Concrete Repair, Rehabilitation and Retrofitting II – Alexander et al (eds) 2009 Taylor & Francis Group, London, ISBN 978-0-415-46850-3
Sulphate resistance of high volume fly ash cement paste composites
E. AydinCyprus International University, Mersin 10 Turkey, North Cyprus
ABSTRACT: This research was carried out to evaluate the effects of using high volume Class C fly ash on strength and sulphate resistance of construction materials. Physical, mechanical and sulphate resistance tests were conducted on the Φ50 mm/100 mm specimens. Physical tests considered were apparent specific gravity, water absorption and dry unit weight. Mechanical properties considered were compressive strength, and flexu-ral strength. The durability properties considered was: sulphate resistance. In general strength and sulphate resistance of High Volume Fly Ash (HVFA) were considerably affected by amount of fly ash. Also, the strength properties for the 20% fly ash mixtures were either comparable or superior to the no-fly ash concrete. The sul-phate resistance of HVFA composites was either comparable to or better than the no-fly ash composites. All the mixtures, with and without fly ash, tested in this investigation conformed to the strength and durability require-ments for excellent quality structural grade concretes. Based on the sulphate test results of this study indicates that the engineering performance of the final product can be adequate for using them in the manufacturing of construction materials (brick, ceramic tile, paving stone and briquette) and various civil engineering applica-tions such as construction of structural fills, embankments, grouting injection, road bases and sub-bases.
Alkali, magnesium and calcium sulphates present
in alkali soils and ground waters react chemically
The consumption of aggregates of all types has been
with the hydrated lime, hydrated calcium aluminate
increasing in recent years. The continued and expand-
and calcium silicate hydrates to form calcium sul-
ing extraction of natural aggregate is accompanied
phate and calcium sulphoaluminate. These products
by serious environmental problems. Often it leads
have a considerably greater volume than the com-
to irremediable deterioration of the countryside. The
pound they replace, so that the reactions with the sul-
use of waste materials such as fly ash to modify the
phates lead to expansion and disruption of concrete
properties of concrete and reducing the proliferation
(Neville, 1995). On the other hand, the conversion
of this potential pollutant also adds desirability to its
of soluble calcium hydroxide to cementitious com-
use in concrete structures. The engineering proper-
pounds decreases bleed channels, capillary channels
ties of concrete, a heterogeneous material composed
and void spaces and thereby reduces permeability. At
of cement paste and aggregate, are greatly affected
the same time, the above chemical reaction reduces
by the pore structure and the moisture content of the
the amount of calcium hydroxide susceptible to attack
medium. Porosity is an intrinsic property of cement
by weak acids, salts or other sulfates. Replacing a
paste and influences the strength and permeability
portion of Portland cement with fly ash reduces the
of cement paste, mortar, and concrete, as well as
amount of reactive aluminates (tricalcium aluminate)
its mechanical properties and durability (Erdogan,
available for sulfate. Fly ash chemically binds free
1997). The porosity of the paste depends on many
lime in cementitious compounds, rendering it una-
factors and is typically decreased by decreasing the
vailable for sulfate reaction. Fly ash activity reduces
water to cement ratio. The type of cement also has
concrete permeability, keeping sulfates from pene-
major role on the amount of hydration products and
trating concrete (Naik, 1992). ACI Committee 226
thereby the pore to solid ratio as a result of the rate
affirms that, the sulphate resistance of either plain
and degree of hydration within the time domain. The
concrete or fly ash concrete is controlled by the same
influence becomes less significant for mortar and
factors which are: curing conditions, exposure and w/c
concrete proportional to the increase in the aggregate
ratio. The effect of fly ash on sulphate resistance is
dependent upon the amount and individual chemical
and physical characteristics of fly ash and cement
dominance over the years (Neville, 1995). Despite
used (Ramyar, 1993). Many investigators stated that
the high energy consumption in cement manufacture,
the sulphate resistance of fly ash pastes was largely
the total energy requirement to make a cubic meter
controlled by the rate of diffusion of sulphate ions
of concrete is much lower than any other structural
into the paste, being a function of pore size distri-
material (Uygar & Aydin, 2005). This also makes
bution. It has been shown that entry size of sulphate
it very attractive in an age where energy conserva-
susceptible pores within the fly ash cement paste
tion and environmental protection considerations are
decreases with an adequate curing (Mather, 1982,
paramount. Furthermore the use of waste materials
Mehta, 1985 & Naik, 1992). Mehta found a corre-
such as fly ash to modify the properties of concrete
lation between the alumina content of fly ash and
while at the same time reducing the proliferation of
sulphate resistance of Portland cement products con-
this potential pollutant also adds desirability to its use
taining the fly ash. He conducted an experiment on
in concrete structures (Baker et al. 1991).
