U.S. Fly Ash Market Size, Share & COVID-19 Impact Analysis, By Type (Class F and Class C), By Application (Cement & Concretes, Fills & Embankments, Waste Stabilization, Mining, Oil Field Service, Road Stabilization, and Others), and Country Forecast, 2023-2030

The U.S. fly ash market size was worth USD 664.7 million in 2022 and is projected to grow at a CAGR of 5.0% during the forecast period.

Fly ash is a fine, powdery residue from coal combustion in power plants. It is usually collected from the flue gas by electrostatic precipitators or baghouses. As a byproduct of coal-fired electricity generation, fly ash primarily consists of inorganic mineral particles, mostly silica, alumina, and iron and calcium oxides. This versatile material possesses cementitious properties and has been used as a supplementary material while preparing the concrete mix, enhancing the durability and strength of the structure. The superior properties of the product and rising demand for sustainable construction materials will drive the U.S. fly ash market growth.

The COVID-19 pandemic had an adverse effect on the fly ash market, primarily through disrupted supply chains, decreased construction activity, and economic uncertainty. Lockdown restrictions and subsequent construction slowdowns reduced the demand for the product. Economic uncertainty impacted investment decisions and infrastructure projects, limiting the demand. However, amidst these challenges, there has been a growing emphasis on sustainability, presenting opportunities for fly ash as a supplementary material while preparing concrete mix.

U.S. Fly Ash Market Trends

Rising Commitment Toward Eco-Friendly Building Materials to Fuel Market Growth

The increasing product demand in the U.S. is closely tied to a growing emphasis on sustainable construction practices. As environmental awareness rises, stakeholders in the construction industry are likely to prioritize materials that contribute to reduced environmental impact. As a byproduct of coal combustion, fly ash offers a sustainable alternative by repurposing an otherwise waste material. Its incorporation into concrete reduces the need for traditional cement production, which is energy-intensive and enhances the overall environmental profile of construction projects. This aligns with broader industry trends and initiatives to achieve eco-friendly and resource-efficient construction methods. Thus, making fly ash a key component in the pursuit of sustainability within the construction sector.

U.S. Fly Ash Market Growth Factors

Rising Demand from the Construction Sector to Drive Market Growth

The construction sector in the U.S. is driven by several key factors, including population growth, urbanization trends, and the need for modernization and maintenance of existing infrastructure. As cities expand and the population grows, there is an increased demand for new roads, bridges, airports, and other critical facilities. In addition to this, ageing infrastructure requires upgrades and repairs, further contributing to the construction sector's growth. As seen in initiatives such as the American Jobs Plan, the government's commitment to stimulate economic growth through infrastructure investments is pivotal in driving the industry forward. The growth in the construction industry significantly influences the demand for fly ash, particularly in concrete production. For instance, in constructing highways and bridges, where durability and strength are paramount, incorporating fly ash into concrete mixtures enhances these properties, contributing to sustainable and resilient infrastructure. The rise in green building practices further enhances the importance of fly ash as a key ingredient, aligning with environmental and construction industry requirements.

RESTRAINING FACTORS

Adoption of Renewable Energy Sources to Reduce Production, Hampering the Market Expansion

The U.S. and many other countries increasingly prioritize cleaner and more sustainable energy options. Renewable energy sources, such as solar, wind, and hydropower are gaining prominence due to environmental concerns and the emphasis on reduced carbon emissions. This is likely to create a shift away from traditional coal-fired power plants to meet the rising energy demand. Consequently, the decline in coal-fired power plants could reduce the overall generation of fly ash. This, in turn, will likely impact its availability for various applications, particularly in the construction industry, where large volumes of fly ash are needed.

U.S. Fly Ash Market Segmentation Analysis

By Type Analysis

Based on type, the U.S. fly ash market is classified into class F and class C.

The class F segment accounted for the largest U.S. fly ash market share in 2022. Class F ash is derived from anthracite or bituminous coal and is suitable for high-performance concrete. It consists mainly of silica and alumina and has a lower calcium content than class C. The class F ash is used as a replacement for 20%-30% of cementitious materials in Portland cement.

Class C ash, produced from sub-bituminous or lignite coal, is a versatile material used for various concrete applications. Choosing between these two types depends on project requirements, concrete properties, and regional availability, making informed selection critical in construction projects. 

By Application Analysis

Based on application, the market is segmented into cement & concretes, fills & embankments, waste stabilization, mining, oil field service, road stabilization, and others.

The cement & concretes segment held a largest market share in 2022 and is likely to grow significantly during the forecast period. Due to its pozzolanic properties, this ash is a supplementary cementitious material. This enhances concrete strength, workability, and durability while reducing the environmental impact of recycling a waste product. This makes fly ash a valuable and versatile material in construction, addressing both performance and sustainability considerations.

The growth of mining and oilfield services segments is associated with the increasing preference for ash in manufacturing slurries, bricks and blocks for mining and oil extraction activities. The new road construction activities and maintenance of existing infrastructure in the country are expected to drive the product demand from road stabilization application.

List of Key Companies in U.S. Fly Ash Market

Key players in the U.S. fly ash market have invested a considerable amount of resources in the research and development of several ash products. A product portfolio supported by superior operational efficiency and safe & novel technology development for composite applications are the strategies used by the market leaders for their growth.

LIST OF KEY COMPANIES PROFILED:

• Eco Material Technologies (U.S.)


• Cemex S.A.B. De C.V.(Mexico)


• Charah Solutions, Inc.(U.S.)


• Titan America LLC (U.S.)


• Salt River Materials Group (U.S.)


• The SEFA Group, LLC (U.S.)


• HOLCIM (Switzerland)

KEY INDUSTRY DEVELOPMENTS:

• November 2021 – A Subsidiary of LafargeHolcim US, Geocycle, received the first delivery of 2,000 tons of coal flue ash from CenterPoint Energy. The companies signed a 6 Mt multi-year coal ash recycling contract to build a circular economy for power plants. LafargeHolcim uses recycled ash to produce cement.


• September 2021 – Charah Solution created a five-year marketing and sales contract to recycle fly ash from the Gavin Power Plant based in Cheshire, Ohio. According to the agreement, Charah Solutions will be responsible for the environmentally friendly recycling and sales of around 35,000 tons to 60,000 tons of the specification grade Class F ash per year from the facility by 2025.


• April 2021 – Charah Solutions will provide fly ash sales and material handling operations for Luminant’s Miami Fort Power Plant and Zimmer Power Plant in southern Ohio through 2027, when both plants are expected to be retired. Approximately 400,000 tons of ash per year from both sites will be recycled and sold for beneficial use in Portland cement.

REPORT COVERAGE

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The study report thoroughly examines key factors such as competitive landscape, applications, and products. It also provides market trends and highlights significant industry advancements. The study includes different variables that have contributed to the market's growth in recent years and the factors listed above. It examines the industry's newest market dynamics and opportunities, as well as historical data and market revenue growth estimates at the country level.

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