Glass recycler doubles capacity

Pennsylvania-based AeroAggregates says it is now operating a second kiln at its facility in Roundstone, Pennsylvania. The new kiln will double the facility’s capacity to produce aggregate products made with recycled glass.

The two kilns use 100 percent postconsumer glass to produce a building aggregate described as lightweight, non-combustible, insulating, free-draining, non-absorbent and resistant to chemicals, rot and acid. According to AeroAggregates, the product is superior for construction, lightweight embankments, load distribution platforms and insulating subgrade, as well as lateral load reduction behind retaining walls and structures. Foamed glass aggregates (FGAs) possess a highly frictional surface, making the product ideal as a lightweight backfill, says the company.

“Our ultra-lightweight FGA can solve the challenges of today’s infrastructure projects, especially for those that require fill to be placed over soft compressible materials, weight-bearing structures or over areas with sensitive underground infrastructure,” says Archie Filshill, CEO and co-founder of AeroAggregates. “We’re excited to fire up our second kiln in order to meet increased demand from the civil engineering and construction markets that require sustainable, lightweight materials due to specialized design and constructability requirements.”

The addition of the new kiln will divert the equivalent of around 32,000 tons of curbside glass bottles each year, according to the company, which says its FGA manufacturing process can use mixed color glass and is unaffected by small amounts of residual paper and other contaminants.

The 60-foot foamed glass kiln was imported from Europe where, for many years, FGA technology and manufacturing have been used heavily by the civil engineering market, according to AeroAggregates.

AeroAggregates’ manufacturing process starts with curbside recycled glass powder that is then mixed with a foaming agent. The mixed powder is sent through a kiln and softened by temperatures reaching 1,800 F. During this process, the foaming agent creates bubbles within the softened glass, which ultimately creates foamed glass aggregates.