Xella, a committed industrialist who invests

While the construction sector is the largest producer of CO2020, Xella construction solutions offer a good carbon footprint, both through their intrinsic qualities (thermal and mechanical) and their manufacturing process. They are a definite alternative for low-carbon construction and comply with the new REXNUMX environmental regulations.



Present in France for over 30 years, Xella covers all market needs in terms of healthy and sustainable construction solutions as well as fire protection thanks to the fire-resistant qualities of cellular concrete. Through its 5 brands – Ytong, Siporex, Silka, Multipor and Hebel – it can respond to multiple projects for individual homes, collective housing, tertiary and industrial buildings, in new construction as well as renovation or rehabilitation thanks to the lightness of the products. Its 3 production sites, based in Saint-Savin (38), Mios (33) and Saint-Saulve (59), allow it to achieve a turnover of 50 million euros in 2021.

To limit its carbon footprint and develop more environmentally friendly production, Xella has launched a €1,1 million modernization plan at its Saint-Savin factory, the headquarters of Xella France and the historic factory of the Ytong brand.

Investment in the Saint-Savin site to recycle production waste



The Saint-Savin production site, located in the Lyon region, manufactures and markets Ytong and Siporex cellular concrete blocks. This 100% mineral material is made from local natural resources : water, sand (60%), lime (15%), cement (15%) and anhydrite (10%), and its production is energy efficient because it is limited to pressurizing the autoclaves.

Sébastien Ray – Director of the Saint-Savin site explains: Cellular concrete is a load-bearing and insulating material that addresses current construction challenges. Eco-friendly, it requires little energy to manufacture because it doesn't require a kiln, but rather an autoclave fueled by steam at 180 degrees. »



As part of its 2020-2022 modernization plan, Xella has invested 1,1 million euros in the Saint-Savin production line. The objective is to limit the consumption of resources and their costs, and to recycle waste from production by reinjecting it.

Indeed, the 170 m000 of cellular concrete produced annually generates powders from the drilling and machining of the linking blocks (approximately 3 m30) and material scraps. These production scraps were previously shipped to other sites. The plant's teams therefore worked on a recipe that would allow 000% of the sand to be replaced with recycled cellular concrete powder. Today, this powder is used in the composition of cellular concrete. The waste is being revalued thanks to an investment of 1,1 million euros in a new crushing and screening system.

The implementation of this new recipe and the investment in equipment make it possible to reduce the consumption of sand required for the production of cellular concrete by 15 to 20%.

Half of the offcuts are transformed into powder and half into crushed stone. The recycling of our waste, 50 tons of powder and 25 tons of crushed stone, is completely internalized. The installation of a processing line, storage silos, and a transportation system were necessary. The amortization of the installation of this virtuous circle is reflected in the savings generated by the replacement of sand and the reduction in transportation..», explains Sébastien Ray.

All of the cellular concrete powder generated by the activity is recycled.

Recycling leftover cellular concrete allows for transport savings:



- For waste : 1 truck per day, instead of 2 trucks previously, which allows a reduction of 220 trucks per year.

- For the sand : Almost 2 out of 10 trucks per day in terms of resupply trips between the sand quarry and the factory.



« Our business is closely linked to sand extraction, so it's important to find solutions to extract as little sand as possible while maintaining the quality of our materials. Furthermore, implementing this recycling process limits sand transportation and therefore reduces the impact on the region's air quality. » Fewer trucks on the roads, fewer resources used, the approach is virtuous.



The return on investment is estimated at 2,5 years.

« With this gesture in favor of natural resources, Xella aims to save 350 euros per year thanks to its new installation. »

Cellular concrete, a low-carbon solution that meets RE2020



Xella construction solutions are sustainable, both in terms of the manufacturing process, the materials used and their implementation. Made from natural and mineral raw materials, they fit perfectly into the concept of the circular economy. Cellular concrete blocks consist of 20% material and 80% air, which makes them load-bearing and gives them excellent insulating qualities.



Used for walls and partitions, They contribute to the energy efficiency of buildings and to building in a low-carbon manner. In this sense, they respond to current issues and are part of RE2020, which aims to reduce the energy consumption of new constructions and the reduction of carbon emissions throughout the construction process.





With environmentally friendly production, resources saved, a 30% reduction in CO² emissions from its production sites by 2030 (through the use of renewable energy or less energy-intensive solutions), a local supply of 80% of raw materials used, a reduced truck transport plan, customer supplies by rail… Xella intends to significantly reduce its environmental footprint.

Well-being and safety at work, a strong commitment at Xella



The work environment is also very important in the Xella strategy. The goal by 2025 is:



- To reduce work accidents with injuries. Moreover, the Saint-Sauvin site is one of the flagships in terms of safety. It can boast 1180 days without a workplace accident.  



- To increase annual training hours by 10% to improve the professional development prospects and knowledge of employees.