fly ash cement mortar specimens with 20% cement
Based on the Electric Power Research Insti-
replacement by high and low calcium fly ashes. After
tute (EPRI) report, more than 600 million tons of
accelerated curing in sulphate solution, he observed
coal ashes are produced annually in the world, with
that low alumina content specimen exhibited 8%
105 million tons per year produced in the United
strength gain, whereas high alumina content speci-
States. The disposal cost of fly ash is $10–20 per ton.
men showed 23% strength decrease (Mehta, 1985).
Therefore, $6 billion is needed per annum. It is neces-
Mather has reported that, 30% replacement of several
sary to utilize a large volume of fly ash for the future
high C A content cements with different high lime
activities (EPRI, 2003). Utilization of high volume
fly ashes made the system less sulphate resistant.
fly ash as a resource has been studied for decades
On the other hand, Mehta, Hooton and Manz et al.
in many areas such as cement/concrete applications,
showed that, some high lime fly ashes may satisfacto-
brick, ceramic tile, lightweight aggregate, highway
rily improve sulphate resistance of concrete (Mather,
pavements (Aydin et al. 2004). Based on the durabil-
1982 & Hooton, 1986). Scholz found that, for high
ity tests of this study indicates that the engineering
quality ash, replacement levels of 40–45% in OPC/
performance of the final product can be adequate
PFA mortars resulted in about same level of resist-
for using them in the manufacturing of construc-
ance as for mortar made solely with sulphate resisting
tion materials (brick, ceramic tile, paving stone and
Portland cement. Scholz also noted that the quality
briquette) and various civil engineering applications
of the ash, determined by its pozzolanic index, par-
such as construction of structural fills, embankments,
ticle size distribution, glass content and surface area,
grouting injection, road bases and sub-bases.
is important to the durability obtained. Wesche and Schubert replaced cement with ash to the 50% level and observed increased resistance, especially when a
cement of low sulphate resistance was used. One of the reasons suggested for the beneficial action of fly
It is necessary to utilize larger volumes of fly ash in
ash in sulphates is the resultant decrease in pH in the
the construction industry. End-products made with
pore solution due to removal of calcium hydroxide; if
HVFA have superior engineering properties, as well
the pH is reduced below about 10, ettringite is unsta-
as economic benefits. The objective of this study is:
ble and thus the large expansions associated with its formation cannot occur (Wesche, 1991).
• To investigate the physical, mechanical, sulphate
The engineering properties of the material both
resistance properties of HVFA fly ash (>75%) m
in fresh and hardened state are highly influenced by
ainly composed of silica fume, lime, cement and
the physical (fineness, grain size distribution, par-
ticle shape) and chemical (pozzolanic activity/rate
• To produce cost-effective and environmental
and degree of hydration) properties of the mix ingre-
friendly building products. These HVFA cement
dients, mainly by the properties of fly ash being the
paste composites can satisfactorily be used in
main constituent (Poon et al. 1997). The design water
manufacturing building materials such as bricks,
content in fresh state, thereby the porosity in hard-
briquettes, tiles and paving stones.
ened state are highly influenced by the physical prop-erties of the mix ingredients (Hewlett, 1998). The
Based on the experimental results obtained in
chemical oxide composition provided in the medium
cold bonded engineering properties, five of the
of the mixes is also of high importance in the char-
mix groups were selected to manufacture the build-
acterization of CSH formation, thereby, the strength
ing materials. Design mix groups were prepared at
development and the formation of pore structure.
100 mm slump for the manufacturing of briquettes,
Concrete has been the most significant building mate-
paving stones, bricks, tiles. Briquettes were prepared
rial for many generations, and has not lost its market
by using briquette molds and the others were by using
50 mm cubic, 40 mm * 40 mm * 160 mm prismatic
of silica fume is 2.20. The chemical composition is
and Φ50/100 mm molds. The workability of the mix-
ture combinations were measured by using slump test
Lime: The specific gravity of lime is 2.17 and its
according to the ASTM C143-90a and flow table test
chemical composition is presented in Table 1. Admixture: A melamine based polymer dispersion
water reducing admixture (WRA) was used in all of
Cement: BS EN 197-1 CEM I 42.5 N cement
was used. The chemical composition is presented in Table 1. The Blaine fineness of the cement is 2905
Five mixture groups with three different slump val-
cm2/gr, and its specific gravity is 3.15. The grain size
ues (0 mm, 100 mm and 200 mm) were studied dur-
distribution of cement is given in Figure 1.
