarily conducted to examine the potential cost efficiency and cash flow in manufacturing these char-based building products. The manufacturing cost of USD 25.83 is lower than the average market price of 64.65 USD/sq. m. for thin bricks. The manufacturing cost of USD 32.65 is lower than the average market price of 129.17 USD/sq. m. for stone veneers. These comparisons present a compelling economic advantage for their commercialization. This comprehensive study has demonstrated the advantages of sustainable char-based stone veneers and thin bricks regarding engineering performance and economic benefits.

Keywords: char product; masonry veneer; engineering properties; net present value; internal rate of return; sensitivity analysis (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2024
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