METECH IN

C.1702,7/F,BLD

G C, R

oward PLAZ

A, W

angjing, 

Chao

yang

 District, Be

ijing

, P.R. C

hina

 100102

Tele: +86

 10 6439

 1879  Fax: +86

 10 6439

 2090

www.m

etech.com.cn

Fly Ash Lightw

eight A

ggregate

2015

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Fly Ash Lightw

eight A

ggregate

FLY AS

H T A GLA

NCE

Brief Introdu

ction of LW

A

MeTech Fly Ash LW

A Project Intro.

Comparison

 of LWC & Normal Con

crete

FLY AS

H AT

 A GLANCE

LWA Ap

plications

Go Green

Fly Ash LW

C Performance & Characteristics

What is 

FLY AS

H?

With

 the ever increasin

g de

mand for coal as a

n en

ergy so

urce th

ere is a grow

ing ne

ed fo

r disposing of th

e waste fly ash which re

sults 

from

 burning

 coal.  This prob

lem is growing 

world wide. 

Total Fly ash produ

ction world 

wide is more then

 600

 million tons  

per a

nnum

.Total con

sumption of Fly ash 

world wide is less th

en 30%

.

Causes vivid enviro

nmen

tal issue

s e.g.. Con

tamination of groun

d water, spill of stored

 fly ash etc. 

Fly ash treated as Hazards 

waste.

To m

axim

ize the usage of fly ashfor d

ispo

sal

FLY AS

H AT A GLA

NCE

Fine

ness factor

<45µ

 abo

ut 35%

Fly ash fusin

g po

int

< 12

00°C

Loss of Ignition

≤5.0%

SiO2

40~50%

Al2O

325

~35%

Fe2O

310

~15%

Na2O

0.5~1%

K2O

0.5~1%

CaO

3~5%

Typical Fly Ash Che

mical Ana

lyses:

Fly Ash Lightw

eight A

ggregate

Brief Introdu

ction of LW

A

FLY AS

H AT

 A GLANCE

Brief Introdu

ction of LW

A

MeTech Fly Ash LW

A Project Intro.

Comparison

 of LWC & Normal Con

crete

Go Green

Fly Ash LW

C Performance & Characteristics

LWA Ap

plications

Brief Introdu

ction of LW

A

1913

1961

Now

Artificial LWA was first m

ade 

in th

e States in19

13

Sintered

 Fly Ash LW

A was 

first m

ade in 1961 in England

The annu

al usage of LWA in th

e de

velope

d coun

tries: abo

ut 80~100 millions m

3The annu

al usage of LWA in th

e Ch

inese market 

so far (clay & sh

ale) : ab

out 4

 million m3

ANew

 Breakthroug

h of 

Techno

logy

From

MeTech Inc

SINTERE

D FLY ASH

 LIGHTW

EIGHT 

AGGRE

GAT

E

Fly Ash Lightw

eight A

ggregate

FLY AS

H AT

 A GLANCE

Brief Introdu

ction of LW

A

MeTech Fly Ash LW

A Project Intro.

Comparison

 of LWC & Normal Con

crete

MeTech Fly Ash LW

A Project Intro.Go Green

Fly Ash LW

C Performance & Characteristics

LWA Ap

plications

MeTech Fly Ash 

LWA Project

After a

gglomeration and palletizing, th

e green pe

llets are sintered

, creating an

 aggregate who

se characteristics are 

supe

rior to natural aggregates. 

Metech’s process u

ses 

approxim

ately 95

% fly ash mixed

 in 

some cases with

 water and

 in so

me 

cases a sm

all volum

e of add

itives. 

MeTech Fly Ash LW

A Project Intro.

Metech has d

evelop

ed a process which con

verts waste fly ash into 

structural lightw

eight a

ggregate, a produ

ct which can

 be used

 to 

econ

omically re

place mined

 ston

e in con

crete, as w

ell as o

ther uses. 

21

Fly

ash

carb

on

addi

tive

mix

ing

aggl

omer

atin

g

wat

er

pelle

tizin

g

sint

erin

gLW

A

dedu

stin

g

Flow

char

t of F

ly A

sh

LWA

Pro

cess

met

erin

g

met

erin

g

Process of LW

A Plan

t (1)

met

erin

g

met

erin

g

1

23

4

Materials

Mixing & 

Agglom

eration

Ignitio

nSintering

Dust 

Collection

Screen

Vertical sh

aft p

lane

tary m

ixer will 

be used for m

ixing, pin m

ixer fo

r agglom

eration. Pan

 type

 pelletizer 

will be used

 for p

elletizing, tilting

 and speed adjustable.

Dry fly

 ash from

 pow

er plant, add

itive 

determ

ined

 by chem

ical con

tents a

nalyzed at 

MeTech Labo

ratory in China. If charcoal ratio < 

5%, carbo

n ne

eds to be

 add

ed to

 assist sinterin

g process. If th

e fly

 ash is to

o coarse, som

e bind

er 

will be requ

ired for p

elletizing. The

 total add

itive 

shou

ld be less th

en 5% in

 the process.

