Sustainable communities - information & resources

Fly Ash Brick

CalStar Products Inc. uses advanced technology to make architectural-facing bricks for the green-building market. Instead of mining virgin clay and firing it, CalStar reclaims fly ash, a byproduct of burning coal, and converts it to a strong, beautiful building material. The products contain 40 percent postindustrial recycled material, use 90 percent less energy to make and generate 90 percent less carbon dioxide than traditional-fired clay bricks. View CalStar’s director of product development discuss sustainability, technology and reinventing the brick.

Highlights

  • Available in modular (3 5/8 by 2 1/4 by 7 5/8 inches) and utility (3 5/8 by 3 5/8 by 11 5/8 inches) sizes.
  • Bricks come in seven colors.
  • Price competitive with traditional products of equivalent quality.
  • ASTM C 618 Class C fly ash, aggregates, mineral-oxide pigments and proprietary ingredients are mixed with water, vibro-compacted and cured into a stable
  • cementitious solid.


Approval, Certifications, Patents

  • ASTM C216 Grade SW, Severe Weathering, suitable for face brick in severe and freeze-thaw conditions
  • ASTM C 216 Type FBX, Dimensional Tolerance
  • CSA A82, Fired Masonry Brick Made from Clay or Shale
  • ASTM C67, Not Effloresced

Contact

CalStar Products Inc.
calstarproducts.com
(510) 793-9500


 

Comments:

The fly ash that Calstar uses for making bricks is loaded with toxic metals - data from EPA’s Toxics Release Inventory for Oak Creek shows that it produces about 114,000 short tons of fly ash annually and the fly ash contains the following toxics: Arsenic: 6,657 pounds Barium: 214,501 pounds Chromium: 18,000 pounds Copper: 20,000 pounds Lead: 4,600 pounds Manganese: 13,000 pounds Nickel: 9,000 pounds Thallium: 10,000 pounds Vanadium: 4,750 pounds Zinc: 6,900 pounds The total amount of toxics contained in Oak Creek’s annual production of fly ash is over 300,000 pounds. JUST ONE FLY ASH BRICK (5 lbs) CONTAINS OVER 3 GRAMS OF HIGHLY TOXIC METALS

Posted by: bkwaas | May 24, 2010 2:28 AM

The leaching of toxic metals from Calstar's fly ash bricks has been confirmed. The data is at: http://calstarproducts.com/resources/gradient-memorandum/ As suspected, fly ash bricks leach toxic metals – the data shows that even with EPAs very liberal leaching tests, metals including arsenic, antimony, beryllium, cadmium, lead, manganese, mercury and nickel rapidly leach from the bricks within just a few hours. The results show that in the case of Arsenic (a listed Carcinogen) –a staggering 800 ug of Arsenic will leach from one brick in one month – or almost 10 mg of arsenic per brick per year. This is enough arsenic to poison over 250 gallons of water. One brick. How about the toxic ****tail of other metals that leach from Calstar’s bricks – beryllium, cadmium, copper, lead, manganese, mercury, nickel and thallium? Over 2 grams of toxic metals will leach from one brick, with the potential to poison over 1,000 GALLONS of water. One brick. Calstar - the toxic brick company.

Posted by: bkwaas | May 24, 2010 2:34 AM

Eye-opening quotes from Calstar: http://www.agrion.org/first_mover_advantage/agrion-en-Fly_Ash_Brick_putting_smokestack_residue_to_use_.htm Calstar's product Manager Julie Rapoport concedes that Calstar’s fly ash bricks product “is a prototype product and has not been field-tested over an extended period”. So, how exactly is Calstar asserting that their product is “Green” and “Eco-firendly” when it is a “Prototype” that has not even been field-tested? How is it that Calstar asserts that its fly ash bricks exceed clay brick specifications when they have not been field-tested? So, why is this untested “prototype” being sold to consumers? Calstar needs guinea pigs to test out its toxic bricks?

Posted by: bkwaas | May 24, 2010 2:38 AM

Where is Calstar’s Product Warranty for their fly ash bricks? Calstar is claiming a “brick” product that is better than clay brick, so it must have a better warranty? Clay bricks have lifetime or 100 year warranties. So where is Calstar’s warranty? No sign of it anywhere. No mention of a warranty or any sort of product guarantee. Maybe there is no warranty because, in the words of Calstar’s Product Manager – Julie Rapoport, their brick is a “a prototype product that has not been field tested over an extended period” (this from (http://calstarproducts.com/wp-content/themes/default/pdf/ConstructionSpecifier_0809.pdf). Since Calstar just started production in February, I guess that Rapoport’s idea of “extended period” is anything over one month. So no product warranty for Calstar’s “Green” and “Eco-friendly” fly ash bricks? Can Calstar provide any sort of warranty for their product? A warranty that it will not fade, flake, effloresce.? A warranty that it will not leach toxic metals? A warranty that it will not poison people or the environment? A warranty that it will not crumble into dust after the first frost? Any warranty? Anything? 10 years? 1 year? No warranty from Calstar? So what does the builder do? What does the homeowner do? Oh, of course, there is no warranty for a experimental “prototype product”! Use Calstar’s fly ash bricks at your own risk! No implied product warranty! Here is a question for Calstar’s Product Manager – Julie Rapoport. Where is the product warranty to back up all of your unproven performance claims for your “prototype” product? And the response from Calstar's Product Manager – to quote: “100-year warranty? Haven’t you read? The world is coming to an end in 2012?. Calstar – the Greenwash Brick company.

Posted by: bkwaas | May 24, 2010 2:40 AM

The EPA is considering regulating fly ash. http://www.google.com/hostednews/ap/article/ALeqM5j8ybrc97riF29IcqTGOVAWufvhKgD9FG9J880 It looks likely that the EPA will opt for regulating fly ash as a “special waste”, under Sub****le C (hazardous waste) of RCRA.

Posted by: bkwaas | May 24, 2010 2:48 AM

The defection of top management from Calstar continues. Jim Greer, the VP of Finance has left Calstar. This follows the departure of the Director of Research, the CEO, and the Director of Marketing. More evidence that Calstar is a Greenwash.

Posted by: bkwaas | February 3, 2011 11:43 AM

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