Compressive Strength of Concret by Fly Ash

International Journal of Innovations in Engineering and Technology (IJIET)
Compressive Strength of Fly Ash Based Cement Concrete

Syed Afzal Basha
Sr.Assistant Professor, Department of Civil Engineering,
G. Pullaiah College of Engineering & Technology, Kurnool, Andhra Pradesh, India
P.Pavithra
PG Student
Kottam Karunakara Reddy Institute of Technology, Kurnool, Andhra Pradesh, India
B.Sudharshan Reddy
Associate Professor, Department of Civil Engineering,
AVR & SVR College of Engineering & Technology, Nandyal, Andhra Pradesh, India
Abstract-Concrete is a vital ingredient in infrastructure development with its versatile and extensive applications. It is the
most widely used construction material because of its mouldability into any required structural form and shape due to its
fluid behavior at early ages. However, there is a limit to the fluid behavior of normal fresh concrete. Thorough
compaction, using vibration, is normally essential for achieving workability, the required strength and durability of
concrete. Inadequate compaction of concrete results in large number of voids, affecting performance and long-term
durability of structures. Since due to the vast construction in the urban development programs there is a high demand of
concrete in bulk and for achieving the requirement of concrete in bulk, fly ash is being used as a mineral admixture in
concrete. In this paper an attempt is made for assessment of compressive strength of Fly ash based cement concrete.
Concrete mixes M25, M30, are designed as per the Indian standard code (IS-10262-82) by adding, 0%, 10%, 20%, 30%
and 40% of fly ash. Concrete cubes of size 150mm X 150mm X 150 mm are casted and tested for compressive strength at
7 days, 14 days, 21 days and 28 days curing for all mixes and the results are compared with that of conventional concrete.
The compressive strength of all mixes is tabulated.
Keywords Fly Ash, Compressive Strength, and M25 & M30 mix
I. INTRODUCTION
Concrete is the most widely used structural material in constructions in the world. Massive concreting in huge civil
projects like dams, power plants, bridges and etc usually is not practicable and it is necessary to be performed in
several layers and the compressive strength of each layer should not be less than the specified compressive strength.
Therefore one should wait 28 days to achieve 28-day strength of each layer of concrete. Thereupon if we have n
layers of concrete we need 28n days to complete the total project. Concrete, typically composed of gravel, sand,
water, and Portland cement, is an extremely versatile building material that is used extensively worldwide.
Reinforced concrete is very strong and can be cast in nearly any desired shape. Unfortunately, significant
environmental problems result from the manufacture of Portland cement. Worldwide, the manufacture of Portland
cement accounts for 6-7% of the total carbon dioxide (CO2) produced by humans, adding the greenhouse gas
equivalent of 330 million cars driving 12,500 miles per year. Fortunately, a waste product can be substituted for
large portions of Portland cement, significantly improving concretes environmental characteristics. Fly ash,
consisting mostly of silica, alumina, and iron, forms a compound similar to Portland cement when mixed with lime
and water. Fly ash is a non combusted by-product of coal-fired power plants and generally ends up in a landfill.
However, when high volumes are used in concrete (displacing more than 25% of the cement), it creates a stronger,
more durable product and reduces concretes environmental impact considerably. Due to its strength and lower
water content, cracking is reduced. Two types of fly ash are available: Class C fly ash, which is typically light or tan
colored and is produced from burning lignite or sub bituminous coal, and Class F fly ash, which is dark grey and is
produced from burning anthracite or bituminous coal. The nature of fly ash, tiny spherically shaped particles that act
as ball bearings, make it able to fill small voids and produce denser concrete that requires less water for installation,
resulting in water savings. Its density makes it less permeable to water in finished form, protecting reinforcing steel
and increasing the concretes durability. Able to produce more cementitious paste, fly ash produces a stronger
concrete. It also lowers the heat of hydration, in turn reducing shrinkage and thermal cracking. Class F fly ash, as
well as some Class C fly ashes, produce a concrete that is more resistant to sulfate attack and alkali-aggregate
reactivity. Materials that last longer reduce the demand for natural resources and reduce the associated
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environmental impacts of extracting and processing them. Furthermore, fly ash concrete has higher ultimate strength
than conventional concrete, so in some applications less material is required to accomplish a given structural need.
Fly ash can also be added to plaster, reducing or eliminating crazing, drying shrinkage cracks, debonding,
expansion, and other defects.
