Development of High Volume Fly Ash Cements For Use in Concrete Construction
Development of High Volume Fly Ash Cements For Use in Concrete Construction
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Abstract
The paper describes a study undertaken to examine the use of high levels of low-lime fly ash (high volume FA) as a cement
component in concrete, beyond the 30% level commonly adopted. The results indicate that FA levels up to 45% by mass can be
combined with Portland cement (PC, C1) to produce the range of practical concrete design strengths, although early strength, which
may be critical in construction, can be reduced compared to PC, and lower level FA concretes. The study progressed to consider the
use of a rapid hardening Portland cement (C2) and low energy clinker (C3) combined with FA at 45%, as a means of overcoming
these early strength shortfalls. Both were found to be effective in matching early strength behaviour of PC concrete. Tests covering
fresh (workability loss, bleeding and moisture loss), engineering (strength development, modulus of elasticity, drying shrinkage and
creep) and durability (absorption, permeability, carbonation rates and chloride diffusion) properties of these concretes were then
carried out. The results indicate that in almost all cases, either similar or enhanced performance was achieved with the high volume
FA concrete, compared to that of PC and these findings offer a route to extending FA use. The practical implications of the study are
also examined.
q 2004 Elsevier Ltd. All rights reserved.
Given current FA production/utilisation levels world- It was decided that, for the high volume FA mixes, a level of
wide and growing pressure for achieving sustainability in 45% by mass FA would be used, such that PC remained the
construction, there is a need to examine the issue of main cement component. In addition, this was considered to
increasing FA levels (as a cement component) in be a reasonable level on which performance could be
concrete. This should build from the strong base that evaluated and from which judgements on higher level use
exists for FA use at 30% in cement, consider the range could be made. The 45% FA mixes were developed by trial
of practical properties and establish how high volume FA mixing, based on extrapolation from the relationships
cement can be used routinely in concrete construction. observed between strength and (total) cement content for
The paper describes the work of a study carried out to the FA mixes of 15 and 30%. The mix proportions used are
address these issues. given in Table 2. As indicated, with increasing FA level, the
water content of the mixes could be reduced (whilst
maintaining workability) and the total aggregate contents
were increased to maintain concrete yield.
2. Portland cement/high volume FA concrete Compressive cube (100 mm) strength tests were carried
out on the concretes (water-cured at 20 8C) at various test
The initial stage of the study involved the development ages to 28 days, using the BS 1881, Part 116 method [15].
of concrete mixes containing high levels of FA. In order to The results from these tests indicate that all mixes achieved
determine suitability for structural concrete, the full range of the required 28 day design strengths, confirming that high
typically used design strength grades (25–70 N/mm2) were FA levels can be used to provide the full range of practical
considered for average workability concrete (75 mm concrete design strength grades typically required. How-
slump). ever, as indicated in Table 3, the early strength of concrete
For this work, a normal Portland cement, referred to as decreased with increasing FA content, as noted previously
C1, Strength Class 42.5 N to BS EN 197-1 [11] was used. [9], reflecting its low early reactivity and high concentration
This was combined with a low-lime FA to BS 3892: Part 1 in the mixes. Between C1 and C1/45FA concretes,
[12]. The main chemical and physical properties of these differences to 14 days of up to 7.5 N/mm2 were noted,
materials are given in Table 1. The aggregates consisted of with the greatest effects tending to be at higher design
single size crushed coarse (20 mm) and crushed sand strength. Tests on air-cured (20 8C and 55% relative
(5 mm) to BS 882 [13] and a filler sand. humidity (RH)) concretes at 7 days, gave corresponding
A series of PC mixes were designed following an differences of up to 5.0 N/mm2. These results, therefore,
established method [14] as a reference. Mixes containing suggest that there may be potential difficulties with high FA
FA in cement at levels of 15% (C1/15FA) and 30% volume concretes in situations where early strength is
(C1/30FA) by mass were also designed to this method. important. These may include, for example, early removal
Table 1 of formwork or applications of load to structural elements,
Main properties of PC (C1) and FA which could have cost implications for the construction
cycle and may prohibit the use of FA at this level.
Property Cement components
C1 FA
Chemical composition (%) 3. Achieving comparable early strength
SiO2 21.2 47.8
Al2O3 4.2 30.7
Fe2O3 2.7 3.8 Given these early findings from the study, the next stage
CaO 64.4 7.1 of the work was concerned with overcoming early strength
MgO 1.5 1.8 depressions at high FA volume. While there are a number of
P2O5 0.1 – different routes that could be used to offset early strength
TiO2 0.2 –
SO3 2.4 0.7
shortfalls, it was decided to take account of these effects, by
K2 O 0.2 0.8 combining the high FA levels (45%) with cements/clinkers,
Na2O 1.3 0.4 which exhibit enhanced early strength characteristics. In
MnO 0.1 – including materials that are available and in current use, this
LOI 1.9 1.3 would represent a straightforward approach to apply in
Mineral composition (%)
practice.
