AXION Makes High-Quality, Long-Lasting, Durable Products that Simply Outperform Traditional Materials


Our Recycled Structural Composite is Perhaps the World's Best Building Material.

AXION's eco-friendly, next-generation building materials represent an entirely new approach.

Our patented processes, developed in conjunction with scientists at Rutgers University, transform recycled consumer and industrial plastics into a myriad of structural products that are ideal replacements for traditional materials made from wood, steel or concrete. From girders, pilings and railroad ties to bridge substructures, AXION's American-made products are ideally suited to a broad array of applications.

People around the world are demanding clean, non-toxic alternative building supplies and methods. AXION's cost effective solutions are formulated using up to 100% recycled plastic and no chemical additives. And compared to traditional building materials like wood, steel or concrete, AXION's products are extremely cost competitive, feature longer life cycles and lower maintenance costs. AXION's long-lasting, durable products simply outperform traditional materials: they won't rust, splinter, crumble, rot, absorb moisture or leach toxic chemicals into the environment. Our materials are completely impervious to infestation by insects, marine borers and other marine parasites and resist creep, graffiti, fading and ultraviolet degradation.

On the job site, these innovative products require no special tools or training to install, enabling a seamless transition from old materials to new with no down time or additional expenditures. AXION's aesthetically-pleasing products are used as-is with no need for paint, stain or treatment.

Finally, as an added bonus, AXION's materials generate a positive impact on greenhouse gases and could potentially be eligible for carbon credits, which are currently traded on the Chicago Carbon Exchange.


AXION Brochure



"This thermoplastic bridge, able to withstand heavy loads with little to no maintenance, expected to last at least 50 years, is no longer the bridge of the future – it's the bridge for today. It also meets national environmental goals of being completely recyclable. This technology is not only good for [the Department of Defense], but should be immediately transferred to state departments of transportation for use with short-span bridges wherever possible."


Daniel J. Dunmire, Director
Corrosion Policy and Oversight Office in the Deputy Under
Secretary of Defense (Acquisition, Logistics, and Technology)



 
 

AXION's General Brochure: click here.

 

 

Patented Technology Formulas – From University Labs to Global Marketplace

Rutgers  

AXION International initiated operations with exclusively licensed technology from Rutgers, The State University of New Jersey AMIPP Center. In the 1980’s, Dr. Tom Nosker began working with federally funded research at Rutgers on an exciting develpment in polymer science. Using 100% recycled plastics and composite materials, he achieved and patented an incredibly strong and durable material formula. The AMIPP Center, located in the school of engineering, is affiliated with the Department of Materials Science and Engineering [MSE] and maintains research laboratories and administrative offices in three buildings at the Materials Complex. Research in the AMIPP Center is directed towards structural materials, functional materials, and nanocomposites. Key application areas include structural materials for regional and national infrastructure redevelopment, structural and functional materials for industrial and commercial applications, biomaterials, and national defense. AXION currently holds a broad portfolio of technology formulas upon which our products are based.


Quality Products Begin with Quality Recycling, Materials, and Manufacturing

Plastic Bales

AXION’s high-quality products are engineered, using their patented formula and contain recyclable items such as milk jugs, detergent bottles, post-industrial scrap, and plastic composites from the transportation industry. These raw materials – high-density polyethylene, polypropylene, and recycled plastic composites containing encapsulated fiberglass – are sourced directly through municipal recycling facilities, major waste haulers, material grinders or recyclers. Prices of recycled materials are far more stable than virgin materials and there is no shortage of post-consumer recycled plastic. AXION is controling the manufacturing quality every step of the way. From sorting the different types and grades of post-consumer plastics - to shredding, grinding, washing, and carefully blending the materials – we make quality the top priority. AXION’s product manufacturing team is lead by our Director of Quality Control, Director of Manufacturing, and Director of Materials Sourcing. Controling and monitoring for consistency of standards, we have ANSI Z1.74 quality sampling standards in place.


Proven Technology – Proven In the Lab & Proven In the Field

TTCI Testing  

AXION’s patented material formulas have outstanding mechanical properties, allowing us to manufacture high-quality products, engineered to outperform. Although thouroughly proven for decades – in the lab, on the test track and in applications around the world – AXION continues extensive third-party testing. For example: at Transportation Technology Center, Inc. (TTCI), Pueblo Colorado (May, 2012), the ECOTRAX® Tie underwent Cyclic-Load Testing – 21,000 lb (9,525 kg) load, rotated between the gage and field sides – and completed over 3,000,000 cycles! There was no abnormal workout of the cut spikes and no cracking developed in the rail-seat area. All of our ECOTRAX® ties exceed AREMA Standards for composite railroad ties. Tests include: Modulus of Elasticity; Modulus of Rupture; Spike Pullout; Rail/Plate Area Compression: Compressive Strength; Screw Pullout; Rail/Plate Area Compression: Permanent Deformation; Coefficient of Thermal Expansion; and Single Tie Lateral Push.

