Applications
Stalite Lightweight Aggregate is used in structural concrete, masonry, geotechnical, and infrastructure applications where reduced weight, high strength, and long-term durability are critical.
Engineered Through the Rotary Kiln Process
Stalite Lightweight Aggregate is produced by expanding select slate in high-temperature rotary kilns, creating a strong, durable lightweight aggregate with a uniform internal structure.
This controlled process ensures consistent quality and reliable performance in structural concrete, masonry, geotechnical, and infrastructure applications.
Raw Material & Mining
Selective 3D geological mapping identifies high-quality argillite slate deposits. Controlled blasting, crushing, and screening produce consistent kiln-ready gradations for strength, durability, and uniform performance.
Staging, Conveying & Processing
A modern fractionation plant and enclosed conveyors prepare, blend, and transport material from quarry to kiln, ensuring proper size, moisture control, and minimal material loss.
Heating & Expanding
Slate passes through patented preheaters and 2,200°F rotary kilns, expanding into lightweight aggregate as sealed air cells form within the material, creating exceptional strength, durability, and low unit weight.
Collecting, Grading & Managing Quality
After cooling, automated systems classify and blend aggregate. State-certified laboratories perform continuous ASTM, AASHTO, and ACI testing to verify gradation, density, and long-term structural performance.
Storing, Transporting, and Shipping
Low-height silos and moisture-controlled stockpiles help prevent segregation. Clean, inspected transport and handling systems help maintain product quality from plant to project, supporting delivery across North America and worldwide.
Case Studies
See how Stalite Lightweight Aggregate helps solve weight, span, and construction challenges in real-world projects.
Offshore concrete gravity structure in Newfoundland utilizing lightweight aggregate for strength and marine durability.
Record-setting 223-ft prestressed girder built with lightweight aggregate for the I-5 Puyallup River Bridge in Tacoma, WA.
Internally cured bridge deck constructed with Stalite Lightweight Aggregate to reduce shrinkage cracking and improve long-term durability.
Courtyard by Marriott Curaçao built with lightweight structural concrete to control loads and ensure durability in a demanding waterfront environment.
Lightweight aggregate reduced settlement and accelerated construction at the Pentagon’s secured entrance in Arlington, VA.
Long-span fjord crossing in Norway constructed using structural lightweight concrete to reduce dead load and optimize cantilever bridge performance.
Lightweight concrete grid deck system used in the replacement of the I-895 bridge superstructure over the Patapsco River Flats in Baltimore.
48-story Wells Fargo Center in Charlotte, NC constructed with lightweight precast double tees to accelerate schedule and reduce structural load.
Spectrum Center, home of the NBA’s Charlotte Hornets, was built using approximately 500,000 lightweight concrete masonry units.
Segmental box girder bridge crossing California’s Carquinez Strait built with lightweight structural concrete to reduce seismic forces.
Lightweight aggregate fill reduced wall pressures and stabilized embankments for Charlotte’s CATS Light Rail parking deck.
