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Less icing and damage
3–4× extended lifespan
Fewer cracks/deformations
2–3× less frequent repairs
3–4× extended lifespan
Fewer cracks/deformations
2–3× less frequent repairs
Strong
300+ cycles
Low
30–50 years
300+ cycles
Low
30–50 years
Lightweight expanded clay as fill
Prefab LECA concrete slabs
Lightweight insulation panels
Heat-retaining anti-ice surfaces
Anti-vibration lightweight concrete
Prefab LECA concrete slabs
Lightweight insulation panels
Heat-retaining anti-ice surfaces
Anti-vibration lightweight concrete
Overall Economic Summary:
- 15–25% reduction in construction cost
- 30–40% savings in long-term maintenance
- 20–25% transportation & load efficiency
- 25–30% labor and time efficiency
• 🇸🇪 Sweden’s Trafikverket: reported 18–22% project cost savings with expanded clay
• 🇷🇺 Russia's Rosavtodor: saved 3–4 billion RUB/km by switching to expanded clay fill (2019)
• 🇯🇵 Japan: reduced thermal-related operational costs by 12%
• 🇷🇺 Russia's Rosavtodor: saved 3–4 billion RUB/km by switching to expanded clay fill (2019)
• 🇯🇵 Japan: reduced thermal-related operational costs by 12%
Conclusion: Long-term bridges using expanded clay require 30–40% less maintenance.
Conclusion: 30% faster construction with smaller teams and equipment.
Conclusion: Total construction costs decrease by 15–20%.
🔷 Expanded clay and expanded clay concrete provide a safe, durable, and energy-efficient material solution for modern bridge projects.
🔷 Actively implemented in Europe, Japan, Russia, and Scandinavia, especially in seismically active and wet areas.
We recommend officially incorporating expanded clay in all bridge designs in Uzbekistan — particularly in mountainous and riverbank areas — with full technical and economic justification.
🔷 Actively implemented in Europe, Japan, Russia, and Scandinavia, especially in seismically active and wet areas.
We recommend officially incorporating expanded clay in all bridge designs in Uzbekistan — particularly in mountainous and riverbank areas — with full technical and economic justification.
Column Foundations
Bridge Decks
Side Barriers / Walls
Pedestrian Walkways
Guardrail Foundations
Bridge Decks
Side Barriers / Walls
Pedestrian Walkways
Guardrail Foundations
Bridges are complex engineering structures that must withstand high loads, temperature variations, moisture, and vibrations. Expanded clay, also known as lightweight expanded clay aggregate (LECA), is increasingly recognized as an innovative material that satisfies these critical structural requirements.
Impact
Expanded Clay Concrete
Application
Component
Weak
50–100 cycles
High
10–15 years
50–100 cycles
High
10–15 years
Heat Retention
Freeze Cycle Resistance
Thermal Expansion
Maintenance Interval
Freeze Cycle Resistance
Thermal Expansion
Maintenance Interval
Conventional Concrete
Feature
Up to 30% faster
25–30% labor reduction
Lower machinery costs
Easier, less fatigue
25–30% labor reduction
Lower machinery costs
Easier, less fatigue
25–35 mins/m³
3–4 workers
Light equipment enough
Minimal
3–4 workers
Light equipment enough
Minimal
45–60 mins/m³
5–6 workers
Heavy equipment needed
High
5–6 workers
Heavy equipment needed
High
Pouring Time
Crew Requirement
Machinery Load
Vibrations Required
Crew Requirement
Machinery Load
Vibrations Required
Gain
Expanded Clay Concrete
Conventional Concrete
Metric
CONCLUSION & RECOMMENDATION
III. PRACTICAL USE CASES IN BRIDGE STRUCTURES
4. International Practice and Validation
3. Operational & Maintenance Savings
2. Construction productivity
2.5× lighter
Lower delivery expense
3–5× longer durability
Less winter heat loss
Reduced labor + faster work
Lower delivery expense
3–5× longer durability
Less winter heat loss
Reduced labor + faster work
800–1200 kg/m³
20–25% lower
300+ cycles
High
Faster
20–25% lower
300+ cycles
High
Faster
2400–2500 kg/m³
High
50–100 cycles
Low
Slow
High
50–100 cycles
Low
Slow
Density
Transport Costs
Freeze Resistance
Energy Efficiency
Pouring Time
Transport Costs
Freeze Resistance
Energy Efficiency
Pouring Time
Benefit
Expanded Clay Concrete
Conventional Concrete
Indicator
1. Material and operational cost savings
• 100% natural, non-toxic, non-degradable.
• Fire classification: NG (GOST 30244).
In the event of accidents, no toxic smoke or fumes are released.
In Japan, fire-resistant slabs using expanded clay are used in seismic regions (e.g., Tokyo Bay Bridge, 2010).
• Fire classification: NG (GOST 30244).
In the event of accidents, no toxic smoke or fumes are released.
In Japan, fire-resistant slabs using expanded clay are used in seismic regions (e.g., Tokyo Bay Bridge, 2010).
5. Eco-friendly and fireproof
• Thermal conductivity: λ = 0.10–0.18 W/m·K (3× lower than concrete).
Reduces ice accumulation on walkways and enhances energy efficiency.
Reduces ice accumulation on walkways and enhances energy efficiency.
4. Excellent thermal insulation — eliminates cold bridging
• Lightweight fill with expanded clay settles less and retains structure.
Replaces heavy fill or gravel in marshy or unstable zones.
According to LECA Sweden, a 20 cm layer reduces pressure on the foundation by 30–40%, ideal beneath bridge supports.
Replaces heavy fill or gravel in marshy or unstable zones.
According to LECA Sweden, a 20 cm layer reduces pressure on the foundation by 30–40%, ideal beneath bridge supports.
3. Stability on slopes and weak subsoils
• Expanded clay resists ≥300 freeze–thaw cycles (GOST 9758:2001).
Ideal for open environments, river crossings, and mountainous regions.
In Finland, Norway, and Russia, bridges using expanded clay concrete have performed well since the 1970s (e.g., Murmansk, Arkhangelsk).
Ideal for open environments, river crossings, and mountainous regions.
In Finland, Norway, and Russia, bridges using expanded clay concrete have performed well since the 1970s (e.g., Murmansk, Arkhangelsk).
2. Exceptional frost resistance and durability
• Density of expanded clay concrete: 800–1200 kg/m³
• Standard concrete: 2400–2500 kg/m³
This reduces the load on the foundation by 2 to 3 times, which is crucial for bridge decks, sidewalks, and sidewalls.
European standards (EN 206, EN 1992-1-1) allow lightweight concrete in bridge superstructures, especially in seismic and geotechnically sensitive areas.
• Standard concrete: 2400–2500 kg/m³
This reduces the load on the foundation by 2 to 3 times, which is crucial for bridge decks, sidewalks, and sidewalls.
European standards (EN 206, EN 1992-1-1) allow lightweight concrete in bridge superstructures, especially in seismic and geotechnically sensitive areas.
1. High strength-to-weight ratio — reduces structural load
II. ECONOMIC AND PRACTICAL ADVANTAGES
I. SCIENTIFIC AND TECHNICAL FOUNDATIONS
EXPANDED CLAY IN BRIDGE CONSTRUCTION — LIGHTWEIGHT, DURABLE, AND ENERGY-EFFICIENT SOLUTION
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