All testing is conducted at third-party test facilities:

• Chicago Transit Authority (CTA)
• Construction Technology Laboratories, Inc. (CTL Group)
• NGC Testing Services
• Rutgers University
• Société Nationale des Chemins de fer français (SNCF)
• STARK Pty, Ltd.

 

• Transportation Technology Center, Inc. (TTCI)
• TRACE Laboratories, Inc.
• U.S. Army Corps of Engineers (USACE)
• Villanova University
• VTEC Laboratories, Inc.

Images show: AXION ECOTRAX® Composite Railroad Ties being tested at TTCI Labs; ECOTRAX® Ties in track at TTC High-tonnage Loop; and ECOTRAX® Ties tested at Long Island Railroad (LIRR) Labs for use in tunnels.
   
TTCI Testing  
             
Tie Testing   Tie Testing   Tie Testing   Plastic Bales
             

Learn More About AXION's Technology

AXION International - Greening Tomorrow's Infrastructure.
To view additional AXION International videos, click here.

 

FAQs About AXION's Technology

Here are the answers to some "Frequently Asked Questions" about AXION International's Technology.
We would be pleased to speak with you to discuss any additional questions you may have.

.

Q: What is this immiscible polymer science behind the AXION materials?

A: AXION has partnered with Rutgers University to develop several proprietary formulations of immiscible polymers. The basic concept is that certain combinations of plastics enable them to co-exist while preserving their key beneficial characteristics. This offers strength and toughness advantages over the individual plastics. An analogy would be how steel rebar is added to concrete to enhance the overall structural properties of the final product.

Q: Doesn't plastic creep when under stress? How do we manage this in our design?

A: Plastic does creep under certain conditions, however if one designs to a maximum compressive stress of 600psi, creep will not be an issue. The AXION engineering team can assist you with specific applications.

Q: How does the weight of the AXION material compare to materials I am familiar with such as wood and steel?

A: The best way to look at this is comparing the density of various materials as follows:

  • Density of AXION material: .029-.031 lb/cubic inch depending upon formula
  • Density of Southern Pine: .021 lb/cubic inch (varies with moisture level)
  • Density of Steel: .283 lb/cubic inch

Q: How are products developed with plastic to provide similar strength properties to that of steel and wood?

A: The key factor that we balance is the "EI" factor which is the product of modulus of elasticity times moment of inertia. We can change the cross- section (geometry) of our products to change the moment of inertia to provide the desired mechanical strength characteristics.

Q: I know that the strength of wood typically degrades over time due to weather factors, insect infestation etc. How does the AXION material perform over time?

A: This is where the AXION material has a great advantage over other material options. The strength does not degrade over time and there is no risk of insect damage or degradation due to moisture infiltration. This makes the AXION product highly viable for marine applications as well as all outdoor applications where weather and moisture are a factor.

Q: I know that designing in wood requires careful consideration of shear stresses. How does AXION material compare to most woods in this mode?

A: This is another area where AXION material provides an advantage. The allowable shear stress of our material is several times that of some wood products. This translates to longer spans in certain designs where shear stress is a primary consideration.

Q: Is it possible to have colors other than black?

A: Our primary product is a graphite/black color however it is possible to produce other colors such as brown . This requires a special feedstock and the addition of a color concentrate. As a result, the cost and minimum run requirements are higher.


 

Ft Bragg Tank Bridge


"The Department of Defense spends $22.5 billion dollars annually on equipment and infrastructure as an impact of corrosion. For the Army, this number is approximately $5.8 billion annually. This bridge is less expensive to build than its alternatives, it provides greater corrosion resistance, and it is practically maintenance free. The Army estimates that we will receive a 34 to 1 return on investment by using this technology."


Dr. Roger Hamerlinck
Ft. Bragg Thermoplastic Bridge Dedication Ceremony
September 2009



 

Building with Our 'Green' Technology is Building Better

Materials matter. Building with AXION products makes a difference.

