Center for

By-Products

Utilization

EFFECT OF SOURCE AND AMOUNT OF FLY ASH

ON MECHANICAL AND DURABILITY PROPERTIES

OF CONCRETE

By Tarun R. Naik, Shiw S. Singh, and Bruce W. Ramme

CBU REPORT NO. REP-282

Department of Civil Engineering and Mechanics

College of Engineering and Applied Science

THE UNIVERSITY OF WISCONSIN - MILWAUKEE

EFFECT OF SOURCE AND AMOUNT OF FLY ASH ON MECHANICAL

AND DURABILITY PROPERTIES OF CONCRETE*

By

Tarun R. Naik, Ph.D., P.E.

Director, Center for By-Products Utilization

Department of Civil Engineering and Mechanics

College of Engineering and Applied Science

University of Wisconsin - Milwaukee

P.O. Box 784, Milwaukee, WI 53201

Telephone: (414) 229 - 6696

Fax: (414) 229 - 6958

Shiw S. Singh, Ph.D., P.E.

Environmental Engineer

Vijay and Associates, Inc.

Milwaukee, WI

and

Bruce W. Ramme, P.E.

Integrated Production Team Leader

Port Washington Power Plant

Wisconsin Electric Power Company

Port Washington, WI

_____________________________

* For presentation and publication at the Fourth CANMET/ACI International Conference on Durability of

Concrete, Sydney, Australia, August 17 - 22, 1997.

EFFECT OF SOURCE AND AMOUNT OF FLY ASH ON

MECHANICAL AND DURABILITY PROPERTIES OF CONCRETE

by

Tarun R. Naik, Shiw S. Singh, and Bruce W. Ramme

Synopsis:

This research was carried out to evaluate the effects of source and amount of fly ash on strength and durability

properties of concrete. Mechanical properties considered were compressive strength, tensile strength, flexural strength, and

modulus of elasticity. The durability properties considered were: shrinkage, abrasion resistance, air and water permeability,

chloride permeability and salt scaling resistance of concrete.

A reference concrete was proportioned to attain the 28-day compressive strength of 41 MPa. Three sources of Class C

fly ash were used in this work. Fly ash from each source was used at three levels of cement replacements (40, 50, and 60% ) in

producing concrete mixtures. The water to cementitious materials ratio was maintained at 0.30 ± 0.02 for all mixtures.

In general strength and durability properties of concrete were considerably affected by both the fly ash source and

amount of fly ash. Also, the strength and durability properties for the 40% fly ash mixture were either comparable or superior to

the no-fly ash concrete. The salt scaling resistance of fly ash concrete was either comparable to or better than the no-fly ash

concrete, except for one source of fly ash at 60% cement replacement level. All the mixtures, with and without fly ash, tested in

this investigation conformed to the strength and durability requirements for excellent quality structural grade concretes.

INTRODUCTION

Fly ash is generated from combustion of coal in power plants. Its physical, chemical, and mineralogical properties are

2

dependent upon type and source of coal, type of combustion system, combustion temperature, type of pollution control system

used, etc. Consequently, fly ash can have varying properties depending upon the source of fly ash.

Use of fly ash in concrete is desirable due to technical and economic benefits. High volumes of fly ash have been used

in concrete for a long time, for reducing cost and controlling temperature increase in order to reduce cracking at early ages. A

systemic investigation was started at CANMET in 1985 for development of high-volume Class F fly ash concrete. Application of

large amounts of Class C fly ash in structural grade concrete and other products began at the University of Wisconsin-Milwaukee

in 1982. More recently, the use of fly ash has been extended to high-strength as well as high-performance concretes. In order

to develop material specifications for concretes incorporating fly ash, their long-term mechanical and durability properties need to

be established. This study was carried out to investigate the effect of source and amount of Class C fly ash on mechanical and

durability properties of concrete.

3

SCOPE

Concrete mixtures incorporating 40, 50, and 60 percent Class C fly ash obtained from three different sources were

proportioned. These mixtures were produced at the concrete laboratory of Center for By-Products Utilization (CBU) at the

University of Wisconsin-Milwaukee (UWM). The water-to-cementitious materials ratio [W/(C + FA)] was kept at 0.30 ± 0.02 for

all mixtures. All laboratory mixtures were air-entrained and superplasticized using an air entraining agent and a

superplasticizer, respectively. Fresh and hardened concrete properties were determined for all mixtures. The fresh concrete

properties measured were unit weight, slump, air content, etc. Test specimens were prepared to measure hardened concrete

properties including compressive strength, splitting tensile strength, flexural strength, modulus of elasticity, drying shrinkage,

abrasion resistance, air permeability, water permeability, chloride permeability, and deicing salt scaling resistance.

LITERATURE REVIEW

A number of publications (1-6) have reported that adding fly ash to concrete mixtures reduces the water content,

increases workability, decreases bleeding, and improves pumpability. Naik and Ramme (6) investigated rheological

properties and setting characteristics of concrete made with high-volumes of Class C fly ash. Their results revealed that initial

and final times of setting were not greatly different when the fly ash replacement for cement is increased up to the levels of

55%. Others (1,7,8) have reported increases in the initial and final times of setting of concrete using low-calcium fly

ashes. Use of class C fly ash has shown a mixed behavior on setting and hardening of concrete.

Air entrainment in concrete systems is provided to prevent damage due to freezing and thawing actions. It is

4

established that inclusion of fly ash in concrete increases the amount of air entraining agent (AEA) compared to the no-fly ash

concrete (1-5,9). The primary reason for the increased AEA dosage rate is reported to be the presence of unburned carbon

content and fineness of fly ash. Gebler and Klieger (10) stated that an increase in the loss on ignition of fly ash leads to an

increase in the amount of air entraining admixture rate. They also found that concrete containing Class C fly ash demanded less

AEA compared to concrete with Class F fly ash.

