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Cement & Concrete Composites 15 (1993) 223-229

Efficiency of Fly Ash in Concrete


K. Ganesh Babu & G. Siva Nageswara Rao
Ocean Engineering Centre, Indian Institute of Technology, Madras 600 036, India
(Received 22 August 1992; accepted 21 June 1993)

Abstract w/(c+f) Water cementitious material ratio


of fly ash concrete
Earlier efforts towards an understanding of the effi- w/(c+ kJ) Water cementitious material ratio
ciency of fly ash in concrete has led to the introduc- of fly ash concrete after correc-
tion of rational methods. Based on the results tion with k e
available on some of the more recent pulverised w/( c+ kff + krf)
fuel ashes, the authors evaluated the efficiency of fly = w/(c + kf)
ash in concrete over a wide range of percentage = W/C o Water cementitious material ratio
replacements (15-75%). It was clearly shown that of fly ash concrete equivalent to
the overall efficiency of fly ash cannot be ade- normal concrete after correction
quately predicted using a single efficiency factor at with k e and kp
all percentages of replacements. The overall effi- Aw Difference between water
ciency factor (k ) has been evaluated at all percen- cementitious materials ratio of fly
tages of replacements considering the general ash concrete and normal
efficiency factor (ke) and the percentage efficiency concrete
factor (kp). This study resulted in a quantitative Aw l The effect of ke on water
assessment of the behaviour of fly ash in concrete, cementitious materials ratio
especially for the 28 day compressive strength at Aw 2 The effect of kp on water
different percentages of replacement. cementitious materials ratio

Keywords: Fly ash, utilisation, efficiency, concrete


construction, compressive strength, cement INTRODUCTION
replacement, water-binder ratio.
The use of pozzolans in conjunction with lime
for mortars and concretes has been in practice for
NOTATIONS many centuries. Fly ash as a pozzolanic material
in cement concretes has been in vogue for many
C Cement content of fly ash con- decades. With the increased use of coal in power
crete production the amount of fly ash available
Co Cement content of control assumed staggering proportions and its disposal
concrete particularly with the associated problems of en-
f Fly ash content vironmental pollution has made it necessary to
k Overall efficiency factor of fly look for effective utilisation possibilities. Earlier
ash researchers have adopted three different methods
ke General efficiency factor of fly for the proportioning of fly ash concrete mixes: (i)
ash a simple replacement method, by an equal mass or
kp Percentage efficiency factor of fly volume; (ii) modified replacement method, in
ash which the amount of fly ash replaced is larger than
w Water content the amount of cement reduced so as to get an
w/c O Water cement ratio of normal equivalent 28 days strength (the additional fly ash
concrete component being adjusted in the aggregate pro-
223
Cement & Concrete Composites 0958-9465/94/$7.00 1994 Elsevier Science Limited, England. Printed in
Great Britain
224 K. Ganesh Babu, G. Siva Nageswara Rao