Natural Gas or O

il etc. can

 be 

used

 for ignition

, dep

ending

 on 

cost and

 availability. The

 ignitio

n tempe

rature is abo

ut 

1,000~1,20

0°

The green pe

llets will be 

sintered to high strength 

at te

mpe

rature abo

ut 

1,200°

C with

 sintering 

process.

Reg

ular

LW

A5-

16m

m

Fine

s5-

0.16

0mm

Dust in

 the process can 

be collected

 by du

st 

collector with

 negative 

pressure, exhaust from

 chim

ney  < 50m

g/m3. 

Process of LW

A Plan

t (2) Control system

Process of LW

A Plan

t (3)

Control system

Compu

ter con

trol sy

stem

•te

mpe

ratu

re a

t ign

ition

•te

mpe

ratu

re a

t dus

t col

lect

or•

met

erin

g co

ntro

l of f

ly a

sh, w

ater

, car

bon

and

adm

ix (i

f nee

ded)

•pe

lletiz

ing

cont

rol

•op

erat

ion

stat

us o

f com

plet

e pl

ant

•em

erge

ncy

stop

•di

agno

sis

of fa

ult a

nd tr

oubl

e sh

ootin

g•

Dai

ly, w

eekl

y an

d m

onth

ly re

ports

cov

er a

ll m

ater

ial c

onsu

mpt

ion

and

prod

ucts

pro

duce

d

Real‐tim

e mon

itorin

g system

User frie

ndly interface 

Compu

ter con

trols

Annu

al capacity

(m3 ) 

100,00

015

0,00

030

0,00

0

Fly ash 

consum

ption/yr/M

T80

,000

120,00

024

0,00

0

Size of b

uilding (m

2 ) 

1000

1300

2600

Power Capacity

 (kW)

720

1200

2400

Labo

r per sh

ift 

58

12

LWA Plan

t Cap

acity

 Available

LWA Plan

t Cap

acity

 Available

Mod

el Plants 

Fly Ash Silos a

nd 

Finished

 Produ

ct 

Storage Area

 

Agglom

eration 

Mixer

Pan 

Pelletizer 

Sintering 

System

 

Dust 

Collector

Control 

Pane

lsMod

elPlan

ts

Sintered

 pe

llets

Green

 pe

llets 

Fina

l Produ

ct

Aggregate Size

5~20

 mm

(size

 adjustable by process)

Bulk Den

sity

650‐85

0 kg/m

3Particle Den

sity

1250

~145

0 kg/m

3Ag

gregate Strength

≥5.0 M

paWater Absorption

≤15%

Characteristics of LW

A prod

uct

Characteristics of LW

A prod

uct

Fly Ash Lightw

eight A

ggregate

Comparison

 of LWC & Normal Con

crete

FLY AS

H AT

 A GLANCE

Brief Introdu

ction of LW

A

MeTech Fly Ash LW

A Project Intro.

Compa

rison

 of LWC & Normal Con

crete

Go Green

Fly Ash LW

C Performance & Characteristics

LWA Ap

plications

Compa

rison

 of LWC & Normal Con

crete

The bu

ilding ba

sic info:

1)Bu

ilding Size：5,02

1m2, 

5 stories，

height: 1

9.5m

2)Structure: Cast o

n site,

first level height: 5.1m

, the rest level height: 3.9m

3)Earthq

uake: G

rade

 84)Wind Load

: 0.35K

N.m

25)Material: Co

ncrete beams,

slabs, colum

ns and

 foun

datio

ns

byNationa

lNorthwestern

Archite

cture

DesignInstitu

te

Normal Con

crete (NC), C

401st b

uilding: 

LWC, LC4

02n

d bu

ilding: 

Item

Levels

Column 

(mm)

Outer Beam 

(mm)

Inne

r Beam 

(mm)

Sub‐Be

am 

(mm)

Slab

 (m

m)

NC

2‐3

700x70

030

0x70

035

0x70

025

0x50

013

04 +

600x60

030

0x70

035

0x70

025

0x50

013

0

LWC

2‐3

650x65

025

0x70

030

0x70

025

0x45

012

04+

550x55

025

0x70

030

0x70

025

0x45

012

0

Dire

ction

Type

 of 

Concrete

Perio

dFoun

datio

n   （

CQC ）

Earthq

uake 

force

Shear force of 

foun

datio

nStress

X NC

0.7726

1,165.16

8,223.83

119,049.40

LWC

0.7929

949.56

6,652.73

95,686.79

COMPA

RISION

‐18.50%

‐19.20%

‐19.60%

YNC

0.766

1,174.88

8,326.81

120,881.10

LWC

0.7751

961.81

6,796.46

97,750.94

COMPA

RISION

‐18.10%

‐18.70%

‐19.10%

Dire

ction

Type

 of 

Concrete

Shear 

displacemen

tAv

erage 

displacemen

tMax. A

ngul 

Displacmen

tWeak 

Layer

X NC

6.53

13.91

1/597

1/75

LWC

6.63

14.33

1/588

1/74

Y NC

6.31

13.65

1/618

1/78

LWC

6.33

13.98

1/616

1/78

Table 1: Size of Structure

Table2:  Earthq

uake fo

rce

Table3:  Earthq

uake displacem

ent

Load

 Type

NC

LWC

Results

Live Loa

d40

8.98

540

8.98

51

Dead Load

6,56

8.07

5,31

4.00

‐19.30%

Total Loa

d6,99

5.00

5,72

2.98

‐18.20%

Table4:  Load

 Com

parisonLWC

NC

Vs

LWC Vs Normal Con

crete

Items

Size

Cost

Price

Concrete 

Usage

(m2 )