A large number of investigations have devoted efforts toward development of fly ash concrete for structural

applications (6-20). These investigations have shown that more than 50% cement can be replaced with fly ash for

manufacture of structure grade concrete.

Gebler and Klieger (21) reported that the abrasion resistance of Class C fly ash concrete with 25% fly ash was

generally superior to Class F fly ash concrete. Tikalsky et al. (22) observed the same trend up to 35% cement replacement

with fly ash. Hadchti et al. (23) indicated that at equal strengths, fly ash concrete is as resistant to abrasion as no-fly ash

concrete. Naik et al. (24-27) indicated higher abrasion resistance of concrete made with up to 50% Class C fly ash and

comparable to concrete with 40% Class F fly ash. Naik et al.(24-27) also showed excellent abrasion resistance of concrete

incorporating high-volumes of Class C fly ash. Bilodeau and Malholtra (28) showed lower abrasion for the fly ash

concretes containing 55 to 60% Class F fly ash relative to concrete without fly ash.

Numerous studies (29-35) have shown very low permeability of concrete incorporating fly ash relative to no-fly ash

concrete. Rodway and Fedirko (29) reported permeability of concrete incorporating Class C fly ash for 68% cement

replacement of about 3.65 x 10-12 m/s. Ellis et al. (30) demonstrated reduction in chloride permeability of concrete with an

5

increase in both Class C or Class F fly ash contents for a fixed amount of cement content. Bilodeau et al. (31) evaluated water

and chloride permeabilities of concretes having 55 to 60% cement replacement. They reported coefficient of water

permeability of fly ash concretes in the range of 1.6 x 10-14 to 5.7 x 10-13 m/s. The values of chloride permeability (less than

650 Coulombs at 91 days) observed in their investigation for fly ash concretes were comparable to chloride permeability of

silica fume concretes. Naik et al. (32) have also reported similar results.

Recently, Naik et al. (32-35) evaluated permeability of concrete incorporating a Class C fly ash for cement

replacement in the range of 0 to 70%. The concrete mixtures up to 60% fly ash content (FA/C+FA = 0.6) exhibited good

resistance to air, water, and chloride permeabilities. Beyond 60% fly ash content, concrete permeability increased

substantially.

Numerous investigations (12, 24, 36, 37, 38) have shown satisfactory performance of Class C fly ash concretes when

subjected to freezing and thawing actions. Yuan and Cook (12) reported excellent freezing and thawing durability of air

entrained concretes containing up to 50% Class C fly ash. Naik and Ramme (36) and others (24, 37, 38) have also observed

similar results for high-volume fly ash concrete systems.

There is a lack of data on effects of Class C fly ash inclusion on concrete resistance to salt scaling (41). Gebler et al.

(42) found that Class C and F fly ash concretes possessed identical deicing salt scaling resistance at a curing temperature of

23C. Naik et al. (41) reported adequate salt scaling resistance of concrete containing up to 60% Class C fly ash.

6

MATERIALS

Portland Cement

Type I portland cement conforming to ASTM C 150 requirements was used in this study. The physical and chemical

properties of the cement are shown in Table 1.

Fly Ash

Three different sources of fly ash (ASTM Class C) were selected for this investigation. These fly ash sources are

designated as F1, F2, and F3. The chemical and physical properties of fly ashes were determined in accordance with ASTM C

311 (Table 1).

Aggregates

The fine aggregate was natural sand with a 6.3 mm nominal maximum size. The coarse aggregate used in this

study was 19 mm nominal maximum size crushed limestone that met ASTM C 33 requirements. The grading and physical

properties of the aggregates are given in Tables 2 and 3, respectively.

Chemical Admixtures

A commercially available synthetic resin type air-entraining admixture (AEA) and a melamine-based superplasticizer

was used in all mixtures. The air-entraining admixture and the superplasticizer met the specification of ASTM C 260 and C

494, respectively.

7

MIXTURE PROPORTIONS

A total of 10 different mixtures were proportioned. One of them was a control mixture and the remaining nine

mixtures contained Class C fly ash as a replacement of cement. For each fly ash source, three levels of fly ash (40, 50, and 60)

were selected. The water-to-cementitious materials ratio (W/(C + FA)) was kept at 0.30 ± 0.02 for all the mixtures. The

desired workability was achieved through the aid of a superplasticizer. Each mixture was air-entrained with a target air

content of 6 ± 0.5 percent using an air entraining agent.

The mixing procedure was according to ASTM C 192. Each batch was mixed in a power-driven revolving tilting drum

mixer using 0.16 m3 batches. For each batch, slump, unit weight, temperature, density, air content, etc. were measured.

8

FRESH CONCRETE PROPERTIES

Just after each concrete batch was mixed, fresh concrete properties were measured. A slump test was

determined in accordance with ASTM C 143. The air content of the concrete was measured according to ASTM C 231. The

unit weight of the concrete was determined following ASTM C 138. All mixture proportions and fresh concrete properties are

shown in Table 4.

CASTING, CURING, AND TESTING OF SPECIMENS

All specimens were cast and cured in accordance with ASTM C 192. Compressive strength, splitting tensile

strength, and modulus of elasticity specimens were cast in 150 x 300 mm plastic molds. Prisms were cast for flexural

strength tests (75 x 100 x 300 mm). Using applicable ASTM Standards compressive strength (ASTM C 39), splitting tensile

strength (ASTM C 496), flexural strength (ASTM C 78), and modulus of elasticity (ASTM C 469) were determined.

Prisms (75 x 100 x 300 mm) were cast for length change measurement of concrete in accordance with ASTM C 157.

Test specimens were cured in lime-saturated water for 28 days, and then transferred to a controlled air drying room. The

temperature and relative humidity of the drying room air were maintained at 23C and 50 ± 4%, respectively.

