s 
 
 14. GS: 
 CIR a<to 
 
 c 5l 
 
 C^td\ &AJU3LM 
 
 STATE OF ILLINOIS 
 
 WILLIAM G. STRATTON, Governor 
 
 DEPARTMENT OF REGISTRATION AND EDUCATION 
 
 VERA M. BINKS, Director 
 
 Lightweight Aggregate 
 From Illinois Shales 
 
 W. Arthur White 
 
 DIVISION OF THE 
 
 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 JOHN C.FRYE, Chief URBANA 
 
 CIRCULAR 290 
 
 1960 
 
 ILLINOIS GEOLOGICAL 
 SURVEY LIBrtAHY 
 
 AHK Z{) | bDU 
 
IL L.NOIS STATE GEOLOGICAL SURVEY 
 
 3 3051 00004 1370 
 
Lightweight Aggregate 
 From Illinois Shales 
 
Digitized by the Internet Archive 
 
 in 2012 with funding from 
 
 University of Illinois Urbana-Champaign 
 
 http://archive.org/details/lightweightaggre290whit 
 
LIGHTWEIGHT AGGREGATE 
 FROM ILLINOIS SHALES 
 
 W. Arthur White 
 
 ABSTRACT 
 
 This investigation was made 1) to determine which shales 
 are self-bloating and which require the addition of bloating agents 
 and 2) to study the mechanism of bloating. Samples of shale rang- 
 ing in age from Ordovician to Pleistocene were collected from brick 
 and lightweight aggregate pits, strip coal mines, outcrops, and drill 
 cores . 
 
 The samples were crushed, screened, and analyzed chem- 
 ically and mineralogically . The coarse material was put in a cru- 
 cible and heated in a furnace at 2200° F(1200° C) for one hour, and 
 the apparent specific gravity was determined. 
 
 The optimum organic carbon content for self-bloating shales 
 was found to be between 0.3 and 1.0 percent. Too much carbon kept 
 the shale from bloating and too little prevented the desired bulk den- 
 sity from developing. Most of the nonbloating shales bloated after 
 the addition of 1 percent of fine coal. 
 
 Too much kaolinite and/or quartz make the material too re- 
 fractory for economic production of aggregate. Too much dolomite 
 and/or calcite cause too narrow a firing range. 
 
 Self-bloating shales probably could be made into lightweight 
 aggregate in both rotary and grate-type kilns. Shales that need 
 bloating agents added could be processed in a grate-type kiln in 
 which the fuel is mixed with the shale. 
 
 INTRODUCTION 
 
 Lightweight aggregate was patented as early as 1875, but its manufacture 
 from shale was advanced most significantly some forty years later when Stephen 
 Hayde built the first Haydite plant in Kansas City. The industry developed slowly 
 until the middle 1940 's, but since the end of World War II there has been increas- 
 ing interest in the uses of lightweight aggregate in the building industry. 
 
 Expanded or bloated clay and shale aggregates are being used more exten- 
 sively in load-bearing as well as nonload-bearing castings and forms. Most of 
 this material currently is being produced by either of two methods. 
 
 In one method a sintering machine is used, and the clay is ground and mix- 
 ed with either ground coal or ground petroleum coke, charged onto a traveling grate, 
 and sintered. When the coal or coke is fired the combustion of the fuel in the 
 clay produces enough heat and gas to bloat the clay mass. The advantage of the 
 sintering machine method is that a clay material can be bloated that could not be 
 bloated by the rotary kiln method. 
 
 The other method uses the rotary kiln and is suitable for bloating only those 
 clays and shales that can be expanded without the addition of a bloating agent. 
 
 [1] 
 
ILLINOIS STATE GEOLOGICAL SURVEY 
 
 KEY 
 
 ° Pleistocene deposits 
 
 3 Cretaceous and Tertiary 
 shales 
 
 • Pennsylvanian shales («°» 
 o Pre - Pennsylvanian shales 
 
 Fig. 1. Locations of shale deposits that were tested for lightweight aggregate. 
 
LIGHTWEIGHT AGGREGATE 3 
 
 The crushed or sized clay material is fed into an oil-, gas-, or coal-fired rotary 
 kiln where the material expands. The sinter may be produced as a large, porous, 
 fused mass that must be crushed and sized, as in the sintering machine proc- 
 ess, or it may be produced to a definite sized aggregate without crushing. The 
 advantage of the second method is that the clay material can be ground to size be- 
 fore firing, so that finished aggregate of definite size can be produced without 
 crushing and screening after firing. The aggregate produced to size during bloat- 
 ing has a skin developed around the lump giving it an outside surface similar to 
 that of gravel . 
 
 The objectives of this study are to determine the shale deposits in Illinois 
 that are self-bloating, those that require the addition of bloating agents, and the 
 mechanism and requirements that control the bloating of shales. 
 
 Several authors (Herold et al . , 1958; Ehlers, 1958; Austin etal., 1942; 
 Riley, 1951; Conley et al., 1948) have conducted investigations to determine the 
 compound or compounds present in naturally expanding shales and clays that are 
 responsible for the production of the gaseous phase that causes bloating. These 
 authors agree that the clay materials must reach a state of fusion during the time 
 of the gas production and need a sufficient amount of glass of the proper viscosity 
 to trap the gas. 
 
 At the present time, four plants in Illinois make lightweight aggregate from 
 Pennsylvanian shales and one makes it from a mixture of shale and loess. Two of 
 these plants use grate-type kilns; the others use rotary kilns. 
 
 SAMPLING PROCEDURE 
 
 Ninety 100-pound samples were taken from coal strip mines, shale pits of 
 brick and lightweight aggregate plants, and outcrops throughout the state (fig. 1). 
 The entire face was sampled whenever possible and the clay materials were tested 
 for the presence or absence of calcium carbonate or lime. 
 
 The clays and shales collected ranged in age from Ordovician through 
 Pleistocene, although the greatest number of samples was collected from shales of 
 Pennsylvanian age. Pennsylvanian strata crop out over a larger area of the state 
 and have a greater number of shale members than strata of any other period. All of 
 the coal mines are in Pennsylvanian deposits; three-fourths of the clay plants and 
 all of the lightweight aggregate plants use Pennsylvanian shale deposits for their 
 manufactured products. 
 
 TESTING PROCEDURE 
 
 A portion of each sample was ground in a jaw crusher. Upon experimenta- 
 tion, it was found that the lumps expanded more readily than the fine material, 
 hence the fine material was used for chemical analyses and clay mineral data and 
 the lumps were used for the bloating tests. 
 
 The clays and shales were fired in a Harpers electric furnace that was 
 heated by 8 globars elements, 3/4 x 37 inches with a central resistance length 
 of 20 inches. The lumps were placed in a crucible in an oven and heated over- 
 night to 230° F (110° C) . After the furnace was raised to the bloating tempera- 
 ture, the samples were placed in the hot furnace and heated to 2200° F (1200° C) 
 for 1 hpur in the oxidizing atmosphere. The furnace temperature would drop about 
 150° F (66° C) and would rise back to its original temperature in about 10 minutes. 
 
 The rapid method for firing was used in the laboratory because the author 
 felt that it would most nearly correspond to the rapid firing in the commercial 
 
4 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 plants. Riley (1951, p. 123) has indicated that the clays would bloat about 100° F 
 lower by the rapid firing method than by the slow firing method. 
 
 In order to determine the apparent specific gravity of the sample, the bloat- 
 ed samples were weighed, coated with paraffin, weighed again, and then immersed 
 in water. The volume of paraffin was calculated from its weight and specific grav- 
 ity and subtracted from the volume of the lump plus paraffin to obtain the volume of 
 the lump. By assuming that the specific gravity of water is 1, the apparent specific 
 gravity of the lump could be determined by the following equation: 
 
 weight 
 
 sp gr = f 2 — 
 
 volume 
 
 The weight per cubic foot can be calculated by the following equation where 
 water weighs 62.5 lbs per cubic foot: 
 
 6 2.5 x apparent sp gr of lump = weight per cubic foot 
 
 and weight per cubic yard can be calculated by: 
 
 weight per cubic foot x 27 = weight per cubic yard. 
 
 CLAY MINERAL DATA 
 
 The clay mineral data are reported by county (table 1). Kaolinite ranged 
 from to 5 parts in 10; chlorite, to 4; swelling chlorite, to 4; swelling illite, 
 to 4; illite, 2 to 7 parts in 10. 
 
 The swelling chlorite and swelling illite clay minerals are considered as 
 mixed-lattice clay minerals throughout this report. They have structural properties 
 similar to either chlorite or illite plus montmorillonite. 
 
