INTRODUCTION

TO
FLY ASH
Ashtech India Private Limited
Agenda
Introduction
What is Fly Ash?
Classification Process
Standards Compliance
Physical and Chemical Properties
Properties of Fly Ash in Concrete



History of the Pozzolan
As a building material, ash has a long history. The
Romans used volcanic ash from the town
Pozzuoli, which gave its name to the term
pozzolan , mixing it with lime to create strong
mortars and concretes for structures. The
Colosseum and Aquaducts in Rome stand
testimony to the durability of pozzolanic materials.

Modern Power Stations that burn pulverized coal
have given the concrete technologist Fly Ash.
Briefly, Fly Ash is a pozzolan, which
means it reacts with water and lime
to form a cementitious compound.
Fly Ash Improves the properties of
concrete in both the plastic and
hardened state. Fly Ash particles
are spherical in shape in contrast
to cement which are angular. This
property enables Fly Ash particles
to flow and blend easily in a
concrete mix.
What is Fly Ash?
Fly Ash (FA) / Pulverized Fuel Ash (PFA)
is the ash produced from the
combustion of powdered coal during
the process of raising steam for the
generation of electric power.
Ash from these hoppers can
be processed into high
quality and consistent
products.
The fly ash is separated from
the air-stream by electrostatic
precipitators and is collected
in a series of hoppers.
Fly Ash (FA) / Pulverized Fuel Ash (PFA)
Typical Chemical Composition Comparison (%)
CaO SiO
2
Al
2
O
3
Fe
2
O
3
MgO
OPC
66 21 5 2.5 1.5
Fly Ash
6 52 32 3.5 1.0
FLY ASH UTILISATION
Quality Enhancement by Processing
Improved Quality
More Consistent
Market Acceptance
Processing
Relative Density 2.20
Surface Area (m
2
/ kg) 3500 (classified)
pH 11 12
Colour Light Grey
Particle Shape Spherical
Particle Size, D
90
45 micron
D
99

Mean Particle Size
110 micron

15 micron


Physi c al Anal ysi s
Typical Chemical Analysis (%)
SiO
2
53.5
Al
2
O
3
34.3
CaO 4.4
Fe
2
O
3
3.6
K
2
O 0.8
MgO 1.0
TiO
2
1.7
L.O.I .

Carbon

Moisture
1.0

0.5

0.3

Spher i c al
FLY ASH STANDARDS
SANS 1491: 2 (South African)
BS 3892: 1(British)
EN 450 (European)
ASTM C 618 (USA)
The above standards are the most commonly used
standards for fly ash as an ingredient in reinforced
concrete. However, one should take care when using
these standards as there are major differences
between these standards which can have a significant
influence on the end-quality of concrete.
Standard:
EN
450
ASTM
C618, F
BS 3892,
part 1
SABS 1491,
part 2
Fineness
(%>45

m)
40% max 34% max 12.0% max 12.5% max
Water demand
(% of OPC Control)
N/A
105%
max
95% max 95% max
FLY ASH STANDARDS
Physical attributes
Comparison of standards
FLY ASH STANDARDS
Chemical attributes
Comparison of standards
Standard:
EN
450
ASTM
C618, F
BS 3892,
part 1
SABS 1491,
part 2
CaO Max 10% Max +/-10% Max 10% N/A
Soundness: 10mm Max 0.8% Max 10mm Max 10mm Max
SO3 3.0% Max 5.0% Max 2.0% Max 2.5% Max
LOI 5.0% Max 6.0% Max 7.0% Max 5.0% Max
Physical attributes
Chemical composition
Particle shape (spherical ?)
Fineness (% > 45m)
QUALITY OF FLY ASH AND ITS
IMPACT ON CONCRETE
PERFORMANCE
Physical attributes
Particle shape (spherical ?)
Fineness (% > 45m)
A fine and spherical fly ash will lower
the water requirement and increase the
workability of concrete. This will result in
a decreased permeability and therefore
improved durability.
QUALITY OF FLY ASH AND ITS
IMPACT ON CONCRETE
PERFORMANCE
Schematic cement / water paste:
A fine fly ash,
when added to
the mix, will fit
between the
cement particles,
replacing water.
A course fly
ash when added
to the mix, will
push cement
particles apart,
Chemical attributes
Reactivity (Pozzolanicity)
Chemical composition
QUALITY OF FLY ASH AND ITS
IMPACT ON CONCRETE
PERFORMANCE
2C
2
S + 4H
2
O