Air and water permeability of concrete was measured according to the Figg Method (33,34). This test method

involved drilling a hole, 40mm deep by 10mm diameter, into the concrete surface. These holes were plugged with a

9

polyethylene foam and the surface sealed with a silicon sealant. A hypodermic needle was then inserted into the plug. For

air permeability testing, the hypodermic needle was subjected to a vacuum pressure of about minus 55 kPa by a hand-held

vacuum pump. The time, taken for the pressure to change from minus 55 kPa to minus 50 kPa, was taken as a measure of

air permeability of concrete. For water permeability testing, a water head of 100 mm was applied to concrete through the

needle. Then the time taken to absorb 2 ml was recorded as a measure of water permeability.

Three 100 x 200 mm cylinders were cast for chloride permeability measurement of concrete. From each cylinder, a

100 mm diameter x 50 mm thick slice was cut from the middle portion using a diamond tipped saw. The chloride ion

permeability of concrete specimen was measured according to ASTM C 1202.

Test specimens of 300 x 300 x 100 mm were cast for abrasion resistance determination of concretes. An

accelerated test method, a modified ASTM C 944, as described in detail elsewhere (25, 26, 27), was used to measure abrasion

resistance of concrete. In this method, a rotating cutter was equipped with washer having smaller diameter relative to the

dressing wheels. Furthermore, an equal amount of silica sand ("Ottawa Sand") was added to the concrete surface during

exposure to abrasion at one minute intervals. One level teaspoon of sand was added each time. At each wear location

(circle of wear), for each wear time, three readings were taken along two lines in the circle; and, the average of these six

readings were recorded as one reading for each experimental condition.

Specimens of 300 x 300 x 100 mm thick slab were cast in wood molds for measuring salt scaling resistance of

concrete surface in accordance with ASTM C 672.

10

RESULTS AND DISCUSSION

Fresh Concrete Properties

The fresh concrete properties such as slump, air content, temperature, and density are presented in Table 4. For a

given air content, dosage of air-entraining admixture (AEA) increased with fly ash content for all the three sources of fly ash

used in this investigation. However, the amount of superplasticizer was lower for the fly ash mixtures compared to the

reference mixture without fly ash for the desired level of consistency of these mixtures (slump was 100 ± 20 mm). This was

due to improvement in workability of concrete mixtures resulting from the presence of spherical fly ash particles. The dosage

of the superplasticizers varied amongst the various sources of fly ash. For a given source of fly ash, the superplasticizer

dosage necessary, for the designated workability, decreased as fly ash content increased.

Hardened Concrete Properties

Compressive Strength

Test data on compressive strength are presented in Table 5 and illustrated in Fig. 1. At early ages up to 3 days,

generally the fly ash mixtures exhibited lower strength compared to the reference mixture without fly ash. At 7 days, all the

mixtures except M5 and M6 attained strength of 40 MPa or greater. At 28 days, the mixtures (except M5, M6, and M9) with

and without fly ash showed strength higher than 50 MPa. The effect of source of fly ash was significant on strength

development of concrete. This was attributed to the differences in the reactivity of fly ashes obtained from different sources.

11

The best results were observed for the mixtures incorporating source F1 fly ash. At early ages, fly ash F1 and F3 (strengths)

were equivalent but F2 strengths were lower. However, the effect of source became small beyond 28 days. At 365 days,

fly ash mixtures attained compressive strength in the range of 65 ± 10 MPa. Best strength was observed for the mixture

incorporating source F1 fly ash. The other two sources generally exhibited equivalent results. Generally 40 and 50 percent

fly ash concrete performed equivalent or better than no fly ash concrete, except at the very early age.

Splitting Tensile Strength

The splitting tensile strength generally decreased with increase in fly ash content up to 7 days (Table 6, Fig. 2). The

level of decrease with fly ash content was markedly influenced by source of fly ash up to 7 days. The best results were

obtained for the mixtures containing source F1 fly ash up to an age of 7 days. The other two sources (F2 and F3) showed

comparable results. The tensile strength of the reference mixture and all sources of fly ash were equivalent at 28-day and

91-day ages. The tensile strength values at 365-day age were generally lower for all fly ash mixtures compared to the

reference mixture without fly ash. The fly ash F1 had equivalent results and F2 and F3 sources were lower compared to the

no-fly ash mixture.

Flexural Strength

The flexural strength of concrete was influenced by the source of fly ash (Table 7, Fig. 3). The values of flexural

strength for the fly ash mixtures varied from 4.3 to 6.8 MPa at 28 days, 4.7 to 6.8 MPa at 91 days, and 5.2 to 7.2 MPa at 365

days. The flexural strength values for the reference mixture were 6.2 MPa at 28 days, 6.9 MPa at 91 days, and 7.4 MPa at 365

days. Generally, fly ash concrete mixtures had lower flexural strength compared to the reference mixture without fly ash.

Typically, fly ash F2 had lower values compared to fly ash F1 and F3.

12

Modulus of Elasticity

At the one day age, the modulus of elasticity of the fly ash concretes were significantly lower compared to the

reference concrete (Table 5 and Fig. 4). The effect of fly ash source was also significant at this early age. At the 7-day age,

the values for fly ash concretes were still lower than the no-fly ash concrete, though not by a significant margin. At 28 days

and beyond fly ash concretes showed equivalent results than the reference mixture. The modulus of elasticity values ranged

between 29.3 to 32.8 GPa at 28 days, 36.6 to 38.3 GPa at 91 days, and 40.4 to 45.5 GPa at 365 days for the fly ash concretes.

The reference concrete showed modulus of elasticity values of 34.5 GPa at 28 days, 37.8 GPa at 91 days, and 45.9 GPa at 365

days.