ing this study. The mix designs were chosen based on
Fly Ash: Fly ash from Soma Thermal Power Plant
the water to binder (w/b) ratio of the composites. The
in Turkey was used in this study. Blaine fineness is
numerical analyses results indicate that the relation-
2050 cm2/gr, the specific gravity is 2.08, and mean
ship between the consistency (w/b, slump, flow), the
grain size is 27 mm. The chemical composition is
physical (apparent specific gravity, dry unit weight)
presented in Table 1. The grain size distribution of fly
and mechanical properties (unconfined compressive
and flexural strength) of fly ash mix groups of differ-
Silica Fume: It is obtained from the ferrochrome
ent physicochemical properties are highly correlated
factory located in Antalya-Turkey. The specific gravity
with each other. Mixture groups by weight of cement were mixed in the Hobart mixer having 2.5 liters capacity. First, fly ash, silica fume, lime and cement
Table 1. Chemical compositions of Soma fly ash, cement,
were mixed together in dry form for 30 seconds and
then tap water was added to the mix. The water to cementitious material ratio was kept as 0.39 to which
the corresponding slump value was 100 mm. The w/c ratio was determined from the previous laboratory
studies based on the relationship obtained for flow
table—slump test. Slump and flow values were meas-
ured and relationship between slump-flow was used
After the mixes were cast and consolidated by
vibration for 1 minute in briquette molds as described
in the ASTM C109M-02 were taken. The samples
were extracted from the molds after 1–2 days and
continued to be kept in the curing room till the time of
Dry bulk density, apparent specific gravity and
water absorption experiments were performed accord-ing to ASTM C127-73.
The compressive strength tests were carried out on
Φ50 mm/100 mm specimens according to the require-ments of ASTM C109M-02. The flexural strength tests
were carried out on 40 mm * 40 mm * 160 mm prisms
according to the requirements of ASTM C348-02.
The soundness of all mix groups were determined
according to the ASTM C88-90 on the specimens fractured in the flexural strength, tensile strength and
compressive strength tests. The purpose of conduct-ing the experiment on cement paste was to obtain the
relevant index values to have an idea of the durabil-
ity of the mix groups against adverse environmental
conditions, though the method is used specifically
for aggregates. The specimens were subjected to two cycles wetting in Na SO solution and drying in oven
Figure 1. Grain size distribution of soma fly ash and
± 5ºC temperatures; the losses in weight then
were found. The mixture proportions of the groups
Table 3. 28—day UCS and 28-day FS values of mix groups.
are presented in Table 2. As the w/b increases, the slump increases as a consequence of the decrease in the interparticle friction. The spherical shape of fly
and for Grade MS compressive strength of 15 MPa
ash particles as well as the presence of glassy phase
on the fly ash surface improves significantly the
Based on the flexural strength (FS) test results
structure of paste. Therefore the paste is effectively
similar behavior to that in UCS is observed. Silica
densified and the water content can be reduced. On
fume replacement increases the FS of Soma fly ash
the other hand the reverse effect occurs, because of
mix groups at early ages probably due to the decrease
the lower fly ash density as compared with cement.
in volume of voids, however relatively decreases the
Consequently, at higher fly ash content in cement the
FS at late ages, since unhydrated silica fume, in the
lack of adequate amount of calcium hydroxide, acts as bond barrier within the CSH network (Hewlet, 1998).
Proper curing is extremely important for fly ash
mix groups. The pozzolanic reaction is very slow and any change in the environment can cause an adverse effect on strength (Neville, 1995). Expansion of gel
due to absorption of pore water or contraction of gel
The dry unit weight (DUW), apparent specific grav-
due to extraction of water reduces the FS values more
ity (ASG) and water absorption values of varies from
in fly ash mix groups. The reduction is eliminated by
13.1 kN/m3 to 16.5 kN/m3, 2.02 to 2.39 and 10.22%
to 31.80% for Soma fly ash mix groups.
Weight loss by sodium sulphate solution of HCP com-
The 28-day unconfined compressive strength (UCS)
posites vary between 9.19–22.75%, 3.75–15.32%, and
and 28-day flexural strength (FS) values varies from
3.50–14.48% for 0 mm, 100 mm and 200 mm slump
3.6 MPa to 18.2 MPa and 0.82 MPa to 3.82 MPa for
values of 7 days curing periods and 8.74–22.55%,
Soma fly ash mix groups. The results are shown in
3.16–15.14%, and 2.49–15.27% for 0 mm, 100 mm
and 200 mm slump values of 28 days curing periods.
