The GCS Model

The adaptability of the GCS Model

GCS’s coal ash repurposing technology lends itself to a very flexible platform. More specifically, the company’s mineral fiber manufacturing operations generally require a small footprint and need very little natural resources such as water when compared with other wood pulp or mineral wool manufacturing operations. What’s more, GCS manufacturing operations can be housed in an existing facility upon slight renovations or in a newly constructed facility. Using an existing facility would render GCS’ largest manufacturing factory operational within six to 10 months whereas, a new-construction GCS factory could take as long as twelve months to render operational depending on state/local zoning requirements. This does not account for GCS’s ability to establish multiple factories at the same time through the use of the latest virtual facilities construction technology platforms, which also enable the most efficient workforce development and training modules.   

GCS’s flexible manufacturing platform also enables the company to co-locate its mineral fiber factories at coal power plants or landfill/ash pond sites for the repurposing of their fresh coal ash inventory. Equally beneficial is the ability of GCS to establish parts of its operations at a coal ash landfill or ash pond site where the toxic ash would be changed in form (formed into cylindrical bricks) and then transported to a second GCS manufacturing facility for the final phase of the mineral fiber manufacturing process.

 
 
 

The aforementioned flexibilities in GCS’ manufacturing operations are designed to fully accommodate the needs of any given community and coal power plant stakeholder in order to ensure a solution that best facilitates a win-win scenario for all the parties. Whether as the solution of choice for the management of fresh coal ash from active coal power plants or as the solution of choice for the reclamation of coal ash landfills and ash ponds, there simply isn’t as complete a solution as GCS’.

Although America’s manufacturing sector job creation challenges and the national coal ash management challenges are independent of each other, an opportunity is at hand for GCS to substantially facilitate the nation’s manufacturing sector revitalization ambitions while addressing the adverse environmental impact of coal electrical power generation with respect of coal ash, however indirectly. To that end, GCS proposes to establish a minimum of 25 mineral fiber manufacturing factories across the U.S. within the next 5 years and as many as 50 factories during the next 10 years to manufacture its PHEENX®  mineral fiber brand while employing a minimum of 6,250 to 12,500 direct employees during that span. Not to mention, the additional creation of an estimated 18,750 to 37,500 Indirect jobs in ancillary and downstream industries.  

 
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With GCS’ operating model lending itself favorably to many of the regions in the U.S that need immediate economic stimulation such as rural/urban communities, the company has already identified the parts of the country with adequate coal ash inventories and/or active coal power plants. GCS would then work with the respective state economic development offices to stand-up the company’s mineral fiber manufacturing facilities, which can be operational within six (6) months where there are existing facilities that can be retrofitted for the company’s manufacturing operations or within twelve (12) months where a GCS factory would need to be constructed anew. As much as GCS can forge its own path and establish its manufacturing facilities in the choicest locations, we are able and willing to fully collaborate with local, state, and federal governments to ensure that as much as possible, GCS’ operations in any given region blend within the going economic development objectives of the region.

With adequate funding on-hand, GCS can establish at least twenty-five (25) coal ash-to-mineral fiber manufacturing plants within a period of five (5) years @ that will provide 6,250 direct jobs; 300 outsourced jobs; an estimated 18,750 indirect (ancillary industries) jobs; a total capital cost outlay of more than $2B into local and state economies for capital equipment and facility construction. Under this proposal, each GCS factory would be able to repurpose a minimum of 300,000 metric tons of coal ash each year and be able to manufacture all the company’s six base mineral fiber products.           

Within the next 5 years, GCS will additionally expand its global headquarters in the U.S. that would:

  • Create 250 direct jobs;

  • Establish 3 regional headquarters throughout the U.S. that would:

  • Create 150 jobs each for a combined 450 total direct jobs;

  • Create additional 375 direct jobs that will be created from GCS’s three (3) regional manufacturing facilities.   

In all, one can expect GCS to generate an average of 1,465 total direct jobs each of the next 5 years from the company’s coal ash-to-mineral fiber manufacturing operations, global & regional headquarters operations, and equipment/machine manufacturing operations. In a ten-year outlook, GCS stands to generate an estimated 12,500 direct jobs and 37,500 indirect total jobs. The GCS economic revitalization solution will also help local, state, and national economies through the company’s annual direct expenditures for the purchase of raw materials and other ancillary operational needs from various sectors such as logistics and hospitality. 

Particularly advantageous with the GCS solution is the required labor skills mix for the company’s operations. Specifically, there is a labor mix of 70% blue-collar (high school diplomas or equivalent) and 30% white-collar (college degree holders). This labor requirement will enable GCS to play a vital and positive role in the immediate revitalization of both rural and urban economies.