By Chris Moretti
Crushed concrete is a byproduct of recycling when concrete from demolished infrastructure projects is processed. In the past, demolished concrete—often mixed with rebar, scrap metal, steel, trash, wood, and other debris—was typically sent to landfills, quickly filling available space and limiting landfill capacity for different waste. The process of recycling concrete, therefore, began as a way to reduce this burden. Large concrete chunks are broken down into smaller, more manageable pieces using impact crushers, jaw crushers, or cone crushers. These crushing plants are equipped with magnets to remove steel and other contaminants from the material. The result is a range of crushed concrete aggregates, which can be sold and used in commercial highway projects, residential developments, and industrial facilities. These recycled aggregates are distributed widely across the East Coast, West Coast, and Gulf Coast regions.
The Concrete Crushing Process
Where I work in the Dallas-Fort Worth area, we use impact crushers, which utilize a high-energy pulverization process. These machines feature a single shaft and a rotor with blowbars attached. A loader dumps the bulk concrete rubble into a hopper, feeding it into the crushing chamber. The rotor spins at a very high speed, not unlike a gigantic, very robust blender. Inside the chamber, the rapidly spinning rotor strikes the concrete with such force that the material essentially explodes apart.
This process takes place within a chamber that is protected by aprons, curtains, and components made from high-tensile, high-wear materials—parts specifically designed to withstand the intensity of the crushing action. Though the procedure is highly energetic and violent, it is fully contained within the machine, keeping personnel safe from the powerful forces at work inside the machine.
Construction Applications of Crushed Concrete
Crushed concrete is primarily used in highway construction, with the highway market being the largest consumer, particularly for infrastructure projects managed by the state-level Departments of Transportation in California, Texas, and Florida. Crushed concrete is also widely utilized by local municipalities and civil markets, mostly for road-building projects.
In addition to roads, crushed concrete plays a significant role in utility projects that often run alongside or beneath roadways. This includes applications such as utility backfill, embedment, and pavement base layers that support the highways and streets we use daily.
Crushed concrete is also in demand for commercial construction. For example, when new warehouses or data centers are built, crushed concrete is used to establish stable foundations. Before construction begins, crushed concrete and other aggregates are laid down to create a solid, dependable base for these buildings.
Technical Specifications and Industry Standards
Crushed concrete must meet specific technical specifications, with one of the most crucial being those set by the Texas Department of Transportation (TxDOT). TxDOT maintains a detailed specification handbook and construction standards. The most common product we sell, known as flex base, falls under TxDOT’s Item 247, which covers the general specification for flex base aggregate. Specifically, we produce a Type D Grade one or two flexible bases made from recycled materials.
There are two main types of flex base: type A and type D. Type A is made from quarried, natural rock—materials sourced directly from the earth. In contrast, type D, which we produce, is made entirely from recycled aggregate. Recycled aggregate is gaining popularity in the TxDOT market and is increasingly being adopted in large-scale applications.
These specifications also apply to high-performance infrastructure projects, including airports like DFW Airport and Love Field, which adhere to FAA standards. Many of these facilities now use recycled aggregates, and when properly produced and carefully monitored, recycled aggregate can perform as effectively as natural rock.
A key logistical advantage of meeting these specifications with recycled materials is their local production. This makes them more accessible than quarried rock, which often needs to be transported from distant locations. Local production not only reduces transportation costs but also enhances efficiency and sustainability.
Conclusion
We take tremendous pride in recycling concrete and producing high-quality materials for a wide and diverse customer base. Our customers come from all kinds of markets, and we are committed to meeting their needs with reliable, top-tier aggregate products.
Each of our facilities is staffed with dedicated individuals whose sole responsibility is to ensure that all steel, scrap metal, trash, and any other contaminants are completely removed from the material. This level of care is crucial to maintaining the integrity and performance of our recycled products, and we do not cut corners.
Quality is at the heart of what we do, and we back that up with an outstanding sales team. They have built strong relationships with our clients and are proactive in addressing any rare issues that may arise. If a problem ever comes up—which is seldom—the team acts quickly and effectively to resolve it.
We are also very proud of the people behind the operation. Our team is made up of unique, diverse personalities who bring dedication and excellence to the work every day. I’m genuinely proud to be part of this organization.
Author Bio
Chris Moretti is the Regional Production Manager for Arcosa Crushed Concrete in the Dallas–Fort Worth area, where he oversees operations across seven plants—including six concrete and asphalt recycling facilities and one cement-stabilized materials plant. With nearly two decades of experience in the construction materials industry, Chris began his career with Texas Industries before moving on to Martin Marietta. His expertise spans cement-stabilized products, both recycled and virgin aggregates and cement stabilization techniques. Known for his deep passion for the stabilized materials market, Chris joined Arcosa Crushed Concrete as a sales representative and was promoted to area operations manager within his first two years. He is currently spearheading a new venture in the Fort Worth area that brings cement-stabilized material to the Dallas-Fort Worth region.