 Kaolinite and halloysite are the most refractory of the clay minerals, but, 
 if not more than 30 to 40 percent is present, they evidently do not increase the 
 refractories above the ranges that are considered economical for bloating shales. 
 The other clay minerals are not considered to be refractory. A minor amount of 
 kaolinite may be desirable if the fluxing elements in the other clay minerals are 
 high and the free quartz is low. 
 
 The clay minerals other than kaolinite furnish most of the flux elements, 
 such as iron, magnesium, calcium, potassium, and sodium. The fluxing elements 
 are probably fairly evenly distributed throughout the clay minerals, thus giving a 
 somewhat more uniform viscosity throughout the mass than is given by calcite, 
 pyrite, or siderite nodules. There would be considerable fluxing action around 
 these nodules or particles, but it would not extend far from them. Therefore, the 
 clay minerals in the shales give the chemical composition that produces the vis- 
 cosity desirable in the production of lightweight aggregate. 
 
 CHEMICAL ANALYSES 
 The chemical analyses are reported by county (table 2). 
 
 Carbon 
 
 Carbon occurs in inorganic state as carbonate, and in organic state as 
 plant and animal remains. The organic matter may be detrital or of colloidal 
 origin. The detrital organic matter probably occurs as pieces of plant tissue among 
 the clay particles. The colloidal organic matter, probably adsorbed between the 
 clay mineral particles, can be either plant or animal in origin although most of it 
 is probably of plant origin. 
 
LIGHTWEIGHT AGGREGATE 5 
 
 The organic carbon ranges from almost none to about 6 percent in the shales 
 and clays used. The minimum amount of organic carbon appears to be about 0.4 
 percent in an oxidizing atmosphere, whereas the maximum would probably not be 
 much above 2 percent for well laminated shales. 
 
 Bloating tests indicate that there can be either too much or too little carbon. 
 Cores of black shale were placed in the kiln at 2200° and 2400° F (1204° and 
 1316° C, respectively) for 1 hour each but did not bloat at either temperature. While 
 organic matter was being distilled out of the core, it burned as a flame at the core 
 surface. The fact that the core could be split into its individual shale layers sug- 
 gests that the distillation process adsorbed so much heat that the core remained 
 well below the vitrification temperature. A thin surface of glass (about 1/8-inch 
 thick) had formed around the core. 
 
 Another piece of the core was placed in a crucible in the kiln at room tem- 
 perature and brought up to 2012° F or 1100° C in 19 hours, allowed to cool to room 
 temperature, and again placed in the kiln at 2200° F or 1204° C and heated for 1 
 hour. The top part of the core, which had oxidized most, bloated, but the lower 
 part of the core did not, retaining its shaly structure inside a fused skin. A 
 piece of this core was placed in a cold kiln and heated at the following rates: at 
 300° F for 6 hours; from 300° F to 1200° F in 6 hours; from 1200° F to 1600° F in 
 11 hours; from 1600° F to 1800° F in Sj hours; from 1800° F to 2175° F in 4j hours, 
 and at 2175° F for 1 hour. This core of black shale bloated, making a good strong 
 aggregate (pi. 1, A and B), suggesting that in rotary kiln operation too much organ- 
 ic matter can be as detrimental as not enough. 
 
 Some shales may bloat more than others, even though they contain less 
 organic matter. It appears that shale which has the organic matter adsorbed on the 
 clay minerals would bloat more uniformly than shale which has the organic matter 
 incorporated as detrital pieces. Another factor may be the degree of orientation of 
 the clay minerals. If the clay minerals are oriented parallel to each other they 
 would have less pore space and be less permeable than the less well oriented clay 
 minerals with more porosity and larger, more permeable voids that allow the oxy- 
 gen to enter more readily to oxidize the organic matter. 
 
 Silica 
 
 Silica may occur as quartz or in the lattices of the clay minerals and other 
 silicate minerals. In this study, silica ranged from 48.38 to 71.39 percent. 
 
 Alumina 
 
 Alumina occurs in the lattices of the clay minerals and other silicate min- 
 erals and ranged from 13.73 to 24.81 percent in this study. 
 
 Iron 
 
 In the shales used, iron occurs in both the ferrous and ferric states. Iron 
 may occur in the lattices of clay minerals and other silicate minerals. It also 
 occurs in pyrite, limonite, hematite, and other iron-containing minerals such as 
 siderite, ankerite, ilmenite, and magnetite. Iron as Fe O and FeO ranged from 
 1.55 to 12.75 percent and may be the source of oxygen in the bloating of shales. 
 
ILLINOIS STATE GEOLOGICAL SURVEY 
 
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10 
 
 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 According to the following equations showing the oxidation and reduction of 
 iron in the illite lattice, it may be possible to bloat shales in either an oxidizing 
 or reducing atmosphere because oxygen is liberated from the clay by the reduction 
 of the iron. We might speculate on what occurs inside the clay lattice. Because 
 most of the clays are dioctahedral in shales of Illinois, we will use a dioctahe- 
 dral illite for speculation. The iron in the dioctahedral chloritic and mixed-lattice 
 clay minerals would probably oxidize and reduce in the same manner as that in 
 illite. 
 
 K 8°4 
 
 K 8°4 
 
 Al.. Fe +3 1A (0^ 
 16-x x 16 
 
 A1 1C Fe +3 o/1 ' 
 16-x x 24 
 
 DH).J 
 
 [ Si 24 M 8°6o] 
 
 A 
 
 16J 
 
 550° C 
 
 Si 24 M 8°60] + 
 
 8H 2 
 
 1200+° C reducing atmosphere 
 
 (1) 
 
 complete reduction of iron 
 
 K q oJaI 1c Fe +2 o/1 
 8 4 16-x x 24 
 
 -lx][ Sl 24 A1 8 O 60; 
 
 or partial reduction of iron 
 
 °^x 
 
 2 X 
 
 K 8°4 
 
 Al. r Fe +3 Fe +2 O/1 , l[si Al O cn 
 16-x x-y y 24-^yJL 24 8 60, 
 
 o 1 
 
 Then if we assume that ferrous iron has partially replaced aluminum 
 
 (2) 
 
 (3) 
 
 K 8°4 
 
 A1 1C Fe +2 1C (OH) 1c 
 16-x x 16-x 16+xJ 
 
 S1 24 A1 8 O 60 
 
 A 
 
 550+° C 
 
 K 8°4 
 
 Al, c F e +3 J[Si ,Al O cn 
 16-x x 24 24 8 60 
 
 H 
 
 8H 2 
 
 (4) 
 
 1200+ ° C reducing atmosphere 
 
 (same as equation 2 or 3) 
 
 Then if we assume that aluminum is partially replaced by both ferrous and ferric 
 iron 
 
 K 8°4 
 
 A1 1C / Je +3 
 16-(x+y) x 
 
 Fe +2 lc (OH). c 
 y 16-y 16+y 
 
 Si 24 A1 2 O 60 
 
 A 
 
 550° C 
 
 K 8°4 
 
 Al F +3 ' 
 
 16-(x+y) x+y 
 
 O 24 Si 24 M 8°60 
 
 H 
 
 8H 2 
 
 (5) 
 
 1200+ ° C reducing atmosphere in bloating shale 
 (same as equation 2 or 3) 
 
LIGHTWEIGHT AGGREGATE 
 
 11 
 
 Then if we assume that aluminum is partially replaced by ferrous and ferric iron and 
 magnesium 
 
 K 8°4 
 
 Al, r , ,Fe +3 Fe +2 Mg o lc , ,(OH) lc , ' 
 
 16-(x+y+z) x y ^2 16-(y+z) 16+(y+z) 
 
 Si 24 Ai 8°60 
 
 A 
 
 550+ °C 
 
 + 3 
 
 rK o 0jAl lc , ,FeT° ,Mg . i |Si Al O cn + H + (8 + \z) H„0 
 
 L 8 4JL 16-(x+y+z) (x+y) y z 24-§z_||_ 24 8 60j y z 2 
 
 1300° C atmosphere reducing in shale 
 
 (6) 
 
 complete reduction of iron 
 
 K 8°4 
 
 Al 
 
 Te* 2 ,Mg O 
 
 16-(x+y + z) re (x+ y r y z w 24i(x+y + z)r 24^8^60 T w |(x + y + z) 
 
 ¥■■ 
 
 .Al-O-J + Oi 
 
 or partial reduction of iron 
 
 (7) 
 
 K 8°4 
 
 + 3 +2 
 
 Al, c / N Fe, .Fe Mg O ni ,, . 
 
