ADMIXTURES

Definition Admixtures are chemical/mineral substances (other than fine and coarse aggregates, cement, or water), which are added in small amounts just before or during the mixing stage to concrete products. They can also be blended during the grinding stage of cement manufacturing. Use

They should normally only be used where it is desirable to modify the properties of either fresh or hardened concrete (or both) for particular reason when such a change cannot be effected by changes in the composition or properties of the normal mix.

Mineral Admixtures Fly ash or Pulverised Fuel Ash (PFA). Silica Fume or Micro silica. Rice Husk Ash. Ground Granulated Blast Furnace Slag (GGBS). Metakaolin. Reason: Why Fly Ash? Annually, more than 110 million tonnes of Fly Ash is being generated in India. Requires approsimately 65,000 acres of land for disposal Generation of Fly ash: Fly ash is a solid, fine-grained material resulting from the combustion of pulverized coal in thermal plant/furnaces Collection of Fly ash: Bottom ash: Collected from boiler bottom Ponded Fly ash: ESP Product Mixed with water Dry Fly ash : Separated from field B & C and stored in silo for loading in bunkers Electrostatic Precipitator

Morphological Characteristics The spherical particles in a flyash samples are its outstanding features specially in the context of its use as a pozzolana or admixture in concrete. Morphology of the particles influenced by modes of collection Smooth, Glassy surface show higher reactivity.

Smooth, glassy surface

SEM of Pond Ash.

Chemical Composition Major constituents of most fly ashes are: SiO2, Al2O3, Fe2O3, CaO and Loss on Ignition (LOI). Other elements are MgO, Na2O, K2O, SO3, MnO, TiO2. The early reaction is due to the presence of silica and alumina in the reactive form (amorphous). Long term strength is due to the crystalline form. Presence of alkalies may affect durability adversely although they may act as activators during the early stage reaction. Activity of the ash is influenced by the presence of important chemical constituent calcium. un burnt Carbon Is the Most Important Component of LOI The higher the carbon content of a fly ash, the more water is needed to produce a paste of normal consistency. IS: 3812 Specifications CHEMICAL PROPERTIES for Grade I & II of FA (percentage by mass) Characteristic Bituminous Coal Ash Lignite Ash 70.0 50.0 1. SiO2 + Al2O3 + Fe2O3 (min.) (min.) 35.0 25.0 2. SiO2 3. Soluble silica (min) 25.0 20.0 4. MgO (max) 5.0 4.0 5. Total Sulphur as SO3 (max) 2.75 2.5 6. Alkalis as Na2O (max) 1.50 1.50 7. Total chlorides (max)0.05 0.05

8. Loss on ignition (max)5.0 5.0 Types of fly ash Low-lime fly ash (CaO < 10% ) Exhibit Pozzolanic properties produces cementitious properties with the help of an activator (cement or lime). High-lime fly ash (CaO > 10% ) Exhibit Cementitious properties itself. Chemical Composition
Chemical Composition % SiO 2 Al2 O 3 Fe 2 O 3 SO 3 CaO MgO Moisture LOI SP-GR Glass Content Phases: ASTM C-618 CLASS - F 44 22 6 0.5 4 1.5 0.6 1.0 2.18 80 - 84 Quartz Mullite Hematite Megnetite Carbon ------ASTM C - 618 CLASS - C 41 20 5 2 17 3 0.3 1.0 2.5 80 - 86 Quartz Periclase Ferrite Spinel Melilite Merisinite ------INDIA FLY ASH RANGE 37-66 20-31 2--12 0.3 - 1.0 1.3 - 5.0 0.3 - 2.9 1.0 - 12 0.3 - 8.8 2.10 - 2.52 --------------3.0 - 8.0 60-85 1.5 - 12 RTPS PROCESSED FLY ASH 61 25 5.0 0.3 4.0 0.3 1.6 1.2 2.2 > 84 Quartz Mullite Hematite Megnetite

LR Mpa CR % Carbon %

> 5.0 > 80 < 1.5

Mineralogical composition Fly ashes consist of non-crystalline particles or glass, and a small amount of crystalline material. Major crystalline phases: Quartz, Mullite, Magnetite, and Hematite in subbituminous fly ashes.

X-RD Scan of Fly Ash(Amorphous Phase)

X-RD of RTPS Pond Ash.