portions); or (iii) by rational methods, in which the may be in the range of 55-60%. However, these
pozzolanic activity of the fly ash is taken into high strengths are achieved mostly by the utilisa-
account. The present state of the art regarding the tion of superplasticisers required for a substantial
use of fly ash in concrete was reported earlier. 1-3 lowering of the water content and thus water/
It can be seen that in spite of the numerous cement ratio. The present paper is not considering
earlier research efforts an exact quantitative this aspect of concretes with chemical admixtures
understanding of the contribution of fly ash to the but is an effort to evaluate only the effect of fly ash
strength of the concrete was still elusive. However, on normal concretes containing ordinary portland
it is recognised that the contribution of the fly ash cements cured under normal conditions. Informa-
is not a constant determined solely by its physical tion available in literature with fly ash replace-
and chemical characteristics like cementitious ments ranging from 15 to 75% has been
compounds, fineness, etc., but can also vary considered for an evaluation. Furthermore, differ-
depending on the nature of cement, water cement ent researchers have used specimens of varying
ratio, etc. It is also not known at present what sizes and shapes and all these have been con-
factors maximise the fly ash contribution. 4 verted to their equivalents for a cube of 15 cm size
The objective of the present effort is to answer through accepted guidelines. ~9 At this juncture, it
at least some of the questions raised earlier is important to emphasis once again that the
through a systematic evaluation of the available specific variations in the composition of fly ashes
results. In this context, it is important to note that used by different investigators has not been con-
fly ash being a silicious material will impart sidered for evaluation. Also, other parameters like
strength to the concrete through its pozzolanic fineness or even the special production and curing
action, but the pozzolanic reaction being slow fly procedures have not been included in the present
ash concretes may not be able to attain an equal study.
strength as that of the control within 28 days.
Furthermore the ashes of yester years, because of
the process of burning coal and the collection EFFICIENCY CONCEPTS
procedures of a generally much lower efficiency,
resulted in a larger fraction of the coarser parti- The efficiency of fly ash is generally defined in
cles apart from a larger proportion of unburnt terms of its strength characteristics with the con-
coal (reflected through its loss on ignition). In trol concrete as the reference. However, knowing
contrast, the fly ashes available today are resulting the improvements in durability due to the addi-
from burning powdered/pulverised coals and tions of fly ash, it is well recognised that other
from the improved collection systems like the characteristics like durability factors can also be
electrostatic precipitators of higher efficiency. In used for such an evaluation, though the exact
view of the above, only the results of the investiga- methodology of the durability test has to be
tions during the past about 10 years were chosen clearly defined. Furthermore, it is possible to
for an evaluation, s-~' All these fly ashes confirm define more than one durability factor (sulphate,
to the minimum characteristics specified by chloride, freeze-thaw, etc.) and it would be diffi-
ASTM C 618-89 for use as mineral admixtures in cult to compare or specify such a factor in codal
portland cement concrete.~ 7 provisions. Also, it is accepted, in general, that the
Early efforts regarding the use of fly ash in strength of concrete is a reasonable indicator of
concrete were mostly limited to replacements up the durability for at least the normal concretes
to a maximum of 35%, and the latest ACI Com- without any chemical modifications and the effi-
mittee recommendations I also limit the utilisation ciency of fly ash concrete is always defined with
to the same extent. This may be due to the respect to the strength of its control.
requirement of additional water for wetting the The simple replacement and modified replace-
finer fly ash which in turn increases the water ment methods were not found to be suitable for a
cement ratio resulting in a reduction of the general understanding of the behaviour of fly ash
strength. However, investigations in recent in concrete. The rational methods were expected
years 7,18 have shown that even with low cement to take into account the characteristic of fly ash
contents, high volume fly ash concretes can pro- which are known to influence the workability a n d
vide an economical material with strengths reach- strength characteristic of concrete. Smith 2 was
ing 60 MPa. Extensive laboratory investigations one of the first to propose a factor known as
indicate that the optimum percentage of fly ash cementing efficiency (k) such that a weight 'f' of
Efficiency offly ash in concrete 225

100
fly ash would be equivalent to a weight 'kf' of \ A & B - Fly ~ Concrete w.r.t, wl(c,f)
~ C & O - Fly q~h Concrete wr.t. wl(c.ket)
cement. The strength and workability of this con- \\ N - Control Concrete w.r.t, wit or
Fly ash Concrete w.r.t, wl(c,kef,kpl)
crete with fly ash is comparable to that of the so