Drying Shrinkage

The drying shrinkage increased with age (Table 9, and Fig.5). Beyond 56 days of age of concrete (i.e., 28-day

shrinkage strain measurements), fly ash concretes showed mostly equivalent or higher shrinkage than the no-fly ash concrete.

The effect of source also became significant at this age and beyond. The highest shrinkage was observed for the concrete

incorporating fly ash from source F3.

Abrasion Resistance

The depth of abrasion increased with increased abrasion time and decreased with increasing age (Table 10). The

abrasion resistance of the concretes for 40% fly ash was comparable to the reference concrete for the fly ash F1; lower abrasion

resistance for fly ash F2; and, generally highest for fly ash F3. As fly ash concentrations increased, the abrasion resistance

decreased compared to the no-fly ash concrete. However, all concretes with or without fly ash had high resistance to

13

abrasion (i.e., wear of less than 2.0 mm).

Air and Water Permeabilities

The air and water permeabilities values for the test mixtures measured by the Figg method were not consistent.

This was primarily due to the destructive nature of the test, as microcracks are believed to be produced during the fabrication of

test holes. These microcracks can affect the result, especially in high-strength concrete, due to their high brittleness, used in

this project. As a result, the air and water permeability data measured by the Figg method are not reported. These data are

available elsewhere (35).

Chloride Permeability

In general, beyond 28 days, the fly ash concretes showed higher resistance to chloride ion than the no-fly ash

concrete (Table 11). The effect of source and amount of fly ash on chloride ion permeability of concrete was insignificant

(Fig. 6). Fly ash F2 had the highest Chloride ion permeability at the 28-day age. At 365 days all the fly ash mixtures

showed chloride permeability of less than 400 coulombs (very low), while the reference concrete showed a value of 1060

coulombs (low) at this age. The "very low" and "low" classifications are in accordance with ASTM Test C-1202.

Deicing Salt Scaling Resistance

In general, all the fly ash mixtures up to 60% cement replacement exhibited equal to or better than resistance to

deicing salt scaling compared to the no-fly ash concrete (Table 12). At 40% cement replacement, the fly ash mixtures

out-performed the reference mixture. Above 40% fly ash content, except the mixture containing 60% fly ash from source F2,

14

the fly ash concretes showed either comparable or better results than the reference mixture. No definite trend could be

established about source of fly ash on salt scaling resistance of concrete. However, fly ash F3 performed the best.

CONCLUSIONS

1. All the mechanical strength properties, such as compressive strength, tensile strength, flexural strength, and modulus of

elasticity were affected by both source and amount of fly ash. But the degree of influence of these factors varied

depending upon age (maturity) of concrete. The difference between the strength properties of the fly ash mixtures

and the reference mixture (no-fly ash mixture) decreased with age. Generally, fly ash source F1 performed the best,

followed by fly ash F3, and then F2.

2. The early age strengths (up to 3 days) of the fly ash mixtures were lower relative to the reference mixture. Beyond 3

days, the 40% fly ash mixture with different sources of fly ash showed either equivalent or superior results when

compared to the reference mixture. The 40% mixtures containing various sources of fly ash showed in excess of 51 MPa

at 28 days. All the mixtures containing 50 to 60% fly ash produced compressive strength in excess of 40 MPa at 28

days.

3. The tensile strength, flexural strength, and modulus of elasticity data followed a similar general trend as that observed for

the compressive strength data. Although, source and amount of fly ash had a much greater impact on actual test values

observed.

4. Up to the age of 56 days, the fly ash mixtures showed drying shrinkage results equivalent to that attained by the

15

reference mixture. But beyond 56 days, with one exception, the fly ash mixtures generally had higher drying

shrinkage compared to the reference mixture.

5. Up to 40% cement replacement, abrasion resistance of concrete was equivalent to that of the no-fly ash reference

concrete. When fly ash content was increased to more than 50%, concrete abrasion resistance decreased slightly for all

sources of fly ash.

6. Concrete resistance to chloride ion permeability decreased substantially at ages beyond 28 days for cement replacements

in the range of 40 to 60% with fly ash. Chloride ion permeability was relatively unaffected by source of fly ash used.

REFERENCES

1. Berry, E.E., and Malhotra, V.M., "Fly Ash for Use in Concrete - A Critical Review," ACI Materials Journal, March-April 1980,

pp. 59-73.

2. Helmuth, R.A., "Water-Reducing Properties of Fly Ash in Cement Pastes, Mortars, and Concretes: Causes and Test

Methods," Proceedings of the Second International Conference on Fly Ash, Silica Fume, Slag, and Natural Pozzolans in

Concrete, Madrid, Spain, V.M. Malhotra, Ed., ACI SP-91, 1986, pp. 723-740.

3. ACI Committee 232, "Use of Fly Ash in Concrete," ACI Journal, September-October, Vol. 84, No. 5 1987, pp. 381-409.

4. Mehta, P.K., "Pozzolanic and Cementitious By-Products in Concrete - Another Look," Proceedings of the Third

International Conference, Trondheim, Norway, V.M. Malhotra, Ed., ACI SP-114, 1989, pp. 1-43.

5. Ravina, D., and Mehta, P.K., "Properties of Fresh Concrete Containing Large Amount of Fly Ash," Cement and Concrete

Research, Vol. 16, No. 6, November 1986, pp. 227-238.

6. Naik, T.R., and Ramme, B.W., "Effects of High-Lime Fly Ash Content on Water Demand, Workability, Time of Set and

Compressive Strength of Concrete", ACI Materials Journal, Vol. 87, No. 6, November - December 1990, pp. 619-627.

16

7. Mass, G.R., "Proportioning Mass Concrete and Incorporating Pozzolans Using ACI 211.1", Concrete International: Design

and Construction, Vol. 4, No. 8, August 1982, pp. 48-55.

8. Munday, J.G.L., Ong, L.T., and Dhir, R.K., "Mix Proportioning of Concrete with PFA: A Critical Review", ACI Publication

SP-79, 1983, pp. 267-288.

