This study focusses on the development of new lightweight aggregate (LWA) that eventually will have comparable properties with existing natural aggregate which is granite. The main objectives of this study is to examine potential use of recycled municipal solid waste incineration (MSWI) ash as raw material in LWA production with a method of cold-bonded palletization process. The ashes are collected from Cameron Highland Incineration Plant, Malaysia that can be divided into bottom ash (BA) and fly ash (FA). This study uses FA as partial raw material to substitute the Ordinary Portland Cement (OPC). The properties FA are studied by means of X-Ray Fluorescence (XRF). The LWA is fly ash lightweight aggregate (FALA). The production of LWA is based on cold-bonded palletization technique. FALA have experienced two different curing process for 28 days namely room-room (RR) and room-water (RW) curing conditions. The percentage of FA used in this study is 10%, 20%, 30%, 40% and 50% of cement replacement and the size is fixed between 10 mm to 20 mm with circular shape. The properties of FALA produced in this study is examined including loose bulk density, and aggregate impact value (AIV). Other physical properties including colour and texture are also being investigated. From the results of LWA it is clearly seen that 20% FA were the best percentage of ash used to produce good quality LWA. Loose bulk density of FALA selected is 716.72 kg/m3 and AIV 13.80%.