(USD

）（USD

/m2 )

（m

3 )

NC: C40

5,02

143

0,80

285

.81,77

1.87

LWC: LC4

05,02

135

6,99

371

.11,49

5.95

Table5: C

ompa

rison

 Results

Compa

rison

 Results

Conclusion

s: Usin

g LW

Awill sa

ve 17.14

%of 

the cost com

pare to

 usin

g Normal con

crete for 

the same bu

ilding

Fly Ash Lightw

eight A

ggregate

LWA Ap

plications

FLY AS

H AT

 A GLANCE

Brief Introdu

ction of LW

A

MeTech Fly Ash LW

A Project Intro.

Comparison

 of LWC & Normal Con

crete

LWA Ap

plications

Go Green

Fly Ash LW

C Performance & Characteristics

21

Structural 

Lightw

eight 

Concrete

Soun

d Proo

f Material

High‐rise 

build

ing

Floo

r and

 Roo

f Screed

sMed

ia Filter fo

r Water treatm

ent

Application ba

sed on

 LWA

Lighterin

weightthan

stan

dard

concrete,bu

tjust

asstrong

,structural

lightweight

concrete

mad

ewith

LWA

offers

significant

dead

load

savings.

This

allowsforlong

cantilevers,slim

mer

gene

ralsectio

nsan

dredu

cedfoun

datio

nssizes,en

ablin

gde

signers

toprod

ucestructures

that

wou

ldbe

impo

ssibleto

build

inothe

rmaterials.

E.g.:B

locks,Bricks

&Slab

setc.

High‐rise bu

ilding

LWA BLOCK

SHigh‐rise bu

ilding

Zhuh

aiInternational Con

ference 

Center Building

Building area: 110,000

 m2 , 24

 stories

1‐8 stories: normal aggregate 9‐24 

stories: LW

A (clay) Load Re

duced 

4450KN

CA

NAR

Y WHA

RF TOWER

, Lond

on.  Saved 15% cost b

y using Fly 

Ash LW

A. 

The foun

datio

n load

 has been 

redu

ced trem

endo

usly

Lightw

eight

Excellent The

rmal prope

rty

Load

 Bearin

g

Low W

ater absorption

LW

C strength: LC3

0, LC4

0, LC5

0

LW

C De

nsity

: <1950Kg

/m3

Soun

d Proo

f Material

Soun

d ab

sorptio

nCa

se

Shanxi Province. LW

A (shale) u

sed for 

all inn

er line

r in 2004

Chim

ney he

ight: 180

 m

Highway Con

struction

Theater Inn

er wall m

aterial

He

at insulatio

n material

Soun

d Ba

rrier

Nan

jing First Y

angze River B

ridge

18,000m3 lightweight a

ggregate (clay) 

used

 to re

duce th

e weight loa

d

Hua

nghe

Bridge, Sha

ngdo

ngProvince, Year 1

973

Floo

r and

 Roo

f Screeds

LWA screed

s are easily placed in dep

ths from 30m

m to

 over 

450m

m. The

y provide an

 excellent m

etho

d of m

aking up

 levels 

and offer the

rmal and

 soun

d insulatio

n, which is especially useful 

on re

furbish

ment p

rojects. Only half the am

ount of cem

ent is 

used

 than

 with

 a sa

nd/cem

ent screed, offe

ring tim

e and cost 

savings. The

 den

sity is also app

roximately half that of 

sand

/cem

ent screeds again re

ducing

 structural building costs.

Land

 Drainage Allowing six

 times m

ore 

water th

rough its void space than

 gravel, 

LWA is an

 excellent m

aterial for drainage, 

either in

 slit tren

ching or in

 bulk

Roof tiles S

pecially 

crushe

d and blen

ded 

grades of LWA allow 

roof tile m

anufacturers 

to m

axim

ize strength an 

density, produ

cing

 lighter units to

 redu

ce 

costs a

nd dead load

Filte

r material

One

 week

Three weeks, 

mem

brane  covered

 on

 LWA

Water Filter M

aterial

Chem

icals

SiO2: 

60～65

  ％Al

2O3:

17～22

  ％K 2O+N

a 2O:

3 ～5 ％

Fe2O

3:5 ～

8 ％CaO + M

gO:

3 ～5 ％

LOS ：

1 ～3 ％

Hortag

Water Filter M

aterial

Fly Ash Lightw

eight A

ggregate

Go Green

FLY AS

H AT

 A GLANCE

Brief Introdu

ction of LW

A

MeTech Fly Ash LW

A Project Intro.

Comparison

 of LWC & Normal Con

crete

Go Green

Fly Ash LW

C Performance & Characteristics

LWA Ap

plications

Energy‐Saving & Enviro

nmen

tal Protection

Energy‐saving in produ

ction process

Natural gas is used for ignition

 in th

e process. After th

e first layer o

f sintering be

d is ignited, th

e rest of 

green pe

llets will be sintered

 by the 

self‐containe

d carbon

 in fly ash with

 draft a

ir. 

