CalStar Publishes EPD for Fly Ash Brick

CalStar Products makes brick with a proprietary manufacturing process and a binder of fly ash.  By using fly ash, the company diverts waste from the landfill (37% recycled content) and eliminates energy-intensive firing — these bricks are cured overnight at temperatures below 200° F, according to CalStar.  To give the market comfort with their sustainability claims, CalStar obtained a lifecycle analysis (LCA) from Perkins + Will and published the results in an Environmental Product Declaration (EPD).

It turns out cradle-to-gate (raw material extraction/transportation and manufacturing) CO2 emissions for a single CalStar brick is 0.13 pounds, compared to 0.81 for a single clay brick.  Cradle-to-gate embodied energy is 1,203 BTU of energy for the CalStar brick versus 6,251 BTU of energy for a traditional clay-fired brick.

In other words, that’s 81% less manufacturing energy and an 84% smaller carbon footprint delivered with the CalStar fly ash brick.  The CalStar brick is available in modular and utility sizing and a palette of earth tones.

Perkins + Will finished the LCA using data sets from GaBi 5.0 software, while the Institute for Market Transformation to Sustainability verified the EPD under the SMaRT Certified rating system, according to a CalStar press release.

[+] More about the LCA and EPD for CalStar bricks.

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  • Clint Borchard


    This product was featured at the 2012 Green build Expo, as I’m sure you are aware, and I agree, what a great product! Talk about a great way to reduce and reuse older building products that would just typically go into a landfill. This product should be utilized by anyone building a home that cares about sustainablity.

    I hope to see many other products enetering the market that incorporate these same type of principle. There is no reason why companies shouldn’t be required to implement at least a small percentage of their production with recycled materials. We all know there is enough out there that just goes to waste.

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  • Krenap

    Great! By using these products, we can stop soil erosion and reduce carbon emissions. Because, using fly ash products is eco-friendly.

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