Recycling Ships' Plastic Waste

Period of Performance: 08/27/1997 - 08/27/1999


Phase 2 SBIR

Recipient Firm

Innovative Research Corp.
P.O. Box 482
Peralta, NM 87042
Principal Investigator


Innovative Research Corporation has successfully completed Phase I of this project. We have demonstrated the feasibility of our I-Rock process to utilize 100% of the Navy's shipboard plastic waste in manufacturing environmentally safe, durable recycled plastic lumber. This includes 10" uniform diameter cores suitable for incorporation into Composite Plastic Pier Pilings (CPPP). During Phase I, IRC converted approximately 1000 lbs of contaminated, densified waste generated on board a surface combatant at sea using the Navy's Plastics Processor. This was accomplished without any cleaning or sortation. Papwer cardboard, glass and metal, as well as plastics, found in the disks were incorporated. The final product was submitted to an EPA certified laboratory for a toxicity leaching procedure. No reportable quantities of any screened substance were detected. I-ROCK lumber has been formulated to exceed 3000 psi in compressive strength and is itself 100% recyclable. Phase II will have three major objectives. IRC will design, develop and demonstrate a commecially viable 12 ton per day (1000 lb. per hour) production facility in Albuquerque. Second, we will perform site selection, and vigorously pursue all zoning and permitting requirements to establish manufacturing factilites in proximity with the Naval Stations at Norfolk and San Diego. This will be undertaken using matching funds already committed by a third party. The third objective, which is to be carried out in the Phase II option, is to complete product development and testing of marine plastic composite lumber including a core fully compatible with an existing certified CPPP.