The GCS Fibers Model

A Scalable National Platform for Advanced Manufacturing and Economic Renewal with the additional benefit of Environmental Remediation

GCS Fibers has engineered a flexible, rapidly deployable manufacturing platform that transforms coal ash into high-value mineral fibers—addressing one of America’s most persistent environmental challenges while rebuilding domestic manufacturing capacity. The modular nature of GCS Fibers’ operations allows the technology to be co-located, scaled, replicated, and deployed across the country in a manner aligned with DOE goals, community needs, and national industrial priorities.

A Flexible, Low-Resource, High-Impact Industrial Platform

Unlike traditional mineral fiber or wood pulp manufacturing facilities, GCS Fibers’ plants require:

  • A relatively small physical footprint

  • Minimal water and natural resources

  • Low emissions with our 96% efficient integrated emissions capture system

  • Significantly reduced permitting and utility burdens

This creates an opportunity for fast and cost-effective deployment with minimal environmental disturbance.

 
 
 

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’.

GCS Fibers’ facilities can be established in:

1. Existing industrial buildings (retrofit)

Operational in 6–10 months – ideal for regions seeking rapid employment and environmental cleanup.

2. Newly constructed purpose-built facilities

Operational in 12 months, depending on local zoning – still far faster than conventional industrial buildouts.

3. Multiple simultaneous deployments

Enabled by GCS Fibers’ virtual factory construction and workforce training platforms, which accelerate engineering, installation, and labor force readiness.

This flexibility ensures that the technology can be placed where the coal ash problem exists and where economic revitalization is most needed.

Direct Co-Location at Coal Power Plants and Ash Reclamation Sites

GCS Fibers’ modular system allows factories to be placed directly at or adjacent to:

  • Active coal power plants

  • Coal ash landfills

  • Legacy ash ponds

  • Utility-owned remediation sites

This co-location model dramatically reduces transportation cost, accelerates cleanup, and supports utility compliance with emerging federal regulations.

Additionally, when site conditions require, GCS Fibers can:

  • Process ash into inert cylindrical bricks onsite, then

  • Transport the stabilized material to a secondary GCS Fibers facility for final mineral fiber production

This dual-site approach enables remediation in even the most constrained or sensitive locations. The result: a fully integrated, end-to-end solution unmatched by any other known technology.

A National Deployment Strategy for Manufacturing Revitalization

Although the challenges of coal ash management and U.S. manufacturing decline are separate issues, GCS Fibers offers a rare opportunity to solve both—simultaneously and at scale.

GCS Fibers proposes the deployment of:

• 25 factories in the next 5 years

• 50 factories in the next 10 years

This national initiative would create:

  • 6,250 to 12,500 direct manufacturing jobs

  • 18,750 to 37,500 indirect jobs in logistics, construction, engineering, maintenance, transportation, and downstream product manufacturing

  • A new American supply chain for six high-value mineral fiber classes under the PHEENX® brand

This pipeline of projects represents over $2 billion in capital investment directly into local and state economies.

Every facility will process at least 300,000 metric tons of coal ash per year, providing a scalable, measurable pathway for utilities and states to address EPA cleanup mandates.

Targeting Regions Most in Need of Economic Stimulation

GCS Fibers has mapped ash inventories and active plant locations across the United States and identified regions where:

  • Coal ash remediation is most urgent

  • Workforce recovery is needed

  • Industrial infrastructure already exists

These include both distressed urban areas and rural coal communities—many of which have seen decades of industrial decline.

GCS Fibers works directly with:

  • State economic development agencies

  • Local governments and workforce boards

  • Federal partners in DOE, EPA, DOL, EDA, and USDA

This collaborative approach ensures alignment with regional economic strategies and supports durable, long-term job creation.

Headquarters and Workforce Expansion Strategy

Within 5 years, GCS Fibers will also expand its corporate and regional operational capacity, including:

Global Headquarters – U.S. Based

  • 250 direct jobs

Three U.S. Regional Headquarters

  • 150 direct jobs each

Three Regional Manufacturing Support Centers

  • 375 additional direct jobs

Combined with factory deployment, GCS Fibers will create an average of 1,465 new direct jobs per year over the next 5 years.

At full 10-year maturity:

  • 13,575 direct jobs created

  • 37,500 indirect jobs supported

These jobs represent sustainable wages, long-term employment, and opportunities for upward mobility.

A Workforce Model Designed for American Communities

GCS Fibers’ operations rely on a 70% blue-collar / 30% white-collar workforce mix, creating broad opportunities for:

  • High school graduates

  • Skilled trades and vocational programs

  • Former coal industry workers

  • Engineers, chemists, and process technologists

  • Underrepresented communities seeking entry into advanced manufacturing

By design, GCS Fibers’ facilities help rebuild the American middle class.

 
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A National Pathway for Manufacturing Revitalization & Coal Ash Management

The GCS Fibers Model provides the United States with:

✓ A scalable and permanent solution to the ongoing coal ash crisis

✓ A domestic supply chain for high-value mineral fibers

✓ A rapid job-creation engine for distressed regions

✓ A pathway to meet EPA waste and emissions requirements

✓ A blueprint for long-term industrial resilience

GCS Fibers is prepared to deploy this solution nationwide—with speed, cost-efficiency, environmental integrity, and a commitment to building stronger American communities.