Coal Ash Matters: April 2023

THIS ISSUE - APRIL 2023

Editorial

NSW Government Make $3.25 million

Investment to use of CCPs as Support

Construction Material

ASTM: C618 Standard Revised

America’s Innovative Use for Fly Ash

Stanwell’s Recent Investments into Sustainable Solutions

BG&E : QTT transforming our existing building stock

Arcadis Use Fly Ash in JFK Airport Redevelopment

Cement Australia Reduces Emissions in QLD

Stanwell Helping Brisbane Airport Reach Net Zero

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ADAA

COAL ASH EDITORIAL TEAM

Views expressed in Coal Ash Matters newsletter do not necessarily reflect the opinion of the Ash Development Association of Australia. All contributions are welcomed, though the publisher reserves the right to decline or edit for style grammar, length and legal reasons. ©2005-23.

Chief Executive Officer: Craig Heidrich

Contributors: Sam Patane, Jarrod Pollard, Dan Webb, Craig Heidrich, Jodi Lidell (Stanwell), Stephanie Hession and Reza Hassani ( BG&E)

Coal Ash Matters is a bi-annual publication

Editor: Sam Patane

Design: 101 Design

Circulation: 2000

MEMBERSHIP

COMPANY MEMBERS

A primary role of the ADAA is to bring together producers and marketers of coal combustion products (CCPs). Our activities cover research and development into CCP usage, advocacy and technical assistance to CCP producers and users, as well as a forum for the exchange and publication of CCP information.

For more information visit us at www.adaa.asn.au

CURRENT MEMBERS

• Adbri Limited

• BG&E

• Bilmar Solutions

• Boral Construction Materials

• Cement Australia

• CS Energy

• Daracon Constructions

• Delta Electricity

• Dr Jane T Aiken Consulting & Environmental Services

• Energy Australia

• Heeleys Consulting Pty Ltd

• Hills Bark Blower (T/A Tremline Pty Ltd)

• Independent Fly Ash Brokers Pty Ltd

• InterGen Australia (Millerran)

• Latrobe Magnesium

• NRG Gladstone Power Station

• Origin Energy - Eraring Power Station

• Sphere One

• Stanwell Corporation

• Transport for NSW

• Ultimate Housing

• Vector Ltd

RECIPROCAL MEMBERSHIPS

• CSIRO www.cmit.csiro.au

• European Coal Combustion Products Association (ECOBA) www.ecoba.org

• UK Quality Ash Association www.ukqaa.org.uk

• American Coal Ash Association www.acaa-usa.org

• World Wide Coal Combustion Products Network (WWCCPN) www.wwccpn.org

EDITORIAL

Welcome to another issue of Coal Ash Matters, and the first for 2023!

The past few months has been an extremely exciting time for the Ash Development Association of Australia, culminating after four (4) years of engagment with the NSW Government, $3.25 million has been committed to support construction material industry efforts to explore and identify investment opportunities pathways for harvesting of stored coal combustion products within NSW.

We then explore the revision of the ASTM C618 – Standard Specification for Coal Ash and Raw or Calcined Natural Pozzolan for Use in Concrete, which comes after four years of focused effort by the American Coal Ash Association members, the ACAA Technical Committee and numerous allies in the concrete industry.

Continuing in the USA where Fly ash has stepped up to the challenge once again, being utilised as the specialised concrete for an innovative bridge-replacement project in Montana, U.S.A.

ADAA member Stanwell Corporation, who have shown dedication to diverting increased volumes of CCPs from landfill can be observed in their various projects that showcase sustainable solutions, aiding a lower carbon future and enabling the government and their customers to meet their sustainability goals and ESG targets

We then hop on the plane and head over the Pacific to New York, where Arcadis have utilise Fly Ash in their recent JFK Airport redevelopment, emphasising the use of sustainability in their practices at the airport.

From one member to another, BG&E have utilised their innovations in sustainability in the construction and engineering of the Quay Quarter Tower in Sydney.

