Headerimage
Headerimage

Production Process

Applications

Advanced Manufacturing for Superior Lightweight Aggregate.

Arcosa Lightweight’s production process begins with the careful selection of premium shale or clay, which is quarried at or near our manufacturing facilities. This raw material undergoes a rigorous process, starting with heating in rotary kilns at temperatures exceeding 2000°F. Under tightly controlled conditions, the extreme heat transforms the material into a structural-grade ceramic lightweight aggregate.

Once processed, the aggregate is carefully screened to achieve the precise gradations needed for various applications, including asphalt surface treatments, structural lightweight concrete, concrete masonry, and geotechnical fill. The resulting product is not only lightweight and highly insulative but also durable, stable, and free draining, making it ideal for demanding projects.

This high-quality lightweight aggregate is valued for its strength-to-weight ratio, making it an excellent choice for applications like asphalt road surfaces, concrete bridge decks, high-rise buildings, precast/prestressed concrete elements, and retaining wall backfill. By combining low density with exceptional toughness, our lightweight aggregate helps improve the performance and longevity of projects across numerous industries.

Step 1:

Raw Material Selection and Quarrying

The production process begins with the careful selection of high-quality shale or clay. These natural materials are quarried at or near Arcosa Lightweight’s manufacturing facilities to ensure easy access and cost efficiency. Only premium raw materials with the right composition are chosen to produce lightweight aggregate that meets our high standards.
Step 2:

Crushing and Screening

Once quarried, the raw shale or clay is transported to the processing facility where it is crushed and screened into smaller, more manageable sizes. This step ensures uniformity in the material size for the next stage of the process.
Step 3:

Rotary Kiln Firing

The crushed shale or clay is fed into rotary kilns, where it is heated to temperatures exceeding 2000°F. Under carefully controlled conditions, the heat transforms the raw material into a lightweight, ceramic aggregate. The rotary kiln’s rotation and high temperatures expand the material, creating the porous, lightweight structure.
Step 4:

Cooling and Processing

After firing, the lightweight aggregate is rapidly cooled to lock in its structural properties. This cooling process helps solidify the material’s ceramic nature, ensuring it is durable and inert. Cooling may involve natural air or water sprays, depending on the specific plant and process.
Step 5:

Screening and Gradation

Once cooled, the lightweight aggregate is screened to specific gradations to meet precise requirements for different applications. This step ensures that the material is uniform and meets the exact specifications for use in asphalt surface treatments, concrete, and other applications.
Step 6:

Quality Control and Testing

Before shipment, the aggregate undergoes rigorous quality control testing to ensure it meets industry standards, including ASTM C330 for structural concrete and ASTM C331 for concrete masonry. Each batch is tested for consistency in density, gradation, and durability to ensure the highest performance in its intended application.
Step 7:

Final Product and Storage

The finished lightweight aggregate is stored in silos or stockpiles, ready for distribution. It is now ready for use in a variety of applications, from road surface treatments and bridge decks to geotechnical fill and precast concrete elements. The material’s low density, high strength, and excellent insulating properties make it highly sought after.
Step 8:

Distribution and Delivery

The final stage of the process involves shipping the lightweight aggregate to customers via truck, rail, or barge. Arcosa Lightweight’s logistical network ensures efficient delivery to meet the demands of projects across the country.

TEXAS

14885 South Interstate 45
Streetman, Texas 75859
(903) 599-3000

Map

CALIFORNIA

17410 E Lockwood Valley Rd
Frazier Park, CA 93225
(661) 245-3736

Map

COLORADO

11728 Highway 93
Boulder, CO 80303
(303) 499-1010

Map

ALABAMA

201 Industrial Street
Livingston, AL 35470
(205) 652-9688

Map

LOUISIANA

12652 Airline Hwy
Erwinville, LA 70729
(800) 342-5483

Map

ARKANSAS

3719 Mounds Rd
Proctor, AR 72376
(800) 342-5483

Map

KENTUCKY

1797 Coral Ridge Road
Shepherdsville, KY 40165
(502) 957-2103

Map

INDIANA

6618 N Tidewater Rd
Mooresville, IN 46158
(317) 831-0710

Map
Map
Manufacturing Locations Terminal Locations

Footer Design