Utilizing virtually 100% recycled plastic, AXION's structural products have the distinct advantage of being environmentally friendly as well as industrial grade building materials. AXION's Recycled Structural Composite address worldwide environmental concerns over deforestation. Utilizing RSC reduces greenhouse gases compared to legacy building materials which increase the same gases. AXION's materials are inert. RSC has no toxic chemicals to leach into the water table or soil. Because AXION's RSC is lighter than legacy materials like steel and cement, the fossil fuels needed to transport the materials is lower as are the transportation costs. And, unlike other legacy materials such as creosote-treated wood, which is toxic waste at the end of its useful life, RSC is 100% recyclable.

AXION technology pioneers the use of recycled materials in a variety of industrial applications. As the world's markets expand, more waste materials appear that can be used in a green smart fashion. AXION intends to be the leader in this activity. AXION is positioned to be an important structural product provider of alternative building products as the basis of building a world class marketing and design company. We believe that these solutions can be both economically competitive and eco-friendly in addition to being structurally superior.

We are nearing a point of crisis regarding the way we treat our environment and AXION's recycled plastic structural products can be a part of the solution. Science writer Susan Freinkel has written a remarkable book - "Plastic: A Toxic Love Story" - that exposes our love/hate relationship with the substance. She leads us down a path, describing how plastics have come to influence our daily lives, our planet, and our world economies, and she points us toward a future where we might learn to live in a responsible and heathy relationship with plastic. AXION's technology is one of a number of creative approaches to improving that relationship that she describes. Below are a few quotes from her book and a link to purchase this remarkable publication.


 

From "Plastic: A Toxic Love Story"
by author Susan Freinkel

"The bridge is unremarkable-Iooking — just a short, plain span connecting one dirt road to another deep in the heart of the New Jersey Pine Barrens. Pitch pines. scrub oaks, and black gum trees line the road leading up to it. Blueberry and leatherleaf bushes cover the river banks on both sides. It's one of dozens of bridges that crisscross the tea-colored waters of the Mullica River as it winds its way through a woods called Wharton State Forest. Unlike the other bridges, however, this one is made entirely of plastic."


"You wouldn't necessarily know that unless you stopped to give it a good once-over. All the same, a spokeswoman for the State Forest told me, it doesn't look out of place." In fact, because it's made entirely from recycled plastics, she said, "it promotes our focus of being green."


"Nearly one million used milk jugs and a lot of old car bumpers were smooshed and melted and remolded to make the plastic I-beams, pilings, and planks that were used to construct the fifty-six-foot-long bridge. Rutgers University polymer scientist Thomas Nosker invented the technology to turn plastic throwaways into durable building materials. He then licensed it to a New Jersey company, AXION International, that's taking it commercial. AXION says the plastic it produces from recyclables can be molded to make bridges, railroad ties, decks, pilings, bulkheads, and levees and will stand up to time and the elements far better than wood or concrete or steel. In just two years the company has created worthy new lives for more than two million pounds of plastics that might otherwise have wound up in a landfill. For AXION founder Jim Kerstein, these kinds of products are karmic payment for a career he spent producing and selling hangers made of virgin plastics that he knew would almost invariably be thrown away. "All the negatives about plastic — that it lasts long and doesn't degrade — are being turned into positives" he said. "You're taking a material that doesn't degrade and putting it to use where we want it to last forever."

 

Plastic

For information about "Plastic: A Toxic Love Story" click here.

AXION International

For Additional Information, please do not hesitate to contact AXION International.

Quality Assurance in Manufacturing Yields Quality Products

QUALITY  

AXION controls and assures the manufacturing quality each and every step of the way from raw materials, to manufacturing, to the final finished product shipped to our customers around the world.

AXION’s product manufacturing team is led by our Director of Quality, Director of Manufacturing, and Director of Materials Sourcing. By addressing and implementing accurate testing methods, controlling the quality of supplied and blended material sources, and reducing variation, AXION continues to improve consistency. Not just better quality – consistently better quality. Our quality control efforts have allowed AXION to objectively demonstrate our ability to create a consistent finished product.

  QUALITY

Quality through Material Controls

Each of our products starts by mixing materials to exacting specifications. To obtain the highest quality and consistency from our patented formulas, AXION demands the highest quality ingredients. In order to establish and maintain consistency in the incoming material streams, several controls and quality practices are in use.

