HIGH VOLUME FLY ASH CONCRETEHIGH VOLUME FLY ASH CONCRETE

APPLICATION IN ROAD PAVEMENTAPPLICATION IN ROAD PAVEMENT

PRESENTEDPRESENTED

BYBY

B.MOHAMED RAFFIB.MOHAMED RAFFI

UNDER THEUNDER THE

GUIDANCE OFGUIDANCE OF

Prof . R. RUDRA PRASAD.Prof . R. RUDRA PRASAD.

INTRODUCTIONINTRODUCTION

FLY ASH

  Fly ash is the pulverised fuel ash extracted from the fuel gases by any suitable process such as by cyclone separation or electrostatic precipitation.Fly ash incorporated concrete is one of the best tools to achieve sustainable, development of a country like India

CASE STUDYCASE STUDY

HVFAV CONCRETE ROADS

First HVFA Concrete Road in India

HVFA concrete road at ropar in the state of Punjab, India.

HVFA concrete road Ambuja nagar

HVFA concrete road at Maratha cement works plant

Gadchandur

HIGH VOLUME FLY ASH CONCRETE

High –volume fly ash concrete (HVFC) technology was developed

by Malhotra and his collegues at Canada Centre for Mineral and Energy Technology(CANMET) Canada,in the 1980s.

This technology utalises special mixture proportioning technique, and involves judicious selection of materials and chemical admixtures to minimize the amount of ordinary Portland cement required to produce high quality concrete for different applications.

This concrete has low cement content,low water/ cementitious material ratio and incorporates up to 55% fly ash.

For Concrete roads For Under water construction For tremie seal and pylon pile cap

Application of HVFA Concrete in construction :

India has huge infrastructure needs. Concrete roads are having proven advantage over the traditional Bituminous roads except that of high initial cost.

The use of Fly ash up to 50% reduces the initial cost of concrete road construction substantially thus bringing concrete roads almost at par with bituminous roads.

Further use of fly ash in concrete roads improves durability and performance. While on the one hand, bitumen has to be imported to meet India’s fast growing huge infrastructure needs, on the other hand, sufficient quantity of good quality of Portland cement as well as class F fly ash are available in India to meet these needs adequately.

Projected availability of fly ash in India is expected to reach 200 million tones in. the year 2010 So, to cater to India’s huge infrastructural needs, HVFA concrete road is one promising solution.

HVFAC CONCRETE ROADS:

Use of fly ash in structural concrete is acceptable as per IS456. The second revision of IS3812:2003(Part I 7 Part II) encourages use of any type of pulverized fuel ash ,as admixture in concrete. The necessary condition for using this material in construction of concrete structures is that it shall satisfy the requirements of the code. The pulverized fuel ash is to be processed when it does not satisfy the requirements of IS 3812:2003. Fly ash collected from the higher field of ESP of a thermal power plant, generally satisfies the specifications of IS3812;2003 and need not be processed.

Use of Fly ash as per IS Code

The proportion of fly ash currently being used in structural concrete in India varies from 15 to 50% .It depends upon the type of construction and characteristics of the concreteUse of concrete in which up to 70% cement has been replaced by fly ash successfully adopted in USA for road construction. Performance in the field after 18 years was reported to be good.In India, 50% of fly ash will be used for HVFA Concrete roads for both conventionally compacted and roller compacted concrete.

Proportion of Fly ash used for pavement

TYPICAL CROSS SECTION OF HVFAC ROADTYPICAL CROSS SECTION OF HVFAC ROAD

Properties of 53 grade OPC used for construction of HVFA concrete roads. Properties Test results

Chemical properties Lime saturation factor 0.96

Ratio of percentage of alumina 1.35To that of iron oxide

Insoluble residue, percent by mass 0.95Magnesia, percent by mass 1.45 Sulphuric anhydride, percent by mass 2.24Total loss on ignition, percent 2.25

Chloride content, percent bymass 0.041Physical properties

Fitness, m2/kg 324.50 Setting time, minutes

Initial 125Final 200

Expansion by Le-chatelier metod, mm 1.00Autoclave, percent 0.06

Compressive strength, Mpa 3-day 47.50

7-day 57.10 28-day 70.30

Properties of Hardened HVFAconcrete used in different projects

Property Ahmedabad

Ropar

Ambujanagar

Gadchandur

Rajkot

Compressive strength, Mpa

I-day 10.5 9.5 9.2 - -

3-day 19.2 18.4 19.5 20.6 18.9

7-day 24.3 24.1 25.5 29.0 24.3

28-day 42.3 41.6 40.0 43.2 40.1

90-day 49.2 - - - -

180-day 53.7 - - - -

365-day 55.7 - - - -

Flexural strength, Mpa28-days

6.7 7.6 6.8 5.7 6.2

Concrete mixture proportions used for construction of HVFA concrete roads

Particulars

Laboratory and Ambujanagar

Ropar Punjab

Gadchandur, Maharashtra

Rajkot, Gujrat

Grade of HVFAconcrete

M40 M40 M35 M40

Ordinay Portland Cement,kg/m2

225 225 225 225

Processed fly ash kg/m3

225 225 225 225

Coarse aggregates (crush sedimentary stone) ,kg/m2

1283 1392 1374 1374

Fine aggregates kg/m3 (river sand)

547 438 456 456

Percent absorption of coarse aggregates

0.93 0.97 0.95 0.94

Percent absorption of fine aggregates

1.89 2.01 1.98 2.00

Super plasticier, kg/m2 2.25 2.25 1.8 2.7

Water to cementitious material ratio

0.32 0.35 0.33 0.33

CONCLUSION:

Based on the laboratory and field trails, the following conclusions can be drawn..1 ) HVFA concrete provides high strength high performance and durable concrete.

2) For new roads , the cost of HVFA concrete road would be almost at par with bituminous roads. 3 ) Like the conventional concrete road, HVFA concrete road has high service life without

major maintenance, needs less lighting, is not affected by rains, allows smooth traffic flow,

causes low wear and tear of vehicles, provides savings in fuel, and is environment –

friendly .

4) HVFA concrete pavements can provide an economical alternative for flexible pavements,

and would be beneficial for developing countries.

5 ) HVFA concrete road would be ideal for national high ways , state and district high ways,

and rural roads.

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