9. Larson, T.D., "Air Entrainment and Durability Aspects of Fly Ash Concrete", Proceedings, American Concrete Institute, Vol.

64, 1964, pp. 266-886.

10. Gebler, S. and Klieger, P., "Effect of Fly Ash on the Air-Void Stability of Concrete", Proceedings of the First International

Conference on the Use of Fly Ash, Silica Fume, Slag and other Mineral By-Products in Concrete, Montebellow, Canada,

V.M. Malhotra, Ed., ACI SP-79, 1983, pp. 103-142.

11. Naik, T.R., and Singh, S.S., "Superplasticized High-Volume Fly Ash Structural Concrete", Presented at the ASCE Energy

Conference on Energy in 1990s, Pittsburgh, PA, March 1991.

12. Yuan, R.L., and Cook, R.E., "Study of a Class C Fly Ash Concrete", Proceedings of the First International Conference on the

Use of Fly Ash, Silica Fume, Slag, and Other By-Products in Concrete, Montebellow, Canada, V.M. Malhotra, Ed., ACI

SP-79, 1983, pp. 307-319.

13. Naik, T.R., and Singh, S.S., "Superplasticized Structural Concrete Containing High Volumes of Class C Fly Ash", ASCE

Journal of Energy Engineering, Vol. 117, No. 2, August 1991, pp. 87-95.

14. Naik, T.R., and Ramme, B.W., "High Strength Concrete Containing Large Quantities of Fly Ash", ACI Materials Journal, Vol.

86, No. 2, March-April 1989, pp. 111-117.

15. Naik, T.R., Singh, S.S., Gillot, M.A., and Hossain, M.M., "Mechanical and Structural Properties of Concrete Containing Fly

Ash", CBU Report No. 185, Center for By-Products Utilization, University of Wisconsin-Milwaukee, A Final Progress

Report Prepared for EPRI, Palo Alto, CA, June 1994.

17

16. Gillot, M., Naik, T.R., and Singh, S.S., "Microstructure of Fly Ash Containing Concrete with Emphasis on the

Aggregate-Paste Boundary", Proceedings of the 51st Annual Meeting of the Microscopy Society of America, August 1993.

17. Naik, T.R., Singh, S.S., and Hu, W.Y., "High-Volume Fly Ash Concrete Technology", EPRI Report No. TR 100473, Palo Alto,

CA, March 1992.

18. Ghosh, R.S., and Timusk, J., "Creep of Fly Ash Concrete", ACI Materials Journal, Proceedings, Vol. 78, No. 5, Sept.-October,

1981, pp. 351-357.

19. Naik, T.R., and Ramme, B.W., "Setting and Hardening of High Fly Ash Content Concrete," Proceedings of the American

Coal Ash Association 8th International Coal Ash Utilization Symposium, Washington, D.C., October 1987.

20. Nasser, K.W. and Al-Manaseer, A.A., "Shrinkage and Creep Behavior of Concrete Containing 50 percent Lignite Fly Ash at

Different Stress-Strain Ratios", Proceedings of the Second International Conference on the Use of Fly Ash, Silica Fume,

Slag, and Other Pozzolans in Concrete, Madrid, Spain, V.M. Malhotra, Ed., ACI SP-91, 1986, pp. 433-448.

21. Gebler, S.H., and Klieger, P., "Effect of Fly Ash on Physical Properties of Concrete", Proceedings of the CANMET/ACI

Second International Conference on the Use of Fly Ash, Silica Fume, Slag, and Natural Pozzolans in Concrete, Madrid,

Spain, V.M. Malhotra, Ed. Vol. 1, ACI SP-91, 1986, pp. 1-50.

22. Tikalsky, P.J., and Carrasquillo, R.L., "Durability of Concrete Containing Fly Ash", A Technical Report, Center for

Transportation Research, The University of Texas at Austin, May 1986, 141 pages.

23. Hadehti, K.M., and Carrasquillo, R.L., "Abrasion Resistance and Scaling Resistance of Concrete Containing Fly Ash," Center

for Transportation Research, Bureau of Engineering Research, University of Texas at Austin, Research Report No. 481-3,

August, 1988, 185 pages.

24. Naik, T.R., Ramme, B.W., Tews, J.H., "Pavement Construction with High Volume Class C and Class F Fly Ash Concrete",

Presented at the Fourth International Conference on the Use of Fly Ash, Silica Fume, Slag, and Natural Pozzolans in

Concrete, Istanbul, May 1992.

25. Naik, T.R., Singh, S.S., and Hossain, M.M., "Abrasion Resistance of Concrete as Influenced by Inclusion of Fly Ash, "

International Journal of Cement and Concrete Research, Vol. 24, No. 2, 1994, pp. 301-312.

18

26. Naik, T.R., Singh, S.S. and Hossain, M.M., "Abrasion Resistance of High-Strength Concrete Made with Class C Fly Ash," ACI

Materials Journal, Vol. 92, No.6, November-December, 1994, pp. 649-659.

27. Naik, T.R., Singh, S.S. and Hossain, M., "Abrasion Resistance of High-Volume Fly Ash Concrete Systems", CBU Report No.

176, Center for By-Products Utilization, University of Wisconsin-Milwaukee, A Final Progress Report Prepared for EPRI,

Palo Alto, CA, January 1993.

28. Bilodeau, A., and Malhotra, V.M., "Concrete Incorporating High Volumes of ASTM Class F Fly Ashes: Mechanical

Properties and Resistance to Deicing Salt Scaling and to Chloride-ion Penetration", Proceedings of the CANMET/ACI

Fourth International Conference on the Use of Fly Ash, Silica Fume, Slag and Natural Pozzolans in Concrete, Istanbul,

Turkey, V.M. Malhotra, Ed., Vol. 1, ACI Special Publication SP-132, 1992, pp. 319-349.

