Advantages of using Fly Ash in Concrete

PPC or site mixing of OPC and fly ash site

By

Anil Banchhor, S. Krishnan
The Associated Cement Companies Limited, Cement House, 121, M. K.
Road, Mumbai, 100 020

The paper presents the results of an experimental investigation that was carried out
to evaluate the effectiveness of key performance characteristics of concrete
incorporating fly ash by means of, inter-ground PPC and site mixing OPC and fly
ash. A host of properties of concrete were studied. Both drum mixer and pan mixer
were used in the stud to evaluate the mixing efficiency. The results of investigations
indicate that the performance of concrete using Fly Ash is better than the OPC
concrete, especially with respect to durability indicator due to pozzolanic action of
fly leading to pore refinement and denser concrete matrix The beneficial effects of
fly ash are seen more pronounced in case of factory-ground Portland Pozzolona
Cement (PPC) than site mixing of fly ash with OPC under normal Indian
construction site conditions. The inter-grinding of fly ash with clinker and gypsum
maximizes the pozzolanic potential of fly ash with more consistent product with
good control on variability, leading to a better performance of PPC concrete.

1.0 INTRODUCTION
Concrete has become an indispensable construction material and it is now used in
greater quantities than any other material. In the present context durability and
sustainable development are key issues for development. Ordinary Portland cement
has a high calcium base affecting the microclimate of concrete and mortar. The
interface bond between the cement paste and aggregates can be improved with
better pore structure and minimised micro cracks using mineral admixtures like fly
ash granulated blast furnace slag rice husk, silica fume etc. Out of the above, the
use of fly ash has gained prominence due to growing awareness about the benefits
and easy availability of the good quality fly ash, RMC plants and bigger construction
sites are using fly ash with OPC in batching plants

An experimental study was conducted to measure the effectiveness of key
performance characteristics of concrete made with OPC, inter-ground PPC and site
mixed OPC & Fly Ash. The comparative performance has been studied for the fresh
and hardened properties of concrete like slump, slump retention, water demand,

compressive strength, , water permeability, drying shrinkage etc. for concrete of
grade M 20 and M-25. The microstructure of the concrete was also studied.

In this study, OPC and the fly ash used were from the same source, as that of
underground PPC. The effect of efficiency of mixing on the properties of concrete
was understood by carrying out mixing in a drum mixer and in a pan mixer The
study will continue for one-year duration.

It has been found that the properties of fresh and hardened concrete of inter-
ground PPC is better than the site blend of OPC and fly ash. One of the major
factors contributing to this appears to be the homogeneity of the blend of fines
particles namely cement and fly ash. The normal drum mixer will not be able to
produce a highly homogenous mix of fine powders whereas, inter-grinding of fly
ash with clinker and gypsum produces a highly homogenous mix with a high level
of inter-particle contact between cement and fly ash grains. This process also
maximises the pozzolanic potential of the fly ash with more consistent product with
good control on variability, which results in to better performance characteristics of
concrete. The intergrinding makes fly ash particles finer, which imparts additional
reactive surfaces for hydration and improves the overall particle size distribution of
the resultant cement In this respect, The ordinary drum mixer is found to be less
efficient as compared to the Pan mixer with respect to homogeneity.

2.0 EXPERIMENTAL PROGRAMME

In this study, normal grades of concrete viz. M20 & M25, which are being used, at
most of the construction sites, have been taken, and the findings can be used
effectively at construction sites.

Another important parameter is the use of Pan mixer and drum Mixer, so that the
construction practice of using batching plant at big projects/ RMC and rotating drum
mixer of smaller sites can be co-related with the performance of the concrete based
on mixing efficiency of mixers.

2.1 Materials for Study
All the cementitious materials from the same source were used to compare the
performance characteristics of concrete made by separate blending and inter-
ground PPC. OPC and PPC from ACCs Wadi Cement Plant were used for the study
purpose. Fly ash from Raichur Thermal Power Plant confirming to IS 3812-2003 was
used for as a separate mineral additive; because fly ash from the same source and

the same quality is being used at Wadi to manufacture inter-ground PPC. The fly
ash having surface area of 289 sq. m. was sieved through 90micron sieve and
coarse particles were removed to bring the fly ash particle to required specific
surface area of 329 sq. m. as per IS 3812-2003. In making concrete for the study,
crushed granite from New Mumbai area was used as coarse aggregates along with
fine aggregates from river Vaitarna.

