Headwaters has acquired the technology to manufacture a variety of concrete products without the use of portland cement. The technology uses fly ash as the cementitious binder.
The technology was previously owned by CalStar. No operating assets were acquired in the transaction. The acquisition provides Headwaters with the exclusive ability to produce a wide variety of concrete products using Class C fly ash. Headwaters will incorporate ash procured by Headwaters Construction Materials, the largest manager and marketer of fly ash in the United States.
Over the past decade, CalStar developed a unique technology to manufacture concrete products without the presence of portland cement. Traditionally, concrete block, pavers, and brick are manufactured using a mix design that includes sand, aggregates, water, and portland cement as the binder material.
The CalStar technology uses fly ash based binders rather than portland cement to manufacture a wide range of engineered building products. The CalStar based products allow architects and specifiers to reduce the energy and carbon footprints of their buildings, while meeting product classifications without compromising budgets. The technology uses proprietary reagents to activate the fly ash pozzolan into a durable cement. This process produces significant environmental benefits by incorporating up to 40% post-industrial content, and reducing the carbon footprint by approximately 80% versus portland cement based products.
The new products produced with the CalStar technology combine the benefits of recycled content and lower energy use, while maintaining traditional beauty and performance. Headwaters intends to market custom colored smooth, ground face, polished, split faced and textured masonry block in regular and oversized units to commercial and institutional projects.
For example, the new American University Law School in Washington DC features CalStar’s sustainable masonry products as its primary façade. Headwaters believes its products will be the most sustainable, environmentally friendly concrete product in the world. Importantly, the unique value associated with the products should allow Headwaters to take advantage of a shipping radius of more than 1,500 miles.
“The new CalStar technology, in conjunction with our eighteen at a time big board machine, should provide us with an opportunity to expand margins and supply the building community with a unique masonry product,” said Bob Whisnant, President of Headwaters Block Group. “We should have our big board machine ready for production towards the beginning of our summer season.”