Energy‐saving in finish produ

cts:  Fly 

ash LW

A ha

s an excellent th

ermal 

insulatio

n prop

erty. C

oncrete mad

e from

 fly ash LW

A ha

s a th

ermal 

insulatio

n ratio

 0.118

‐0.6w/m

.k, 

20%‐25%

 better tha

n regular 

concrete.

Environm

ental Protection : C

onsume 

large qu

antity of fly ash for d

ispo

sal, 

also sa

ving

 agricultural lan

d an

d redu

cing

 pollutio

n.

Dust collection system

 : Dust 

collectors a

re used in th

e process 

to ensure air e

xhau

st to

 meet E

PA 

regulatio

ns.

2015

/6/1

1*

•LW

A Water Absorption

•Fly Ash LW

C Design Ba

sics

•Ce

men

titious M

aterial  Vs. D

ensity of C

oncrete

•Ce

men

titious M

aterial  Vs. C

oncrete Strength

•Water –Ce

men

titious Ratio Vs. Stren

gth

•Cu

ring Pe

riod tim

eVs. Stren

gth

•Fly Ash LW

C Durab

ility Study

•LW

C  Anti‐Freeze Ch

aracters

•LW

C Shrin

kage Perform

ance

•An

ti‐cracking

 Perform

ance

•Self‐compa

cting LW

C•

Strength of S

elf‐c

ompa

cting LW

C•

Self‐compa

cting LW

C Shrin

kage Perform

ance

•Self‐compa

cting Ch

lorid

ion Pe

netrating Qua

lity

Fly Ash LW

C Pe

rforman

ce & Cha

racteristics

2015

/6/1

1

water

absorptio

nun

derd

ifferen

tpressure

LWA water absorption is abo

ut 13%

 und

er normal pressure, th

e higher 

pressure, the

 highe

r water absorption

water absorption(%)LWA Water Absorption:

Tim

e (h

rs.)

2015

/6/1

1Usage of flyash

0% 15%

30%

45%

Total

cemen

titious m

aterial 

used

 for e

ach m

3

300 kg/m

3

350 kg/m

3

400 kg/m

3

450 kg/m

3

500 kg/m

3

550 kg/m

3

Sand

  pe

rcen

tage

40%

Slum

ps

200±

20mm

Fly Ash LW

C DesignBa

sics

2015

/6/1

1

Fly Ash 

Cemen

titious 

Material

Cemen

tFly Ash

Sand

LWA

Water

Additiv

e

0%

300

300

074

9 57

0 25

87.20

 

350

350

072

6 56

0 25

48.40

 

400

400

070

4 54

9 24

49.60

 

450

450

068

1 53

9 23

710

.80 

500

500

065

9 52

8 23

812

.00 

550

550

063

6 51

7 23

913

.20 

15%

300

255

4574

4 56

7 24

46.66

 

350

297.5

52.5

721 

555 

233

7.77

 

400

340

6069

7 54

4 23

38.88

 

450

382.5

67.5

674 

533 

232

9.99

 

500

425

7565

1 52

2 23

411

.10 

550

467.5

82.5

627 

511 

240

12.21 

30%

300

210

9073

9 56

3 23

46.12

 

350

245

105

715 

551 

236

7.14

 

400

280

120

691 

539 

227

8.16

 

450

315

135

667 

528 

225

9.18

 

500

350

150

643 

516 

223

10.20 

550

385

165

619 

504 

225

11.22 

45%

300

180

120

736 

561 

233

5.76

 

350

210

140

711 

548 

228

6.72

 

400

240

160

687 

536 

247

7.68

 

450

270

180

662 

524 

231

8.64

 

500

300

200

638 

512 

247

9.60

 

550

330

220

613 

500 

251

10.56 

2015

/6/1

1

The higher usage of cem

entitious m

aterial, the higher den

sity 

concrete will be, th

e more fly

 ash, the

 lower den

sity of con

crete.

Densituy

Cem

entit

ious

Mat

eria

l

Cmen

titious

Material U

sage Vs. Den

sity of C

oncrete

2015

/6/1

1

Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 0.083B ‐1

2.02

R² = 0.963

7df =

 0.092B ‐7

.422

R² = 0.952

28d

f = 0.09B

 ‐0.366

R² = 0.976

56d

f = 0.108B + 0.341

R² = 0.960

Strength

Cemen

titious M

aterial

1

Mix Design  with

out 

Fly Ash

（FA=0%

）

Cmen

titious

Material U

sage Vs. Con

crete Strength

2015

/6/1

1Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 0.050

B ‐0

.607

R² = 0.880

7df =

 0.082

B ‐5

.563

R² = 0.980

28d

f = 0.080

B + 5.45

7R² = 0.970

56d

f= 0.053

B+ 24.38

6R² = 0.907

Strength

Cemen

titious M

aterial

2

Mix Design with

 15%

fly ash as c

emen

titious 

material

Strength

2015

/6/1

1

Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 0.076

B ‐1

5.99

R² = 0.976

7df =

 0.078

B ‐9

.779

R² = 0.981

28d

f = 0.082

B + 0.46

7R² = 0.993

56d

f = 0.095

B + 0.51

9R² = 0.975

3

Mix Design with

 30%

fly ash as 

cemen

titious 

material

Cemen

titious M

aterial

Strength

2015

/6/1

1Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 0.057

B ‐1

0.29

R² = 0.947

7df =

 0.059

B ‐5

.685

R² = 0.996

 