 16-(x+y+z) (x+y-a) a z 24-^(a+z) 
 
 Si 24 M 8°60 
 
 i(a+z) 
 
 (8) 
 
 In the clay minerals, oxidation or reduction is possible without outside 
 oxygen. Barnes (1930) has found that hydrogen is liberated from hornblende if 
 heated above 800° C. The iron in hornblende is oxidized from the ferrous to the 
 ferric state by the oxygen of the hydroxyl group and at the same time hydrogen is 
 liberated. Because this reaction takes place in hornblende, it probably also takes 
 place in the closely related mica-type clay minerals. 
 
 The minerals limonite and hematite probably also would behave as the iron 
 in equations 1, 2, and 3. 
 
 Pyrite and marcasite have the same chemical composition but have different 
 crystalline structures. (Both are considered as pyrite in this paper.) Pyrite is quite 
 common in unweathered shales. When pyrite is heated the first sulfur is driven off 
 at 665° C; when marcasite is heated the sulfur is removed at 450° C. 
 
 2FeS _i^ 2FeS + 2S inert atmosphere 
 
 2FeS -=** 2FeS + 2SO 
 2 1 
 
 a|o 
 
 t A 
 
 2FeO 
 
 0- Fe 2°3 
 
 (9) 
 
 (10) 
 
 Both pyrite and marcasite require the addition of oxygen from the outside. 
 
 Siderite is another iron mineral which can contribute to the bloating of 
 shale. Rowland and Jonas (1949, p. 55 2) showed that in the presence of air sid- 
 erite began to decompose near 425° C. The iron oxidized immediately or as soon 
 as the oxygen could reach it after the CO was driven off, but in an inert atmos- 
 phere the iron did not oxidize. 
 
12 
 
 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 The reaction would be as follows: 
 
 xFeCO, 
 
 oxygen 
 1200+° C 
 
 =rxFe„0„ + xCO, 
 
 A 
 
 xFe0 + d or 
 2 ox 
 
 Fe +3 Fe +2 0ll L ' 
 x-y y l£x-fy 
 
 + O, 
 
 2Y 
 
 In reducing atmosphere 
 
 FeCO — FeO + CO 
 •1 2 
 
 From the above equations, it appears that the iron in the clay lattices 
 might be oxidized without the addition of oxygen from the atmosphere by splitting 
 off the hydrogen atoms from the hydroxyl groups. At higher temperatures, the oxy- 
 gen might be removed by reduction of part of the iron. 
 
 Hematite and limonite are already in the ferric state, hence do not require 
 oxidation. When they are partially reduced at higher temperatures, oxygen is 
 liberated. 
 
 Because the iron in pyrite and siderite is in the ferrous state, it must be 
 oxidized before it can contribute oxygen at the bloating temperature. In order to 
 oxidize the iron from the ferrous to the ferric state, oxygen must be introduced 
 before the shale has reached the bloating temperature. If this is not accomplished, 
 the iron from pyrite and siderite probably helps only as a fluxing agent close to 
 the pyrite and siderite particles. 
 
 Alkaline Earths 
 
 Calcium occurs as an exchange cation for the clay minerals and also is 
 present in calciam, gypsum, dolomite, and many of the silicate minerals such as 
 amphibole, pyroxenes, garnets, and plagioclases. 
 
 Magnesium, on the other hand, occurs as exchangeable cations for the 
 clay minerals as well as in their lattices. Magnesium occurs in dolomite and 
 ankerite and in many silicate minerals found in shales, such as amphiboles, py- 
 roxenes, olivines, spinels, micas, and chlorites . 
 
 In the shales studied, the calcium ranged from 0.05 to 6.75 percent 
 and averaged 0.60 percent The magnesium ranged from 1.02 to 4.92 percent 
 and averaged about 2.15 percent. Seventy-five of the shales averaged only 
 0.41 CaO and three averaged 5.45 percent. In the good bloating shales, the total 
 for CaO and MgO is less than 4 percent. If the total is above 6.0 percent, as for 
 samples 1424, 1331B,and 1321A, the fluxing action is too great and the bloating 
 range is too narrow. Research by Everhart et al. (1958, p. 39) suggests that cal- 
 cium adds strength to the glass formed in the aggregate. 
 
 Alkalies 
 
 Sodium probably occurs as exchangeable cations on the clay — in the lattices 
 of micas, feldspars, and other silicate minerals. Much of the sodium probably 
 occurs as sodium chloride in the shale. Potassium occurs as exchangeable cations 
 on the clay minerals — on the lattices of illite, in mixed-lattice clay minerals of the 
 illite type, in micas, and in feldspars. 
 
LIGHTWEIGHT AGGREGATE 13 
 
 Sodium ranged from 0.02 to 1.50 percent and potassium from 1.29 to 5.88 
 percent in the study. The total alkalies ranged from 1.56 to 6.12 percent. 
 
 Loss on Ignition 
 
 The loss on ignition includes all the materials that escape as gas, such as 
 CO2, H2O, H2S, and sulfur oxides. The ignition loss ranges from 3.67 to 12.34 
 percent. Most of the self-bloating shales have ignition losses greater than 6 per- 
 cent. However, some of the self-bloating shales have ignition losses less than 
 6 percent whereas some of the poor bloating shales have ignition losses greater 
 than 6 percent. 
 
 MECHANISM OF BLOATING 
 
 Riley (1951, p. 123) states: 
 
 Two conditions must be fulfilled before bloating can take place during the 
 firing of a clay. Enough of the material must fuse to fill the pore spaces so that 
 gases being formed will be trapped. The fused material must, of course, be vis- 
 cous enough so that the gas does not escape by bubbling through it. The second 
 condition is that some mineral, or combination of minerals, must be present that 
 will dissociate and liberate a gas at the time when the mass of clay has fused to 
 a viscous melt. 
 
 Riley (1951, p. 123) gives a composition diagram of the major oxides show- 
 ing the area in which the clays fire to a mass viscous enough to insure good bloat- 
 ing. Figure 2 is a composition diagram of the clay materials used in this study 
 with Riley's area superimposed (solid line). Compositions of some of the good 
 bloating shales used in this study fell outside of Riley's bloating area and are 
 enclosed by a dashed line in figure 2. 
 
 Riley (1951, p. 126-8), Austin et al . (1942, p. 149-60), Planje (1958) and 
 Ehlers (1958, p. 98) have discussed the role that gases from various sources 
 might contribute to the bloating of shales and clays. All rule out the crystalline 
 (OH) water from the clay lattice and most rule out CO2 from various carbonates 
 (calcite, dolomite, and siderite), but Ehlers (1958, p. 98) attributes the bloating 
 to the CO2 from the decomposition of calcite. He says that the outside surface 
 of the shale or clay reaches a temperature high enough to make it viscous by the 
 time the temperature inside is high enough to decompose the calcium carbonate. 
 Sullivan et al. (1942, p. 139), however, obtained a good bloat on a clay for which 
 the CO2 content was recorded as nil, but the sample contained 0.3 percent of 
 carbon other than in carbonates. Planje (1958) believes that most of the bloating 
 is due to oxidation of organic carbon. 
 
 The chemical analyses of two shale samples, 1354A and 1338B, indicate 
 they do not have enough inorganic carbonates to be detected, but they are good 
 bldating shales. Sample 1354A has an organic carbon content of 1 percent and a 
 density of 42 pounds per cubic foot; 1338B has an organic carbon content of 0.41 
 percent and a density of 51 pounds per cubic foot. 
 
 Samples 1331B and 1308E each contained 5.31 percent of C0 2 - In sample 
 1331B most of the CO2 is probably due to calcite, inasmuch as the CaO content is 
 6.75 percent, whereas in 1308E it occurs as about one-fourth calcite and about 
 three-fourths siderite with some magnesium substituting for calcium and iron to 
 fill the requirements for CO2 content. Neither of these samples was a good bloat- 
 er and both had low organic contents--1331B contained 0.22 percent and 1308E 
 contained 0.08 percent. Sample 133 IB had a density of 59 pounds per cubic foot, 
 and 1308 E bloated very little if at all. 
 
14 
 
 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 SiO 
 
 KEY 
 
 Riley's composition of 
 good bloating cloys 
 
 Extension of Riley's 
 composition diogrom 
 as shown by this study 
 
 Al o 
 
 2 3 45 40 35 30 25 20 
 
 10 5 
 
 Fe 2 3 , FeO, 
 CaO, MgO, 
 Na 9 0, K,0 
 
 Fig. 2. Chemical composition of shales. 
 