PHYSICAL CHARACTERISTICS OF FLY ASH Grain size distribution Grain size distribution plays an important role in determining the activity of fly ash. The particles in the size range of 5 to 30 m plays a decisive role in determining the activity of fly ash. For fly ashes with low glass content and normal carbon, the reactivity was found to be directly proportional to the amount of particles smaller than 10 m, and inversely proportional to the amount of particles greater than 45 m for low calcium fly ashes. The particles below 45 m, which are mostly present in an amorphous form or as glass in the ash, are responsible for the pozzolanic effect. But the enhancement in compressive strength appears to be related more to particle sizes below 10 20 m.

Fineness One of the principal parameters to define the aptitude of the ash to be added to cement as it influences the rate of development of mechanical strength and relative values to be attained. However, there is an optimal fineness above which the increase in strength becomes less significant because of the increase in the specific surface. Researchers have also stated that finer the fly ash, the higher is the pozzolanic activity. Fineness can be expressed in terms of specific surface area determined by Blaines Air Permeability method. The values are seen to range from 200 600 m2/kg

Specific Gravity Specific Gravity varies significantly for particles of different shape, color and chemical composition Irregular shaped, black, coal particles, which contain few mineral grains, have a specific gravity between 1.3 and 1.6 - are non-reactive and dilute the active Pozzolanic material in fly ash Variations in the particle densities is due to the presence of bubbles in the glassy particles and voids in the agglomerated particles In general, it appears that specific gravity does not have any direct influence on the reactivity of the ash IS: 3812 Specifications PHYSICAL PROPERTIES Characteristic Grade I 1.Fineness-specific surface in m2/kg by Blaines permeability method, minimum 320 2.Particles retained on 45 micron IS sieve (wet sieving) in percent, maximum. 34

Grade II 250 40

3.Lime reactivity average compressive 4.5 3.5 strength in N/mm2 , minimum 4.Compressive strength at 28 days --- Not less than 80%, minimum of the strength of core.
Plain cement mortar cubes

Properties of Concrete with Pozzolans Hydration Process Sio2+Ca(OH)2 CSH A- Cement B- Water C- CSH D-Calcium Hydroxide Pozzolanic activity of fly ash Hydration Process Sio2+Ca(OH)2 CSH A- Cement B- Water C- CSH D- Calcium Hydroxide Reaction products may include Calcium aluminate hydrate (C4AH19) Ettringite (C3A.3CS.H32) 6

 Gehlenite (C2A.S.H8) Calcium mono sulpho aluminate hydrate (C3A.CS.H12) Provides reduced settling and more homogeneous concrete The mix is strongly cohesive and, in consequence, there is very little bleeding or even none. Blocking of the capillary pore/ channels both by physical action due to fine particle size and due to the formation of new products of pozzolanic reaction results in lower permeability of concrete

Increased Compressive and Tensile strength due to lack of Bleed pockets and formation of dense hydrated cement paste.

Permeability The use of pozzolanic material reduces the permeability by refining the capillary pores(regarded as flaws in concrete)

Increased surface area, as determined by air permeability tests, in many cases correlates well with quality of a fly ash from a single source

Reduced Permeability means more resistance to chemical attack, (Sulphate attack, Acid attack, Chloride induced corrosion etc.,)

Applications Innovative Applications Blended cements Fly ash Concrete High Volume Fly Ash Concrete Self Compacting Concrete Roller Compacting Concrete Geo-technical Applications Building blocks Structural fills Fine Aggregate Agricultural applications Waste stabilization Others (as filler in paints, metal castings etc.,) Concluding Remarks Fly ash is produced in large quantities in India and requires to be utilised for sustainability of resources. Indian fly ashes are mostly Class F fly ashes containing low calcium content. It contributes to strength and durability by way of filler effect and pozzolanic action. It enhances workability and cohesion due its spherical nature. It has become an important component of cement concrete. Reference: 1. Properties of Concrete, A.M. Neville, Fourth Edition, Pearson Education Asia pvt., Ltd., 2000. 2. Concrete- Microstructure, Properties and Materials, P.K. Mehta and Palulo J.M. Monteiro, Tata Mcgraw Hill., 2006. 3. Concrete Technolgy Theory and Practice, M.S. Shetty, S. Chand and Company Ltd.,, 2005. 4. Current Literature..,