CalStar Products unveiled high fly ash content architectural brick and pavers at the U.S. Green Building Council’s 2009 Greenbuild International Conference
CalStar Products unveiled high fly ash content architectural brick and pavers at the U.S. Green Building Council’s 2009 Greenbuild International Conference and Expo in Phoenix, which drew a record 30,000-plus. The mid-November launch was in advance of the company’s anticipated start-up this month of a Caledonia, Wis., production line. Deriving Class C fly ash from Wisconsin Energy’s Oak Creek station, the facility will have initial distribution, primarily in the Midwest, through 30 local or regional masonry dealers.
CalStar’s process of molding product from proprietary, portland cement-free mixes, and steam versus kiln curing, results in a) an 85 percent reduction in energy consumption compared to conventional clay brick making; and, b) a 70 percent reduction in carbon dioxide emissions compared to conventional concrete paver production. The CalStar Fly Ash Brick (ASTM C 62 or C 216 compliant) will be available in modular or utility sizes and eight colors. The 60 mm-thick Fly Ash Pavers (ASTM C 902 compliant) will be available in 4- _ 8-in. Holland stone sizes, an array of colors, and standard or tumbled finishes.
Class C ash, whose lime content provides sufficient binding in the presence of water, would appear to represent most, if not all, of the 40 percent post-industrial recycled material the company notes in product specifications. Reduced energy consumption during production, coupled with the recycled material content, position the brick and pavers as rating-point candidates under LEED 2009 Environmental Features sections, including Sustainable Sites, Water Efficiency, Energy & Atmosphere, Materials and Resources, Indoor Environmental Air Quality and Innovation in Design.
Venture capital backers of Newark, Calif.-based CalStar Products have enlisted Holcim (US) Inc., Hanson Aggregates/Pioneer Concrete and U.S. Gypsum veteran Michael Kane to head the business. He was most recently senior vice president, Holcim East Region, based in Duluth, Ga.