 The work by Grim and Johns (1951, p. 71) on firing of brick suggests that 
 when an endothermic reaction is taking place the temperature of the brick remains 
 at the decomposition temperature until the reaction is completed. This suggests 
 that the crystal water and carbonates would tend to hold the temperature constant 
 until the reactions are completed. They also found, by analyzing for organic carbon 
 and sulfur at different stages and heating rates during the firing cycle, that the 
 organic matter and sulfur from pyrite oxidized slowly. 
 
 The work by Austin et al. (1942, p. 154) indicates that most of the C0 2 
 and water in their samples A and B had been driven off by the time the temperature 
 reached 2000° F,as is the case in sample C. The carbon which remains above 
 2000° F is most likely organic carbon. The CO2 and water remaining above 2000° F 
 is probably from the oxidation of organic matter. 
 
 In my study the poorly laminated shales and clays did not bloat as well as 
 the well laminated shales. Some cores of shale were placed in the kiln and heated 
 to the bloating temperature. The shales bloated perpendicular to the bedding (pi. 1). 
 Some of the shales were ground and extruded as brick. If the shales were extruded 
 so that the clay minerals were oriented parallel to the sides of the die, the sample 
 bloated perpendicular to the sides of the brick (pi. 2, A, B) . If the sample was ex- 
 truded so that the clay flowed as cones, the sample bloated in all directions 
 (pi. 2, C, D). 
 
LIGHTWEIGHT AGGREGATE 15 
 
 X-ray data from other work in my laboratories indicate that the clay minerals 
 in well laminated shales are parallel to the bedding, but that in clay and poorly 
 laminated shales, the particles have a random orientation that creates considerably 
 greater porosity and permeability than the parallel orientation. The regular bloat- 
 ing of some of the cores would suggest that the organic matter is adsorbed on the 
 clay mineral surfaces. The lack of bloating of certain thin layers in the core 
 (pi. 1, D) indicates the absence of a gas-forming material. A layer on one side 
 of the core may not be bloated whereas on the other side it can be bloated. 
 
 Due to the greater porosity and permeability, the clays and poorly laminated 
 shales would probably require more organic carbon for bloating than well laminated 
 shales. During the firing, oxygen could penetrate the clays and poorly laminated 
 shales and oxidize the organic matter much more readily than it could in a well 
 laminated shale. 
 
 Most of the bloating of the material probably takes place after the glass 
 begins to form. The oxidation of organic matter during the bloating process probably 
 has to come from within. Iron is the most probable source of the oxygen, which 
 would be released by the reduction of the iron by the organic matter. The gases that 
 would be produced would depend on the composition of the organic matter; they 
 would be water, CO2, H„S, SO.., SO„, and possibly a trace of one of the nitrogen 
 oxides. 
 
 EFFECTS OF WEATHERING 
 
 The upper weathered part of some shale deposits did not bloat as well as 
 the lower unweathered part. Dr. John C. Frye (personal communications, 1958) 
 stated that although the weathered part of a shale in Kansas did not bloat, shale 
 dug from further back in the bank bloated better, and they found the unweathered 
 part of the deposit to be an excellent bloating shale. 
 
 When a shale weathers, rainwater is adsorbed by the clay minerals caus- 
 ing them to swell and increase the thickness of the deposit slightly. Upon drying, 
 the water is lost, leaving cracks in the shale which air can penetrate. After this 
 happens repeatedly, the oxygen carried in with the rainwater and air oxidizes the 
 organic matter and pyrite. The organic matter in contact with oxygen acts as a 
 catalyst in the oxidation of the pyrite. These reactions produce C0 2 , water, and 
 sulfur oxides. The sulfur oxides combine with water to form sulfuric acid. The 
 iron of the pyrite oxidizes to the ferric state and adsorbs water to form limonite. 
 The sulfuric acid reacts with carbonates to form sulfates; it reacts with calcite 
 to form gypsum and COj, with dolomite to form gypsum and magnesium sulfate 
 that is removed by leaching, and with siderite to form iron sulfate that also is 
 leached from the shale. Gypsum leaches more slowly than the other sulfates. 
 
 If the organic matter content is low in the shale, after decades or centuries 
 it may be so oxidized that it is too low to give a good bloat. If the organic matter 
 is high, weathering may reduce it until the shales will give a good bloated 
 product . 
 
 A shale may be weathered from several feet to tens of feet from the out- 
 crop. The amount of weathering will depend upon the length of time the outcrop 
 has been exposed to weathering and the rate at which the weathered shale is 
 being removed. If a stream is actively undermining a shale outcrop, only a few 
 feet of shale near the surface may be weathered. The depth of weathering will 
 depend on the size of the stream and on the vigor with which it is cutting laterally. 
 If the shale outcrop is on a valley wall away from the stream, the shale may be 
 weathered back several tens of feet from the surface. 
 
Illinois State Geological Survey 
 
 Circular 290, Plate 1 
 
 B 
 
Illinois State Geological Survey 
 
 Circular 290, Plate 2 
 
 
 '■&■■ 
 
 
 
 t£*./> 
 
 "* 
 
 •-**"* 
 
 B 
 
 ' PLATE 2 shows bloating perpendicular to the sides of the brick or to the 
 lamination of the clay minerals in the brick. A and B had the same dimensions 
 before firing. C and D were extruded a little wetter than brick in A and B. C 
 shows the cores; D extended in length as well as width. 
 
 -* PLATE 1 shows core of shale which was high in organic matter. A, brought 
 
 up to 2175° F in 33 hours, allowed to soak 1 hour, bloated. B, put into the furnace 
 at 2400° F and soaked 1 hour, did not bloat but could be cleaved into its shale 
 partings. C and D were the same length before firing, but after firing at 2200° F 
 for 1 hour, C was three times as long as D. Bloating was perpendicular to the 
 lamination or bedding of the shale. 
 
18 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 If an area is covered by glacial till or loess, the upper part of the shale, 
 or even the whole shale bed, may have been weathered before the till or loess 
 was deposited. To determine the extent of weathering, it may be necessary to 
 drill a few holes in the area and test the material brought to the surface for bloat- 
 ing properties. This may help determine the kind of operation that will be necessary 
 to bloat the shale. 
 
 SHALE AND CLAY DEPOSITS ANALYZED 
 
 Alexander County 
 
 1423 NW{ NW| sec. 21, T. 15 S., R. 3 W. About \\ miles south of Thebes along 
 Mississippi River bluff on east side of Missouri Pacific Railroad, behind farm 
 house. About 6 to 8 feet of blue-gray clay of Cretaceous age is exposed; over- 
 burden may vary from to 30 feet. Upon addition of 1 percent coal and extru- 
 sion, the lightweight aggregate was light gray and had an apparent specific 
 gravity of 0.86 at 2400° F. This can be used in plasters and for similar 
 products . 
 
 1424 SE^ SE{ sec. 28, T. 15 S., R. 3 W. In hollow about 1 mile north of Fay- 
 ville. About 20 feet of dark gray, well laminated shale exposed on north cut 
 bank of ravine in east bluff of Mississippi River about 1/8 mile east of Mis- 
 souri Pacific Railroad. The hollow contains remains of old, abandoned powder 
 plant. Sample represents top 20 feet of Orchard Creek Shale. The bloated 
 product had an apparent specific gravity of 0.92. The shale should be fired 
 at a temperature somewhat below 2200° F. 
 
 Bond County 
 
 1415 NE± NW| sec. 13, T. 6 N., R. 5 W. Richards Brick Company pit. About 
 3 miles east of New Douglas, south side of blacktop road. Illinoian till 5± 
 feet; shale yellow, plastic,6± feet; blue shale, not so plastic, 8 feet. The 
 shale is in the Bunje Cyclothem. The lightweight aggregate had an apparent 
 specific gravity of 0.35. It bloats as individual particles with small pores. 
 Very little sticking of particles when fired at 2200° F. 
 
 Brown County 
 
 1337A-B SE| SE| NW^ sec. 24, T. 1 S., R. 4 W. North shale pit of Frederic 
 Brick and Tile Company north of gravel road in west cut bank of Dry Fork 
 Creek. Purington Shale exposed. Sample A is bottom blue shale; B is top 
 buff shale, face about 30 to 40 feet. The lightweight aggregate has an appar- 
 ent specific gravity of 0.85. At 2200° F the shale bloated as individual chunks 
 with small pores . 
 
