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Area Development - Site Selection, Facility Planning and Workforce Development

AeroAggregates Expands Operations at Eddystone, Pennsylvania, Plant

01/16/2019
AeroAggregates, the first vertically-integrated manufacturer in North America to produce ultra-lightweight, closed cell foamed glass aggregates is now operating its second kiln, doubling production in Eddystone, Pennsylvania. The facility is a brownfield redevelopment site at the former Baldwin Locomotive Works.

“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,” explained Archie Filshill, CEO & 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,” he added.

According to company officials, kilns at AeroAggregates use 100 percent post-consumer recycled glass to produce a building aggregate that is lightweight, non-combustible, insulating, free-draining, non-absorbent, and resistant to chemicals, rot and acid.

This makes FGA 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 also possess a highly frictional surface which makes it ideal as a lightweight backfill.

With the addition of the new AeroAggregates kiln, the equivalent of more than 140 million recycled curbside glass bottles (or 32,000 tons) will be diverted each year, bringing relief to municipal recycling operations.

The new 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.

Unlike the non-combustible nature of FGA, materials like expanded and extruded polystyrene, commonly used when lightweight construction materials are specified, are falling out of favor in the industry due to their flammability.

The company’s unique FGA manufacturing process, obtained through an exclusive license from a Europe-based firm, starts with curbside recycled glass powder which is then mixed with a foaming agent. The mixed powder is sent through a kiln and softened by temperatures reaching 1,800 degrees Fahrenheit.

During this process, the foaming agent creates bubbles within the softened glass, which ultimately creates foamed glass aggregates. The output produced is a remarkable material that creates a superior building product offering many sustainability benefits.

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