FLY ASH

FINELY DIVIDED RESIDUE RESULTING FROM COMBUSTION OF POWDERED COAL

AN ARTIFICIAL POZZOLAN COMMON INGREDIANT IN CONCRETE FIRST USED IN CONSTRUCTION OF HUNGRY HORSE DAM IN USA IN INDIA, FIRST USED IN RIHAD DAM HIGH VOLUME FLY ASH IS OF CURRENT INTEREST QUALITY OF FLY ASH IS GOVERNED BY IS:38121981
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WHY CHARACTERISTICS?
NOT A SPECIALLY MANUFACTURED PRODUCT GOVERNED BY STRICT RULES VARIATION IN CARBON, PARTICLE SHAPE AND SIZE DISTRIBUTION, PRESENCE OF MINERALS, ETC. EXHIBITS DIFFERENT CHARACTERISTICS WITH DIFFERENT COMPOUNDS

NO PROPER PROCEESING IS AVAILABLE

CHANGE IN THE BEHAVIOUR OF CONCRETE
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TYPES OF FLY ASH(ASTM C 618)

CLASS F ANTHRACITE OR BITUMINOUS COAL HAS <5% CaO

POZZOLANIC PROPERTIES ONLY

CLASS C LIGNITE OR SUB BITUMINOUS COAL HAS >10%CaO POZZOLOANIC & CEMENTATIOUS PROPERTIES
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Physical requirements as per IS: 3812-1981: Sl n o 1 Fineness- specific surface in m2/kg by Blaines permeability method, Min Lime reactivity- Average compressive strength in N/mm2, Min Compressive strength at 28 days N/mm2, Min Dry shrinkage, %, Max Soundness by autoclave test expansion of specimen, %, Max 320 Characteristic Requirement

4.0

Not less than 80% of the strength of corresponding plain cement mortar cubes 0.15 0.8
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4 5

Chemical requirements as per IS: 3812-1981:

Characteristic by mass SiO2 + Al2O3 + Fe2O3, Min SiO2, Min MgO, Max SO3, Max Na2O Max Loss on ignition, Max Requirement 70.0 35.0 5.0 2.75 1.5 12.0

Microscopic photographs of fly ash (left) and Portland cement (right):

Magnified view of the fly ash

EFFECT OF FLY ASH ON FRESH CONCRETE

WORKABILITY

MOISTURE CONTENT TIME OF SETTING BLEEDING PUMPABILITY HYDRATION REACTIONS

WORKABILITY
INCREASED DUE TO HIGHER FINENESS AND SPHERICAL SHAPE OF FLY ASH PARTICLES IMPROVED PLASTICITY AND COHESIVENESS

MOISTURE CONTENT
MAX ALLOWABLE MOISTURE CONTENT IS 3% (ASTM C618) LESS WATER IS REQUIRED WHEN FLY ASH IS USED HIGHER FINENESS OF FLY ASH CREATES GOOD SURFACE FINISH AND EVAPORATION IS REDUCED

TIME OF SETTING
ALL CLASS F AND MOST CLASS C FLY ASH INCREASE SETTING TIME

BLEEDING
REDUCED GREATER FINES AND LOWER WATER CONTENT

PUMPABILITY
INCREASED

LUBRICATING EFFECT OF SPHERICAL FLY ASH PARTICLES

IT HELPS IN PUMPING LONGER DISTANCES

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HYDRATION REACTIONS
THE HYDRATION REACTION DOESNOT START OFF IMMEDIATELY AS IN CASE OF NORMAL CONCRETE
CLASS F FLY ASH DOESNOT HAVE SELF CEMENTATIOUS PROPERTIES SHOULD MIX WITH Ca(OH)2 AND ALKALIS WHERE Ca(OH)2 IS FIXED BY SILICA AND ALUMINA IN FLY ASH CLASS C FLY ASH WHICH HAS MORE LIME CONTENT AND REACTS DIRECTLY WITH WATER AND REACTION IS FASTER COMPARED TO CLASS F FLY ASH