 1351 A SW{ SWi NE| sec. 8, T. 1 S., R. 3 W. About { mile north of Mt. Sterling 
 on east side of Illinois Highway 99 on south cut bank of stream east of highway 
 fence. Underclay below limestone, 5 feet, noncalcareous (the underclay of 
 No. 4 Coal), grades from a dark, plastic clay at top into sandstone or sandy 
 shale at bottom. The lightweight aggregate had an apparent specific gravity of 
 1.46 at 2250° F and 1.15 at 2350° F. After 1 percent coal was added and the 
 mixture was extruded, the apparent specific gravity was 1.00 at 2200° F; at 
 2400° F the apparent specific gravity was 1.02 with 1 percent coal added. Too 
 refractory for ordinary lightweight aggregate. 
 
LIGHTWEIGHT AGGREGATE 19 
 
 Bureau County 
 
 1404 NW} SW{ NEi sec. 24, T . 16 N. , R. 6 E . Sheffield Shale Products Com- 
 pany pit west of Sheffield, south of U . S. Route 6. The Sheffield Shale, above 
 No. 6 Coal, is gray and rather blocky, about 15 to 20 feet thick. Overburden 
 is thin. The shale bloated very little. When 1 percent ground coal was mixed 
 with the ground clay and the mixture was extruded, the lightweight aggregate 
 had an apparent specific gravity of 0.71 when fired at 2200° F. 
 
 Calhoun County 
 
 1349A NE^ NE{ NE^ sec. 11, T. 9S., R. 3W. Southwest of paved road, south- 
 west cut bank of tributary to Fox Creek behind farm buildings, about 5 miles 
 west of Kampsville. Sample of Hannibal Shale represents lower 15 feet of blue- 
 gray shale in exposure. The lightweight aggregate had an apparent specific 
 gravity of 0.91 at 2300° F. It was underfired at 2250° F and overfired at 2350° F. 
 
 1352A SW| NE{ SW{ sec. 17, T. 11 S., R. 2 W. About 5 miles north of Batchtown 
 on west side of road in east bluff of Mississippi River Valley. Sample represents 
 the middle 20 feet of exposed Maquoketa Shale, is bluish gray, and weathers 
 into fairly thin laminae. The shale contains very little CaC03, if any. The 
 lightweight aggregate had an apparent specific gravity of 1.06 at 225 0° F, 0.90 
 at 2300° F.and 1.00 at 2350° F. 
 
 Christian County 
 
 1428 SEi NEi sec. 33, T. 11 N., R. 1 E. About l| miles south of Pana in north 
 cut bank of ravine about 100 yards west of U. S. Highway 51 . About 8 feet of 
 weathered gray shale in the upper part of McLeansboro Group is exposed. Over- 
 burden is relatively thin. The lightweight aggregate had an apparent specific 
 gravity of 1.06 at 2300° F. When 1 percent coal was mixed with the clay and 
 the material was extruded, the aggregate had an apparent specific gravity of 
 0.92 at 2300° F. 
 
 Clark County 
 
 1345 NE{ NE| SW| sec. 16, T. 11 N., R. 11 W. About l\ miles east of Marshall 
 and about 1 mile south of Livingston. About 15 feet of shale in the upper part 
 of McLeansboro Group is exposed in the southwest cut bank of Big Creek. The 
 shale is dark gray and well laminated; overburden is about 50 feet. The light- 
 weight aggregate had an apparent specific gravity of 1.01 at 2200° F and 0.59 
 at 2300° F. 
 
 Clay County 
 
 1420 SEi NW{ sec. 19, T. 4 N., R. 6 E. About 3j miles west of Louisville. 
 About 3 feet of shale in upper part of McLeansboro Group is exposed in road 
 ditch west of farmhouse. Shale is weathered, brownish gray \- inch laminae. 
 Overburden thin. The aggregate had an apparent specific gravity of 1.31 at 
 2300° F. When 1 percent coal was added to the clay and the material was 
 extruded, the aggregate had an apparent specific gravity of 0.79 at 2200° F. 
 
20 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 Clinton County 
 
 1414 SW| sec. 1, I. IN., R. 1 W. About l\ miles northwest of Centralia in 
 south cut bank of Crooked Creek east of bridge. About 8 feet of shale in the 
 upper part of McLeansboro Group is exposed. The bottom of the shale rests 
 on a fossiliferous limestone that is 3 feet above water level during summer 
 season. At the outcrop, sand and gravel overlie the shale. The aggregate 
 had an apparent specific gravity of 0.93 at 2200° F and 2300° F. It bloated 
 as individual particles. 
 
 Crawford County 
 
 1421 SWi SWi NE| sec. 1, T. 5 N., R. 12 W. About three-quarters of a mile 
 west of Flatrock. In west bank of ravine inside fence north of bridge west 
 of farmhouse, 3 feet of gray shale in upper part of McLeansboro Group is ex- 
 posed. Overburden would be thin in this area. The aggregate had an apparent 
 specific gravity of 0.66 at 2200° F. 
 
 Cumberland County 
 
 1353A NE} NW± SW{ sec. 36, T. 10 N., R. 9 E. About 1 mile north of Greenup, 
 10 feet of dark gray shale below Greenup Cyclothem in south cut bank of Bell 
 Creek about 50 yards west of old road west of Illinois Highway 130. The aggre- 
 gate had an apparent specific gravity of 0.62 at 2250° F and 0.56 at 2325° F. 
 
 1346A NW{ NW} SW± sec. 2, T. 9 N., R. 9 E., northwest corner of Greenup. 
 Northeast roadside cut along Illinois Highway 121 in south bluff of Embarrass 
 River. Lower 10 feet of shale below Greenup Cyclothem sandier than sample 
 1353A and lower in shale section. Shale in this area ranges from 20 to 30 feet 
 thick. The aggregate had an apparent specific gravity of 0.87 at 2250° F, 0.71 
 at 2300° F,and 1.00 at 2350° F. 
 
 Edwards County 
 
 1326A NE± NE£ sec. 11, T. 2 S., R. 10 E. Pit of Albion Brick Company south 
 of Albion, 20± feet of shale in upper part of McLeansboro Group is exposed. 
 The aggregate had an apparent specific gravity of 0.47 at 2200° F. 
 
 Effingham County 
 
 1416 NW{ SW£ sec. 1, T. 6 N., R. 5 E. About 4 miles northeast of Mason on 
 north side of Illinois Highway 37 about 100 yards west of Illinois Central Rail- 
 road. About 4 feet of shale in the upper part of the McLeansboro Group is 
 exposed in road cut. Overburden is shallow. The aggregate had an apparent 
 specific gravity of 0.73 at 2200° F. 
 
 Fayette County 
 
 1427 NE£ NE± sec. 28, T. 7 N., R. 3 E. About a quarter of a mile west of St . 
 Elmo, north of Pennsylvania Railroad and south of county road. Sample repre- 
 sents about 20 feet of dark blue shale (in the upper part of McLeansboro Group) 
 which contains siderite concretions in pit west of plant. The aggregate had an 
 apparent specific gravity of 0.46 at 2200° F; pores were small. Bloated as 
 individual particles without sticking. 
 
LIGHTWEIGHT AGGREGATE 21 
 
 Fulton County 
 
 1322A Sec. 7, T. 5 N., R. 5 E., Pine Ridge Coal Company pit. The Canton Shale 
 is exposed. Sample was taken from shale bin at Peoria Brick, and Tile Company. 
 The aggregate had an apparent specific gravity of 1.12 at 2300° F. Some bloat- 
 ing at 2200° F and overfired at 2425° F, a long bloating range. When 1 percent 
 coal was added to the clay and the material was extruded, the aggregate had an 
 apparent specific gravity of 0.80 at 2200° F. 
 
 135 0A Truax Coal Corporation pit southeast of Fiatt exposes about 40 feet of 
 
 Canton Shale that is blue-gray and has an overburden 15 to 20 feet thick. The 
 aggregate had an apparent specific gravity of 0.92 at 2250° F and 0.69 at 
 2325° F. Good bloating at 2250° F, small pores, overfired at 2325° F. 
 
 Greene County 
 
 1355A SE^NWisec. 30, T.12N., R. 11 W. About l\ miles northeast of White 
 Hall, 15 feet of Purington Shale, brownish yellow, weathered, overburden 15 to 
 20 feet. The aggregate had an apparent specific gravity of 1.80 at 2250° F and 
 1.15 at 2350° F, has small pores. When 1 percent coal was mixed with the 
 clay and the material was extruded, the aggregate had an apparent specific grav- 
 ity of 0.37 at 2200° F. 
 
 Grundy County 
 
 1401 SW± sec. 11, T. 33 N., R. 6 E. Morris Clay Company pit about 4 miles 
 southwest of Morris. Upper 20 feet of the Francis Creek Shale, brownish 
 gray and sandy. Overburden is thin. The aggregate had an apparent specific 
 gravity of 1.14 at 2300° F. When 1 percent coal was added to the clay and 
 extruded, the aggregate had an apparent specific gravity of 0.77 at 2300° F. 
 