Supplied Material Controls
AXION produces ECOTRAX® Composite Railroad Ties (and other products) that are blended from a specific formulation of recycled plastic and post-industrial, fiber-filled polymer. The plastic component requires specific density, melt flow, and moisture characteristics, while the fiber polymer requires evaluation for fiber content and moisture. Upon receipt of supplied materials, AXION tests the raw components for these characteristics using a sampling frequency in accordance with ANSI Z1.4-2003. Test data is recorded electronically and reviewed by Site Leadership daily. Material that fails to meet the specifications is quarantined and returned to the supplier to prevent possible use. Qualifying material is placed into designated storage locations for blending.

Blended Material Controls
Materials are pulled from their respective storage locations and blended to meet the specific needs of the product. Blends typically consist of a low percentage of tie regrind which is scrap material that is reprocessed for use. This scrap material is generated through normal processing and quality verification practices, including extruder “vent blow” and (destructive) lot acceptance testing. The regrind process is an important recycling practice in itself, which reduces waste and improves overall material usage. Blend composition is verified and moisture content is checked after each blend to validate that the proper fiber and moisture content is attained. The main concern with moisture is its potential for creating excessive voids and reducing extruder throughput. If necessary, the compostion/moisture level is adjusted to meet proper specifications. Test data is recorded electronically and published daily for review by Plant Leadership.


Quality through Manufacturing Process Controls

AXION attains product consistencies through the monitoring and control of several factors during the extrusion process. Sensors are placed in several locations throughout the extrusion process, but are most critically monitored along the manifold which feeds the mold bank(s). The extruder itself has several heat zones which are also automatically monitored and controlled for temperature and pressure, both of which are impacted by the speed of the screw which is manually controlled to maintain optimum material flow.

Most of the manifold heat zones are controlled automatically, but can be adjusted to prevent or eliminate occasional hot or cold spots that could lead to improper filling or cooling. Since the extent and range of controls are potentially limitless, it is important that specified settings or ranges of settings are maintained to reduce or eliminate variation induced by constant adjustment. These settings are documented, posted, and closely monitored by both operators and supervisors. One key input that has a critical impact on tie weight is pack time of the mold. For mold sets with varying lengths, these times are recorded on the Production Report, which is the most critical process control form. The Production Report separates the molds into specific lots and indicates when to change the Lot Code on the stamp (after the tie is removed from the mold).

Once the ties have “set-up”, they are removed from the mold, weighed, and stamped with the location, date, shift, and lot code. Ties that do not meet specifications are placed in a designated scrap location and reprocessed (ground-up) for use in future blends. Acceptable ties are then moved to cooling racks to “cure”. At the end of each shift, the Production Reports are submitted to QA for reconciliation and testing. Graphical analyses of Tie Weights are reviewed bi- weekly by the Senior Leadership Team.


Quality through Control of Finished Goods

Finished Goods Controls
Example: ECOTRAX® Ties that have finished curing are removed from cooling racks and are conveyed through X-Ray and embossing. X-Ray is used to determine if there are any critical voids, particularly in potential fatigue locations or areas where spikes or other hardware may be driven.

During this process, ties are also 100% inspected visually for anomalies that impact fit, form, or function. Aesthetic applications are also evaluated at this time and random sample selection is performed for lot acceptance testing (LAT), in accordance with ANSI Z1.4-2003.

Dimensional and mechanical tests are performed on all LAT samples. Dimensional tests include length, width, height, end perpendicularity, and straightness. Variable data is collected on length, width, and height for all LAT samples and perpendicularity and straightness are visually verified on all ties, with suspect ties measured variably.

All LAT samples are tested for Modulus of Elasticity (MOE) and Modulus of Rupture (MOR) equivalencies. MOR (min) tests are performed to 3000 psig and one LAT sample per shift is destructively tested to acquire MOR (max) values.

The broken tie is also cross-sectioned within the rail seat area and the core and shell measured and photo-documented.

Ties that fail a 100% inspection are rejected and placed in the designated scrap area for regrinding. LAT failures result in quarantine of the entire lot and additional testing is required in accordance with ANSI Z1.4-2003. Disposition is made pending those results.

After testing is complete, ties are reconciled with the Production Report, insuring that all scrap is documented and correctly quarantined. Finished goods are moved to a designated location and all testing and production documentation is submitted for review by Plant Leadership. Graphical analyses of QA Testing are reviewed bi- weekly by the Senior Leadership Team



 

About ANSI Sampling Standards


We would be pleased to speak with you to discuss any additional questions you may have.

Q: What is ANSI?