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HEAT OF HYDRATION
REDUCED DUE TO LESSER CEMENT CONTENT

CANMET (Canada centre for mineral and energy technology) REPORTS THAT HEAT OF HYDRATION WAS LESS BY 15-25 C OF CONVENTIONAL CONCRETE
BLOCK SIZE 3.05X3.05X3.05 METERS MAX TEMP REACHED WAS 54 C

WITH ASTM TYPE I CEMENT MAX TEMP WAS 83 C

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EFFECT OF FLY ASH ON HARDENED CONCRETE AND DURABILITY

STRENGTH DEVELOPMENT RESISTANCE TO FREEZE THAW SULFATE RESISTANCE COEEFICIENT OF THERMAL EXPANSION PERMEABILITY

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STRENGTH DEVELOPMENT
USUALLY STRENGTH DEVELOPMENT IS VERY SLOW DUE TO POZZOLANIC REACTION OF FLY ASH LATER AGE STRENGTH IS HIGHER EXCEEDS THE STRENGTH OF CONCRETE WITH OUT FLY ASH ENOUGH CURING SHOULD BE AVAILABLE FOR LONG TIME FLY ASH UNDER WATER WILL BE MORE BENEFICIAL
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Typical strength gain of fly ash concrete Source:www.flyash.info

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COEEFICIENT OF THERMAL EXPANSION

FOR 40% REPLACEMENT OF FLY ASH THE COEFFICIENT OF THERMAL EXPANSION REDUCES BY 4% (Source: Malhothra and Berry,1986)

PERMEABILITY
REDUCED

FLY ASH BLOCKS BLEED CHANNELS REACTING WITH LIME AND ALKALIS FILLING PORE SPACES
INCREASED FINES AND REDUCED WATER CONTENT

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Permeability of fly ash concrete Source: www.flyash.info

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RESISTANCE TO FREEZE THAW

SINCE MORE STRENGTH IS ATTAINED IT CAN WIH STAND MORE FREEZE THAW

BECAUSE INTRUSION OF AIR VOIDS IS NOT THERE, FREEZE THAW EFFECT IS LESS

SULFATE RESISTANCE
CLASS F FLY ASH HAS IMPROVED SULFATE RESISTANCE

CLASS F FLY ASH CONSUMES Ca(OH)2 WHICH IS THE MAIN CAUSE OF SULFATE ATTACK
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DURABILITY OF FLY ASH CONCRETE

SUFFICIENTLY CURED FLY ASH CONCRETE HAS A DENSE STRUCTURE AND HENCE MORE RESISTANCE TO DELETERIOUS SUBSTANCES

THIS REDUCES THE CORROSION OF REINFORECEMENT

CLASS F FLY ASH REDUCES ALKALI -SILICA REACTIVITY BECAUSE OF THE DENSE STRUCTURE AND HENCE EXPANSION IS REDUCED WHICH INCREASES DURABILITY

BECAUSE OF THE REDUCED PERMEABILITY THE CHLORIDE INGRESS IS REDUCED

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UTILIZATION OF FLY ASH

Fly ash mission project sites

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 MANUFACTURE OF PORTLAND CEMENT

ADDITIVE TO CEMENT
AVAILABLE NEAR TO CEMENT PLANTS

CEMENT CONCRETES
CONSTRUCTION OF DAMS

LINING OF TUNNELS AND CANALS

BRIDGES

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SINTERING OF FLY ASH

SOLID AND HOLLOW CONCRETE BLOCKS USED IN MULTI STORIED AND CHEAP HOUSINGS LIGHT WEIGHT AGGREGATES

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Fly ash utilization in Mass concrete or Dam construction

Sl. No 1. 2. 3. 4. 5. 6. Structures Gurgoan tunnel Jawar sagar Dam Kakki Dam Navora barrage Rihad Dam Sone Barrage Umium Project Chandil dam State Haryan a Rajast han Kerala U.P. U.P. Bihar Assam Bihar Cement replaced (%) 15 Source of fly ash Delhi Delhi 20 Neyveli 20

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15 15 Not available 25

Harduaganj Bokaro Bokaro

7.
8.

