History The results of previous work carried out on the Tapley Hill Formation shale showed that, while a light weight aggregate could be produced from it, the narrow bloating range made processing difficult, owing to agglomeration of the material in the kiln. An investigation of a process of sand injection to overcome this difficulty was recommended. Objective The object was to determine whether the tendency of Tapley Hill shale to agglomerate in the rotary kiln during expansion could be overcome by the injection of sand into the kiln to produce a coated aggregate, and, if such a coated aggregate could be produced, to then test it in concrete. Summary of Work Done Silica sand was injected at the burner end of the kiln during expansion of the shale, the behaviour of which was observed under various conditions of temperature, residence time, feed rate and feed size. The expanded product was used to prepare concrete cylinders which were tested for unit weight and compressive strength. Conclusions By injecting sand into the kiln to prevent sticking of the bloating particles it is possible to produced lightweight aggregate from Tapley Hill shale by continuous expansion in a laboratory rotary kiln. The product, though lacking in uniformity, is suitable for making lightweight concrete of structural grade. Recommendations It is recommended that the shale deposit should be further investigated to determine whether it contains more uniform and less weathered material, from which a more uniform expanded product might be obtained.