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

Quality Assurance in Manufacturing Yields Quality Products


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 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

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 Structural Innovations

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


Allen Kronstadt
Executive Chairman
Office: (301) 530-9700 x44
Fax: (301) 816-9175
E-mail: akronstadt@axionsi.com

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. Allen has over 35 years of experience in property management, construction, brokerage, and investments. Raised in Washington D.C., he attended Babson College and the University of Denver.

Allen joined the Board of AXION International Holdings, Inc. in late 2011. In 2016, he led the management team in its effort to reorganize the company and take it private. Mr. Kronstadt is now the company’s principal owner, and he serves as its Executive Chairman.

Claude Brown, Jr.
Office: (740) 452-2500 x220
Fax: (740) 452-5488
E-mail: cbrown@axionsi.com

Mr. Brown has over 24 years of experience in the development, commercialization and manufacturing of innovative building materials. He served as President of Eovations, LLC, a new business venture focused on the development, production and launch of an innovative structural polymer technology that he spun out of Dow Chemical. Mr. Brown also served as Director of Research and Development for both Dow Solar Solutions and Dow Building Solutions, and he established the technology and operations strategy for various building products and lead their development and commercialization.

Prior to his roles with Dow, Mr. Brown served as Vice President of Technology for Alcoa Home Exteriors and Vice President of Research and Development for CertainTeed Vinyl Building Products. Mr. Brown received BS and MS degrees in Ceramic Engineering from The Ohio State University.

Donald W. Fallon
Chief Financial Officer
Office: (740) 452-2500 x224
Fax: (740) 452-5488
E-mail: dfallon@axionsi.com

Mr. Fallon has over 30 years of broad senior-level financial and accounting management experience, having served in various capacities including CFO and founder of both publicly- and privately-held companies. Mr. Fallon received his MBA in Finance from Loyola University, Maryland, and his BS in Accounting from the University of Baltimore.

Matt Elli
Executive Vice President
Corporate Administration
Office: (740) 452-2500 x203
Fax: (740) 452-5488
E-mail: melli@axionsi.com

Mr. Elli has over 30 years of diverse management experience in the business, education and non-profit sectors. He held executive positions in the plastics industry over the last five years, served as VP for Institutional Advancement at Muskingum College, and was the Foundation Director with The Longaberger Company. Mr. Elli received his MA from Ohio University and BA from Muskingum College.

Dave Crane
Executive Vice President
Sales and Commercial Strategy
Office: (740) 452-2500 x222
Fax: (740) 452-5488
E-mail: dcrane@axionsi.com

Mr. Crane is a former General Manager of Engineered Wood Products with Georgia-Pacific LLC, a manufacturer of paper and building products with over $18 billion in revenue, where he developed and launched high performance structural framing systems. He held various executive positions with several large building product corporations including: BlueLinx Corporation (NYSE:BXC), AGC Flatglass North America and SieMatic Möbelwerke USA. Mr. Crane received a BS in Environmental Science and Business Management from Juniata College in Pennsylvania.



Susan Bieterman
Vice President, Procurement and Strategic Sourcing
Office: (740) 452-2500 x205
Fax: (740) 452-5488
E-mail: sbieterman@axionsi.com

Bob Combs
Vice President, Engineering
Office: (740) 452-2500 x204
Fax: (740) 452-5488
E-mail: bcombs@axionsi.com

Dennis Durando
Vice President, Technology
Office: (740) 452-2500 x223
Fax: (740) 452-5488
E-mail: ddurando@axionsi.com

R. Russell Hall
Vice President, Production and Quality Systems
Office: (740) 452-2500 x225
Fax: (740) 452-5488
E-mail: rhall@axionsi.com

William Jordan
Vice President, Commercial Development
Office: (740) 452-2500 x226
Fax: (740) 452-5488
E-mail: wjordan@axionsi.com

John Williams
Vice President, Operations
Office: (740) 452-2500 x215
Fax: (740) 452-5488
E-mail: jwilliams@axionsi.com

Advisory Board

David Connell
Vice President of Engineering, Union Pacific Railroad (retired)

A highly experienced and accomplished railroad engineering professional with a career that spanned more than 30 years, David Connell most recently served as the vice president of engineering for Union Pacific Railroad. In this capacity, he led the design, construction and maintenance of the nation’s largest railway. His previous positions during his long career at Union Pacific included regional vice president of operations, associate vice president of construction, regional chief engineer and various roles in engineering and field maintenance. Active in his profession, he is past chair of the Railroad Design Committee at the Transportation Research Board. He is also past chair of the Heavy Axle Load Committee and past vice chair of the Research Technology Working Committee at the Association of American Railroad’s Transportation Technology Center. In addition, he served as governor and subcommittee chair of the American Railway Engineering and Maintenance-of-Way Association (AREMA) prior to his retirement.

David A. Jack, Ph.D.
Associate Professor, Baylor University, School of Engineering and Computer Science

David Jack has established himself as a leader in the numerical modeling of injection molding of fiber-reinforced polymer systems. His expertise blends physics-based constitutive modeling with experimental polymer characterization, providing him with a rare breadth of technical capability. Among other entities, the National Science Foundation funds some of Jack’s research. He is currently developing a model to analyze data taken from graphite- or glass fiber-reinforced composites. This leads to the creation of 3D images and has the potential to revolutionize the inspection and repair of structures utilizing composite materials. Jack has submitted three patent applications in his field of study. He has also developed and delivered nearly 30 archival journal articles and more than 75 peer-reviewed national and international conference papers.

Frederick Deans
Advisor – Composites and Industrial Applications

Mr. Deans has more than 40 years of sales/marketing, technical service, manufacturing, business development and business management experience at companies such as General Electric and Pittsburgh Plate Glass (PPG), working in the automotive, architectural and industrial market segments. He is an expert in product evaluation, processing, production, product engineering and in coordinating new product introductions. Among his many accomplishments are his work engineering the development of an automotive glass-forming process, introducing monolithic tempered privacy glass for sport-utility vehicles (SUVs); development of the first unidirectional GMT composites for new-generation automotive bumper systems; and managing a next-generation long-fiber thermoplastic composite development (D-LFT) for underhood (IFES, underbody shields) and off-road vehicle load floors. He is a current member of the Board of Directors of the Society of Plastics Engineers’ (SPE’s) Automotive and Composites Divisions, past chair of the SPE Automotive Composites Conference & Exhibition (ACCE), and an SPE Honored Service Member.

Dr. David Allen
Advisor – Railroad Application and Modeling

Dr. Allen is an internationally recognized researcher in viscoelastic and nonlinear material modeling with over 100 major archival publications. Dr. Allen has served as the Dean of the College of Engineering and Computer Science at The University of Texas – Pan American and currently serves on the Aerospace Advisory Board. He is a 1972 graduate of Texas A&M University in the Department of Aerospace Engineering. His textbook “Introduction to Aerospace Structural Analysis,” John Wiley and Sons, Inc., 1985, was widely adopted by and used in aerospace engineering departments.


Sir Charles Dahan
Advisor – International

Mr. Dahan is an international adviser who has worked in conjunction with the World Bank on renewable energy, the National Institutes of Health and other private interests. Mr. Dahan has other varied business interests and manages these projects through his corporation, Asset Management, LLC. Charles Dahan has received several distinctions and awards, including 1000 Points of Light Award from President George Bush (1990); The President’s Volunteer Action Award from President Clinton (1994); and the Chevalier Du Wissam Al Moukafaa At Watania (Knight of the Order of National Merit) presented by HM Mohammed VI of the Kingdom of Morocco (2000). He speaks French, English, Arabic, Hebrew and Spanish.