Based on the UCS values of HCP (hardened cement
Based on the results of sodium sulphate solu-
paste) composite; the final composites are adequate
tion indicate that a moderate to high perform-
for manufacturing precast/prestressed elements, con-
ance in terms of the durability of the composite is
struction of structural fill, base and sub-base course,
expected. The cement replacement for Soma fly ash
construction of catch basins and manholes and both
mix groups decreases the weight loss by enhancing
non-load bearing and load bearing elements. The
the cementitious compound formation. The silica
final composites can also be used in manufacturing
fume replacement also reduces the weight loss for
Class MX and Class NX paving bricks, standard and
fly ash type C which was provided that it does not
special type tile production and manhole brick Grade
increase the demand for mixing water, leading to
MS and Grade MM; those bricks are intended to be
the increase in the volume of voids. The WRA addi-
used in manholes and catch basins not requiring high
tion also reduces the weight loss to a greater extent
degrees of abrasive resistance. The final composites
provided that the volume of voids is not increased
are not suitable for heavy vehicular brick applica-
due to the decreased amount of mixing water for the
tions. The compressive strength requirements of those
corresponding compactive effort. The results indi-
applications are not satisfied (i.e. for Class MX, Class
cate that a moderate to high performance in terms
NX, Grade MS compressive strength of 17.2 MPa
of the durability of the composite is expected, when
the relatively severe laboratory simulation conditions
achieved. For this reason the best results in durability
are considered. In Figure 2, Briquette samples after
is obtained in superplasticized enriched fly ash mix
durability test-Oven-dry and in Figure 3, Briquette
groups (Aydin et al. 2004). As the cement content
samples after durability test-prior to end of the cycle
in the concrete mixture increases, hydration product
Ca(OH) will also increase and hence the amount of
The use of fly ash influences the physico—chemical
Ca(OH) with which the fly ash will enter into reac-
effects associated with pozzolanic and cementitious
tion will increase, then an increased amount of C-S-H
reactions that result in pore size reduction and grain
will result. Consequently, in this way, fly ash will be
size reduction phenomena. This affects the strength
used more efficiently (Aimin & Sarkar, 1994). Super-
and durability of hardened cement paste (Aydin &
plasticizer causes a better hydration of fly ash Port-
Doven, 2006). The durability properties of the final
land cement pastes (Papadakis, 1999). Based on the
composites are directly related with its porosity. Lower
sodium sulphate test results; the final composites are
the porosity higher the durability properties could be
classified as medium to high sulfate resistant (stand-ard specification of weight loss should be in between 6–16%). With the continuous hydration and reactions of the HVFA pastes and the improvement of the bond between the fly ash particles and matrix, the fly ash particles become more effective inclusions in the sys-tem. The filler effect leads to reduction in porosity of the matrix and provides a dense microstructure and thus increases the strength of the system. Also since a part of the paste volume is occupied by fly ash particles even after long term curing, the hydra-tion and reaction products are required to fill a much smaller space. However; addition of silica fume or WRA into the system increases the resistance against sodium sulphate (Aydin & Doven, 2006). The higher strength developments and reduction in weight loss with silica fume are due to pore size refinement and matrix densification, reduction in content of Ca(OH)
and CH (Hewlett, 1998). As the silica fume is finer than the cement particles, the finer particles of silica fume fill the gap between cement particles resulting in impermeable microstructure of the cement paste (Montgomery et al. 1981).
Figure 2. Briquette samples after durability test-Oven-dry.
Utilization of high volume fly ash as a resource has
been studied for decades in many areas such as cement/concrete applications, brick, ceramic tile, light-weight aggregate, highway pavements. Based on the physi-cal and mechanical tests of this study indicates that the engineering performance of the final product can be adequate for using them in the manufacturing of construction materials (brick, ceramic tile, paving stone and briquette) and various civil engineering
Table 4. Minimum compressive strength values of base, Sub-base and Sub-grade courses (ACI, 1985).