28d

f = 0.048

B + 10

.02

R² = 0.932

56d

f = 0.086

B + 2.3

R² = 0.987

Strength

4

Mix Design with

 45%

 fly

 ash as c

emetitiou

smaterial

Cemen

titious M

aterial

Strength

2015

/6/1

1Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 18.00

B/W ‐8.11

8R² = 0.974

7df =

 19.95

B/W ‐3.10

7R² = 0.963

28d

f = 19.39

B/W + 4.010

R² = 0.978

56d

f = 23.03

B/W + 5.997

R² = 0.943

Strength

Water‐Cem

entitious ra

tio 

Water –Ce

men

titious Ratio Vs. Stren

gth

1

Mix Design  with

out 

Fly Ash

（FA=0%

）

2015

/6/1

1

Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 11.95

B/W ‐0.88

3R² = 0.913

7df =

 19.04

B/W ‐4.95

1R² = 0.956

28d

f = 18.98

B/W + 5.474

R² = 0.98

56d

f = 12.59

 B/W

 + 24.16

R² = 0.935

Strength

Water‐Cem

entitious

ratio

 

2

Mix Design  with

 15%Fly Ash（

FA=15%

）

2015

/6/1

1

Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 16.06

B/W ‐13

.62

R² = 0.983

7df =

 16.40

B/W ‐7.13

5R² = 0.975

28d

f = 17.40

B/W + 3.095

R² = 0.997

56d

f = 20.01

 B/W

 + 3.442

 R² = 0.984

Strength

Water‐Cem

entitious

ratio

3

Mix Design  with

 30%

 Fly Ash（

FA=30%

）

2015

/6/1

1

Curin

g Pe

riod

Regression

 Equ

ation

Related coefficient

3df =

 15.91

B/W ‐14

.01

R² = 0.972

7df =

 15.99

B/W ‐8.81

4R² = 0.972

28d

f = 13.58

B/W + 6.651

R² = 0.974

56d

f = 23.66

 B/W

 ‐2.96

8 R² = 0.998

Strength

Water‐Cem

entitious

ratio

4

Mix Design  with

 45%

Fly Ash（

FA=45%

）

2015

/6/1

1

FA（%）

Regressio

n Equatio

nRe

lated coefficient

0f =

 0.09B

 ‐0.366

R² = 0.976

15f =

 0.080B + 5.457

R² = 0.970

30f =

 0.082B + 0.467

R² = 0.993

45f =

 0.048B + 10.02

R² = 0.932

Strength

Cemen

titious

Mat

eria

l

Usage of C

emen

titou

s Material V

s. Stren

gth 

Mixde

sign

for 2

8dStrength

The higher volum

e of cem

entitious m

aterial, the higher strength of con

crete for 

28d. The

 highe

st strength achieved with

 15%

 of fly ash,  higher th

an 15%

, the

 strength decreasing.

2015

/6/1

1Mix Design for：

LC20

，LC25

，LC30

，LC35

，LC40

，LC45

，LC50

Trial M

ix design based on

 following form

ula：

fcu.o≥

fcu,k+1.64

5σ

Strength Stand

ard Varia

tion:  σ（MPa）

Strength Grade

< LC20

LC20

‐LC3

5> LC35

σ4.0

5.0

6.0

Mix design Ba

sed on

 28d

Strength

2015

/6/1

1

Strength 

Grade

Cemen

t（kg/m

3 ）Fly Ash

（kg/m

3 ）

Natural 

Sand

（kg/m

3 ）

LWA

（kg/m

3 ）Water Agent

（kg/m

3 ）

0%  Fly Ash

LC20

318

074

356

53.8

LC25

373

071

855

44.5

LC30

429

069

454

15.1

LC35

484

066

953

05.8

LC40

558

063

951

36.7

15% Fly Ash

LC20

242

4374

957

13.4

LC25

295

5272

255

64.2

LC30

349

6269

354

14.9

LC35

401

7166

652

75.7

LC40

472

8363

150

76.7

30% Fly Ash

LC20

208

171

703

536

4.5

LC25

266

217

657

507

5.8

LC30

323

265

611

478

7.1

45% Fly Ash

LC20

237

102

725

552

4.1

LC25

280

120

696

537

4.8

LC30

322

138

668

522

5.5

LC35

365

156

640

507

6.3

Mix design Ba

sed on

 28d

Strength

2015

/6/1

1FA（%）

Regressio

n Equatio

nRe

lated coefficient

0f =

 0.107

 B + 0.341

R² = 0.960

15f =

 0.052

 B + 24.38

R² = 0.907

30f =

 0.094

 B + 0.519

R² = 0.975

45f =

 0.086

 B + 2.3

R² = 0.986

Strength

Cem

entit

ious

Mat

eria

l

Mix 

design

 for 5

6dStrength

The higher volum

e of cem

entitious m

aterial, the higher strength of con

crete for 5

6d.