We then come back to Australian shores where Cement Australia are supplying cement as part of Hanson’s contribution to new Cross River Rail project. Made up of 10.2 km of rail line including 5.9km of twin tunnels running under the Brisbane River and CBD, the project aims to transform the way Queenslanders travel across the whole of South East Queensland.

With another Coal Ash Matters airport twist, we head to Brisbane Airport where a recent renewable energy agreement between ADAA member Stanwell Corporation and Brisbane Airport Corporate (BAC) has been established, enabling Brisbane Airport to be powered by 100% renewable energy. Lastly, the Ash Development Association of Australia would like to say a big thank you to all members, as well as all of our contributors of this edition of Coal Ash Matters. This issue, like all issues, would not be possible without the support of our members. We are looking forward to working together with members for the next edition of Coal Ash Matters, as well as other upcoming and exciting projects.

NSW GOVERNMENT MAKE $3.25 MILLION INVESTMENT

TO USE OF CCP’S AS SUPPORT CONSTRUCTION MATERIAL

NSW Government make $3.25 million investment to support construction material industry efforts to explore and identify investment opportunities pathways for harvesting of stored coal combustion products within NSW into existing and new markets to further reduce carbon emissions and mitigate climate change in NSW.

Craig Heidrich, CEO of the Ash Development Association of Australia stated that, ‘the Association welcomes this announcement and funding commitment by the NSW Government to support economic and employment opportunities associated with coal combustion products. Studies and inquiries into carbon abatement opportunities in NSW identified coal combustion products for funding under the Carbon Recycling and Abatement initiatives which is pleasing’.

Mr Heidrich noted, ‘over the next 24 months the Association will work closely with its members, construction materials stakeholders, key government agencies (e.g. TfNSW) and the NSW EPA implementation team to deliver the first milestone project – Coal Ash Pathways Research Partnership’

‘Finally, whilst the funding is critical to our projects, wide stakeholder engagement and building clear understanding about future investment opportunities will be a core focus for harvested coal combustion products’ Mr Heidrich said.

About the Carbon Recycling and Abatement Fund

The Carbon Recycling and Abatement Fund initiatives targeting coal combustion products opportunities are outlined below.

Carbon Abatement Opportunities for Circular Economy study identified several remanufacturing and recycling opportunities based on carbon abatement potential. The Carbon Recycling and Abatement Fund will support the following opportunities concerning coal combustion products:

1. Coal Ash Pathways Research Partnership: The Environment Protection Authority (EPA) will partner with Ash Development Association of Australia to map and characterise ash repositories in NSW, gaining a better understanding of resource supply and applications to inform industry investment. $950,000.

2. Coal Ash Harvesting Infrastructure Fund: The EPA will provide funding to support feasibility trials targeting infrastructure and technology that improve access to stored coal ash repositories, informed by the findings of the Coal Ash Pathways Research Partnership with the Ash Development Association of Australia. $2 million.

3. New and Updated Government Material Specifications for Geopolymer and Portland Cement: The EPA will partner with NSW Government agencies to fast-track new and updated material specifications to build demand for geopolymer cement applications and coal combustion products in Portland cement. $200,000.

4. Publishing Coal Ash Supply Chain Information: The EPA will partner with NSW Government agencies to publish coal ash supply chain information and anticipate future demand. $100,000.

For more information about these initiatives, visit the EPA website or contact the Ash Development Association of Australia to learn more and get involved.

ASTM: C618 STANDARD REVISED

The ASTM Committee C09 on Concrete and Concrete Aggregates in the US has just approved revision of the ASTM C618 - Standard Specification for Coal Ash and Raw or Calcined Natural Pozzolan for Use in Concrete, in a unanimous vote, to include harvested coal ash and bottom ash. from brown coal fly ash harvested from the repository at the Yallourn Power station.