2.11 Cement & Fly ash
Source ACC - Wadi Cement Works. Test results given in Table 1. Fly Ash from
Raichur Thermal Plant was tested
And results are given in Table 2.

2.13 Aggregates:
Coarse aggregate of Crushed Granite from New Mumbai
Maximum size Metal 1 10 mm ; Metal 2 20 mm
Fine aggregate
Type: River sand
Zone: II
Retention on 600 micron: 48.0%
Source: Vaitrana Riverbed


Table 1 : Properties of cement Table 2: Properties of fly ash as
per IS 3812-2003

Property PPC OPC-
53
Std. Consistency
(%)
29.5 27.3
Specific Surface
(m2/kg)
351 334
Setting Time
(minutes)
Initial
Final

165
310

210
280
Soundness test
Le Chatelier
(mm)
Autoclave (%)

0.5
Nil

0.5
Nil
Comp. Strength
(M Pa)
3 Days
7 Days
28 Days

30.0
43.0
52.0

41.0
52.5
62.0






2.2 Testing of Fresh concrete
Fresh concrete was tested for Slump, slump retention at 30 minutes, bleeding, and
yield. Slump was maintained around and not less than 100mm to represent the
typical conditions prevalent at most small/medium construction sites in the country.

2.3 Testing of Hardened concrete
Hardened concrete testing includes compressive strength at ages 1D, 3D, 7D, 14D,
28D, 56D, 90D , 180D and 360D.. Rapid Chloride penetration Test (RCPT) as per
ASTM C-1202-97, Initial Surface Absorption Test as per (ISAT) as per BS 1881
1970 , Water Permeability as per DIN 1048 1991 , UPV and hammer test, pH of
concrete, and Modulus of elasticity. were carried out for 28D,

2.4 Testing of mortar
Physical Analysis of Fly Ash
Specific Gravity 2.14
Residue on 45 micron
percent
23
Specific Surface in m
2
/ kg 289
S. Surface after sieving
with 90 micron sieve &
before use
329
Lime Reactivity (M Pa) 4.53
Cement Reactivity ( %) 85%

Chemical Analysis of Fly ash
Constituent Percentage
SiO
2
62.1
Al
2
O
3
26.0
Fe
2
O
3
4.5
CaO 2.7
MgO 1.4
IR 86.3
LOI 0.6
Na
2
O 0.16
K
2
O 1.54
Chloride 0.003

The mortar separated from concrete by sieving the same through a 4.75 mm sieve
as taken for evaluation. These includes compressive strength and water absorption
of mortar cubes at 1,3, 7 and 28D, 56D, 90D, 180D and 360D,

2.5 Mix Proportions
Two series of mixes, one for M-20 and the other for M-25 grade of concrete were
used. In each grade, concrete with only OPC, only factory ground PPC and site
mixed OPC-fly ash blend were made. Total Cementitious material; content per cubic
metre was kept constant for all mixes in each grade. Corrections were made only
for specific gravity differences. Each of the mixes was made in a typical tilting
drum one bag drum mixer and a lab mixer of 80-litre capacity. The study is on the
performance of factory ground PPC (containing 25% fly ash) and site blended OPC
and fly ash in concrete. OPC was included in the study as a reference. Table -3
Table 3: Mix Proportions
Grade M - 20 Grade M 25
Type of concrete OPC PPC OPC
+ Fly
ash
OPC PPC OPC
+ Fly
ash
Material kg/m
3

kg/m
3
kg/m
3
kg/m
3
kg/m
3
kg/m
3

Cement 325 325 244 357 357 268
Fly ash -- (25%
)
81 -- (25%
)
89
Sand 855 845 845 827 815 815
Coarse aggregate
10 mm
518 518 518 487 487 487
Coarse aggregate
20mm
557 557 557 580 580 580
Water 179 179 179 187 187 187
Water to binder
ratio
0.55 0.55 0.55 0.52 0.52 0.52