\ ~\j~ Low Vcluene Fly ash


normal concrete with a water cement ratio of [w/ \ / ~ NormGI Concrete
Concrete

(c + k)9]. Based on the experimental investigations ~r/~/~ - High Volume Fly ~ Concrete
~ 80 %,
and the results available, the value of the cement-
ing efficiency factor k was assessed to be 0.25.
This method was seen to be insensitive to the
cement used, curing conditions, etc., apart from
2O ke ~
the fact that it was not suitable for richer mixes. 21
Later investigations22 have shown that the fly
ash efficiency factor was a minimum of 0.3 and 0
0.20
l
0.30
t
0.40
1
0.50
I
0.60
I
0.70 0.80
I I
0.90 1.00
this value was also used in the German Concrete w/(c*~) or w / ( c . k e f ) or wl(tkel*kpf)
Standard DIN 1045. However, a more recent Fig. 1. Conceptual diagram showing the effect of efficiency
evaluation through studies on concretes contain- factors.
ing different cements and fly ashes 23 (fly ash con-
tents up to 28% and with water/cement ratios
varying between 0.5 and 0.65) has shown that a ash. Figure 1 shows the relation between the 28
value of 0.5 is more appropriate for this efficiency day compressive strengths of concrete and the
factor. These studies also indicated that with water cementitious materials ratio for normal and
increasing fly ash content the efficiency of the fly fly ash replaced concretes. As can be seen, lower
ash tends to diminish and that the efficiency of fly replacement levels (may be up to 20%) show
ash increases with decreasing water cement ratio. strengths higher than the control concrete while
It was also observed that the significant differ- replacements of higher magnitude result in con-
ences in the properties of fly ashes used (particu- cretes of lower strengths. ~ and 'B' are the two
larly fineness) influenced the compressive typical water cementitious material ratios of con-
strengths at 28 days only marginally. It was only at cretes at the higher and lower percentages of
greater ages the effect of the differing pozzolanic replacement, with that of the control concrete
reactivities of fly ashes were felt. The efficiency of being at 'N' for the same strength. The method
fly ash also did not show much variation in the now tries to bring the [w/(c+f)] ratios nearer to
range 20-28% replacements adopted. One that of the control concrete by applying the
important contribution of this work was that it cementitious efficiency of fly ash (k). Now the
defined the consequent reduction in water figure is replotted to check whether a unique
cementitious materials ratio of fly ash concrete as value of k can help in bringing both 'X and 'B' to
compared to the water cement ratio of the refer- 'N'. This means that the correction (Aw) required
ence concrete (A w concept) as can be achieved by the unique cementitious effi-
ciency (k) at all percentages of fly ash replace-
ment. However, this was not possible as the
={w/(c+ kf)}-{w/(c+ f)} percentage of replacements were far too different
=(w/c)[1/{1 + k(f/c)}- 1/{1 + (f/c)}] and the result was that while the high volume
replacements approach the control values due to
The above formulation clearly shows that this this correction the low volume replacements
reduction depends not only on the size of the effi- resulted in a slightly higher conservative estimate.
ciency factor (k), but depends additionally on the For this reason the value of k which is generally
water cement ratio and more importantly the fly applicable for all the replacement percentages is
ash content of the concrete mix. from henceforth defined as the general efficiency
factor (ke). This means that the points ~ and 'B'
now shift to their revised locations 'C' and 'D' due
EVALUATION OF EFFICIENCY to the application of the general efficiency factor
(ke) with the axis as [w/(c+ kJ)]. Thus the original
In principle the evaluation of efficiency was points ~2 and 'B' have been shifted to 'C' and 'D',
attempted by what was earlier discussed as the by a distance of A w~. The revised correction now
rational method. 20 The A w concept explained required (Aw2) was considered to be the effect of
earlier was used in evaluating the efficiency of fly the percentage replacement. To counteract this
226 K. Ganesh Babu, G. Siva Nageswara Rao