A. Considerations & Standard specifications:
Fly ash is one of three general types of coal combustion byproducts (CCBPs). The use of these byproducts offers
environmental advantages by diverting the material from the waste stream, reducing the energy investment in
processing virgin materials, conserving virgin materials, and allaying pollution. Thirteen million tons of coal ash is
produced in Texas each year. Eleven percent of this ash is used which is below the national average of 30 %. About
60 70% of central Texas suppliers offer fly ash in ready-mix products. They will substitute fly ash for 20 35% of
the Portland cement used to make their products. Although fly ash offers environmental advantages, it also improves
the performance and quality of concrete. Fly ash affects the plastic properties of concrete by improving workability,
reducing water demand, reducing segregation and bleeding, and lowering heat of hydration. Fly ash increases
strength, reduces permeability, reduces corrosion of reinforcing steel, increases sulphate resistance, and reduces
alkali-aggregate reaction. Fly ash reaches its maximum strength more slowly than concrete made with only Portland
cement. The techniques for working with this type of concrete are standard for the industry and will not impact the
budget of a job. This section also addresses wall-form products. Most of these products have hollow interiors and are
stacked or set in place and then filled with steel-reinforced concrete creating a concrete structure for a house. Some
wall-form materials are made from EPS (expanded polystyrene) which is a lightweight non-CFC foam material.
There are also fiber-cement wall-form products that can contain wood waste. The EPS/concrete systems offer high
insulating qualities and easy installation. The fiber-cement blocks offer insulating qualities as well. Some EPS
products also have recycled content. Fly ash for use in Portland cement concrete shall confirm to the requirements of
ASTM C 618, Standard Specification for Fly ash and Raw or calcined Natural Pozzolana Class C Fly ash for use as a
Mineral Admixture in Portland cement. The concrete supplier shall furnish a notarized certificate from the fly ash
marketer at the time of submittal of concrete mix designs for approval indicating conformance with these
requirements. Also, a copy of the most recent chemical analysis shall be provided. At no time during the course of the
project will a change of fly ash source (plant) be permitted without the prior written consent of the Engineer or
Architect. For sulfate environments, only Class F fly ash will be permitted and under no circumstances will Class C
fly ash be used.
Fly ash
Fly ash is defined in Cement and Concrete Terminology (ACI Committee 116) as the finely divided residue
resulting from the combustion of ground or powdered coal, which is transported from the firebox through the boiler
by flue gases. Fly ash is a by-product (mineral admixture) of coal-fired electric generating plants. Two classifications
of fly ash are produced, according to the type of coal used. Anthracite and bituminous coal produces fly ash classified
as Class F. Class C fly ash is produced by burning lignite or sub bituminous coal. Class C fly ash is preferable for the
applications presented in the Green Building Guide and is the main type offered for residential applications from
ready-mix suppliers.
B. Health considerations:
Some building health experts have raised concerns about the presence of trace heavy metals in the fly ash. Others
maintain that the metals are effectively locked into the cementitious matrix, preventing their release. Furthermore, by
using fly ash in concrete rather than sending it to a landfill, the potential for the metals to leach into the environment
is reduced. Concerns have also been raised about the higher incidence of Radium-226 in fly ash than in cement.
However, a study conducted by the EPA suggests that the slight increased risk imposed by the greater exposure was
offset by the reduced exposure to radon gas, which is less likely to pass through the denser, less permeable structure
of fly ash concrete.
Characteristics: Ash is a residue resulting from combustion of pulverized coal or lignite in Thermal Power Plants.
About 80% of total ash is in finely divided form which is carried away with flue gases and is collected by
Electrostatic precipitator or other suitable technology. This Ash is called (dry) Fly Ash or chimney Ash or Hopper
Ash. The balance 20% of the Ash gets collected at the bottom of the boiler and is referred as Bottom Ash. When Fly
Ash and Bottom Ash is carried to storage pond in the form of water slurry and deposited, it is termed as Pond Ash.
Fly Ash consists of inorganic materials mainly silica and alumina with some amount of organic material in the form
of un burnt carbon. Its fineness is comparable to cement, however, some particles have size less than 1 micron in
equivalent diameter. It possesses pozzolanic characteristics. However, all kind of Ashes are sometimes referred as Fly
Ash by common people. The different kind of ashes suitable for different applications as given below:
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Fly Ash: For use as pozzolana and admixture in cement, mortar, concrete (/Cellular light weight concrete)
Fly Ash: Lime pozzolana Mixture Applications (Bricks, Blocks etc.) (The quality parameters are not as stringent as
in above application)
Bottom Ash/Pond Ash: Sintered Applications, Geotechnical Applications, Structural Fills, Clay- fly Ash bricks
(burnt type), Agricultural Applications, etc.
Fly Ash as Pozzolana:
Pozzolans are defined as siliceous and aluminous materials which in themselves possess little or no cementitious
value but, will in finally divided form and in the presence of moisture chemically react with calcium hydroxide at
ordinary temperature to form compounds possessing cementitious properties. The properties of pozzolanic materials
which are to be used for the manufacture of pozzolana Cements, Concrete, Lime/Cement based bricks/blocks are
governed by stipulated standards which differ from country to country. The requirement of Fly Ash for these
applications in terms of pozzolanic properties is as follows:
S.
No.