The highest stren

gth achieved

 with

 15%

 of fly ash and

 450

 Kg/m3 of to

tal  cemen

titious m

aterial

2015

/6/1

1

Strength 

Grade

Cemen

t（kg/m

3 ）Fly Ash

（kg/m

3 ）

Natural 

Sand

（kg/m

3 ）

LWA

（kg/m

3 ）Water Agent

（kg/m

3 ）

0% Fly Ash

LC30

351

073

1557

4.2

LC35

397

071

0547

4.8

LC40

459

067

3539

5.5

LC45

505

065

2529

6.1

LC50

551

064

1515

6.6

15% Fly Ash

LC30

222

3975

8606

3.1

LC35

302

5372

4579

4.3

LC40

409

7267

8542

5.8

LC45

489

8664

4515

6.9

LC50

570

100

610

487

8.0

30% Fly Ash

LC30

278

119

692

567

4.8

LC35

315

135

667

554

5.4

LC40

363

156

641

533

6.2

LC45

400

172

621

517

6.9

LC50

438

187

596

504

7.5

45% Fly Ash

LC30

230

188

678

555

5.0

LC35

262

214

644

543

5.7

LC40

304

249

614

518

6.6

LC45

336

275

591

500

7.3

LC50

368

301

568

482

8.0

Mix design Ba

sed on

 56d

Strength

2015

/6/1

1

Fly ash LW

A  Con

crete An

ti‐Carbon

izatio

n Performance

3d

Carbonization

28d

Carbonization

Fly Ash LW

A Co

ncrete Durab

ility Study

 

Carbon

ization:

CO2from

airp

ermeate

into

concrete

from

itssurface,andwill

have

alkalinereactio

n.Th

esteelb

arinsid

eof

concrete

willbe

gettingrusted

becauseof

thepassivationlayerd

estroyed

.

2015

/6/1

1

a. 0%  Fly Ash                                                                    b. 15%

 Fly Ash

Depth of Carbonization

(1)

Cemen

titious 

material 

Volume Vs 

Performan

ce of 

Anti‐

Carbon

ization 

(1)

The

more

cemen

titious

material,

the

better

performan

cefor

Anti‐

Carbon

ization,

The

higher

intensity

ofthe

concrete

will

be,the

speed

of

Carbon

izatio

nslo

ws,

the

Carbon

izatio

nde

pth

redu

ced,

therefore,

the

less

CO2

perm

eate

into

concrete.

a. 30%

  Fly Ash                                                                    b. 45%

 Fly Ash

Cem

entit

ious

Mat

eria

l

Cem

entit

ious

Mat

eria

l

2015

/6/1

1

Cementitious M

aterial

Fly ash Vo

lume 

Vs. C

arbo

nizatio

n Pe

rforman

ce  (2

)

Thehigher

volumeof

flyash,

thehigher

depthof

carbon

izatio

n,with

400kg/m3cementitious

material,thede

pthof

carbon

izatio

nfor4

5%fly

ashis2.3tim

esof

0%fly

ash.

Theredu

cedcement

caused

Ca(OH)2redu

ced,

theintensity

ofconcrete

atearly

stagecan’tbe

raise

d,thecapabilityof

anti‐

carbon

izatio

nisredu

cedaccordingly.

Testingresultshow

s:fly

ashLW

Aconcrete

hasb

ettera

nti‐carbo

nizatio

npe

rforman

ce.

Depth of Carbonization

2015

/6/1

1

Based on

 Experience, Artificial ra

pid carbon

izatio

n & Natural carbo

nizatio

n follows:

X—t years con

crete Natural Carbo

nizatio

n de

pth mm 

X 0—Ra

pid Carbon

izatio

n de

pth mm ；

C —Natural carbo

nizatio

n  CO2content in Air，

％；

c0—Ra

pid carbon

izatio

n  CO2content in Air，

％；

t 0—Ra

pid carbon

izatio

n pe

riod (year)

T—Natural carbo

nizatio

n pe

riod (year)

Cemen

titious 

Material

（kg/m

³）

50 years

100 years

0%15%

30%

45%

0%15%

30%

45%

300

5.19

8.05

10.14

13.48

7.34

11.38

14.35

19.06

350

4.21

5.24

8.05

11.61

5.96

7.41

11.38

16.42

400

3.09

3.50

6.50

7.24

4.38

4.95

9.19

10.24

450

2.08

2.44

4.66

5.23

2.94

3.45

6.59

7.40

500

0.96

1.42

2.03

4.60

1.36

2.01

2.87

6.50

550

0.44

0.45

0.77

1.73

0.63

0.64

1.09

2.45

LWA concrete Natural carbonization depth predication（

mm）

Artificial rap

id carbo

nizatio

n de

pth for 2

8d is similar to Natural ca

rbon

ization de

pth for 5

0 

years. W

ith 15%

 fly ash an

d 400kg/m³C

emen

titious m

aterial, the na

tural carbo

nizatio

n de

pth 

for 5

0 years is 3.5mm, for 100

 years is 4.95 mm.

Pred

ictio

n of 

Carbon

ization 

Dep

th (3

)

2015

/6/1

1

Concrete

strength

redu

ced

because

offreeze

and

thaw

cycles.

