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What is Haydite?

For nearly a century, ESCS (Expanded Shale, Clay and Slate) has been used successfully around the world in more than 50 different types of applications. The most notable among these are concrete masonry, high-rise buildings, concrete bridge decks, precast and prestressed concrete elements, asphalt road surfaces, soil conditioner and geotechnical fills.

What is ESCS? It is a unique, ceramic, lightweight aggregate prepared by expanding select minerals in a rotary kiln at temperatures over 1000°C. The production and raw material selection processes are strictly controlled to insure a uniform, high quality product that is structurally strong, stable, durable and inert, yet also lightweight and insulative.

ESCS gives designers greater flexibility in creating solutions to meet the challenges of dead load, terrain, seismic conditions, construction schedules and budgets in today's marketplace.

The Production Process

shale.JPG (5644 bytes) Raw Shale: The raw material is the same high grade shale as that used to manufacture face brick. The shale contains all of the constituents necessary for bloating.
shovel.JPG (4208 bytes) Shale Excavation: The overburden is stripped by conventional earth moving methods.
pittruck.JPG (4101 bytes) Shale Delivery to Crusher: The shale is mined in open pits and delivered to the crusher by truck. It is crushed to the proper size and conveyed into storage silos.
kilns.JPG (3541 bytes) Rotary Kilns: The shale is introduced to the rotary kiln at the cold end. The kiln is fired at the discharge end with natural gas. The material is retained in the kiln approximately one (1) hour. During this time, minerals which are subject to decomposition at high temperatures, are evolving gases.
fireport.JPG (2705 bytes) Fired @ 2200° F: The shale is simultaneously being softened by heat.  The resulting vitreous material contains a large number of tiny non-connecting cells or pockets formed from the gas. The expanded material is discharged from the kiln into a grated cooler. It is moistened prior to crushing to eliminate dust and to minimize segregation.
finesstock.JPG (4089 bytes) Material Stock Piles: The clinker is crushed and screened to achieve properly balanced gradations for different end uses. The various sizes of Haydite are stored in bins or in a stocking yard for loading into trucks and railroad cars.
wetstock.JPG (3725 bytes) Wetted Stockpiles: Special stockpiles of material are maintained in a prewet or saturated condition for pumping of lightweight concrete.
mainplant.JPG (3318 bytes) Large Inventory: We maintain a large inventory of Haydite lightweight aggregates to meet the demands of today's industry.
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