3.0 OBSERVATIONS:

3.1 Fresh Concrete Properties:
3.11 Slump: The slump of concrete was measured immediately after discharge
from the mixer and also at 30 minutes. All the mixes were cohesive and the initial
slump of PPC concrete was found to be higher as compared to OPC+FA and OPC

concrete. The slump loss after 30 minutes also found to be lower in case of PPC
concrete. Figures 1 to 4


Figure 1. Slump and Retention M 20 - Drum Mixer
100
120
90
40
50
30
0
20
40
60
80
100
120
140
OPC+FA PPC OPC
Type of Concrete
S
l
u
m
p

m
m
INITIAL
30 MIN

Figure 2: Slump and Retension M 25 -Drum Mixer
90
120
80
40
55
30
0
20
40
60
80
100
120
140
OPC+FA PPC OPC
Type of Concrete
S
l
u
m
p

m
m
INITIAL
30 MIN


Fi gur e 3. Sl ump and Reent i on M- 20 Pan Mi xer
105
130
100
30
50
40
0
20
40
60
80
100
120
140
OPC+FA PPC OPC
Type of Concr et
I N I T
3 0 M I N

Figure 4: Slump and Retention M25- Pan Mixer
90
40
55
30
120
100
0
20
40
60
80
100
120
140
OPC+FA PPC OPC
Type of Concrete
S
l
u
m
p

m
m
INITIAL
30 MIN


3.12 Bleeding: In concrete, after compaction in place bleed water comes on the
top, indicating formation of channels, which would affect durability. The bleeding of
PPC concrete was found to be lower than the OPC and the mix of OPC and FA, in
drum mixed concrete. Bleeding of OPC-Fly ash concrete was lower for pan mixer
as compared to the drum mixer. However, with both the mixer types, PPC had the
lowest bleeding. ( see table 4) Allowing the fresh concrete to stand in a measuring
cylinder and removing the bleed water by a pipette after 1hr bleeding was
determined
Table 4: Bleeding in ml after 1 hour
.
M 20 Drum Mixer M 20 Pan Mixer M 25 Drum Mixer M 25 Pan Mixer
OPC+F
A
PP
C
OP
C
OPC+F
A
PP
C
OPC OPC+
FA
PP
C
OP
C
OPC+F
A
PP
C
OPC
15 7 17 6 5 11 12 6 15 5 5 10



3.2 Hardened Concrete Properties:

3.21 Compressive strength: Compressive strength of concrete of both the grades
is given in Figures 5-8. Strength development of OPC + Fly ash concrete lags at all
ages, compared to factory made inter-ground PPC. However, these differences are
much less in pan mixed concrete.


Figure 5: Comcrete Compressive Strength M 20 Drum
Mixer
5.7
7
8.6
9.7
14
17
14.2
16.4
21.3
28
31
25
0
5
10
15
20
25
30
35
OPC +FA PPC OPC
Type of Concrete
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

m
P
a
1
3
7
28

Figure 6: Comcrete Compressive Strength M 25 Drum
Mixer
5.9
8
9.2
10.5
16
20
16
19
25.4
29
32
34
0
5
10
15
20
25
30
35
OPC +FA PPC OPC
Type of Concrete
C
o
m
p
r
e
s
s
i
v
e

S
t
r
e
n
g
t
h

m
P
a
1
3
7
28



Figure 7: Concrete Compressive Strength M 20 Pan Mixer
6.2
7
9
13
15
18
17
18
23
30
32
27
0
5
10
15
20
25
30
35
OPC +FA PPC OPC
Type of Concrete
C
o
m
p
r
e
s
s
i
v
e

S
t
r
e
n
g
t
h

m
P
a
1
3
7
28

Fi gure 8 : Comcret e Compressi ve St rengt h M 2 5
Pan M i xer
6. 5
8. 6
9. 5
14
16
20
19
21
27
31
32
34
0
5
10
15
20
25
30
35
40
OPC +FA PPC OPC
Type of Concr et e
1
3
7
28




3.22 Modulus of elasticity: Modulus of elasticity values of the drum mixed
concrete are given in Table. 5 The values were determined on a 150mm dia x 300
m length cylinder in wet condition. Higher E values of PPC was observed because of
pore filling effect of fly ash.