 1331A SW{ SWi sec. 12, T. 31 N., R. 8 E. East of East Brooklyn pit of Northern 
 Illinois Coal Corporation. Upper 5 feet of blue-gray shale above No. 7 Coal, 
 about 18 feet of overburden. The aggregate had an apparent specific gravity of 
 0.72 at 2200° F and 0.31 at 2300° F. Bloated as individual particles at 2200° F, 
 overfired at 2300° F. 
 
 1331B Location and age same as 1331A. Blue-gray siltstone, 5 feet, and clay 5 
 feet above 1331A, overburden about 8 feet. Overfired at 2100° F, short bloat- 
 ing range due to presence of CaC03» 
 
 1331F Same location and age as 1331A. About 5 feet of blue-gray shale below 
 1331A. Probably bloats as well as 1331A. 
 
 Hancock County 
 
 1408 SWi SW{ sec. 26, T. 3 N., R. 5 W. Southeast bank of Williams Creek 
 about 200 yards southeast of Augusta-Clayton road about 2 miles south of 
 Augusta. Francis Creek Shale, gray, about 30 feet exposed; about 30 feet of 
 overburden. Aggregate had apparent specific gravity of 0.51 at 2200° F. 
 
22 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 Jackson County 
 
 1336A NW{ SW{ NW{ sec. 10, T. 9 S., R. 2 W. West bank of ravine about 200 
 yards upstream from mine. About 16 feet of medium gray to brownish gray shale 
 of Tradewater Group, very silty, hard, spheroidal weathering, some plant traces, 
 poorly to fairly well bedded. When 1 percent coal was mixed with the clay and 
 this blend was extruded the aggregate had an apparent specific gravity of 0.76 
 at 2200° F. 
 
 1336B SE| NE| NE} sec. 18, I. 5S..R. 2 W. Southwest cut bank of creek just 
 west of first bridge on north- south section-line road. Bottom 8 feet of 35 feet 
 of shale in the Tradewater Group. Shale, hard, medium gray, silty, very poorly 
 bedded, semiconchoidal fracture, lower 2 feet becomes better bedded and carbo- 
 naceous. Aggregate had apparent specific gravity of 1.51 at 2200° F and 0.64 
 at 2300° F. Overtired at 2300° F. After 1 percent coal was added and the clay 
 was extruded the aggregate had an apparent specific gravity of 0.61 after heat- 
 ing to 2200° F for 1 hour. 
 
 Jasper County 
 
 1411 SE^ SEj SE{ sec. 35, T. 7 N., R. 9 E. Northwest edge of Newton on east 
 cut bank of tributary to Embarrass River, about 10 feet of shale in upper part 
 of McLeansboro Group is exposed. Shale, sandy, blue-gray, laminated. The 
 aggregate had an apparent specific gravity of 0.40 at 2200° F. The pores are 
 about the same small size. 
 
 Kankakee County 
 
 1324B NW| NE{ sec. 8, T. 31 N., R. 9 E. Pit No. 11 of Northern Illinois Coal 
 Company. Francis Creek Shale, blue-gray, approximately 20 feet thick. When 
 1 percent coal was added and the clay was extruded, the aggregate had an appar- 
 ent specific gravity of 0.63 at 2200° F. 
 
 Knox County 
 
 1347A SE| sec. 17, T. 11 N., R. 2 E. Purington Brick Company pit, southeast 
 of East Galesburg. Purington Shale, about 20 feet exposed. When 1 percent 
 coal was added and clay was extruded the apparent specific gravity was 0.81 
 at 2200° F. 
 
 LaSalle County 
 
 1324A SW|SW|sec. 5, T. 33 N., R. 4E. Laclede-Christy Division of H. K. 
 Porter Company pit, l| miles east of Ottawa, north of U. S. Highway 6. Lower 
 10 feet of Francis Creek Shale. Shale, blue-gray, clayey. The apparent specif- 
 ic gravity of the aggregate was 0.61 at 2200° F and 0.37 at 2300° F. The pores 
 are small. Aggregate tends to be light gray. 
 
 1403 SW| SW| SW{ sec. 9, T. 33N., R, 3E. Illinois Valley Mineral Company 
 pit, l| miles west of Ottawa, Francis Creek Shale, lower 8 feet, blue-gray, 
 clayey, some pyrite. The apparent specific gravity of the aggregate was 0.69 
 at 2200° F. Bloated as individual particles, small pores, light gray. 
 
LIGHTWEIGHT AGGREGATE 23 
 
 Lawrence County 
 
 1426 SE^ SW{ NW| sec. 5, T. 3N., R. 11 W. East cut bank of Embarrass River, 
 north of U. S. Highway 50. Upper 10 feet of 30 to 40 foot shale in upper part of 
 McLeansboro Group was sampled. Overburden 10 to 15 feet; shale, brownish 
 gray, weathered. The apparent specific gravity of the aggregate was 0.65 at 
 2200° F; small pores. 
 
 Livingston County 
 
 1321A SW{ SW{ sec. 34, T. 27 N., R. 8 E. Pit, north of Chatsworth. About 15 
 feet of Wisconsin till, blue-gray. The fluxing action of MgO and CaO is too 
 great to form a good aggregate . 
 
 Macoupin County 
 
 1407 NE| NW| NE| sec. 9, T. 9 N., R. 7 W. South cut bank of Honey Creek, 
 south of road. About 15 feet of sandy shale of Trivoli Cyclothem exposed, 
 overburden thick. The apparent specific gravity of the aggregate was 1.13 
 at 2250° F. Bloated as individual particles, pores both large and small. When 
 1 percent coal was added and the clay was extruded, the aggregate had an appar- 
 ent specific gravity of 0.72 at 2200° F. 
 
 Madison County 
 
 1344A SE± SE{ NE{ sec. 35, T. 6 N., R. 10 W. Alton Brick Company shale pit 
 east of road, south of Coal Creek, north of North Alton. Purington Shale, lower 
 10 feet, dark gray, along east face of shale pit. The apparent specific gravity 
 of the aggregate was 0.89 at 2200° F and 0.60 at 2300° F. Pores about same 
 size . 
 
 Marshall County 
 
 1400 SEi NW| sec. 23, T. 12 N., R. 9 E. Road cut west side of Illinois High- 
 way 29 between the Hydraulic-Press Brick Company plant and Sparland. Farm- 
 ington Shale, weathered gray, lower 15 feet, overburden thick. With 1 percent 
 coal added and clay extruded, the apparent specific gravity was 0.51 after 
 firing to 2200° F for 1 hour. 
 
 McDonough County 
 
 1325A-B SE| NE} sec. 12, T. 5 N., R. 4 W. Pit of Colchester Brick and Tile 
 Company, north edge of Colchester. About 20 feet of Francis Creek Shale 
 above No. 2 Coal, no overburden. The apparent specific gravity of aggregate 
 for lower 10 feet of shale was 0.65. The upper 10 feet is weathered and did 
 not bloat. When 1 percent coal was added to the upper 10 feet of shale and 
 extruded, the apparent specific gravity was 0.65 at 2200° F. 
 
 Menard County 
 
 1330A SW{ SE{ sec. 11, T. 18 N., R. 7 W. Springfield Clay Products Company 
 pit north of Petersburg. About 35 feet of shale of Trivoli Cyclothem with 20 feet 
 of overburden. When 1 percent coal was added, the apparent specific gravity 
 was 0.45 at 2200° F. 
 
24 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 Mercer County 
 
 1348A SW{ NW{ sec. 8, T. 14 N., R. 2 W. Shale pit of Hydraulic-Press Brick 
 Company at Shale City. Francis Creek Shale and shale of Greenbush Cyclothem, 
 30 feet, blue-gray. This sample represents the shale of the Greenbush Cyclo- 
 them or lower shale below coal and underclay. When 1 percent coal was added 
 and clay was extruded, the aggregate had an apparent specific gravity of 0.87 
 at 2200° F. 
 
 Montgomery County 
 
 1412 NW± SW{ sec. 30, T. 8 N., R. 2 W. About l| miles northeast of Coffeen, 
 5 to 6 feet of iron- stained gray shale in upper part of McLeansboro Group with 
 plant fossils and coal band in middle of shale exposure, on west bank of East 
 Fork Creek. The apparent specific gravity of the aggregate was 0.58 at 2200° F. 
 Bloated as individual particles. 
 
