CalStar Products started production on its pilot line last week, clearing the path to open its first factory for low-carbon bricks in Caledonia, Wis., in December.

The startup, which recently emerged from stealth, makes bricks using fly ash, a byproduct of coal-fired power plants. The company also developed a proprietary mix of standard industrial chemicals that reduces the energy intensity of the entire brick-making process.

Read the rest of “CalStar gives sneak peek of low-carbon brick factory” on cleantech.com

Some more input from CalStar on their pending entry into the building materials market. I had asked about who set the standards for what is a “brick.”

The answer from CalStar: “ASTM is not the gatekeeper for new products – national and local building codes are. As with any new building material, we need to start with the standards that are available for similar products, and then develop a suitable ASTM standard for fly ash brick in due course. Despite what the BIA may try to make people believe, there’s no particular magic here – the ASTM standards that test the suitability in real live applications for concrete products, clay bricks, and other masonry products are remarkably similar despite the fact they’re made of different raw materials.

Read the rest of “Brickbats over bricks” on zdnet.com

One California-based company is going to try. And they’re going to make those “green” bricks in Wisconsin, not ship them in from China.

The new-fangled brick has been pioneered by CalStar Products. A basic ingredient of the CalStar brick is coal ash, residue from burning coal. There are huge mounds, huge ponds, huge heaps of it all over coal-burning states in the U.S.

I recently spoke with CalStar’s CEO, Michael Kane, a veteran of decades in the building supply industry. As I’ve heard from innovators in wallboard and windows and other materials: the new, green product has to look and act and handle just like the energy-sucker it replaces.

Read the rest of “Could you green the world brick by brick?” on zdnet.com

A technological breakthrough may be about to help the humble brick play a small but significant part in helping to reduce greenhouse gas emissions.

The makers of a new “green brick” say that the chemical manufacturing process requires up to 90 per cent less energy and generates 90 per cent less CO2 than traditional bricks.

Read the rest of “Reinventing the humble brick to cut carbon emissions” on timesonline.co.uk

Most Silicon Valley investors and entrepreneurs are more comfortable talking about software algorithms and chips than bricks and concrete. But some of them are trying to reinvent the building industry with green tech.

Calstar Products later this year plans to open a factory to manufacture a brick that uses fly ash–the residue from burning coal at power plants–as an ingredient while drastically reducing the amount of energy used in production.

Read the rest of “Using coal residue to make a greener brick” on cnet.ncom

When you think of a chemical curing room inside of a factory, hot temperatures and noxious fumes probably come to mind.

Actually, it was sort of like a spa: A fine mist swirled through the air and the room was a few degrees cooler inside than out. A CalStar Products employee periodically came in with a fresh tray of the company’s bricks to set on a rack.

Industrial spa treatments like CalStar’s lay at the heart of the movement toward eliminating embedded energy in manufactured products. The company has devised a “green” brick that requires 85 percent less energy to produce than conventional clay bricks and consists of 40 percent fly ash, the waste emissions captured at coal-burning power plants.

Read the rest of “Inside the Green Brick House” on greentechmedia.com

Silicon Valley sees a profitable future in the humble brick thanks to a low-energy production process that illustrates the greening of the U.S. technology capital.

Brick maker Calstar Products is heavy on PhDs and backed by venture capitalists whose vision is to create buildings less expensively and in a way that saves energy.

Read the rest of “Silicon Valley reinvents the lowly brick” on Reuters.com

Press Release
Contact: Luke Pustejovsky, CalStar Products, Inc.
Ph. # 877-700-9501
E-mail: lukep@calstarproducts.com

Recognized as a major endorsement for the future of FAB (fly ash brick) masonry, seasoned brick sales executive Gene Guetzow has joined CalStar Products, Inc. as its U.S. National Sales Manager.

“I am thrilled to be part of the Green Revolution in masonry. The CalStar Products, Inc. team is extremely talented and passionate about fly ash brick—a brick with 1/10th the CO2 and energy of a fired clay brick. CalStar’s devotion to superior quality, green brick and paver products will help set benchmarks for the entire masonry industry”, said Gene.

Prior to joining CalStar Products, Inc., Gene was an Architectural Sales Manager for Arriscraft International, now a division of General Shale, one of the largest brick manufacturers in the U.S. Arriscraft’s “cement-free” calcium silicate masonry units achieved widespread recognition and success in the design communities, even if the product met initial skepticism from competitors. Eventually, the larger masonry market accepted Arriscraft’s innovative product and architects became educated on its benefits over traditional masonry.

Prior to joining Arriscraft, Gene was President and partner at Building Stone Products in Wisconsin, a distributor of Arriscraft products. Trained in Chicago, he spent the first 13 years of his career as a sales representative for the largest brick distribution firm in the U.S., Illinois Brick.

Gene Guetzow is a LEED® AP, AIA and ALA Professional Affiliate, a long-time CSI member and a Certified BIA Green Brick Specialist. Gene has extensive masonry experience covering a variety of masonry product types and correct installation methods required. With over 25 years of experience in the masonry industry, Gene has presented over 500 AIA accredited “lunch and learn” programs to architects and material specifications professionals.

“As we’re building out our dealer network, we’re speaking with many of the top sustainable design firms around the country about iconic projects incorporating brick. As we gear up for product launch in late 2009, we plan to have a number of demo installations in our target region—and are always interested in hearing about compelling green projects”, Gene added.