Glass – 83.4
Mullite – 11.0 It was, therefore, decided that a rapid-hardening Portland
Quartz – 2.2 cement (C2), Strength Class 52.5 N to BS EN 197-1 [11]
Magnetite – 1.3 and a low energy (high early strength) clinker (C3) would be
Hematite – 0.7 used. The first of these is a commonly available material
Physical properties from cement suppliers. The latter represents a more recent
SSA (m2/kg) 320 7.0a
development in cement manufacture, which is produced
a
% retained on 45 mm sieve. with the use of mineralisers, e.g. CaF2 and fluxes, to enable
M.J. McCarthy, R.K. Dhir / Fuel 84 (2005) 1423–1432 1425
Table 2
Mix proportions of C1 and C1/FA concretes
reduced temperature clinkering, which can lower fuel was used in some of the higher design strength mixes to
requirements and CO2/NOx emissions, and extend kiln achieve the required workability. The final mix proportions
service life [16]. This clinker exhibits rapid reactivity (with developed and early strength results are given in Tables 5
the addition of water), which precludes using it neat. and 6, respectively.
However, its combination with high levels of FA, should In order to achieve the same strength profiles to 28 days
bring benefits to both materials. The properties of C2 and C3 and allowing for the water saving with FA, the cement
are given in Table 4. contents of the C2/45FA and C3/45FA (i.e. C2C45FA and
The main objective in using these materials was to match C3C45FA) concretes were higher than that of C1 by
the early age and 28 day strength of the PC (C1) concrete between 40 to 100 kg/m3 and 25 to 75 kg/m3, respectively,
(under water curing at 20 8C) and to maintain workability over the range of design strengths, see Table 5, with the
(75 mm nominal slump). Trial mixes were therefore carried greatest increases necessary at higher design strength. The
out, initially using the same mix proportions as the C1/45FA levels of C2 and C3 in the FA concretes were, however,
concretes, and then refined to meet the above criteria. In these significantly lower than those of C1 in the reference
cases, a superplasticizing admixture to BS 5075, Part 3 [17] concretes.
The early strengths of C1, C2/45FA and C3/45FA are
Table 3 given in Table 6 for the 25, 50 and 70 N/mm2 design
Early cube strengths of C1 and C1/FA concretes (water cured at 20 8C)
Table 5
Mix proportions of C1, C2/45FA and C3/45FA concretes
strength concretes. As indicated, the combination of C2 The results are given in Fig. 1 and indicate that
and C3 with FA, lead to their being very little difference workability loss rates increased with design strength for
between these and the corresponding C1 concretes. This, all concretes. While at 25 N/mm2 design strength, there
therefore, provided a viable route to overcoming problems was little difference in rate of workability loss between
associated with early strength development in high volume concretes, at the other design strengths, this was slightly
FA concretes. greater in the C2/45FA and C3/45FA concretes, in
The study therefore progressed to examine the range of particular, at test times beyond 60 minutes. However
practical properties for these concretes. The mixes given in such differences at these compacting factors are not
Table 5 were used in the subsequent tests, except for practically significant. Given the greater cement contents
workability loss and bleeding, where minor modifications in the FA concretes at equivalent design strength to those
were made, as described below. In the majority of cases, of C1, this seems likely to reflect differences in rheology
unless noted otherwise, concretes of design strength 25, 50 and rates of water combination with the cements between
and 70 N/mm2 were tested. Similarly, for the hardened concretes.
property tests, the concretes were cured in water at 20 8C to
the test age or 28 days, unless indicated otherwise. In all
cases, 2–3 duplicate tests/test specimens were used.
Table 6
Early cube strengths of C1, C2/45FA and C3/45FA concretes (water cured
at 20 8C)
4. Fresh concrete properties
Concrete mix Compressive strength (N/mm2)
4.1. Workability loss and bleeding Cement Design strength Age at test (days)
(N/mm2) 3 7 14
Tests for workability loss were carried out for each C1
cement type (C1, C2/45FA and C3/45FA) using the 25 10.5 16.5 20.5
compacting factor method, which involves comparing the 50 23.5 34.5 41.5
70 39.0 52.5 62.5
ratio of weights of a fixed volume of partially and fully
C2/45FA
compacted concrete, as described in BS 1881, Part 103 [18]. 25 11.0 16.0 20.0
The workability was controlled such that a compacting 50 26.0 34.5 41.5
factor of approximately 0.95 was achieved, (i.e. high initial 70 39.0 50.5 60.5
workability) carried out by adjusting both the water and C3/45FA
cement contents of the mixes given in Table 5, while 25 12.0 15.5 20.0
50 26.5 34.0 42.5
maintaining the W/C ratio and modifying the aggregate
70 40.5 51.5 61.0
contents to maintain concrete stability and yield.
