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We Energies 228 Coal Combustion Products Utilization Handbook
Chapter 10 Minergy LWA – Structural, Masonry, and Geotechnical Lightweight Aggregates Introduction The unique process developed by Wisconsin Electric and its affiliate Minergy Corp. (both companies are subsidiaries of Wisconsin Energy Corporation), in which fly ash, municipal wastewater sludge, and paper mill sludge are converted to an environmentally inert structural lightweight aggregate for use in the construction market was closed in 2000 thus ending five years of quality lightweight aggregate production. Wisconsin Electric’s lightweight aggregate plant, which was located in Oak Creek, Wisconsin, started production in 1994 and was the world’s only commercial-scale facility that produced structural-grade lightweight aggregate from coal combustion fly ash and wastewater sludge. The stone-like end product, Minergy LWA, was suitable for use in a broad range of concrete products and geotechnical applications. Minergy LWA was sold to concrete producers throughout the Midwest. It is used to reduce dead loads and improve fire ratings of concrete in numerous construction projects. For example, past projects include office buildings in the Chicago area; a student commons facility at St. Olaf College in Minnesota; a hospital in Ft. Wayne, Indiana; Michigan Tech University’s Environmental Sciences Building; and in Wisconsin, VA Hospital in Madison, 8th Street Bridge in Sheboygan, and Miller Park, Midwest Express Center and the Hilton Hotel in Milwaukee. Minergy LWA was also used to produce lightweight concrete masonry. Compared to conventional masonry units made with sand and stone, lightweight concrete masonry has higher fire ratings and higher R-values. 229 We Energies Coal Combustion Products Utilization Handbook
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Ramme - Tharaniyil Second Edition A
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This book is dedicated to all the i
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Contents Chapter 5 Controlled Low-S
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Contents Appendix A Product Data Sh
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Chapter 1 Background and History o
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The United States is the world's se
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are currently installed on about 25
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problems. In the late 1920’s, cin
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Chapter 2 CCPs and Electric Power
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for loading dry bulk semi tankers o
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Figure 2-2: Basic Diagram of an IGC
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Properties of Fly Ash Fly ash is a
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for air entraining admixtures, maki
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Fly ash is an artificial pozzolan.
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Table 2-6: Geotechnical Properties
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Table 2-9 shows the chemical compos
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Table 2-12: Typical Chemical Compos
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The following coal fired power plan
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All bottom ash is removed as necess
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ottom ash is removed by a hydraulic
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Chapter 3 Properties of We Energie
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that distribute and test fly ash to
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Physical, Chemical and Mechanical P
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However, some engineering propertie
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----------------------------U.S. ST
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Results of Testing to AASHTO Standa
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Table 3-8: Summary of We Energies B
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Chapter 4 Concrete and Concrete Ma
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alumina in the pozzolan may also re
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Dunstan summarized his work in term
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The level of shrinkage strains depe
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strength tests were performed at va
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Discussion of Test Results - 4,000
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Other important observations from t
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Figure 4-3: Compressive Strength vs
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300 290 AMOUNT OF WATER, lbs 280 27
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Table 4-8: PPPP ASTM C618 Class C F
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The final setting time for 5000 psi
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Table 4-12: Length Change* NON-AIR-
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Table 4-14: Freeze-Thaw Tests* (Air
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Abrasion resistance tests were perf
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Table 4-16: Compressive Strength Te
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4 DEPTH OF WEAR, mm @ 60 Minutes 3.