The approved revision comes after four years of focused effort by the American Coal Ash Association members, the ACAA Technical Committee, and numerous allies in the concrete industry who worked extensively to develop the revised standard. C618 now specifically includes bottom ash and acknowledges fly ash may come from a harvesting site rather than directly from the power plant.

The approved changes include:

• Replacing the word “coal fly ash” with “coal ash.”

• Adding a maximum of 10 percent retained on No. 100 sieve requirement to bottom ash and harvested fly ash.

• Adding definitions for coal combustion products, bottom ash, and harvested ash.

• Adding a materials and manufacture section stating that harvested ash and bottom ash require processing to meet C618.

• Adding a requirement for disclosing the type of material being certified (harvested ash, bottom ash, etc.)

A key to building consensus for the changes was a “Literature Review on the Use of Harvested Coal Ash as a Supplementary Cementitious Material” developed by Dr. Doug Hooton, University of Toronto, and Dr. Michael Thomas, University of New Brunswick. The changes will allow expanded quantities of coal ash for use in concrete, helping to build more durable infrastructure and reduce the carbon footprint of concrete construction.

If you would like to learn more about the American Coal Ash Association, visit their official website.

Photo: The famous fly ash ingot.

AMERICA’S INNOVATIVE USE FOR FLY ASH

Fly ash has stepped up to the challenge once again, being utilised as the specialised concrete for an innovative bridge-replacement project in Montana, U.S.A.

The specialised concrete was developed by Montana State University (MSU) engineering researchers, Mike Berry and Riley Scherr back in January 2018 in the MSU concrete lab, in collaboration with the Montana Department of Transportation (MDT) as part of a federal initiative to encourage states to adopt ultra-high performance concrete.

Understandably, this material has been around for a number of years but has only been available as proprietary mixes for certain contractors, evoking a material that is expensive and not always readily available.

Evidently, with the need for a newly developed mix, MDT asked Mike Berry for help in establishing a non-proprietary and affordable version of the material that could be used by local contractors.

It was a large feat for the team but with persistence and vigour, their intentions soon became reality and an MSU-developed ultra-highperformance concrete was forged.

Mike Berry describes the material as “normal concrete on steroids”, detailing the technical evolution of the specialised material, explaining, “Fine particles of bi-products like the fly ash from coalfired power plants fill in tiny voids surrounding the larger particles in the concrete to create a dense mixture, while polymers allow it to flow with less added water and needle-like filaments of steel bond the otherwise brittle product together once it has cured. Still, sourcing the ingredients and developing a process for reliably formulating and mixing the material was a challenge,” he said.

The next step was applying the material to a real-life project with the selection of the Trail Creek bridge replacement on Highway 43 near the town of Wisdom, Florida. This bridge replacement presented a critical link between the Bitterroot and Big Hole valleys and was the first infrastructure to trial and test the specialised material.

The project was facilitated by Mike Berry’s team, consisting of Kirsten Matteson, assistant professor of civil engineering, MDT,

and the project contractor, Tyler Baumberger of Dick Anderson Construction, who all worked closely to educate the construction workers on how to mix the material to save valuable time in the field.

The utilisation of the ultra-high-performance concrete saw the joining of several long concrete slabs that formed the bridge deck as well as bond the deck with metal pilings that were pre-drilled to expedite construction. The material’s ability to cure to a high strength within roughly a day made it possible to open the new bridges for traffic 12 hours ahead of the 96-hour target for completion; an extremely short time for replacing a bridge.

The material supplied the bridge with substantial benefits including significantly stronger concrete, enhanced durability, and a cost-effective solution due to the material being half the cost of proprietary concrete after factoring in the use of local contractors. Subsequently, the material enabled the success of the project and resulted in MDT’s partnership with MSU being recognised and presented with an award by the American Association of State Highway and Transportation Officials during the organisation’s annual meeting.

Mike Berry commented on his gratitude for the award explaining, “It’s exciting to receive this recognition...It’s really the culmination of years of research and collaboration, he said.