3.23 Water permeability: Water permeability tests were carried out as per DIN
1048 specification on 150 mm cube specimens. The specimens were air dried in
laboratory conditions, before being subjected to the tests, as this will be closer to
field conditions of normal concrete. The values of permeability are given in Table 6.

Table 5: Modulus of elasticity and Water Permeability- Drum Mixer 28 day


Type of
concrete
Modulus of
elasticity in Gpa
at 28 days
Water
Permeability in
mm at 28 days
M-20 OPC + FA 32.9 10
M-20 PPC 34.5 9
M-20 OPC 30.17 12
M25 OPC + FA 32.9 10
M 25 PPC 34.5 8
M25 OPC 32.9 10


3.24 Initial Surface Absorption (ISAT): This test was carried out as per BS
1881 on 150 mm cube specimens. The specimens were kept for open-air sun
drying for 48 hrs, before being subjected to the tests, as this will be closer to field
conditions of normal concrete. The test was carried out on a side surface as the top
surface in a laboratory specimen tends to be rich in paste up to a few mm of depth,
due to trowelling action, while finishing the specimen in the mould. The values of
permeability are given in Table 7

Table 7: Initial surface absorption - Drum Mixer 28 day
Initial surface absorption in ml/ m
2
/ sec

Type of
Concrete
Time of measurement
from start in minutes
10 30 60 120
M-20 OPC + FA 0.045 0.03 0.02 0.015
M-20 PPC 0.035 0.0250.0180.012
M-20 OPC 0.05 0.04 0.0250.018
M25 OPC + FA 0.04 0.0250.0180.013
M 25 PPC 0.03 0.0220.0150.011
M25 OPC 0.043 0.028 0.02 0.015


3.25 Optical Microscopy: Optical microscopic examination of polished sections of
concrete brings out the following.

In all the samples hard and partly hydrated, un hydrated cement grains are seen In
the case of OPC + Fly ash site mixed concrete, fly ash grains are not well
distributed, whereas in the case of PPC concrete, Fly ash grains are well distributed
in the mass of concrete.


PPC based concrete is showing better distribution of fly ash particles and
compactness of binder phase
Concrete samples which are made in a pan mixer appears to be comparatively
more homogeneously distributed than that of drum mixer, in reference to
aggregate and binder phases

3.26 pH of concrete: The concrete samples was ground and mixed together
before drawing a representative sample. Water was boiled to remove dissolved air
and cooled before mixing with the sample. PH meter was used to measure the pH
of the solution

Table for M-25 grade concrete.

Table for M-25 grade concrete
(( or we can also mention that similar results have been obtained for M-25 grade
concrete)




3.3 Mortar Properties:

Compressive Strength: The compressive strength values of mortar separated from
concrete is given in Table 8.
The trends are similar to those of concrete.

Water absorption: Mortar cubes made from concrete were dried at 110 deg C for
24 hrs. to constant weight. Then these were immersed in water for 30 minutes
and at the end to this period, they were removed, surface dried and weighed. The
Grade of concrete Cementitious
mix
Age of
hydration
pH of 5%
solution
OPC+ Fly ash 7 days 12.1
28 days 12.1
PPC 7 days 12.1
28 days 12.2
OPC 7 days 12.3
28 days 12.5
M 20
M 20
M 20

percentage increase in weight is recorded as percentage water absorption. These
were given on Table 9.

The results are in line with the trend observed on concrete, with factory made ppc
having a lower level of absorption.
Table 8: Mortar Compressive strength MPa
Drum Mixer Pan Mixer
M 20 M 20
Type 1
day
3
day
7 day 28
day
1 day 3 day 7 day 28
day
OPC + FA 6.3 12.2 16.2 27.6 7 14 17.5 29
PPC 7.2 14.2 19.1 33.6 7.5 15.8 21.2 35
OPC 7.6 17 24 34 7.8 18 25 36
M 25 M 25
OPC + FA 6.5 13 17 31 7.5 14 18 32
PPC 7.5 15 21 35 7.8 16 23 35
OPC 7.6 17 25 36 8 20 27 36