29. Rodway, L.E., and Fedirko, W.M., "Superplasticized High Volume Fly Ash Structural Concrete", Proceedings of the Third

International Conference on the Use of Fly Ash, Silica Fume, Slag, and Natural Pozzolans in Concrete, Trondheim,

Norway, Supplementary Papers, 1989, pp. 98-112.

30. Ellis, W.E., Jr., Riggs, E.H., and Butler, W.B., "Comparative Results of Utilization of Fly Ash, Silica Fume, and GGBFS in

Reducing the Chloride Permeability of Concrete", Proceedings of the Second CANMET/ACI International Conference on

Durability of Concrete, Montreal, Canada, V.M. Malhotra, Ed., ACI SP-126, 1991, pp. 443-458.

31. Bilodeau, A., Sivasundaram, V., Painter, K.E., and Malhotra, V.M., "Durability of Concrete Incorporating High Volumes of

Fly Ash From Sources in the USA", ACI Materials Journal, Vol. 91, No.1, January-February 1994, pp. 3-12.

32. Naik, T.R., Collins, W.C., Patel, V.M., and Tews, J.H., "Rapid Chloride Permeability of Concrete Containing Mineral

Admixtures", Proceedings of the CBU/CANMET International Symposium on the Use of Fly Ash, Silica Fume, Slag, and

Other By-Products in Concrete and Construction Materials, Milwaukee, WI, November 1992.

33. Naik, T.R., Singh. S.S., and Hossain, M.M., "Permeability of Concrete Containing Large Amounts of Fly Ash", International

Journal of Cement and Concrete Research, Vol. 24, No. 5, 1994, pp. 913-922.

34. Naik, T.R., Singh, S.S., and Hossain, M.M., "Permeability of High-Performance Concrete", ASCE Energy Engineering, 1995.

19

35. Naik, T.R., Singh, S.S., and Hossain, M.M., "Permeability of Concrete Incorporating Large Quantities of Fly Ash", CBU

Report No. 180, Center for By-Products Utilization, University of Wisconsin-Milwaukee, A Progress Report Prepared for

EPRI, Palo Alto, CA, March 1993.

36. Naik, T.R., and Ramme, B.W., "Freezing and Thawing Durability of High-Lime Content Class C Fly Ash Concrete",

Proceedings of the Second CANMET/ACI International Conference on Durability of Concrete, Montreal, Quebec, Canada,

August 1991.

37. Johnson, C., "Effects of Microsilica and Class C Fly Ash on Resistance of Concrete to Rapid Freezing and Thawing and

Scaling in the Presence of Deicing Agents", Proceedings of the Katharine and Bryant Mather International Conference on

Concrete Durability, Atlanta, GA, V.M. Malhotra, Ed., 1987, pp. 1183-1205.

38. Naik, T.R., Singh, S.S., and Hossain, M., "Freezing and Thawing Durability of Concrete Incorporating Class C Fly Ash", CBU

Report No. 199, Center for By-Products Utilization, University of Wisconsin-Milwaukee, A Final Progress Report Prepared

for the EPRI, June, 1995.

39. Tikalsky, P.J., and Carrasquillo, R.L., "Durability of Concrete Containing Fly Ash", A Technical Report, Center for

Transportation Research, The University of Texas at Austin, May 1986, 161 pages.

40. Naik, T.R., Singh, S.S., and Hossain, M., "Salt Scaling Resistance of High-Volume Class C Fly Ash Concrete", CBU Report

No. 206, Center for By-Products Utilization, University of Wisconsin-Milwaukee, A Progress Report Prepared for EPRI,

Palo Alto, CA, June, 1994.

41. Naik, T.R., Singh, S.S., Kraus, R.N., and Hossain, M.M., "Deicing Salt Scaling Resistance of High-Volume Fly Ash Concrete

Using Various Sources of Fly Ash", Proceeding of the Workshop on Flowable Slurry Containing Fly Ash and other Mineral

By-Products Special Session on Coal Ash Research in Progress, Fifth CANMET/ACI International Conference on the Use of

Fly Ash, Silica Fume, Slag and Natural Pozzolans in Concrete, June 4-9, 1995, 56 pages.

42. Gebler, S.H., and Klieger, P., "Effects of Fly Ash on the Durability of Air-Entrained Concrete", Proceedings of the Second

International Conference on the Use of Fly Ash, Silica Fume, Slag and Other Mineral By-Products in Concrete,

Montebellow, Canada, V.M. Malhotra, Ed., AI SP-79, Vol. 1, 1986, pp. 123-142.

20

Table 1: Properties of Cement and Fly Ashes Used Chemical composition

(%)

Cement

Type I

ASTM C150,

Type I

F1

F2

F3

ASTM C618,

Class C Silicon dioxide, SiO2

20.0

-

32.2

34.9

30.9

-

Aluminum oxide, Al2O3

4.3

-

18.1

19.6

18.3

-

Ferric oxide, Fe2O3

2.5

-

5.6

6.2

5.2

-

Total, SiO2 + Al2O3 + Fe2O3

26.8

-

55.9

60.7

54.4

50.0 min.

Sulfur trioxide, SO3

2.3

3.0 max.

2.6

2.3

3.4

5.0 max.

Calcium oxide, CaO

65.0

-

31.9

27.6

31.4

-

Magnesium oxide, MgO

2.0

6.0 max.

4.7

5.4

6.1

5.0 max.

Titanium dioxide, TiO2

0.0

-

1.6

1.4

1.5

-

Potassium oxide, K2O

0.6

-

0.3

0.4

0.3

-

Sodium oxide, Na2O

0.3

-

2.0

1.8

2.6

1.5 max.

Moisture content

-

-

-

-

-

3.0 max.