Lenci Kappes, an MDT engineer who worked on the project, emphasised MDT’s plans for the future, explaining, MDT is eager to continue ways of using the material, including for resurfacing bridge decks to increase their lifespan and reduce long-term maintenance costs, he said.

If you would like to learn more about the MSU-developed concrete, click here.

Image credit: Montana Department of Transportation - The Trail Creek Bridge during final stages of construction.

Image credit: Informed Infrastructure –The development of the High-Strength Concrete in 2018

STANWELL’S RECENT INVESTMENTS INTO SUSTAINABLE SOLUTIONS

Coal Combustion Products (also known as CCPs) are solid waste materials produced when coal is burned to generate electricity. Gannawarra Energy Storage System (GESS), the first of its kind in Australia.

In approved applications they derive substantial benefits including conserving natural resources, saving energy, and reducing associated carbon emissions, resulting in measurable economic benefits. ADAA member, Stanwell Corporation, are continuously diverting hundreds of thousands of tonnes of coal combustion products (CCP) from landfill by treating them as a resource instead of as waste.

Stanwell’s dedication to diverting increased volumes of CCPs from landfill can be observed in their various projects that showcase sustainable solutions, aiding a lower carbon future and enabling the government and their customers to meet their sustainability goals and ESG targets.

Some of Stanwell’s recent investments in sustainable solutions include the:

• CCP recovery and placement sustainability road

• Tarong Power Station fly ash plant investment

• Stanwell Power Station high CCP utilisation in pavement design trial,

• Design guide for rural pavements which is currently under development.

Tarong Power Station

Tarong Power Station is a newly built CCP offtake facility and one of Stanwell Corporations’ recent projects that are driving the circular economy forward. The offtake facility has the capacity to support 400,000 tonnes per annum of high-quality cement-grade fly ash. This will allow Tarong Power Station to decrease the CCP stored at site and facilitate the use of CCP in infrastructure projects.

Stanwell Power Station Road Repair

The road repair demonstration at Stanwell Power Station is an additional project highlighting sustainable solutions by increasing ash utilisation in major infrastructure projects. Stanwell Corporation is currently working with local councils and civil contractors to investigate the possibility of incorporating CCPs into future road design and construction.

Coal Combustion Products (CCPs) can be used in a wide range of bound and unbound applications. Bound applications chemically transform the resource into a final product such as cement, concrete, and supplementary cementitious materials. Unbound applications include the CCPs as an alternative to traditional quarry materials in applications such as soil stabilisation, pipe bedding, engineered fills, and cable bedding.

Image: Ash Offtake Facility at Tarong Power Station

Image: Road Repair Trail at Stanwell Power Station

BG&E : QQT TRANSFORMING OUR EXISTING BUILDING STOCK

Recent legislative changes in Nordic nations and the United Kingdom have seen traditional “raze and rebuild” development proposals only be accepted in the absence of a compelling argument for the upcycling of the existing building – promoting the adaptive reuse of structures.

Adaptive reuse is the most efficient strategy to lower the amount of carbon that is embodied during construction - while also evolving our built environment to best meet the needs of all stakeholders. It should come as no surprise that nations are turning to adaptive reuse in the battle to meet net-zero targets and sustainability pledges, given that the building and construction sector now contributes to approximately 40% of the world’s greenhouse gas emissions.

The Quay Quarter Tower, a 51-storey vertical village located in the heart of Sydney’s CBD, focuses on sustainability and is widely regarded as the highest and largest adaptive reuse project ever completed. During this project, a 190-meter tower constructed in the 1970s was upgraded to a 216-meter tower that meets modern requirements. Recent accolades include the renowned 2022/23 International HighRise Prize and the World Architecture Festival’s 2022 “Global Building of the Year.”