 • Peoria County 
 
 1402 SE£ NW{ sec. 13, T. 11 N., R. 6 E. Northwest corner of Princeville. Shale 
 occurs on east bank of Prince Run Creek; 8 feet of gray shale, which is either 
 from the Sparland or Brereton Cyclothem.is exposed; overburden is thin. The 
 apparent specific gravity of the aggregate was 0.16 at 2200° F, bloated as 
 individual particles. 
 
 Perry County 
 
 1323A NE| SW{ NE^ sec. 5, T. 4 S., R. 4 W. About 2 miles northeast of Coulter- 
 ville, along east bank of north-flowing tributary to Mud Creek about an eighth 
 of a mile east of road. Shale in upper part of McLeansboro Group, 12 feet, hard, 
 well laminated, gray-brown grading to blue-gray. The apparent specific gravity 
 of the aggregate was 0.61 at 2200° F, pores fairly even in size. 
 
 1309A SW{ NW| sec. 5, T. 6S., R. 1W. North of Duquoin. Taken from core of 
 J. H. Forester well No. 1, 42 to 55 feet beneath the surface. Weathered shale of 
 the Brereton Cyclothem. The apparent specific gravity of the aggregate was 0.77 
 at 2200° F. Overfired at 2400° F. 
 
 Randolph County 
 
 1418 NW{ NE^ sec. 32, T. 7 S., R. 6 W. About 2 miles southeast of Chester, 
 west cut bank of Chester and Mt. Vernon Railroad, and of county road in west 
 valley wall of Marys River, southwest of Illinois Highway 3. About 30 feet of 
 Waltersburg Shale of Chester age, dark gray, with considerable organic matter; 
 shale thinly laminated in lower 20 feet, beds massive and cemented in upper 
 10 feet. The apparent specific gravity of the aggregate was 0.36 at 2200° F, 
 pores uneven in size. 
 
 1338A NW{ SW^ SE± sec. 5, T. 7 S., R. 5 W. Near Wine Hill along gully flow- 
 ing south, due south of church in Wine Hill. Shale of the Caseyville Group is 
 greenish gray and silty in bottom 2 feet, grades upward to green and purple 
 (variegated), less silty, and more weathered in top 8 feet. After 1 percent 
 coal was added and clay was extruded, the apparent specific gravity was 1.16 
 
LIGHTWEIGHT AGGREGATE 25 
 
 when fired to 2200° F. At 2400° F the apparent specific gravity is 0.88 with 
 1 percent coal added. At 2300° F the apparent specific gravity is 0.91 with 1 
 percent coal added. 
 
 1338B NW{ NW{ SW^ sec. 6, T. 7 S., R. 5 W. About l{ miles west of Wine 
 Hill. Shale of Caseyville Group is exposed in south branch of Hornbastel 
 Branch beside road about 200 feet south of the southernmost bridge across 
 Hornbastel Branch. Shale, light brownish gray, well bedded, 9 feet, over- 
 burden thin. The apparent specific gravity of the aggregate was 0.82 at 
 2200° F; some layers bloated, others did not. 
 
 1308A NE| NW| sec. 36, T. 4 S., R. 5 W. F. Birchler hole No. 1, shale in 
 lower McLeansboro Group 58 to 75 feet beneath surface. 
 
 1308B Same location and age as 1308A except 75 to 141 feet below surface. Com- 
 posite sample. 
 
 1308C Same location and age as 1308A except 101 to 103 feet below surface. 
 
 1308D Same as 1308A except 103 to 115 feet below surface. 
 
 1308E Same as 1308A except 115 to 121 feet below surface. 
 
 1308F Same as 1308A except 121 to 131 feet below surface. A composite of all 
 1308 samples was made, 1 percent of coal was added, and the sample was ex- 
 truded. The aggregate had an apparent specific gravity of 0.69 at 2200° F. 
 
 Richland County 
 
 1413 NE corner sec. 14, T. 2 N., R. 10 E. About l{ miles north of Parkersburg 
 along south-flowing tributary to Sugar Creek, south of unimproved dirt road. 
 About 3 feet of weathered shale in the upper part of the McLeansboro Group is 
 exposed in tributary. The apparent specific gravity of the aggregate was 1.68 
 at 2200° F and 2250° F. When 1 percent coal was added and the clay was ex- 
 truded, the aggregate had an apparent specific gravity of 0.47 at 2200° F. 
 
 Rock Island County 
 
 1354A SW{ SW± SE^ sec. 6, T. 16 N., R. 5 W. About l\ miles southeast of 
 Muscatine, Iowa, along north road cut of Illinois Highway 99 on east bluff of 
 Mississippi River. About 30 feet of well laminated, organic, rich, dark 
 gray shale in the lower part of the Tradewater Group. The apparent specific 
 gravity of the aggregate was 1.07 at 2200° F and 0.67 at 2350° F, bloated 
 with small pores. At 2350° F the aggregate was light gray. 
 
 St. Clair County 
 
 1334A NW| NE{ sec. 31, T. 2 N., R. 8 W. Hydraulic- Press Brick Company pit, 
 about 2 miles east of Edgemont. Shale in lower part of McLeansboro Group, 
 blue-gray, about 40 feet. The apparent specific gravity was 0.41 at 2200° F, 
 0.66 at 2000° F, and 0.51 at 2100° F. 
 
26 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 1333A NE| SW} sec. 32, T. 2 N., R. 8 W. Hill Brick Company pit, about 3 miles 
 east of Edgemont. About 40 feet of sandy shale in lower part of McLeansboro 
 Group. The apparent specific gravity of the aggregate was 1.03 at 2200° F. 
 When 1 percent coal was added, the apparent specific gravity was 0.70 at 2200° 
 F. Some layers did not bloat, but others did. 
 
 1329B Center SW{ SW{ sec. 21, I. 1 S„ R. 7 W. About 1 mile east of Freeburg, 
 north side of road on east side of stream valley. Shale in lower part of Mc- 
 Leansboro Group, 10 to 12 feet, gray, taken from road level to top of shale. 
 The apparent specific gravity of the aggregate was 0.70 at 2200° F. Bloating 
 was not uniform. 
 
 1329A SW| NW| NWi sec. 21. T. 2 N., R. 8 W. About 2 miles east of French 
 Village, west bank of tributary of Little Canteen Creek. Shale in lower part 
 of McLeansboro Group, olive gray grading to dark gray, 16 to 17 feet. When 
 1 percent coal was added and the clay was extruded, the aggregate had an ap- 
 parent specific gravity of 0.72 at 2200° F. 
 
 Saline County 
 
 1327A SE{ SE{ sec. 21, T. 9 S., R. 6 E. Pit of Harrisburg Brick and Tile Com- 
 pany, southeast edge of Harrisburg. Sample represents lower 8 feet of shale, 
 which is either in the McLeansboro Group or the Carbondale Group. The ap- 
 parent specific gravity of the aggregate was 0.70 at 2200° F; bloated individ- 
 ual particles. 
 
 Sangamon County 
 
 1332A SW| sec. 1, T. 15 N., R. 5 W. Poston Brick and Concrete Products Com- 
 pany, southeast part of Springfield. Shale of Trivoli Cyclothem, gray, mas- 
 sive, 35 feet. The apparent specific gravity of the aggregate was 0.48 at 
 2200° F- pores are fairly uniform in size. 
 
 1330B Section 1 1, T. 15 N . , R. 5 W. Springfield Clay Products Company pit, 
 southeast part of Springfield. Shale of Trivoli Cyclothem, massive, blue- 
 gray, 30 feet. The apparent specific gravity of the aggregate was 0.5 2 at 
 2200° F. The shale bloated as individual particles with fairly uniform pores 
 at 2200° F. 
 
 Schuyler County 
 
 1410 SEi SW£ SW{ sec. 27, T. 2 N., R. 2 W. About 2 miles west of Rushville, 
 north road cut on east valley wall of Harvey Branch. Shale of Carbondale Group, 
 light blue-gray, 20 feet. The apparent specific gravity of the aggregate was 
 0.72 at 2200° F. The shale bloated as individual particles with fairly uniform 
 pores at 2200° F. 
 
 Shelby County 
 
 1422 NW corner, sec. 24, T. 11 N., R. 3 E. About 1 mile southwest of Shelby- 
 ville on east road cut in south valley wall of creek. Shale in upper part of Mc- 
 Leansboro Group, about 6 feet exposed, overburden thin. The apparent speci- 
 fic gravity of the aggregate was 1 .26 at 2300° F; very little bloating at 2200° F 
 
LIGHTWEIGHT AGGREGATE 27 
 
 and bloating not uniform at 2300° F. When 1 percent coal was added and the 
 clay was extruded, the apparent specific gravity of the aggregate was 0.73 at 
 2200° F. 
 