LWA Co

ncrete Anti‐Freeze characters

2015

/6/1

1

Freeze‐Tha

w Cycles

dynamic modulus of elasticity

Freeze‐Tha

wC

ycle

s

Weight LossThemorecycles

offreeze‐thaw,the

less

ofdynamicmod

ulus

ofelasticity,the

moreweightlost.A

fter

150cycles,d

ynam

icmod

ulus

ofelasticity

isabou

t78

.3%,

weightlossisa

bout

3.2%

.

Testingresultshow

s:LW

ACo

ncrete

Anti‐Freeze

charactersisexcellent.

2015

/6/1

1

（1）

15%

fly

ash

（2）

30%

fly

ash

•Theearly

stageshrin

kage

increasedfast

•Themorecemen

titious

material,theless

shrin

kage

•Themorefly

ash,

themoreshrin

kage,

theshrin

kage

with

30%

offly

ashincreased

5.7%

comparin

gwith

15%of

flyashforL

C40

concreterw

ith60

dcurin

gpe

riod.

LWA Co

ncrete shrinkage perform

ance

2015

/6/1

1

Chlorid

ionerosiven

ess to 

steel bar insid

e of con

crete 

will re

duce th

e pe

rformance 

of con

crete du

rability & 

safety

Chlorid

ionErosiven

ess  

2015

/6/1

1

•Testing Re

sults

 show

: Chloridiondiffusion coefficient  for 28d

 DRC

M< 

6×10

‐12m2/s.

•LW

A concrete has better p

erform

ance fo

r Anti‐Ch

lorid

ionerosiven

ess 

than

 normal con

crete, to

tally m

eet the

 requ

iremen

t of d

urab

ility design. 

2015

/6/1

1

The cracking

 from

 con

crete will re

duce its a

nti‐p

ermeability pe

rformance, eventually 

redu

ced the du

rability of con

crete.

Anti‐cracking

 Perform

ance

2015

/6/1

1

Gra

deL-Ⅰ

L-Ⅱ

L-Ⅲ

L-Ⅳ

L-Ⅴ

Tota

l cra

ckin

g ar

ea（

mm

2 /m2 ）

c≥10

0070

0≤c＜

1000

400≤

c＜70

010

0≤c＜

400

c＜10

0

Con

cret

e Ea

rly st

age A

nti-c

rack

ing

abili

ty g

rade

Testing result: Air blow

 24h

，LC30

‐LC5

0 An

ti‐cracking

 ability

L‐Ⅲ

，the pe

rformance is excellent。

2015

/6/1

1

b. 30m

in slum

p

d. Pressure de

vice（15MPa）

With

 pressure of 15M

Pa, P

umping

 slum

p 

is similar to slum

p of 30 minutes 

a．Early

 stage Slum

p

c．1h

 Slump 

LWA Co

ncrete Pum

ping

 Perform

ances

2015/6/11

Self‐compa

cting LW

C

Sample 

No.

FACe

men

titious 

Material (total)

（kg/m

³）

Cemen

t（kg/m

³）Fly Ash（

kg/m

³）Sand

（kg/m

³）LW

A（kg/m

³）Ad

ditiv

e（kg/m

³）

ZA50

15%

500

425

75666

514

6.0

ZA55

550

467.5

82.5

643

503

6.6

ZA60

600

510

90620

492

7.2

ZA65

650

552.5

97.5

596

481

7.8

ZA70

700

595

105

573

469

8.4

ZB50

30%

500

350

150

658

508

6.0

ZB55

550

385

165

634

496

6.6

ZB60

600

420

180

610

484

7.2

ZB65

650

455

195

586

473

7.8

ZB70

700

490

210

562

461

8.4

Desig

n basic

s：

（1）

15% and

 30%

 of fly ash as c

emen

titious m

aterial

（2）

Sand

 percentage 40%；

（3）

Slum

p is controlled un

der（

24±2）

cm

2015

/6/1

1

2015

/6/1

1

Sample No.

FAPressure Stren

gth（

MPa）

Water‐

Cementitions

Ratio

Slum

p（mm）

Extention

（mm）

3d7d

28d

56d

ZA50

15%

16.6

28.3

33.8

47.0

0.49

 220

460

ZA55

22.3

30.5

35.1

51.7

0.47

 240

550

ZA60

27.0

31.7

43.0

54.8

0.43

 260

540

ZA65

28.3

32.3

48.9

57.5

0.42

 280

650

ZA70

30.6

38.3

52.4

66.3

0.40

 285

670

ZB50

30%

12.0

20.1

32.4

45.2

0.56

 260

650

ZB55

16.5

26.8

34.1

50.8

0.50

 255

500

ZB60

16.9

29.0

39.9

52.4

0.45

 260

650

ZB65

19.6

31.7

45.3

56.0

0.44

 270

600

ZB70

20.9

32.4

48.7

59.7

0.41

 260

600

Strength  &

 Slump of self‐c

ompa

cting LW

C

Strength of self‐c

ompa

cting LW

C

2015

/6/1

1

（1）

15% of Fly Ash

（2）

30% of Fly Ash

With

 cem

entitious m

aterial  increased & water ra

tio re

duced, th

e be

tter strength 

will be ob

tained

, the

 strength with

 30%

 fly ash is less th

an with

 15%

 of fly ash.

