Image courtesy of EnviroGLAS web site

Terrazzo is an ancient building application. No one is absolutely certain of its origin or exact age, but it’s been found in buildings dating back thousands of years. Many believe the modern version we would easily recognize started in Venice. It was invented by Venetian builders as a low cost flooring option. Back then, floors were often composed of marble slabs. During construction there was always leftover broken pieces. These marble chips from more expensive floors were set in a binder, back then usually clay, and sealed with goat milk. Recycled content was a core feature of the material right from its earliest version.

During the 1920s concrete was readily available and replaced the clay binder. Industrialization also led to mechanized grinders to polish the finished surface. And more recently, quick set versions of the concrete composed of polymer epoxy have become the standard. Yet, even with updates and improvements to the basic product and process, terrazzo essentially remains an artisan product crafted by hand.

Image courtesy of EnviroGLAS web site

Several hundred years after terrazzo’s introduction, Tim Whaley, CEO and founder of EnviroGLAS, was installing commercial roofs in Plano TX and wondering how he could develop a new, low cost, durable roofing material with a smaller ecological footprint. He couldn’t shake this thought when a friend suggested he investigate terrazzo. At the same time, an article in the paper about a local municipality having trouble finding a market for the crushed glass collected for recycling, caught Tim’s eye. In 2002 the city was amassing more glass every week with no foreseeable use, and the idea of EnviroGLAS was born.

As the building artisans of Venice were seeking a way to utilize those accumulating marble chips rather than throwing them away, Tim knew he had an option for all the city’s stockpiled glass. He swapped the marble chips with crushed glass to create a new kind of terrazzo. Like those ancient craftsman, EnviroGLAS hand makes its product on request. They maintain no inventory. When an order is created, it’s totally custom. Consumers select the matrix or binder color, the glass size and color, and whether mirror or other unique aggregate substitutes are added. Each slab requires a six to eight week process from order to delivery.

Images courtesy of EnviroGLAS web site

Today, Tim’s operation demands more glass than the local municipality can supply. The majority of his glass aggregate needs are locally sourced through a company called Strategic Materials. The size and processes of EnviroGLAS allows them to source unique additives that their larger competitors cannot. As an example, nearby plumbing manufacturer Kohler Co. had accumulated several hundred tons of reject toilets and sinks for years without any real plans for reclaim or reuse. Tim was able to secure crushed porcelain from this discarded material in three sizes for his products. He also found reject glass marbles from a local maker of margarita glasses. Two tons of these 3/4” glass balls have air bubbles that make them unusable for glass production, but are perfect as terrazzo aggregate.

Like other terrazzo materials, EnviroGLAS is 80% recycled content and 20% binder by volume. But while most of his competitors are figuring out how to mass produce recycled glass terrazzo slabs for countertops, Tim is continuing a tradition of ancient hand craft. His slabs are hand mixed, hand poured, hand ground, and hand polished.

Image courtesy of EnviroGLAS web site

EnviroGLAS offers five primary products:

• EnviroMODE – is a new terrazzo surface made from recycled tubs, sinks and toilets.
• EnviroTRAZ – is poured in place recycled glass and porcelain terrazzo. If you’ve ever flown through Dallas Fort Worth Airport you’ve seen this product.
• EnviroSLAB – are 1″ thick, 27″ x 84″ or 60” x 84”, countertops which can be cut and installed to size by a local installer.
• EnviroPLANK – are 1/2″ nominal thick recycled glass and porcelain terrazzo floor tiles that measure 6″ x 36″.
• EnviroSCAPE – is the newest trend in decorative, eco-friendly, sustainable landscaping.

Although we’ve been familiar with Tim and his company for quite some time, we’ve not had the pleasure of using it in any of our designs. Do you have any experience with EnviroGLAS? Let us know what you think. We’re hoping to make a trip to Tim’s production facility for a tour in the near future and we’re optimistic that we’ll have a project in his region where we’ll be able to experience his beautiful craft.

Thank you, Tim, for your time!

related posts:

• January 4, 2010 -- on tour: Vetrazzo (1)
• December 13, 2009 -- stories of sustainability: IceStone (7)
• March 17, 2010 -- stories of sustainability: Black’s Farmwood (0)
• March 11, 2010 -- preview: Eco De Vita (0)
• February 22, 2010 -- on tour: epOxy Green (1)