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Table 4-19: Mixture Proportions Usi
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12000 COMPRESSIVE STRENGTH, PSI 100
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Table 4-21: Air Permeability Test R
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Table 4-22: Water Permeability Test
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Table 4-23: Chloride Permeability T
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Tax Incremental Financing (TIF) was
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Figure 4-20 : Maple Avenue roadway
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Figure 4-22: Finishing touch to We
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Table 4-26: Concrete Mixture and Si
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6. The high-volume Class C fly ash
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Table 4-31: Average Tensile Strengt
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Table 4-35: Changes in Ultrasonic P
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Table 4-38: Results of De-Icing Sal
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Table 4-40: Abrasion Resistance of
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Summary Based on the data recorded
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3.00 M 101.5 MM WRAPPED UNDERDRAIN
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mixture and concrete mixture. Also,
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Testing Program The testing program
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Test Results Table 4-46 shows the c
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Fly Ash Concrete for Precast/Prestr
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Table 4-49: Concrete Mixture Propor
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Figure 4-27: Electrical Resistance
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Table 4-51: Electrical Properties o
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fly ash by weight of total cementit
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Table 4-53: Compressive Strength of
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Chapter 5 Controlled Low-Strength
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Table 5-1: Mixture Proportions and
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1800 COMPRESSIVE STRENGTH, psi 1600
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Table 5-3: Chemical and Fineness Te
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1800 COMPRESSIVE STRENGTH, psi 1600
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and corresponding compressive stren
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conductivity tests were conducted u
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It can be concluded from this resea
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Table 5-13: Compressive Strength of
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(4) Compatible with copper, aluminu
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Mechanical Properties The compressi
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Figure 5-10: Electrical permeabilit
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Pilot Projects Using We Energies CL
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WisDOT Low Permeability CLSM with W
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material for foundations, changing
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Chapter 6 Commercial Applications
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The report also evaluated frost sus
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Field Study Following the initial s
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Figure 6-3: Bottom ash base course
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Table 6-2: Permeability and Drainag
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Bottom Ash as an Aggregate in Aspha
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Table 6-4: Total Elemental Analysis
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We Energies Bottom Ash as a Soil In
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The coal combustion materials landf
Page 185 and 186: The only other compounds detected t
Page 187 and 188: affect combustion. The resulting fl
Page 189 and 190: Table 6-7: Dry-Cast Concrete Block
Page 191 and 192: Table 6-10 Compressive Strength of
Page 193 and 194: Chapter 7 Fly Ash Stabilized Cold
Page 195 and 196: Using the back-calculated SN values
Page 197 and 198: Falling Weight Deflectometer tests
Page 199 and 200: unconfined compressive strength of
Page 201 and 202: Chapter 8 Fly Ash Metal Matrix Com
Page 203 and 204: The green density of the aluminum f
Page 205 and 206: Table 8-1: Alloy Samples Tested in
Page 207 and 208: Cenospheres Cenospheres are hollow,
Page 209 and 210: Chapter 9 Environmental Considerat
Page 211 and 212: judgment is required for new applic
Page 213 and 214: Table 9-2: NR 538 Fly Ash Analysis
Page 215 and 216: Table 9-3: NR 538 Fly Ash Analysis
Page 217 and 218: Table 9-4: NR 538 Bottom Ash Analys
Page 219 and 220: Table 9-5: NR 538 Bottom Ash Analys
Page 221 and 222: Table 9-7: ASTM D3987 Extraction An
Page 223 and 224: Table 9-8: Typical Heavy Metals Fou
Page 225 and 226: The voluntary C 2 P 2 Challenge Pro
Page 227 and 228: General Usage - NR 538 Applicabilit
Page 229 and 230: * Use Property Owner Notification -
Page 231 and 232: Mercury Removal-Ash Beneficiation (
Page 233 and 234: the air slide inlet was set at 538
Page 235: equired removal temperatures of 813
Page 239 and 240: Chapter 11 Sample Specifications
Page 241 and 242: Part 2 - Products 2.01 Concrete Mat
Page 243 and 244: 3.02 Embedded Items A. All sleeves,
Page 245 and 246: C. Provide adequate number of units
Page 247 and 248: B. Reinforce or replace deficient w
Page 249 and 250: show the strength of masonry strong
Page 251 and 252: 3.02 Bottom Ash Placing and Compact
Page 253 and 254: 3. The CLSM shall meet the followin
Page 255 and 256: 3.02 CLSM Depositing A. CLSM shall
Page 257 and 258: 11.5 Sample Specification for We En
Page 259 and 260: D. Basis of Payment This item, meas
Page 261 and 262: If the reprocessed asphaltic base-f
Page 263 and 264: Chapter 12 References 1. American
Page 265 and 266: 33. University of Wisconsin-Milwauk
Page 267 and 268: 69. Naik, T.R., Kraus, R.N., and Si
Page 269 and 270: Appendix A Product Data Sheets Min
Page 271 and 272: Personal Protective Equipment Speci
Page 273 and 274: FirstAid Eyes Inhalation Ingestion
Page 275 and 276: Appendix B Radioactivity in Coal a
Page 277 and 278: annual number of curies of each of
Page 279 and 280: is divided among cosmic (30 mrem),
Page 281 and 282: constructed with fly ash building m
Page 283 and 284: Appendix C Field Guide for Recycli
Page 285 and 286: ‣ Blend the fly ash and prepared
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Index AASHTO See American Associati
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Index Backfill material, 6, 43, 138
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Index Disposal costs, 5 See also La
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Index Pavement, 26, 109, 187; botto
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Index Size, boiler slag, 22; bottom
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About the Authors Bruce W. Ramme B
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