Table 9. Percentage water absorption of mortar Drum Mixer

Type of
Concrete
Percentage water
absorption
M-20 OPC + FA 6.8
M-20 PPC 5.6
M-20 OPC 6.5
M-20 OPC + FA 6.1
M-20 PPC 5.6
M-20 OPC 6.1

4.0 DISCUSSIONS:

4.1 Fresh Concrete Properties
1. Workability: the concrete made with Fly ash show improved workability
and this aspect can be used for making concrete of higher strength by
reducing the water content. The workability of interground PCC is found
to be better than OPC+FA mix because the fly ash particles of PPC
become much finer due to intergrinding. The slump retention of PPC is
also found to be better than OPC+FA mix and OPC. This is due to
retention of water within the finer mass of concrete and improved water
holding capacity of the PPC because of improved particle size distribution.

2. Bleeding: The addition of fly ash reduces the rate of bleeding. Since the
fly ash particles are finer than cement particles, they modify the minute
space in wet concrete and block the flow of water in the channels and

thus reduce the bleeding. It was also observed that the control of internal
bleeding plays an important part in determining the strength of the
transition zone between aggregates and the cement paste and therefore
the mechanical properties of the concrete.

4.2 Hardened Concrete Properties

1. Compressive Strength: Compressive strength of factory ground
blended cement values were higher than the site mixed concrete and this
appears to be due to the finer and desirable particle size distribution of
the fly ash particles due to grinding as well as the optimum level of
gypsum presence.

2. Elastic Modulus: Values of fly ash blended concrete were higher
probably due to the pore filling effect of the fly ash particles, compared to
OPC and this is more pronounced in the case of factory ground PPC due
to the enhanced effect of this parameter

3. Water permeability: The values of water permeability are lower for fly
ash blended concrete due to pore refinement and this is more pronounced
in factory produced PPC concrete, due to greater secondary reaction
products, because of more number of reactive fly ash particles and their
desirable particle size distribution.

4. ISAT: The values of initial surface absorption test are lower for fly ash
blended cement concrete due to pore refinement and this is more
pronounced in factory produced PPC concrete, due to greater secondary
reaction products, because of more number of reactive fly ash particles
and their desirable particle size distribution.


4.3 Effect of Intergrinding of Fly Ash with clinker for manufacturing
PPC:


1. Improved Sphericity: The intergrinding creates new reactive surfaces
for the fly ash and improves the sphericity of the coarse angular fly ash
particle. In short it can be attributed to the rounding of corners of fly ash
and also breaking of larger particles to smaller sizes having near spherical
shapes. This also creates larger surface for reaction as compared to un-
ground fly ash.





Spherical fly ash particles Grinding to smaller rounded particles


2. Improved Particle size distribution: The intergrinding of clinker with
Fly ash delivers much better particle size distribution as compared to
separately mixed fly ash with OPC. Crow & Dungstan concluded that:
fineness appeared mor critical for the reactivity of low calcium ash than
to those with high calcium fly ash. However apart from than fineness,
many other fly ash related variables influence strength development and
there in an optimum level of fineness (450 to 480 Blaine) up to which the
strength increases. Beyond this the water demand increases and thereby
a drop in the strength.

3. Gypsum Content: Gypsum is known to activate the alumnus phase of fly
ash thereby improving pozzolanicity and strength/ durability. During
intergrinding, gypsum is added as percentage of total mass of clinker and
fly ash. But in the case of site mixed fly ash, extra gypsum is not added
towards fly ash and thereby the aluminous phase in not utilised to fullest
extent. The site mixing of gypsum is possible at RMC plants, where good
quality control is possible which is not available at most of the
construction sites, where ordinary drum mixers are used..

4.4 Mixing efficiency of the concrete mixers and the prevalent construction
practice
1 Mixing efficiency: The mixing efficiency of the ordinary drum mixers at
site is poor as compared to Pan mixer / twin shaft mixers of batching
plant, particularly at low water content. The mixing in the ordinary drum
mixer is due to free falling action of the ingredient and the shearing action
of baffle plates are not very effective. Pan mixers and high RPM twin shaft
mixers of batching plant are much better in terms of high efficiency.

