Brains
When a massive landslide took out a section of Wyoming Highway 22 on June 8, 2024, it didn’t just damage pavement—it cut off a lifeline. Known as the Teton Pass “Big Fill Slide,” the collapse destroyed a key stretch of road that connects eastern Idaho’s Teton Valley with Jackson Hole, Wyoming—a world-class destination for outdoor enthusiasts. The sudden failure, triggered by extreme weather and unstable slopes, sent geotechnical teams scrambling for a fast, sustainable, and reliable solution to rebuild the steep 100-foot embankment.
Enter Aero Aggregates and their ultra-lightweight, foamed glass aggregate (UL-FGA). Made from 100% recycled glass, this innovative material offered the strength of traditional stone with a fraction of the weight—85% lighter, to be exact. That made it ideal for stabilizing the slope without adding extra pressure to the already compromised terrain. It’s also water-draining, rot-proof, fire-resistant, and eco-friendly.
Instead of conventional soil or stone backfill, the Wyoming Department of Transportation (WYDOT) chose to go with Aero’s UL-FGA, making the project the tallest foamed glass aggregate slope stabilization effort in the United States. “The foamed glass aggregate provided by Aero Aggregates was the product of choice for the WYDOT ‘Big Fill Slide’ project on the Teton Pass,” Pete Schexnayder said of Ames Construction, the lead contractor. “The product not only allowed continuous placement, but it was also less susceptible to weather conditions, decreased the weight of mass exerting forces on the existing material below the embankment, and was ecologically friendly for the surrounding national forest.”
In total, around 60,000 cubic yards of the lightweight material were trucked into the mountains—material that would have taken six times as many truckloads if heavier traditional fill had been used. That meant fewer emissions, less traffic impact, and faster progress in one of the West’s most sensitive alpine environments.
Aero Aggregates’ CEO and Co-Founder Archie Filshill emphasized the team effort behind the scenes.
“Working with Ames Construction and the WYDOT engineering and implementation team on the Teton Pass repair was an exceptional collaborative experience,” he said. “As a team of geotechnical engineers, we didn’t just deliver aggregate; we provided a comprehensive technical solution that addressed both weight and water drainage concerns in the slope reconstruction. Additionally, this project demonstrated our ability to quickly supply material to any location, even to the top of the Tetons.”
The foamed glass was produced at Aero’s plant in Dunnellon, Florida, using glass diverted from landfills through curbside recycling programs in Central Florida. It was shipped efficiently across the country using intermodal rail and truck, proving that smart infrastructure can be both high-tech and sustainable.
With approval from 25 state DOTs and a growing list of major projects, Aero Aggregates’ foamed glass aggregate is quickly becoming a go-to material for infrastructure repair in tough terrain. For the Teton Pass, it helped turn a disaster into an opportunity. By mid-July the work of reconnecting communities and restoring access to one of the most scenic highways in the Rockies should be fully completed.
