Road Material

Safer, Longer-Lasting
Road Surfaces.

Government agencies and private road owners, including municipalities and state and federal departments of transportation, face growing pressure to extend pavement life, improve safety, and control maintenance costs amid increasing traffic volumes and limited budgets. Stalite Lightweight Aggregate delivers proven performance in asphalt surface treatments and maintenance applications, providing superior skid resistance, long-term durability, and measurable cost efficiencies without compromising constructability or roadway performance.

Completed multi-lane roadway showcasing smooth, durable pavement built with lightweight aggregate materials

Lightweight Aggregate
for Road Materials

Across the United States, road networks are subjected to increasing traffic loads, environmental exposure, and aging pavement structures. Agencies and owners must maintain safe, reliable road surfaces while working within tight schedules, weight restrictions, and limited budgets. Traditional aggregates can polish over time, contribute to stone loss, and increase hauling and placement costs.

Lightweight aggregate produced with Stalite expanded slate offers a proven alternative. Its lower unit weight provides greater surface coverage per ton, reducing transportation and handling costs while allowing trucks and paving equipment to operate at full capacity without exceeding legal weight limits.

Beyond logistics, Stalite delivers long-term roadway performance. Its rough, angular surface resists polishing, maintains skid resistance over time, and bonds effectively with asphalt binders and traffic paint. The result is safer, cleaner, and more durable road surfaces throughout their service life.

Key Benefits

  • Improved Safety and Skid Resistance
    Stalite continually exposes fresh, angular texture as it wears, unlike conventional aggregates that polish smooth. This self-renewing surface maintains long-term skid resistance, reducing hydroplaning risk and improving safety in wet, high-speed, and high-traffic conditions.

  • Lower Transportation and Placement Costs
    With a significantly lower unit weight than traditional aggregates, Stalite provides more surface coverage per ton. Fewer loads are required, hauling costs are reduced, and placement efficiency is improved, particularly on weight-restricted routes and urban projects.

  • Superior Binder and Coating Bond
    Stalite’s cubical shape and surface void structure promote strong mechanical bonding with asphalt emulsions and traffic paint. This results in reduced stone loss, improved surface integrity, and longer-lasting pavement markings.

  • Reduced Maintenance and Cleanup
    Lightweight particles are less likely to fracture or dislodge under traffic, minimizing windshield damage, vehicle complaints, and post-application cleanup. Road surfaces remain intact and visually consistent longer, reducing maintenance cycles.

  • Predictable Performance Through Controlled Gradations
    Carefully controlled gradations ensure consistent placement, uniform surface texture, and reliable performance across a wide range of road maintenance and surface treatment applications.

Surface texture comparison of polished granite aggregate and Stalite Lightweight Aggregate showing long-term skid resistance

Surface texture comparison showing polished granite aggregate versus Stalite Lightweight Aggregate maintaining angular texture for long-term skid resistance.

Field-Proven Performance in High-Traffic Conditions

Stalite Lightweight Aaggregate has a long track record in demanding roadway applications, including use by state departments of transportation on high-traffic corridors such as North Carolina Highway 421, with average daily traffic of approximately 14,000 vehicles. In these applications, Stalite has performed successfully as a ride surface without requiring a blotting seal, streamlining construction while delivering durable, long-lasting results.

Its naturally darker appearance blends seamlessly with conventional asphalt, producing a uniform surface that meets both performance and aesthetic expectations.

Cost-Effective Crack Sealing and Surface Preservation

Surface cracks allow moisture intrusion that accelerates pavement deterioration and structural damage. Traditional skin patching methods can leave loose aggregate that shortens service life and damages vehicles.

Stalite’s rough texture bonds tightly with asphalt emulsions, creating an effective and economical seal without loose debris. Its lightweight particles remain in place under traffic, providing long-term crack sealing that performs reliably and maintains a clean roadway appearance.

Common Uses

  • Asphalt surface treatments
  • Scrub seals and slurry seals
  • Portable patch paving operations
  • Hot mix asphalt
  • Preventive maintenance programs
  • Roadway rehabilitation and preservation projects

With decades of proven use by departments of transportation, including North Carolina, South Carolina, and Georgia, Stalite is considered a preferred material in many roadway maintenance and safety programs.

Related Case Studies

Supporting Documents

Frequently Asked Questions

Lightweight aggregate is used in road materials such as asphalt surface treatments, chip seals, scrub seals, slurry seals, and hot mix asphalt. Stalite Lightweight Aggregate improves skid resistance, enhances surface durability, and reduces transportation and placement costs in roadway construction and maintenance.

Yes. Stalite lightweight aggregate is field-proven on high-traffic roads, including state highways and DOT-maintained corridors. Its rough, angular surface bonds strongly with asphalt binders and maintains long-term friction under heavy traffic volumes.

Unlike traditional aggregates that polish smooth over time, Stalite maintains a non-polishing surface that continually exposes fresh texture. This helps preserve skid resistance, reduces hydroplaning risk, and improves roadway safety in wet or high-speed conditions.

Yes. Strong bonding with asphalt binders and traffic paint reduces stone loss, surface wear, and premature cracking. In addition, the lower unit weight of lightweight aggregate reduces stress on pavement structures, contributing to longer service life and reduced maintenance cycles.

Yes. Stalite can be placed using conventional paving, chip seal, and surface treatment equipment. No special handling, installation methods, or equipment modifications are required.

Stalite has a naturally darker color that blends seamlessly with conventional asphalt. This produces a uniform surface appearance and often eliminates the need for a blotting seal layer while maintaining excellent performance.