A: The American National Standards Institute (ANSI) was founded in 1918. As the voice of the U.S. standards and conformity assessment system, the American National Standards Institute empowers its members and constituents to strengthen the U.S. marketplace position in the global economy while helping to assure the safety and health of consumers and the protection of the environment. AXION follows ANSI quality sampling standards to ensure consistant quality manufacturing of our products.
ANSI website >>


AXION International

For Additional Information, please do not hesitate to contact AXION International.

Quality Leadership at AXION International, Inc.


EXECUTIVE MANAGEMENT



Claude Brown  

Claude Brown, Jr.

Chief Executive Officer

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

cbrown@AXIH.com


Donald Fallon  

Donald W. Fallon, CPA, MBA

Chief Financial Officer and Treasurer

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

dfallon@AXIH.com

         
 
Dave Crane  

David Crane

Executive Vice President, Building Products

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

dcrane@AXIH.com

  Dennis Durando  

Dennis Durando

Director
Process Engineering & Technical Support

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

ddurando@AXIH.com

         
 
Randy Hall  

Randy Russell Hall

Director
Quality Management

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

rhall@AXIH.com

William Jordan V  

William Jordan V

Director
Business Development

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

wjordan@AXIH.com

         
 
Randy Hall  

Cory Burdick

Global Manager
ECOTRAX® Rail Division

CONTACT:

Tel: +1 740 452 2500
Fax: +1 740 452 5488

AXION International, Inc.
4005 All American Way
Zanesville, Ohio 43701 USA

cburdick@AXIH.com

   

 

         
 



ADVISORY BOARD



Photo Coming Soon  

Thomas J. Nosker, Ph.D.

Principal Investigator, AMIPP (Advanced Materials via Immiscible Polymer Processing)
Research Professor
Ceramics and Materials Engineering
Rutgers University

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Sir Charles D. Dahan  

Sir Charles D. Dahan

International Advisor

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Tony Perez  

Tony Perez

International Advisor

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Verdugo  

Gonzalo G. Verdugo

International Advisor

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Board of Directors at AXION International, Inc.



Perry Jacobson  

Perry Jacobson

Chairman of the Board of Directors

Perry P. Jacobson, Managing Director. In his role at Brookstone Partners, Mr. Jacobson is responsible for managing B.P. Mezzanine Capital, LLC, a captive mezzanine fund which primarily invests alongside Brookstone Partners' equity capital as well as working with the firm's Limited Partners.

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Steven Silverman  

Steven L. Silverman

Vice-Chairman of the Board of Directors

Prior to being appointed to Vice-Chairman of the Board of Directors, Steve Silverman served as AXION's President and Chief Executive Officer from January 2011 until August 2014. Mr. Silverman, age 46, was the President and Chief Operating Officer of the Company beginning October 11, 2010 and has been a Director since November 2, 2010.

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Tom Bowersox  

Thomas Bowersox

Board of Directors

Since 1997, Tom Bowersox has been a Principal with Shreve Bowersox, P.C. in Bethesda, MD, which provides quality, personalized financial and management services tailored to the sophisticated needs of high wealth individuals and growing entrepreneurial businesses.

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Allen Hershkowitz  

Allen Hershkowitz

Board of Directors

On May 25, 2011, AXION appointed Dr. Allen Hershkowitz to the Company's board of directors. Dr. Hershkowitz is a Senior Scientist at the Natural Resources Defense Council ("NRDC") and a leader in the movement to make environmental responsibility understandable and achievable for every individual and institution.

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Anthony Hatch  

Anthony Hatch

Board of Directors

Tony Hatch has been a senior transportation analyst on Wall Street for over twenty years, starting at Salomon Brothers; proceeding to Argus, PaineWebber, and most recently at NatWest Markets (USA) prior to starting his independent analyst/consultantcy in 1999.

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Allen Kronstadt  

Allen Kronstadt

Board of Directors

Allen Kronstadt is the Founder and President of A. R. Kronstadt Realty Investors, Inc., a firm specializing in the development and asset management of retail, industrial and indoor sports facilities. Raised in Washington, D.C., Allen attended Babson College and the University of Denver, leading to a career in real estate.

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Samuel G. Rose  

Samuel G. Rose

Board of Directors

Samuel Rose is a Founding Partner at Greenebaum & Rose Associates and assumes overall responsibility for the commercial development activities of the company. He has over forty years of experience in commercial development primarily in the Washington, D.C. Metropolitan area.

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