2015

/6/1

1

Self‐compa

cting LW

C shrin

kage perform

ance

Sample No.

1d3d

7d14d

28d

45d

60d

ZA50

0.92

1.43

4.07

5.6

6.17

6.37

6.41

ZA55

0.2

1.02

3.87

5.09

5.7

5.96

6.23

ZA60

0.61

1.32

3.44

4.57

5.39

5.77

5.78

ZA65

0.03

0.61

3.36

4.48

5.12

5.68

5.88

ZA70

0.31

0.71

3.46

4.21

4.98

5.49

5.56

ZB50

0.31

1.32

4.99

6.31

7.13

7.31

7.48

ZB55

0.72

1.33

5.31

6.64

7.38

7.41

7.46

ZB60

0.41

1.12

4.15

5.06

6.47

6.96

7.21

ZB65

1.41

2.21

4.63

5.44

6.35

6.69

6.82

ZB70

0.82

1.63

4.48

5.13

6.05

6.58

6.73

2015

/6/1

1

（1) 15%

 of fly ash

（2）

30%

of f

ly a

sh

Testingshow

s:early

stage

ofconcrete

hasrapid

shrin

kage,the

varia

tion

redu

cedas

curin

gpe

riodextend

ed,with

cemen

titious

materialincreased,

the

shrin

kage

ratio

redu

ced.

2015

/6/1

1

Self-Compacting LWC Chloridion Erosiveness

Sample 

No.

Total o

f Ce

men

titious 

Material

（kg/m

3 ）

Cemen

t（kg/m

3 ）Fly Ash

（kg/m

3 ）Sand

（kg/m

3 ）LW

A（kg/m

3 ）Water Ratio

Cl‐ Erosivene

ss 

Coeffie

nt（10

‐12 m

2 /s）

ZA50

500

425

75700

617

0.49

6.32

ZA55

550

467.5

82.5

675

603

0.47

4.41

ZA60

600

510

90651

590

0.43

3.22

ZA65

650

552.5

97.5

626

577

0.42

2.95

ZA70

700

595

105

602

563

0.40

2.89

ZB50

500

350

150

691

610

0.56

11.67

ZB55

550

385

165

666

596

0.50

9.01

ZB60

600

420

180

641

581

0.45

8.47

ZB65

650

455

195

615

567

0.44

7.80

ZB70

700

490

210

590

553

0.41

6.89

2015

/6/1

1With

 30%

 of fly ash, Chloridiondiffu

sion coefficient  D

RCM> 6×

10‐12m2/s，

which is highe

r than no

rmal con

crete.

Better Chloridionanti‐diffu

sion pe

rformance by increasin

g cemen

titious 

material and

 redu

cing

 water ra

tio, because th

e intensity

 of con

crete will be 

increased, porosity

 of con

crete will be redu

ced.

2015

/6/1

1

Conclusion

s

1.LW

Awater

absorptio

nisab

out13%

unde

rno

rmal

pressure,the

higher

pressure,thehigher

water

absorptio

n,an

dwith

pressure

of15

MPa,

pumping

slum

pissimilartothe30

minutes

naturalslump.

2.Th

estrength

for56dismuchhigher

than

28d,

with

largevolumeof

fly

ash,

itisto

suggestu

sethestrength

of56dfore

valuation.

2015

/6/1

1

3.Th

ehigher

cemen

titious

material,thehigher

capa

bilityof

AntiCa

rbon

ization,

4.Th

ehigher

density,the

less

CO2pe

rmeate

into

concrete.

5.Artificialrap

idcarbon

izatio

nde

pthfor28dissimilarto

Natural

carbon

ization

depthfor5

0years.With

15%fly

ashan

d400kg/m³C

emen

titious

material,the

naturalcarbo

nizatio

nde

pthfor5

0yearsis3

.5mm,for

100yearsis4

.95mm.

6.Th

emorecycles

offreeze‐tha

w,the

less

ofdyna

micmod

ulus

ofelasticity,the

moreweightlost.After150cycles,dyna

mic

mod

ulus

ofelasticity

isab

out

78.3%,weightloss

isab

out3.2%

.LW

ACo

ncrete

Anti‐Freeze

characters

is

excellent.

2015

/6/1

1

7.With

cemen

titious

materialincreased

,the

density

andthecapa

bilityof

Anti-

Chlorid

ion

diffusion

ofLW

Aconcrete

increases,

Chlorid

ion

diffusion

coefficient

for28dDRC

M<6×

10‐12m2/s，

better

than

norm

alconcrete,

totally

meetthe

requ

iremen

tofd

urab

ility.

8.With

cemen

titious

materialincreased

andthevolumeof

flyashredu

ced,

the

shrin

kage

redu

ced.

Forstrength

grad

eof

LC40

with

60dcurin

gpe

riod,

the

shrin

kage

with

30%of

flyashincreased5.7%

compa

ringwith

15%of

flyash.

9.A

nti-c

rack

ing

test

results:Airblow

24h，

LC30

‐LC5

0An

ti‐cracking

ability

Level‐Ⅲ

，thepe

rforman

ceisexcellent。

ww

w.m

etec

h.co

m.c

n

THAN

K YO

U