AES helped Aero Aggregates bring a foam glass aggregate manufacturing facility to life by combining front-end engineering, project management, conveyor systems, glass handling equipment, fabrication, installation, utility coordination, startup, commissioning, and training into one integrated project.
Overview
Aero Aggregates created a process to turn municipal recycled glass into foam glass aggregate, a lightweight, porous material used in road construction, agriculture, and other applications.
AES was selected to lead front-end engineering design and project management, then expanded its role to include system installation, supplementary system design, fabrication, heavy power coordination, gas utility installation, commissioning, and training.
What problem did AES solve?
AES helped Aero Aggregates transform a facility concept into a working foam glass aggregate manufacturing operation. The project required front-end engineering, project management, conveyor systems, glass unloading and cleaning systems, powdered glass feeding, bulk storage, fabrication, mechanical and electrical installation, gas utility installation, startup, commissioning, and training.
Scope of Work
- FEED & Project Management
- System Design
- Conveyor Systems
- Bag Unloading System
- Rigging & Millwrighting
- Electrical Installation
- Powdered Glass Feed System
- Welding & Fabrication
- Gas Main Installation
- Start-Up, Commissioning & Training
- Mechanical Installation
The Challenge
Aero Aggregates had a vision to create a manufacturing facility that could process recycled glass cullet into lightweight foam glass aggregate. The project required more than individual equipment purchases; it needed coordinated engineering, material handling, utilities, fabrication, installation, and startup support.
Because the facility was built around a specialized recycled glass manufacturing process, AES had to help connect multiple systems into one reliable production environment. This included glass handling, conveying, feeding, storage, structural support, utility coordination, and integration with key production equipment.
The main challenges we had to address:
- Municipal recycled glass had to be converted into a consistent manufacturing feedstock.
- Conveyor systems had to move glass material through the production process.
- Supplementary systems were needed for glass unloading, cleaning, and bulk storage.
- Powdered glass feeding had to integrate with the broader production process.
- AES had to coordinate with Aero Aggregates and European furnace and kiln suppliers.
AES needed to provide a complete turnkey system that combined equipment selection, controls, installation, structural steel, startup, commissioning, and training into one coordinated project.
The AES Solution
AES led the front-end engineering design and project management needed to help move Aero Aggregates’ foam glass aggregate facility from concept to operation. The project included conveyor systems, glass handling equipment, powdered glass feeding, bulk storage, fabrication, and utility coordination.
As the project developed, AES also provided installation of system components, supplementary system design, silo and support structure fabrication, heavy power coordination, gas utility installation, mechanical installation, electrical installation, startup, commissioning, and training.
AES System Components
The foam glass aggregate manufacturing facility included:
- Conveyor systems
- Bag unloading system
- Powdered glass feed system
- Glass unloading system
- Glass cleaning system
- Bulk storage systems
- Fabricated silos
- Structural support steel
- Gas main installation
- Integrated mechanical and electrical systems
The completed system gave Aero Aggregates the material handling, feed, storage, and utility infrastructure needed to support foam glass aggregate production from recycled glass cullet.
By combining engineering, project management, fabrication, installation, commissioning, and training, AES helped turn a facility concept into a working manufacturing operation.
The Results
With the completed foam glass aggregate manufacturing facility in place, Aero Aggregates gained the process infrastructure needed to turn municipal recycled glass into a valuable lightweight aggregate product.
The project was successfully commissioned in May 2017, giving Aero Aggregates a working production facility supported by AES engineering, project management, fabrication, installation, utility coordination, startup, and training.
Download the Full Case Study
See how AES helped Aero Aggregates build a foam glass aggregate manufacturing facility with front-end engineering design, conveyor systems, glass handling equipment, fabrication, installation, commissioning, and training.
A Turnkey Manufacturing Facility Built Around Recycled Glass
This project shows how a properly engineered material handling and manufacturing system can turn a difficult waste stream into a valuable finished product. For Aero Aggregates, AES helped connect recycled glass handling, feeding, storage, utilities, fabrication, installation, and commissioning into one coordinated facility project.
For recycling operations, aggregate producers, building materials manufacturers, and industrial facilities handling recycled feedstock, AES designs custom systems around the production process, facility layout, material characteristics, and long-term operating goals.
Frequently Asked Questions
Foam glass aggregate is a lightweight, porous aggregate made from recycled glass cullet. It can be used in road construction, agriculture, and other applications.
Aero Aggregates needed engineering, project management, system design, fabrication, installation, utility coordination, startup, commissioning, and training support to help bring its foam glass aggregate facility into operation.
The project included conveyor systems, a bag unloading system, powdered glass feed system, glass unloading and cleaning systems, bulk storage, fabricated silos, support structures, gas main installation, and integrated mechanical and electrical systems.
AES led front-end engineering design and project management, then expanded its role to include installation, supplementary system design, fabrication, utilities coordination, commissioning, and training.
Yes. AES designs and installs custom material handling, conveying, storage, feeding, and processing support systems for recycling operations and industrial manufacturing facilities.