C
3
S
2
H
3
Ca(OH)
2
+
Cement + Water Calsium Silicate Hydrate + Calsium Hydroxide
Ca(OH)
2
+ S H
2
O + CSH

Calsium Hydroxide + Fly Ash Water + Calsium Silicate Hydrate
Pozzolanic Reaction
Non stable
by-product
Chemical attributes
Reactivity (Pozzolanicity)
QUALITY OF FLY ASH AND ITS
IMPACT ON CONCRETE
PERFORMANCE
A reactive fly ash combines with the
calcium hydroxide released during cement
hydration and forms additional
cementitious compounds which increases
strength and fill pores in the cement
matrix. The ultimate result is a more
durable concrete.
Pozzolanic Reaction
Chemical attributes
Reactivity (Pozzolanicity)
Chemical composition
Concentration of SiO
2
, Al
2
O
3
, Fe
2
O
3

Mineralogical phase
QUALITY OF FLY ASH AND ITS
IMPACT ON CONCRETE
PERFORMANCE
A high Al
2
O
3
content will result in increased chloride binding.
A portion of the CaO may be present as free lime . This may
lead to expansion and unsound concrete. High CaO contents
in fly ash may also result in lower sulfate resistance.
High SO
3
contents will result in increased setting times and
reduced sulfate resistance.
High LOIs will result in an increased water and admixture
demand in concrete.
% > 45 Micron (Lethabo Dura Pozz)
0
5
10
15
20
25
30
35
40
45
50
0 50 100 150 200 250 300
+45 mi cron (Max 12,5%)
7 per. Mov. Avg. (+45 mi cron (Max 12,5%))
ASTM C618 (max 34,0% > 45 micr on)
EN 450 (max 40,0% > 45 micr on)
SABS 1491/2 (max 12,5% > 45 micr on)
Therefore
fly ash used in reinforced concrete should be
fine
spherical
reactive
sound (chemical composition)
These parameters are controlled in various
local and International Standards and are
intended to safeguard the user against poor
quality materials
Lower Water demand (-18 l/m3)
FLY ASH IN CONCRETE
FLY ASH IN FRESH CONCRETE
FLY ASH IN HARDENED CONCRETE
Increased Workability
Increased Cohesion
Lower Bleed-rate
FLY ASH IN CONCRETE
FLY ASH IN FRESH CONCRETE
FLY ASH IN HARDENED CONCRETE
Good early strength
Increased late strengths
Similar to OPC
+ 25% @ 56 days
+ 45% @ 90 days
FLY ASH IN CONCRETE
FLY ASH IN FRESH CONCRETE
FLY ASH IN HARDENED CONCRETE
Good early strength
Increased late strengths
Increased durability
Marine environment
Sulphate attack
Alkali Silica Reaction
Lower Heat of Hydration
Later & Lower peak temperature Higher Tensile Strength Capacity

Typical Heat of Hydration of Concrete
20
30
40
50
60
70
80
0
1
0
2
0
3
0
4
0
5
0
6
0
Time (days)
T
e
m
p
.

(
o
C
)
OPC
OPC/30FA
OPC/40FA
55.9
o
C @ 147 hours
61.4
o
C @ 131 hours
68.5
o
C @ 83 hours
Effect of FLY ASH on Cracking
induced by Heat of Hydration
UTILISATION OF FLY ASH
A future Indian Success Story ??
Anil Kumble got 10
wickets in the 2
nd
test
against Pakistan in
February 1999
Ash utilisation in India
can achieve the same
(10 out of 10) with
proper management &
marketing!!!