effect of the percentage replacement an additional percentages of replacement. It can now be clearly
factor kp has been evaluated for each percentage seen that while some of the concretes with
of replacement in a very similar way. These two replacements up to 25% show strengths higher
corrections together will bring the points W and than the control, while the higher percentage
'B' to 'N' so that the water/cement ratio of the replacements show a reduction corresponding to
control concrete and the water/cementitious the percentage replaced and the [ w/(c+ f)].
material ratio [w/(c+kJ+kvf)] will all be the At this stage, the authors studied the variation
same for any particular strength. of compressive strength with different general
efficiency factors (k~) ranging from 0.2 to 0.8.
From these studies it was observed that at a
RESULTS AND DISCUSSIONS general efficiency factor of 0.5 the compressive
strengths of fly ash concretes come closest to the
As already stated, the results of different inves- control as shown in Fig. 3 (with the A w~ correc-
tigators 5-16 were compiled from literature for con- tion applied). This resulted in the concretes con-
cretes containing ordinary portland cement with taining replacements up to 35% showing strengths
fly ash replacements ranging from 0 to 75%. Table slightly higher than the corresponding control and
1 presents the characteristics of fly ash and the
different percentages of replacements utilised in
the above studies. In general, it was seen that as 10o -~ *..*_*%.* 75 FA
the replacement percentage and the water cement ~" \,, U " . I I J 67 FA
k',, AA,,U~ 50 FA
ratios increase the strength of concrete decreases. ~ , ao oN,., '~,,:.~"~. 35 ~: FA
However, it was also evident that while concretes
e \\ ~o~. o o oQooo 0 FA
above 70 MPa can be produced with replace-
ments up to 25% fly ash, replacement of about
75% can still lead to concretes of 40 MPa through
suitable adjustments in water/cement ratio and "... " -. .. ,~ ~'-'~..~..

other concrete constituents.


The variation of the 28 day compressive
strength with the parameter [w/(c+f)] for all con-
cretes considered with the different percentage of 0,30 0.40 0.50 0,60 0.70 0,80 0,90 .00
w/(c+O
replacement were presented in Fig.2. The curves
drawn were the best fits for each of the different Fig. 2. Variation of compressive strength with w/(c + f).

Table 1. Details of the fly ash concretes evaluated in the present investigation

Serial Ref. Year Fly ash characteristics L1 % Replacements


number studied
SiOe + AI,_O~+ Fe,O~ CaO SO~

1 5 1981 88.74 7.87 0.41 2'10 35


2 6 1982 94.40 2.20 -- 4.50 25
3 7 1986 (a) 87.52 5.18 0.76 1"36 35
(b) 90"06 1"83 0.57 5"16 35
(c) 91'35 2.21 0.65 5"28 35
4 8 1989 86"50 1.71 0.83 4.34 50, 15
5 9 1989 91"10 1.44 0.16 2'00 67, 50, 35, 25, 15
6 10 1984 76-20 15"30 0.30 0"60 75, 67, 50
7 11 1986 76"20 15.30 0.30 0.60 75, 67, 50
8 12 1986 75-71 13-30 1.16 0-14 35
9 13 1986 56"03 25-76 3.55 0"16 75, 50
10 14 1986 61.76 17.32 3.05 0"36 25
11 15 1989 72"60 12.40 0-80 0-61 50
12 16 1990 63"03 25.30 2.98 0"45 65, 35, 25

ASTM 618-89 Requirements Class C Class F


(Si z + AI203 + Fe203) min % 50.0 70.0
SO3 Max % 5.0 5.0
L1 Max % 6 6
Efficiency offly ash in concrete 227

loo 1.00
I *.*.lt*.J' 75 S FA
"4~, I,I ~ l J 67 ~ FA oolee 28 Days
k")'~ ~ 50 FA 0,80
'ao el', ~ e.O..,l,~,35 ~ FA
"~.~
\'~,L
=-~.~m.~ 25 ~
~.tx.l~ 15 ~
FA
FA
2 0,60
K~'~ ..... O~ FA

u. 0.40

"~ 0.20
4O

8 ~ -0.0o( 10 20 30 40 ~ 60 70 E~
Percentage Replacement "~...4L_.,____e
~ 20
~_-o.2o!
-0.40

w/(c+k.f)
Fig. 5. Variation of k v with fly ash replacement.
Fig. 3. Variation of strengths after correcting for k~.

