FLI Precast Turns Power Plant Byproduct into Low Carbon Innovation

Project

From Ashes to Concrete: Trinity College Dublin and FLI Precast Solutions Turn Power Plant Byproduct into Low-Carbon Innovation

Date

June 2025

Location

FLI Precast, Co. Carlow

Partners

Construct Innovate, Bord na Mona

Business Sectors

Precast Concrete Manufacturing

Services (Technical Disciplines)

Concrete Science and Manufacturing

Project Objectives/ Outcomes

Utilize biomass ash as a resource:
Transform the biomass ash byproduct from Edenderry Power Station into a valuable material for concrete production.
Reduce carbon emissions in concrete production:
Develop low-carbon and carbon-free concrete alternatives by:

· Partially replacing Portland cement with biomass ash.

· Completely eliminating Portland cement through geopolymerization using biomass ash and metallurgical slag.

Demonstrate performance and scalability:
Ensure that the newly developed concrete solutions maintain high performance while achieving up to 51% reduction in carbon emissions, making them practical and scalable for real-world construction.
Support Ireland’s carbon neutrality and circular economy goals:
Align with national sustainability targets by promoting circular economy practices—reusing industrial byproducts in construction—and reducing reliance on high-carbon materials.
Foster industry collaboration and adoption:
Partner with FLI Precast Solutions and other industry stakeholders to pilot, refine, and expand the use of this sustainable concrete technology across Ireland’s construction sector.
Advance sustainable construction innovation:
Set a new benchmark for eco-friendly construction materials and encourage broader adoption of greener technologies through research, development, and demonstration.

Our Role

·       Collaboration on research and development:
FLI Precast worked closely with Construct Innovate and Trinity College Dublin researchers to test and apply the biomass ash-based concrete formulations in real precast concrete products.·       Providing industry expertise and validation:
As a specialist in precast concrete, FLI Precast helped ensure that the developed materials met practical performance standards and could be integrated into existing manufacturing processes.·       Supporting sustainability goals:
The company aligned its corporate vision with the project’s aims by actively participating in the development of sustainable, low-carbon concrete solutions. Their involvement demonstrated a commitment to environmental responsibility and innovation.·       Enabling real-world implementation:
FLI Precast’s participation helped bridge the gap between laboratory research and market-ready products, contributing to the project’s success in demonstrating scalability and practical feasibility.

Geoscience Ireland Contact

Luke O’Connor

loconnor@flipreacst.com

Photo shows

FLI Precast Manufacturing Facility, Co. Carlow, Group photo with production team, Sara Pavia & Dr. Zehao Lei (Trinity College Professor and Phd student), David McDonnell (Batching & Lab Manager, FLI Precast) & Luke O’Connor (FLI Precast Chartered Structural Engineer)

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