HOW DO YOU MAKE A

better brick?

calstarproducts.com

PERFORMANCEGrade FBX

Weather SW

Compressive Strength 7,000+ psi

Saturation Coefficient 0.50

Fire Resistance 1 hour

ASTM C1790-14 Standard Specification for Fly Ash Facing Brick is now available.

INNOVATING TO BUILD A better world

HOW DO YOU MAKE A BETTER BRICK?The production of clay bricks has remained essentially the same for thousands of years. Bricks are fired to 2,000°F for up to four days in kilns that operate around the clock for months at a time. As a result, each clay brick you see is responsible for emitting almost a pound of CO2 and consuming more than 6,000 BTUs of energy. In a typicalyear, U.S. brick kilns can generate as much CO2 as over half a million cars and use about as much energy as the households of 1 million people.

Make it sustainable.CalStar has developed a patented formula and manufacturing process to make a better and more sustainable brick. With no firing and no Portland cement, CalStar’s process consumes 81% less energy and releases 84% less CO2. Plus, we use 37% post-industrial recycled material that would otherwise wind up in a landfill.

Make it economical.CalStar proves that sustainability doesn’t need to be more expensive. By replacing mined clay with recycled by-products and reducing manufacturing energy, we take cost out of the equation; the same innovations that make our products sustainable also make them affordable.

And make it perform.Of course, we’ve retained all the features that everyone loves about brick. CalStar’s brick durability, low maintenance, and in-wall performance are comparable to clay brick. Many masons can’t tell the difference; it handles and installs the same. Additionally, the warm, rich appearance is suited to a wide range of building styles, from traditional to ultra-modern.

“We advocated for this product because of what CalStar does, its mission, and the bricks’ aesthetic and environmental attributes.”

– Jorge Riano, GreenBy3

CalStar creates Green jobs in four facilities across the U.S.

Clay (BEES Online)

6251

1203

EMBODIED ENERGY Clay

Manufacturing electricity 552 1151

Manufacturing gas 465 4844Raw material extraction/ transportation

186 256

Total (BTUs) 1203 6251

{81% Savings}

CARBON FOOTPRINT Clay

Manufacturing electricity 0.10 0.15

Manufacturing gas 0.02 0.62Raw material extraction/transportation

0.01 0.04

Total (lbs.) 0.13 0.81

{84% Savings}Clay

(BEES Online)

0.81

0.13

INNOVATING TO BUILD A better worldHow do we stack up?CalStar brick is installed the same way clay brick is. The big differences in the life cycles of CalStar and clay brick result from differences in raw material extraction and manufacturing phases (known as the “Cradle-to-Gate” life cycle). Below is a Cradle-to-Gate comparison of CalStar and the average fired clay brick of the same size.

“CalStar has created a beautiful, sustainable alternative to an age-old, energy-intensive product.”

– Justin Zahner, Architect

Modular 3 5/8” x 2 1/4” x 7 5/8”

Utility 3 5/8” x 3 5/8” x 11 5/8”

King 2 3/4” x 2 5/8” x 9 5/8”

Roman 3 5/8” x 1 5/8” x 11 5/8”

SHAPES AND DIMENSIONS

Monarch 3 5/8” x 3 5/8” x 15 5/8”

Engineer 3 5/8” x 2 3/4” x 7 5/8”

Royale 90mm x 79mm x 257mm

Norman 3 5/8” x 2 1/4” x 11 5/8”

Ambassador 3 5/8” x 2 1/4” x 15 5/8”

PAVERSHolland, 4” x 8” x 60mmPermeable, 5” x 10” x 80mm12” x 12” x 60mm

STRUCTURAL UNITS8” X 4” X 16”12” X 4” X 16”8” X 8” X 16”12” x 8” x 16”

ARCHITECTURAL MASONRY VENEER4” x 8” x 16”4” x 4” x 24”4” X 8” X 24”4” x 12” x 24”

81% less energy 84% less CO2 37% recycled content

Walgreens Evanston, IL -- the nation’s first “Net Zero Energy” retail space, featuring CalStar.

Don’t take our word for it. CalStar worked with leading architectural firm Perkins+Will to perform an ISO-compliant life cycle assessment (LCA) for brick. We’ve had our CalStar LCA results third-party verified and published our findings in the first environmental product declaration (EPD) for brick. The CalStar EPD outlines 13 different environmental impacts over the entire life cycle of our product, from raw material extraction through end-of-life.

CalStar brick has achieved SMaRT© Sustainable Platinum rating. Sustainable Materials Rating Technology (SMaRT) is the world’s leading sustainable product standard and is approved for credit by the US Green Building Council’s LEED program globally and the Canada Green Building Council.

What else can we make better?

Headquarters: 105 South Mangum Street, Durham, NC 27701Plant #1: 2825 4 Mile Road, Racine, WI 53404 Plant #2: 340 Charleigh D. Ford Junior Drive, Columbus, MS 39701Research Labs: Silicon Valley

877.700.9501 calstarproducts.com