For the project, ADAA member BG&E offered their services in structural engineering, construction engineering, materials testing and structural monitoring. Two-thirds of the floor plates and supporting columns as well as the entire core wall system of the old structure

were kept during construction based on rigorous materials testing and structural design of the structural components.

This project introduced a new iconic structure to Sydney’s skyline while reducing embodied carbon by almost 12,000 tonnes. Through this, BG&E has demonstrated that even older, more complicated structures can be upcycled to both cut carbon emissions and extend a structure’s service life for future requirements.

The symbiotic relationship between reusing existing structures and lowering embodied carbon was highlighted by Senior Associate Reza Hassani who was the key lead engineer on that project. The challenges on that project included linking the 50-year-old structure with the newly constructed elements. Importantly also, fly ash was used in the concrete mix supplied for the new construction. It was also likely used in the construction of the original 50 year old structure as part of the binder.

BG&E truly is at the forefront of adapting the necessary complex engineering strategies to construct stock sustainably.

Image: Long shot of QQT : Photo by Phil Noller

ARCADIS USE FLY ASH IN JFK AIRPORT REDEVELOPMENT

Fly Ash concrete mix has been utilised by Arcadis in their recent redevelopment of one of the largest airports in the world, JFK airport in New York.

Arcadis Global Airports Solutions Director Nick Hutchinson emphasises that everything seen in the structure of the redeveloped buildings is centred around recycling, including the fly ash used in the concrete mix.

Hutchinson described the use of Fly Ash concrete mix in all the concrete that is used at the airport as a critical part of Arcadis’ plan of sustainability in practice and significantly reducing carbon footprint.

“These days, it is not just about environmental aspects - it is also about ESG’s, so it’s environmental, social and governance metrics. ESG is about sustainability goals, we weave all of those sustainability goals into everything that we do”, Hutchinson said to Airways.

“There are a few neat factors in this project. It is all about ensuring that we are conservative with our resource usage. We’re not polluting, so we’re managing carbon. As an example, we used a high fly ash concrete mix which significantly reduces the carbon footprint of all of the concrete that is used at the airport”.

“We focus on all of the materials that are used in the building process. Everything that you see in the structure and the envelope of the building, from the roof to the apron, in terms of materials - centres around recycling. So, it is the ability to reuse the materials in the long term, so we are not wasting them again”.

The US $400 million expansion and modernisation of the airport has created five new widebody gates, four widebody parking positions, an expanded baggage handling system and an expansion of terminal eight by 130,000 square feet.

The use of ash in this airport project showcases the potential that fly ash has in reducing carbon footprint for future redevelopment and construction projects.

REDUCES EMISSIONS IN QLD

ADAA member Cement Australia - owned by 50% Hanson and 50% Holcim - are supplying ALL Hanson concrete other than precast for the world-class project, with Wagners holding the precast contract.

The project includes four new underground stations and a new aboveground station, all of which are manufactured with Hanson cementitious materials including Bulwer GP, Central QLD Fly Ash, and Bulwer Slag. In some cases, as much as 60% of cement in concrete mixes can be substituted for waste materials. Additionally, approximately 2,000 tonnes of manufactured sand from glass have been utilised as pipe embedment and bedding material under pavements.

The sizeable use of fly ash, slag, and glass waste in the Cross River Rail allows the project to play a critical role in reducing Queensland’s carbon footprint in the future, as more Queenslanders opt to use public transport.

More than just a rail project, Cross River Rail also presents opportunities for urban renewal and precinct development at each of its major station locations, including Boggo Road, Woolloongabba, Albert Street and Roma Street.Major construction works on Cross River Rail are due to be completed in 2024, ahead of extensive safety testing and commissioning, with services expected to commence in 2025. If you would like to learn more about Cement Australia, visit their official website

Image: Project Tunnel, credit: Corss River Rail

The sunshine state is getting even brighter thanks to the new Cross River Rail project. Made up of 10.2 km of rail line including 5.9km of twin tunnels running under the Brisbane River and CBD, the project aims to transform the way Queenslanders travel across the whole of South East Queensland.