 Stark County 
 
 1398 NE| NW{ sec. 25, T . 13 N. , R. 6 E . About three-quarters of a mile north 
 of Wyoming, south cut bank of tributary to Spoon River south of road. Expo- 
 sure consists of 8 feet of shale in the Brereton? Cyclothem. After adding 1 
 percent coal and extruding the clay, the aggregate had an apparent specific 
 gravity of 0.80 at 2200° F. 
 
 Tazewell County 
 
 1322B Peoria Brick and Tile Company pit. Sample of Canton? Shale taken from 
 shale bin. The apparent specific gravity of the aggregate was 0.98 at 2200° F, 
 pores fairly uniform in size. 
 
 Union County 
 
 1425 SW{ NW{ SE{ sec. 14, T. 12 S., R. 2 W. About 2 miles west of Anna, 
 
 west of State Pond dam on south valley wall of creek below dam. Shale of the 
 New Albany Formation, 20 feet, black, fissile. The shale did not bloat. 
 
 1335A NE| SE{ NE{ sec. 11, T. 13 S., R. 2 W. About 3i miles west of south of 
 Jonesboro, cut bank southeast side of creek along west fork of hard road. 
 Springville Shale, pinkish brown to tan to maroon to light gray, silty at top, 
 less silty at bottom, grading from massive to poorly to thinly bedded, 50 feet; 
 entire bluff is shale. After 1 percent coal was added and the clay was extruded, 
 the aggregate had an apparent specific gravity of 0.70 after firing to 2200° F. 
 
 Vermilion County 
 
 1342A NW{ NE| sec. 14, T. 19 N., R. 12 W. Western Brick Company pit, about 
 1 mile southeast of Batestown. About 25 feet of shale of Sparland Cyclothem is 
 exposed. The apparent specific gravity of the aggregate was 0.80 at 2200° F 
 and 0.31 at 2300° F. The shale bloated as individual particles at 2200° F with 
 small even pores, but was overtired at 2300° F. 
 
 1343A Ej sec. 4, T . 19 N. , R. 1 2 W. Harmattan Mine of Fairview Collieries, 
 about 1 mile west of Hillery. Lower 10 feet of blue-gray shale of Sparland 
 Cyclothem. The apparent specific gravity of the aggregate was 0.50 at 2200° 
 F, 0.44 at 2300° F, and 0.78 at 2350° F. The pores were small at 2200° F 
 and 2300° F, but the shale was overtired at 2350° F. 
 
 1343B Same location as 1343A except upper 10 feet of shale of Sparland Cyclothem 
 is more weathered. After 1 percent coal was added and the clay was extruded, 
 the aggregate had an apparent specific gravity of 0.50 after being fired to 2200° 
 F. With 1 percent coal added, the apparent specific gravity was 0.58 at 2100° 
 F and 0.88 at 2000° F. 
 
28 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 Washington County 
 
 1339A SE± SW{ SW| sec. 18, T. 2 S., R. 4 W. About l\ miles south of east of 
 St. Libory, road cut west side of Elkhorn Creek. Shale in lower part of Mc- 
 Leansboro Group, olive gray, clayey, fairly well bedded, plant fossils, iron- 
 stone concretions, 12^ feet. The apparent specific gravity of the aggregate 
 was 1 .41 at 2200° F. Bloating is not uniform. When 1 percent coal was added, 
 the apparent specific gravity was 0.49 at 2200° F. 
 
 White County 
 
 1409 NW| SWi SW| sec. 11, T. 5 S., R. 9 E. About 1 mile northwest of Carmi, 
 about 200 yards east of road on south bank of Big Hill Branch. Shale in the 
 upper part of McLeansboro Group, dark gray, about 8 feet. The apparent speci- 
 fic gravity of the aggregate was 0.77 at 2200° F. The pores are fairly uniform 
 in size. 
 
 Williamson County 
 
 1419 S| N| sec. 21, T. 9 S., R. 4 E. Delta Mine-Carmac Coal Company, about 
 2 miles east of Crab Orchard. Canton Shale, blue-gray, about 20 feet. The 
 apparent specific gravity of the aggregate was 0.55 at 2200° F. The pores 
 are uniform in size. 
 
 1429 SE{ SE{ sec. 25, T. 10 S., R. 3 E. About half a mile east of Creal Springs, 
 east face of old stone quarry. Shale of Tradewater Group, gray, about 6 feet. 
 The shale did not bloat. When 1 percent coal was added and the clay was ex- 
 truded, the aggregate had an apparent specific gravity of 0.92. 
 
 CONCLUSIONS 
 
 Several conclusions may be drawn from this study of lightweight aggregates 
 from Illinois shales. 
 
 1) Probably the best organic content for a good bloating shale that will 
 make strong aggregate is between 0.3 and 1.0 percent or less. 
 
 2) Organic contents of from 1.0 to 2.0 or slightly higher will produce much 
 lighter aggregate that may have special uses, although it will not be as strong as 
 aggregate produced with less carbon. 
 
 3) If the organic content is too high, the shales will not lend themselves 
 to rapid bloating processes, although they may be bloated by firing slowly for a 
 longer period of time. 
 
 4) The best bloating probably is accomplished in those shales in which 
 the organic matter is adsorbed on the clay surfaces, rather than occurring as 
 detrital particles. 
 
 5) Clays may require more organic matter for bloating than shales because 
 the clays are more porous and permeable, hence the organic matter oxidizes 
 more rapidly. 
 
 6) In shales the bloating takes place normal to the bedding. 
 
LIGHTWEIGHT AGGREGATE 29 
 
 7) Calcium and magnesium carbonate may be desirable in small quantities, 
 but in quantities of 5 or 6 percent or more, they tend to have too great a fluxing 
 action. 
 
 8) Iron should be present in percentages greater than 3 or 4 percent for 
 a shale to be a good bloater. 
 
 9) Shales that do not need coal added can probably be bloated in either 
 a rotary or a grate kiln whereas the shales which require coal to obtain a good 
 bloated product probably have to be bloated in a kiln in which the fuel is added 
 to the clay. 
 
 REFERENCES 
 
 Austin, C. R., Nunes, J. L., and Sullivan, J. D., 1942, Basic factors involved 
 in bloating of clays: Am. Inst. Min. Met. Eng., v. 148, p. 149-160. 
 
 Barnes, V. E., 1930, Changes in hornblende at about 800° C: Am. Mineralogist, 
 v. 15, p. 393-417. 
 
 Conley, J. E., Wilson, H., Klinefelter, T. A., et al . , 1948, Production of light- 
 weight concrete aggregates from clays, shales, slates, and other materials: 
 U. S. Bur. Mines Rept. Inv. 4401, p. 121. 
 
 Ehlers, E. G., 1958, The mechanism of lightweight aggregate formation: Am. 
 Ceramic Soc. Bull., v. 37, p. 95-99. 
 
 Everhart, J. O., Ehlers, E. G., Johnson, J. E ., and Richardson, J. H., 1958, A 
 
 study of lightweight aggregates: Ohio State Univ. Eng. Experiment Station 
 Bull. 169, p. 69. 
 
 Grim, R. E.,and Johns, W. D., 1951, Reactions accompanying the firing of brick: 
 Jour. Am. Ceramic Soc., v. 34, p. 71-76. 
 
 Herold, P. G., Kurtz, P., Jr., Planje, T. J., and Plunkett, J. D., 1958, Study of 
 Missouri shales for lightweight aggregate: Missouri Geol. Survey and 
 Water Resources Rept. Inv. 23, p. 39. 
 
 Planje, T. J., 1958, Study of Missouri shales for lightweight aggregate: Preprint 
 of talk given at Mid-America Industrial Minerals Conference of Am. Inst. 
 Min. Met. Eng., St. Louis, Mo., October 1958. 
 
 Riley, C. M., 1951, Relation of chemical properties to the bloating of clays: Jour. 
 Am. Ceramic Soc, v. 34, p. 121-128. 
 
 Rowland, R. A., and Jonas, E. C, 1949, Variations in differential thermal analysis 
 curves of siderite: Am. Mineralogist, v. 34, p. 550-558. 
 
 Sullivan, J. D., Austin, C. R., and Rodgers, E. J., 1942, Expanding clay products: 
 Am. Inst. Min. Met. Eng. Trans., v. 148, p. 139-148. 
 
 Illinois State Geological Survey Circular 290 
 29 p., 2 figs., 2 pis., 2 tables, 1960 
 
nnmzn 
 
 CIRCULAR 290 
 
 ILLINOIS STATE GEOLOGICAL SURVEY 
 
 URBANA