Minimum unconfined compressive strength at 7 days, psi (MPa)
Figure 3. Briquette samples after durability test-prior to
Table 5. Compressive strength requirements of tiles
the physical and mechanical properties of mix groups
are highly correlated with each other, good enough to construct a nomograph enabling target slump and
strength based mix design. However; combination of WRA, silica fume together with HVFA shows better
engineering properties than HVFA cement paste mix-
tures. Higher ash replacements are become acceptable
and some ashes which normally do not meet activity
standards is become acceptable. Published research
on mixtures containing both a fly ash and WRA is limited. The importance of making trial mixes with each source of fly ash is emphasized. The fly ash used
Table 6. Compressive strength requirements of paving
in this study is a Class C (high lime, Soma) fly ash,
and the mix proportions shown are for this specific fly ash.
The properties of cement–based materials are pri-
marily affected by the w/c ratio, chemical and mineral
composition of binder material, microstructure and
pore geometry of the cementitious materials. When
siliceous by products are introduced, they change the
behavior of cementitious composites significantly. The addition of fly ash can increase the fluidity of the fresh mixture. The effect of water reduction and the contribution of the fly ash to the mixture com-
applications such as construction of structural fills,
bination much depend on the source of the fly ash
embankments, grouting injection, road bases and
or the pozzolanicity. The w/b affects the strength and
sub-bases (Table 4, Table 5 and Table 6).
the durability of the material to a great extent due to its influence on the physicochemical (porosity and degree of hydration) properties of the cement paste
in hardened state. Slump values of Soma fly ash mix groups are more sensitive to change in w/b ratio are
The originality of this study is to manufacturing of
due to its well graded grain size distribution. As the
cost-effective environmental friendly building prod-
w/b increases, the slump increases as a consequence
ucts by using HVFA cement paste. Based on the
of the decrease in the friction between the cement and
report published by the Governmental Development
of Turkish Republic, for 1 tone of brick production
The engineering properties of the material both
1.3 tones, and for 1 brick/tile production, 4 kilogram
in fresh and hardened state are highly influenced
raw material (clay, shale, etc.) is needed. The replace-
by the physical (fineness, grain size distribution,
ment of fireclay and shale material by fly ash could
particle shape) and chemical (pozzolanic activ-
save about $ 10 per tone for materials, the cost of the
ity/rate and degree of hydration) properties of the
energy, and the time required to complete burnout of
mix ingredients, mainly by the properties of fly ash
the clay component is replaced by fly ash. The clay
being the main constituent. The design water content
minerals in coals are fired during coal combustion,
in fresh state, thereby the porosity in hardened state
so the energy consumption from firing during brick
are highly influenced by the physical properties of
manufacture is not needed, resulting in energy sav-
the mix ingredients; the Soma fly ash, having a well
ings. Few published literature is available on this sub-
graded grain size distribution is more sensitive to the
ject and neither of them is included HVFA cement
change in w/b in terms of variation in the slump and
HVFA composites show adequate sulphate resist-
As an admixture, fly ash functions as either a
ance and the trend is exponentially increasing by fly
partial replacement for or an addition to Portland
ash content for all slump classes. Use of silica fume
cement and is added directly into ready-mix concrete
together with WRA shows better sulphate resist-
at the batch plant. Researches on high volume fly
ance than ordinary Portland cement-fly ash system.
ash utilization have been started by CANMET since
Removal of calcium hydrates (CH) and decrease of
1980 s. Chemical compositions and physical proper-
porosity by C-S-H formation causes an improvement
ties of all kinds of fly ashes and their various usages
in sulphate resistance. The numerical analyses results
in concretes have been studied by many researchers.
indicate that the relationship between the consistency,
Although, using high volume fly ash (HVFA) has
numerous advantages from the structural as well
Aydin, E. & Doven, A.G. 2006. The Influence Of Water
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ESTADO DO MARANHÃO SECRETARIA DE ESTADO DA SAÚDE - SES COMISSÃO SETORIAL DE LICITAÇÃO/CSL/SES PREGÃO PRESENCIAL N.º 007/2011/CSL/SES ATA DE REGISTRO DE PREÇOS N.º 002/2011/CSL/SES PROCESSO N.º 75/2011/SES PREGÃO N. ° 007/2011/CSL/SES VALIDADE DA ATA: 18/05/2011 à 17/05/2012 Aos dezoito dias do mês de maio do ano de 2011 o ESTADO DO MARANHÃO , por interm
Summary of provincial changes affecting group benefit plans Each year, provincial governments make changes that Quebec Parental Insurance Plan (QPIP) introduced – affect coverage under both public and private benefit The province of Quebec implemented the Quebec plans. Outlined below are the changes Great-West Life Parental Insurance Plan to provide maternity, paternity belie