STANWELL HELPING BRISBANE AIRPORT REACH NET ZERO

Flying out of Brisbane Airport has never been so environmentally friendly...until now. A recent renewable energy agreement between ADAA member Stanwell Corporation and Brisbane Airport Corporate (BAC) has been established, enabling Brisbane Airport to be powered by 100% renewable energy.

Stanwell Corporation is a major provider of electricity and energy solutions, currently driving the development of a renewable hydrogen export industry in Central Queensland and keeping the lights on as the State’s energy industry transforms.

Brisbane Airport is customer number one in its renewable energy pipeline, benefiting from the supply of 185 GWh of renewable energy each year. This will facilitate all airport operations from the runway lights to the terminals, travellators, escalators, retail shops, administration, IT, and electric vehicle refuellers.

Stanwell supports the state’s decarbonisation efforts, with a noticeable focus on supplying cleaner and cheaper energy from small businesses to large corporates like Brisbane Airport.

The Palaszczuk Government are looking to expand on the renewable energy projects, storage and hydrogen projects with a $4.5 billion investment into additional government-owned energy companies over the next 5 years. Additionally, Stanwell will be investing $1.8 billion in the clean energy transformation.

Brisbane Airport Corporate Chief Executive, Gert-Jan de Graaff, explains the agreement will see Brisbane Airport meeting its net zero

emissions commitment by 2025, 25 years earlier than expected. He continues, “Queenslanders can travel through our terminals knowing their journey begins and ends at one of the world’s most sustainable airports once this green energy begins flowing from regional Queensland,” he said.

Stanwell CEO, Michael O’Rourke, explains they are proud to be supporting the acceleration of Brisbane Airport’s net zero target by 2025.

He emphasised Stanwell’s transformative, tailored offerings, explaining, “this is the first of many renewable energy options Stanwell Energy will be offering to support our commercial and industrial customers meet their decarbonisation requirements,” he said.

He continued, “Stanwell is unique in its approach when it comes to its service offering. Our dedicated account managers are able to work with customers to develop tailored energy contracts that provide flexibility, security, and access to renewable options.

The partnership with Brisbane Airport Corporation will be linked to renewable energy from the Clarke Creek Wind Farm and Blue Grass Solar projects.

REMEMBER THE CCGP JOURNAL?

The CCGP Journal is a joint publication between the University of Kentucky Center for Applied Energy Research and the American Coal Ash Association. The CCGP is an international peer-reviewed, online journal that encompasses the science and technology of the production, sustainable utilisation, chemistry, and environmentally sound handling of all by-products. Annual Masters Builders-Bankwest Excellence in Construction Awards.

Since 2008, CCGP has played an important role in keeping track of new advancements in the industry, with around 4 papers a year being published and advertised. This year, the journal has received 0 published papers, with 3 submissions, which requested to be published without undergoing the review process.

The Journal’s livelihood depends on new, submitted papers submitted by various researchers and authors. The Ash Development Association of Australia would like to encourage its members to reach out if there is anything you believe may be helpful to The Journal.

Topics of interest:

• Fly Ash

• Bottom Ash

• Boiler Slag

• Geotech

• FGD Products

What can be submitted?

• Original research results

• Proceedings of symposia

• Surveys

• Reviews

• Book reviews

• Overviews of recent literature

• Letters to the editor

• Ponds

• Beneficial Use

• Landfills

• Chemistry

• Regulations

• Gasification Residues

• Mining & Reclamation

• Cement & Concrete

• Construction Materials

• Disposal

• Aggregates

• Chemical Classification

• Rare Earth Elements

• Coal-Fuel Blend By-Products

• Groundwater & Environment

The CCGP Journal is free to publish and is available online creating a great opportunity for those who enter in The Journal.

Please send us an email at: info@asa-inc.org.au if you wish to make a submission.