2 Quantity of water and mixing time: The quantity of water is not
controlled in most of the small construction sites where drum mixers are
being used and the operator tend to add more water in the mix than
recommended to reduce the mixing time and quickly unload the concrete
for the waiting workers gang to transport it. Masons also prefer concrete
mix of large slump so that their efforts for compaction and finishing are
reduced. Hence the mixer operator is constantly under pressure from the
concreting gang for early unloading of the mix from mixer and the
masons demand for higher slump. Hence presence of a supervisor is a
must for control in the quantity of water. In many sites, it has been
observed that as soon as the supervisor leaves mixer location for some
other work, the control on the quantity of water is lost.

3 Addition of required Quantity of fly ash: Strict control on the quantity
of the fly ash also needs to be exercised in case of ordinary drum mixer.

This points to the fact that at smaller construction sites fly ash should not
be added in making concrete with ordinary drum mixer, if a strict quality
control is not possible.

4 Variation in quality of fly ash: Moreover the quality of fly ash will not
be uniform if it is the collected from in different fields and variations may
also be due to variations in quality of coal, grinding & burning conditions
etc.. Therefore testing facility of fly ash as well as expertise in testing is
required before using fly ash at construction sites for proper quality
control.


5.0 CONCLUSIONS:

It has been found that addition of fly ash to OPC in concrete improves the
properties of fresh concrete and enhance parameters of which indicate
durability. Here also, the properties of fresh and hardened concrete of inter-
ground PCC is better than the site blend of OPC and fly ash.
The inter-grinding of fly ash with clinker and gypsum maximise the
pozzolanic potential of the fly ash with more consistent product with good
control on variability, which results in to better performance characteristics
of concrete. The variability in type & quality of fly ash, control on doses and
mixing plays a vital role in imparting strength and durability to the concrete.
The intergrinding makes fly ash particles finer, which imparts additional
reactive surfaces for hydration and improves the particle size distribution of
the resultant cement.
The site mix fly ash concrete also do not have adequate gypsum, as
compared to inter-ground PCC in which gypsum is added based on the
overall quantity of clinker and fly ash while grinding. The gypsum (SO3) is
know to activate the aluminous phase of the fly ash and it is absent in the
site mixed fly, whether it is a batching plant or a smaller construction site.

The fly ash should be mixed at site in the batching plant only since mixing
efficiency of the ordinary drum mixers is poor at low water content.
Improper distribution of fly ash particles may result in to some catastrophe.


Proper precautions on quantity of water and mixing time needs to be taken
care along with strict control on the quantity and quality of the fly ash also
needs to be exercised.

The testing facility of fly ash as well as expertise in testing is required before
using fly ash at construction sites apart from quality control at site in
batching.

Factory interground PPC takes care of all the problems mentioned above, wherein
fly quality is checked regularly. The performance of the cement is also checked at
regular interval, which takes care of all the ingredients and the product
performance is guaranteed as per the BIS code 1489 part 1. Fly ash should be
added only in the batching plant, where good control on quantity and quality can be
ensured. Ordinary drum mixer should not be used for site mixed fly ash concrete.


References

1. Mehta P. K. & Moteiro Paulo J. M.- Concrete Microstructure, Properties &
Materials

2. IS 456 2000, Plain & Reinforced Concrete Code of Practice

3. IS 3812 2003 Pulverised Fuel Ash- Specification

4. Mullick, A. K. Use fo Fly Ash in Structural Concrete: Part II- How much?, The
Indian Concrete Journal, June 2005 Vol.. 79, No. 6, PP. 10-14

5. Malhotra V.M. and Mehta P. K. - High-Performance, High Volume Fly Ash
Concrete: Materials, Mixture Proportioning, Properties, Construction Practice
and Case Histories

6. Banchhor Anil & S. Krishnan Performance Evaluation of interground PCC
and site Mixed Fly Ash Concrete, ICI-Asian conference, Mumbai ACECON-
2005 Sept.22-25, 2005,

7. Banchhor Anil, Krishnan S. Khadilkar S. A. and Karandikar M. V. Study on
concrete made with PPC, OPC & site mixed fly ash with OPC 9
th
NCB
international seminar at Delhi 11-13