Durgapur
Talcher
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Fly ash Experimental Housing Schemes By National Buildings Organisation

Location Hindustan Prefab Ltd. Staff Quarters, New Delhi Application 15% replacement of fly ash in precast RCC components. 20% fly ash in cement and mortar

Government double storied staff quarters R.K.Puram at New Delhi 4 storied Government quarters at dhaulakuan New Delhi
Double storied building at the S.E.R.C.Chennai. Dwelling units at Pankha road, New Delhi Flats at Besant Nagar, Chennai

20% fly ash in cement and mortar

Precast reinforced channel units Foundation, Concrete mortar flooring plaster some RCC items Cement mixture
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Use of flyash based cellular light weight aggregates at Hyderabad & Chennai

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Fly ash used in the construction of buildings at Chennai

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Buildings constructed using fly ash blocks at New Delhi

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Saraswati Sishoo Mandir School Near Dadri

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Fly ash used in Delhi Metro

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Fly ash used in Ready Mix Concrete (RMC) plants at Delhi

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ADVANTAGES PROPERTY WISE

Increased workability. Concrete is easier to place with less effort, responding better to vibration to fill forms more completely. Increased ease of pumping. Pumping requires less energy; longer pumping distances are possible.

Improved finishing. Sharp, clear architectural definition is easier to achieve

Reduced bleeding. Fewer bleed channels decreases porosity and chemical attack. Improved paste to aggregate contact results in enhanced bond strengths.
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Reduced segregation. Improved cohesiveness of fly ash concrete reduces segregation that can lead to rock pockets.

Greater strength. Fly ash increases in strength over time, continuing to combine with free lime. Decreased permeability. Increased density and longterm pozzolanic action of fly ash, which ties up free lime, results in fewer bleed channels and decreases permeability.

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Increased durability. The lower permeability of concrete with fly ash also helps keep aggressive compounds on the surface, where destructive action is lessened. Fly ash concrete is also more resistant to attack by sulfate, mild acid, and soft water Reduced alkali silica reactivity. Fly ash combines with alkalis from cement that might otherwise combine with silica from aggregates, thereby preventing destructive expansion.

Reduced heat of hydration. The pozzolanic reaction between fly ash and lime generates less heat, resulting in reduced thermal cracking when fly ash is used to replace a percentage of Portland Cement.
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CONCLUSIONS
IMPROVED MEANS OF CLASSIFYING AND SPECIFYING FLY ASH SOURCES IS NEEDED
CLASS F FLY ASH MIGHT NOT HAVE CEMENTATIOUS ABILITY,THIS HAS TO BE FURTHER BLENDED WITH OTHER BY PRODUCTS CAN BE SUGGESTED FOR HIGH PERFORMANCE CONCRETE HAS TECHNICAL ADVANTAGES AND ALSO COST BENEFITS OVER NORMAL CONCRETE, PAST AND PRESENT RESEARCHES HAVE HELPED IN BETTER UNDERSTANDING OF THE PRODUCT AND CAN BE UTILIZED EFFECTIVELY.
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References
Shetty M. S. (2003), Concrete Technology, S.Chand & company. Ltd, New Delhi.
Neville A. M. (1997), Properties of Concrete, Addison Wesley Longman, London. Malhotra V. M. (2003), Hydration reactions and pozzolanic activity of fly ash, ACC users manual-III, Bangalore. Ashok Dhariwal (1999), Utilization of fly ash in scenario of 21st century, Proceedings of fly ash characteristics,Indian Institute of Science, Bangalore. www.useit.umeciv.maine.edu/ashcrete.html www.tfhrc.gov/hnr20/recycle/waste/cfa51.html www.flyash.info

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