Loss on ignition

2.0

3.0 max.

0.9

0.5

0.4

6.0 max.

Physical Properties of Cement Air content (%)

9.5

12 max.

-

-

Fineness (m2/kg)

351

280 min.

-

-

Autoclave expansion (%)

-0.02

0.8 max.

-

-

Specific gravity

3.16

-

-

-

Compressive strength, MPa

1-day

3-day

7-day

28-day

13.7

24.1

29.2

37.4

-

12.3 min.

19.2 min.

-

-

-

-

-

-

-

-

-

Vicat time of initial Set (min)

145

45 min.

375 max.

-

-

Physical properties of fly ashes Fineness retained on No. 325 sieve (%)

-

-

25.5

15.4

16.9

34 max.

Pozzolanic activity index with cement,

28-day (% of control)

-

-

85.4

98.7

97.4

75 min.

Water requirement (% of control)

-

-

97.1

95.0

95.0

105 max.

Autoclave expansion (%)

-

-

0.04

0.01

0.05

0.8 max.

21

Specific gravity - - 2.58 2.62 2.68 -

Table 2

Grading Aggregates

Fine Aggregates

Coarse Aggregates

Sieve Number

% Passing

ASTM C-33 %

Passing

Sieve Size % Passing

ASTM C-33 %

Passing

4

(4.75 mm)

100

95-100

1"

(29.4 mm)

100

100

8

(2.36 mm)

89

80-100

3/4"

(19 mm)

94

90-100

16

(1.18 mm)

76

50-85

1/2"

(12.7 mm)

57

-

30

(600 μm)

58

25-60

3/8"

(9.5 mm)

30

20-55

50

(300 μm)

27

10-30

#4

6

0-10

100

(150 μm)

8

2-10

#8

2

0-5

Table 3

Physical Properties of Aggregates

Aggregates

Bulk

Specific

Bulk Specific

Gravity (SSD)

Apparent

Specific

SSD Absorption

(%)

Dry Rodded Unit

Weight (kg/m3)

Percent

Voids (%)

Fineness

Modulus

22

Gravity Gravity Fine Aggregates

2.65

2.69

2.76

1.5

1849

30.2

2.42

Coarse

Aggregates

2.68

2.71

2.78

1.4

1737

35.2

3.12

Table 4: Mixture proportions using various sources of

Class C fly ash - 41 MPa specified strength

Mixture No.

C1

M1

M2

M3

M4

M5

M6

M7

M8

M9

Cement (kg/m3)

368

231

195

156

229

193

155

229

193

154

Fly ash (kg/m3)

0

156

199

241

154

197

237

154

196

261

FA/(C + FA)

0

40

50

60

40

50

60

40

50

60

Water (kg/m3)

144

119

120

121

115

114

116

113

116

117

[W/(C+FA)]

0.31

0.31

0.30

0.30

0.30

0.29

0.30

0.30

0.30

0.30

Sand, SSD (kg/m3)

886

852

854

834

827

836

842

844

850

818

19 mm aggregates, SSD (kg/m3)

1085

1047

1041

1026

1040

1032

1016

1032

1126

1016

Slump (mm)

127

127

89

121

85

89

83

89

85

89

Air content (%)

6.0

6.0

5.6

5.6

6.4

6.3

6.5

6.4

6.1

6.4

Superplasticizer (L/m3)

3.5

3.2

2.7

2.3

2.8

2.6

2.1

2.1

1.9

1.9

Air entraining agent (liq.ml/m3)

354

423

523

577

412

462

538

385

404

462

Air temperature (C)

18

62

16

16

17

17

17

17

17

17

Concrete temperature (C)

17

16

14

13

13

13

17

18

17

17

Fresh concrete density (kg/m3)

2424

2395

2397

2387

2379

2373

2353

2381

2368

2345

Hardened concrete density, SSD (kg/m3)

2440

2441

2445

2429

2448

2411

2401

2283

2401

2416

Table 5: Compressive Strength Test Data

Mixture No.

C1

M1

M2

M3

M4

M5

M6

M7

M8

M9

Fly Ash, %

0

40

50

60

40

50

60

40

50

60

23

Fly Ash Source - F1 F1 F1 F2 F2 F2 F3 F3 F3 Test Age, Days

Compressive Strength, MPa

1

30.2

17.0

7.0

0.8

9.7

4.8

2.3

16.4

13.1

10.4

3

40.3

42.8

34.3

26.9

32.6

23.4

22.1

37.7

33.9

25.8

7

48.6

55.3

44.0

43.7

44.6

36.8

28.6

46.3

42.2

40.0

28

53

67.9

51.2

60.6

52.9

43.4

41.9

51.1

51.3

44.5

365

66.5

72.5

66.9

60.8

63.3

55.1

52.9

62.9

-

55.7

Table 6: Splitting Tensile Strength Data

Mixture No.

C1

M1

M2

M3

M4

M5

M6

M7

M8

M9

Fly Ash, %

0

40

50

60

40

50

60

40

50

60

Fly Ash Source

-

F1

F1

F1

F2

F2

F2

F3

F3

F3

Test Age, Days

Splitting Tensile Strength, MPa

1

3.4

1.9

0.7

0.1

1.4

0.5

0.4

1.7

1.7

1.2

7

3.8

3.7

2.0

1.8

2.3

2.9

2.4

3.1

2.8

2.8

28

3.8

3.9

3.7

3.1

3.5

3.2

3.0

3.4

3.5

3.6

91

4.1

4.6

4.6

4.2

4.2

4.1

4.3

3.9

4.5

4.5

365

6.0

6.4

6.0

5.3

4.5

4.3

3.8

4.4

4.6

4.9

Table 7: Flexural Strength Data

24

Mixture No. C1 M1 M2 M3 M4 M5 M6

M7

M8 M9

Fly Ash, %

0

40

50

60

40

50

60

40

50

60

Fly Ash Source

-

F1

F1

F1

F2

F2

F2

F3

F3

F3

Test Age, Days

Flexural Strength, MPa

7

5.6

4.3

4.8

3.8

4.7

4.3

3.2

3.2

3.7

4.2

28

6.2

4.5

5.1

5.3

5.5

4.8

4.7

5.4

6.0

4.3

91

6.9

6.8

5.9

6.5

6.6

5.5

5.2

6.2

6.7

4.7

365

7.4

6.4

6.5

6.5

5.7

5.9

5.2

6.9

7.2

5.2

Table 8: Modulus of Elasticity Data

Mixture No.

