TXI ES&C is manufactured from select shale and clay. This raw
material is fed into a rotary kiln where it heated and expanded,
producing a very strong, but lightweight, clinker. This clinker is then
crushed and sized to meet the requirements of coarse aggregate for the
ready mix and precast concrete industries and other applications. While
the manufacturing process is designed to manufacture coarse material to
serve those industries, a considerable portion of the material flow ends
up as fine aggregate.
TXI has historically adapted our facilities to capture much of these
fines that would otherwise be land filled. Expanded shale and clay fine
aggregates (-3/8”) are a recycled material that many concrete
block producers have adopted as suitable for manufacturing lightweight
concrete masonry units. Engineers have solved problems using
lightweight grout in masonry. Bear in mind that this material has the
same physical attributes as our coarse aggregate. These recovered fines
qualify as a recyclable material as defined by the LEED 4.1 and 4.2
Recycled Material Credit.
Although a recycled material, TXI ES&C exceeds all the requirements
of ASTM 331, “Standard Specification for Lightweight Aggregates
for Concrete Masonry Units”. Of the three general types of
lightweight aggregate covered by this specification, expanded shale and
clay consistently out-performs in many ways the other types of
lightweight aggregates, such as volcanic or coal waste lightweights.
Worry will not keep you up at night because the use of TXI ES&C in
masonry systems ensures that possible harmful industrial contaminants
will not be in the masonry walls or on your jobsite.
“TXI ES&C fine lightweight aggregate is a structural-grade
recycled material for lightweight block and grout in masonry
systems.”
Concrete units containing TXI ES&C are manufactured by independent
block manufacturers – our direct customers. Block manufacturers
have historically evaluated our lightweight aggregate, not only for its
chemical and physical characteristics, but also for its impact on the
block manufacturing process. Block made from TXI ES&C has the right
ratio of strength, weight, and fire ratings for hitting the
“sweet spot” of engineering expectations. Engineering
professionals have counted on concrete units that meet, and preferably
exceed, linear drying shrinkage, strength, absorption, and other
requirements of ASTM C90 – and lightweight block made with
expanded shale and clay fine lightweight aggregate have shown they can
be relied upon.
Owners, design professionals, block manufacturers, and masonry
contractors can insure a sustainable, safe, reliable, and thermally
efficient building when specifying and using concrete masonry units that
contain TXI ES&C as the only lightweight aggregate in the mix
design. See our Guide Specification for Lightweight Concrete Masonry
Units. Savings will include less dead load - saving on steel
reinforcing, concrete, labor and transportation costs. The lightweight
masonry wall system, like the PyroTherm Masonry Wall System, could
very well be the solution that will allow you to build smarter.
