FreeShip- Prolite FR50, Refined, Repurposed Fly Ash, Lightweight Filler for Resins- (Prompt rebate on orders with 3 or more FreeShip items!)

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PROMPT REBATE ON ORDERS WITH 3 OR MORE “FreeShip” ITEMS! WANT TO KNOW YOUR TOTAL REBATE BEFORE PURCHASE? CONTACT US!

Prolite FR 50* is a processed fly ash which has been developed especially as a filler for resin (polyester or vinyl ester in this case, but in epoxy for other applications) used to make bathroom countertops with built in sinks. Standard raw fly ash is dark brown in appearance and most fillers for resins need to be white or translucent. We have a standard fly ash, unrefined, that is intended to be used as a pozzolanic additive with portland cement mixtures because it is a dark color. For White Portland cement it could not be used because the dark color of the standard would defeat the purpose of using white portland cement. This light colored fly ash could be tested with white portland cement to see if the color is acceptable and whether it has the same pozzolanic properties as the darker, standard fly ash.

This fly ash has been refined to be white and the particles have been separated by weight. This grade of Prolite is the lightest weight type of the various grades available. There are lighter weight fillers available, but prolite is probably the lowest cost among them. Fillers which are extremely light such as hollow glass spheres are very expensive and require special mixing considerations since a main problem with them is breakage which raises their weight, negating the reason they are used in the first place. Prolite may be light but it still makes a structurally sound casting material. Fly ash consists primarily of oxides of silicon, aluminum, iron, and calcium. Magnesium, potassium, sodium, titanium, and sulfur are also present to a lesser degree. When used as a mineral admixture in concrete, fly ash is classified as either Class C or Class F ash based on its chemical composition.
Prolite fills the requirement of lower weight when going up against the main alternate filler used for the application of bathroom countertops, calcium carbonate (which is quite heavy since it is basically powdered limestone). Fly ash which is the raw material to make prolite occurs in microspheres, and although they are not hollow there are benefits to a spherical shape of the filler particulate in a resin system.
Prolite Provides Superior Wetting, Flow and Air Release in a resin blend.
Conventional lightweight fillers can be difficult to wet out and require extra mixing time. Resulting matrixes are often dense and “stiff”; resisting flow and inhibiting air release. This is not the case with Prolite. Prolite’s unique spherical particle distribution allows for quick and easy dispersion in resin, rapid flow under minimal vibration and the free movement of air to the surface of the part.
An additional benefits of Prolite is lowering of exotherm and improved adhesion when finished parts are painted. It also improves general performance of a resin mix when roto-casting.

The advantages of using less resin are:
-lower cost
-less shrinkage
-reduced chance of stress fractures and cracking during cure
-decreased chance of warping
-lower VOC emissions
The advantages of lighter parts are:
-less labor used in manufacturing, handling and installation
-lower shipping and distribution cost
-less potential for part damage during installation

Prolite FR50 typical mixtures are 47/53 parts of resin to prolite by weight. This amount will give a blend of 800 to 1000 cps casting mix at a temperature of 70 F. Using heated resin systems can further lower viscosity and allow higher filler loading. The bulk density of FR50 is 28 lbs/cubic foot, the specific gravity is 1.0 (the same as water, not stone as with calcium carbonate or portland cement counters).

*environmentally, the use of fly ash is a form of recycling. Fly ash is produced at power plants where it is removed from the exhaust on the outlet of the burning chamber, captured before it can add ash to the environment. Just like using ground up rubber from discarded tires in the asphalt of roads!