This study focused on the adaptation of Aspergillus niger tolerating high concentration of heavy metals for bioleaching of fly ash. The Plackett-Burman design indicated that Al and Fe inhibited the growth of A. niger (AS 3.879 and AS 3.40) significantly. The single metal (Al and Fe) and multi-metals adapted AS 3.879 strain tolerated up to 3500 mg/L Al, 700 mg/L Fe, and 3208.1 mg/L multi-metals, respectively. The order of metal extraction yield in two-step bioleaching of 60 and 70 g/L fly ash using Al adapted, multi-metals adapted and un-adapted AS 3.879 strains was as follows: multi-metals adapted > Al adapted > un-adapted. The multi-metals adapted strain grew with up to 70 g/L fly ash and secreted 256 mmol/L organic acids after 288 h, where 87.4% Cd, 64.8% Mn, 49.4% Zn and 45.9% Pb were dissolved. The extracted metals in TCLP test of the bioleached fly ash by multi-metals adapted strain were under the regulated levels in China. (C) 2008 Elsevier Ltd. All rights reserved.