C1

M1

M2

M3

M4

M5

M6

M7

M8

M9

Fly Ash, %

0

40

50

60

40

50

60

40

50

60

Fly Ash Source

-

F1

F1

F1

F2

F2

F2

F3

F3

F3

Test Age, Days

Modulus of Elasticity, GPa

1

26.8

16.9

12

7.9

11.7

6.6

6.2

16.6

12.8

12.8

7

30.4

27.9

27.3

26.6

27.6

23.8

22.4

25.2

26.6

25.2

28

34.5

32.8

31.4

31.1

31.1

29.7

30.7

29.7

32.8

29.3

91

37.8

38.3

38.3

38.6

38.0

36.6

37.3

34.8

37.6

36.6

365

45.9

45.5

45.5

44.9

42.4

40.4

45.5

41.4

-

45.5

25

Table 9: Drying Shrinkage Test Data After 28-Day Initial Water Curing*

Mixture No.

Fly ash (%)

Fly ash source

Drying shrinkage strain, x 10-6

4-day

7-day

14-day

28-day

56-day

112-day

224-day

448-day

C1

0

-

132

193

243

374

396

410

469

538

M1

40

F1

219

238

300

498

536

669

681

790

M2

50

F1

157

-

254

279

454

522

568

733

M3

60

F1

114

221

340

361

468

493

521

621

M4

40

F2

84

139

196

276

274

324

503

620

M5

50

F2

167

235

279

291

386

493

526

770

M6

60

F2

79

290

329

354

426

664

771

872

M7

40

F3

140

312

498

450

612

705

752

836

M8

50

F3

202

250

345

462

578

670

712

891

M9

60

F3

174

275

327

456

556

704

705

886

* Test results are an average of three observations

26

Table 10: Abrasion Resistance Test Results

Mixture No.

7 C 4 (P)

M1

M2

M3

M4

M5

M6

M7

M8

M9

Fly Ash, %

0

40

50

60

40

50

60

40

50

60 Fly Ash Source

-

F1

F1

F1

F2

F2

F2

F3

F3

F3

Age, Days

Average depth of wear, mm

28*

0.62

0.55

1.26

1.16

1.05

1.30

1.88

0.81

2.25

2.39

91*

0.40

0.76

0.97

1.32

1.49

1.14

1.40

0.94

1.08

0.75

365*

0.44

0.61

0.74

0.61

1.05

0.81

1.13

0.63

1.05

0.96

28**

1.3

1.18

2.25

2.03

1.97

2.20

3.09

1.68

3.37

3.45

91**

1.25

1.38

1.59

2.36

2.02

2.00

2.26

1.57

1.93

1.63

365**

1.10

1.15

1.46

1.49

2.10

1.54

2.04

1.2

1.98

1.91

* Abrasion time = 30 minutes

**Abrasion time = 60 minutes

27

Table 11: Chloride Permeability Test Results*

Mixture

Fly ash

(%)

Fly ash

source

Charge, coulombs

28-day

91-day

365-day

C1

0

-

2290

2020

1060

M1

40

F1

3160

1260

255

M2

50

F1

3515

1205

-

M3

60

F1

2040

-

-

M4

40

F2

1755

890

305

M5

50

F2

2595

760

260

M6

60

F2

4170

925

290

M7

40

F3

1665

770

320

M8

50

F3

2235

1090

375

M9

60

F3

1370

680

-

*The results are an average of three observations

28

Table 12: Deicing Salt Scaling Test Results

Mixture No.

Specimen No.

Fly ash (%)

Fly ash source

ASTM C 67 2 Visual Rating

Corresponding to Various Cycles*

5 10

15

20

25

30

35

40

45

50

C1

1

0

-

1

1

1

3

3

3

3

4

4

4

2

1

1

1

1

1

2

2

2

2

2

3

1

1

1

1

2

2

2

2

2

2

M1

1

40

F1

0

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

3

1

1

2

2

2

2

2

2

2

2

M2

1

50

F1

2

2

3

3

3

3

3

3

3

4

2

1

2

2

2

2

2

2

2

2

2

3

1

2

2

2

2

2

2

2

2

2

M3

1

60

F1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

2

2

2

2

2

2

2

2

2

2

M4

1

40

F2

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

M5

1

50

F2

0

1

1

1

1

1

1

1

2

2

2

0

1

1

1

1

1

1

1

2

2

3

0

1

1

1

1

1

1

1

1

1

M6

1

60

F2

0

1

1

2

2

2

3

3

3

3

2

0

2

2

2

3

3

3

3

3

3

3

0

1

2

2

2

2

2

2

3

3

M7

1

40

F3

-

-

-

-

-

-

-

-

-

-

2

-

-

-

-

-

-

-

-

-

-

3

-

-

-

-

-

-

-

-

-

-

M8

1

50

F3

1

1

1

2

2

2

2

2

2

2

2

1

1

1

1

1

1

2

2

2

2

3

1

1

1

1

1

1

1

1

2

2

1

0

1

1

1

1

1

1

1

2

2

29

M9 2 60 F3 0 1 1 1 1 1 1 1 2 2

3

0

1

1

1

1

1

1

1

1

1