M.J. McCarthy, R.K. Dhir / Fuel 84 (2005) 1423–1432 1427
Bleeding of concrete was tested using the ASTM C232 reported previously [20]. While the bleeding results
method [19] by collecting water from hand compacted indicate that more water is held in FA concretes than
concrete in a 14 l container over a 180 minutes period. in PC, this does not cause significant differences in
These tests were carried out on the same concrete mixes as workability loss, suggesting that the controlling mechan-
those used for workability loss. The results are given in isms between the properties are different.
Fig. 2 and indicate that the bleeding characteristics were
also dependent on concrete design strength, generally 4.2. Moisture loss
reducing as this increased. Initial rates of bleeding were
lower in the C2/45FA and C3/45FA concretes than in C1. The results obtained for the moisture loss tests, carried
By the end of the test period, however, at 25 N/mm2 design out by periodic weighing of specimens stored at 20 8C
strength, there were only minor differences between and 55% RH, after removal from the moulds at 24 h, are
concretes. At 50 N/mm2, the C2/45FA and C3/45FA given in Fig. 3, with respect to the net water content of
concretes exhibited bleed levels approximately 50% of C1 the mixes. As indicated, the rate of moisture loss
at this time, while at 75 N/mm2, the FA concretes gave no reduced with increasing concrete design strength. At
bleed water, compared to 0.45% for C1. equivalent design strength, similar, or slight reductions in
The results suggest that the water retention properties moisture loss at a given time (particularly at early ages)
of FA have an influence on bleeding behaviour, as were noted in the FA concretes (and thus the actual
weight loss in the latter was lower in all cases). This 5. Strength development of equivalent concrete mixes
suggests that the water retention effects referred to
earlier in the fresh concrete are not apparent in this test The influence of high volume FA cements on strength
data. development of concrete was tested using concrete cubes
Fig. 4. Strength development of C1, C2/45FA and C3/45FA concretes under (a) water and (b) air curing.
M.J. McCarthy, R.K. Dhir / Fuel 84 (2005) 1423–1432 1429
the combined enhancement of the microstructure, as chemical admixtures. However, there is likely to be an upper
indicated by the permeation tests, and the relatively high limit, beyond which (i) early strength of high FA concrete
alumina content of FA, providing chloride immobilising cannot reasonably match that of PC concrete and (ii) there is
properties to concrete, which have been reported previously no further benefit (i.e. a ceiling is reached), through reducing
to increase with FA content [10]. lime availability for activation of all FA included. Further
work by the Authors is currently exploring this.
As shown in the results obtained from this study,
8. Practical implications many aspects of concrete performance are enhanced and
the risk of problems normally associated with high
The results have shown that the use of low-lime FA at cement contents, including, heat of hydration, creep and
levels greater than 30% may lead to a reduction in early damaging alkali-silica reaction would be reduced with
strength, of equivalent 28 day design strength concrete, high volumes of FA. Furthermore, this approach is likely
which may be unacceptable in some practical situations and to provide a number of environmental and economic
could be up to 7.5 N/mm2 at 7 days, over the range of design benefits to concrete construction.
strengths commonly used in practice. This may then extend
the period to the striking of formwork by several hours, or
more, depending on the type of construction and the ambient
conditions. Where early strength is not of concern, related
work [28] has shown that the use of high FA levels (45%)
with normal PC (e.g. C1) give similar performance, over the
range of properties, at equivalent design strength, to that
achieved with C2/45FA and C3/45FA concretes reported in
this study.
It has been demonstrated that problems with early
strength can be overcome by utilising active early strength
cement/clinker, with both a conventional rapid
hardening Portand cement and a low energy clinker proving
effective with high levels of FA, in matching early strength
profiles of PC concrete. In using these and taking
advantage of the water reducing properties of FA (for the
fine ash used), small increases in cement content (i.e. C2C
45FA, C3C45FA) were required compared to those of PC
concrete.
It may be possible to further extend FA volumes in
concrete, beyond those used in the study, for example by the Fig. 8. Chloride diffusion coefficients of C1, C2/45FA and C3/45FA
introduction of other cementitious materials or the use of concretes.
1432 M.J. McCarthy, R.K. Dhir / Fuel 84 (2005) 1423–1432