100 1.50
|
i~ *..*-**J 75 ~ FA
LIPIlul 67 FA lllll 28 days
a.
~1.25
so ~,'J o.O.,0,e.935 FA
~, ~.q.apa 25 FA +
== ~ ~.~.A.A 15 ~ FA
~',~o a .... o ~ FA II 1 . 0 0 '
so
v

.i
0. 4C
o
0.75

o.5o
._.e
o

"~ 2C
=
0.25
o

0 % ...... 61~ . . . . . . . . . .0.40


. . . . . . . . . . . . . . . . .o.so
. . . . . . . . . . . . . . . . .o.so
. . . . . . . . . . . . . . . . .1.oo
. . . . . . . . . . . . . . . . .1.2o
.......... 1.40 1.so 1.8o 2.0o o o.oo o ....... ~'~ ....... h'd ....... L6 ....... ~,'d ....... ~'~ ....... ~'d ....... V'~ ....... ~o
w/(a+k,f+kpf) Percentage Replacement

Fig. 4. Variation of strengths after correcting for ke and kp. Fig. 6. Variation of overall efficiency with fly ash replace-
ment.

those containing replacements between 50 and


75% showing slightly lower strength with respect crete strengths at all the percentages of replace-
to the parameter [w/(c+ kd) ]. Thus it was felt that ment ranging from 15 to 75%. It was clearly
an average value of 0.5 can be assumed for the observed during these evaluations that some of
general efficiency factor (ke). This also agrees well the specific parameters like curing conditions,
with the observations of a recent study discussed addition of admixtures and in certain cases even
earlier. 23 This means that instead of using an over- the type of aggregates and modifications of their
all efficiency factor like the earlier research- proportions have significant effect on the effi-
e r s 2'22'23 the general efficiency factor was kept a ciency of fly ash.
constant for all the percentages of replacement. The variation of kp with the percentage
Now, the differences between the water cement replacement was presented in Fig. 5 and the varia-
ratio including the effect of general efficiency tion of the overall efficiency factor k ( -- k e + kp)
factor and that of control concrete was computed was presented in Fig. 6. It can now be seen that a
(Aw 2) for the individual mixes at various water replacement of about 10% will increase the
cement ratios and the effect of percentage cementitious efficiency up to about 1.25 times for
replacement was calculated through an additional the 28 day cube compressive strength and a
percentage efficiency factor (kp). Considering the replacement of around 20% will not alter the
average of the kp values for the different percen- compressive strength of control concrete at the
tage the variation of compressive strength with corresponding water/cement ratio. Replacements
parameter w/(c+ kd+ krf ) was presented in Fig. in excess of 20% will reduce the compressive
4. It can be clearly seen that this has resulted in a strengths of the concrete continuously and it was
reasonably close agreement with the control con- seen that a 75% replacement resulted in a reduc-
228 K. Ganesh Babu, (7. Siva Nageswara Rao

tion of efficiency of the fly ash to about 35% (0.35 ke=0.5) will result in conservative values
times). upto about 40% fly ash replacement as
Thus, the proposed method clearly distin- reported by earlier researchers.
guishes the effect of fly ash replacement in terms . The results clearly show that the strength of
of the general efficiency factor (ke) and the factor concrete decreases continuously from 100
corresponding to the percentage replacement to 35% at replacements varying from 20 to
effect (kp). It was also shown that while the general 75% respectively.
efficiency factor (ke) was a constant (0.5) for the . Finally, the method presented using both
28 day compressive strength for all percentages of the general and percentage efficiency factors
replacements the factor representing the percen- is able to predict quantitatively the strength
tage replacements (kp) varies between 0.75 and variation of concrete at different percen-
-0.15 resulting in the overall efficiency factor k tages of fly ash replacements and at different
varying between 1.25 and 0.35 for replacement water to ash cementitious materials ratios.
percentages of 10 to 75% of cement by an equiva-
lent weight of fly ash respectively.
ACKNOWLEDGEMENTS

The authors gratefully acknowledge Professor P.


CONCLUSIONS
Schiessl, Director, Institut fiir Bauforschung,
RWTH, Aachen for the information made avail-
This study, reporting the efficiency of fly ashes in
able and the detail discussions which helped in
concrete containing ordinary portland cements
narrowing the study to specific aspects. In particu-
and cured under normal conditions, had led to the
lar, it was his views that made us look for the
following general conclusions.
pozzolanic efficiency at the different percentages
1. It was seen that a unique value of the overall of replacement resulting in the present general
efficiency factor (k) will not be able to pre- and percentage efficiency factors.
dict the strength behaviour of fly ash con-
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