Component/
Characteristics
Unit
British
Standard
BS:3892
American
Standard
ASTM :C618
Indian Standard:
3812 (Part 1) : 2003
Fly Ash
SPFA
CPFA
Indian Standard:
3812(Part 2) : 2003
Fly Ash
SPFA
CPFA
Chemical Requirements
SiO2 + Al2O3 +
Fe2O3
Sio2 Min
Total CI, Max
0.05
0.05
0.05
Loss on Ignition, Max
12
10
Moisture content, Max
1.5
50
25
5
5
1.5
0.05
5
-
M2/kg
variable
325
320#
200
32
34(optional)
50(optional)
255
N/mm2
4.5
Not less than 80% of the

strength of corresponding
plain cement mortar cubes
-
0.8
1
2
70
70
50
70
35
25
35
20
20
Reactive SiO2 Min

(Optional)
CaO, Max
MgO, Max
Total S as SO3, Max
2.5
Alkali as Na2O, Max
1.5
1.5
1.5
1.5
Physical Requirements
1
2
Specific
surface(Blaine)
Sieve residue on 45
um sieve, Max
Control figure
(Product of loss and
sieve residue on 45 m
sieve), Max
Lime reactivity**
(Average compressive
strength), Min
Compressive strength
at 28 days, Min
N/mm2
Drying shrinkage, Max
Soundness
(Autoclave), Max
0.8
Part I :
For use as pozzolana in cement, cement mortar and concrete
Part II :
For use as admixture in cement, cement mortar and concrete
SPFA:
Siliceous Pulverized Fuel Ash
CPFA:
Calcareous Pulverized Fuel Ash
Fly Ash of fineness 250 m2/kg is also permitted to be used in the manufacture of Portland pozzolana cement by intergrinding it with Portland cement clinker if the fly ash when ground to fineness of 320 m2/kg or to the fineness of the
resultant Portland pozzolana cement whichever is lower, meets all the chemical and physical requirements. The
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method of test covers the procedure for determining the reactivity of the pozzolanic material with hydrated lime, as
represented by compressive strength of standard mortar test cubes prepared and tested under specific conditions as per
IS 1727:1967.
Fly Ash collection and storage in the Thermal Power Plant:
The fly ash is collected in most of the old power plants in India through wet system, since it is cheaper than any other
mode of transport. In the wet system, fly ash is mixed with water and sluiced to the settling ponds or dumping areas
near the plant. However, due to limited disposal area many of the TPPs are in the process of converting to dry
collection system (through ESPs) particularly the NTPC Power Plants. ESPs are most popular equipment and
widely used for emission control today which enables the collection of dry fly ash. In the dry collection system, after
arresting the fly ash in the ESP, it is taken to the silos for storage by pressurized or vacuum pneumatic system. When
required, this can be obtained in a container for further transportation directly from the silos or conveyed further to the
delivery point by pneumatic pressurized system. All new plants commissioned recently/being commissioned has
provision for dry fly ash collection system. Fly ash collected through dry collection system is preferred for pozzolanic
applications (i.e. in Building Industry).
Need for Processing of as received Fly Ash:
The chemical composition and physical characteristics of a fly ash from a coal fired furnace are controlled by the type
of coal and processing conditions of the furnace. These vary not only from one plant to another but also within the
same plant. Large variation in the chemical composition of fly ashes is, therefore, natural. Fortunately, however, the
pozzolanic properties of a fly ash are not governed so much by the chemistry but by the mineralogy and the particle
size of the fly ash. It may be noted that modern coal fired thermal power plant generally produce good quality fly ash
that is characterized by low carbon and high glass content with 75% or more particles finer than 45 microns. For
coarse fly ashes or those with high carbon content, a number of beneficiation technologies are available to improve
their suitability for use by the cement and concrete industries. Another road block to the increased use of fly ash as a
component of cement and concrete is the uniformity of ash from a single source of supply. With industrial byproducts, the variability in physical and chemical characteristics is unavoidable. However, this need not be an unsurmountable task to make the product suitable for its desired use. As for years, the cement and concrete plants have
practiced the art of blending inhomogeneous batches of material to obtain end-products of acceptable and uniform
quality. As can be seen from the above there is a need to provide the fly ahs in graded form so that the needs of the
individual industries can be catered to. The fly ash is available from different fields of ESP (also varies from plant to
plant) from 1000 Blaines to 6000 Blaines. It will not be economical to collect the ash from different fields and
moreover is required to classify the fly ash after dry collection in the plant and also to grind the surplus amount of
coarse ash. Hence, to increase the market of the fly ash it is required to grade and grind the fly ash to meet the
requirement of wide spectrum of market.
Fly ash based innovative & commonly produced building products in India:
Some of the innovative and commonly manufactured environmental friendly building materials utilizing Fly Ash are
covered below:
Cellular Light Weight Concrete (CLC) Blocks: Cellular Light Weight Concrete (CLC) blocks are substitute to bricks
and conventional concrete blocks in building with density varying from 800 kg/m3 to 1800 kg/m3. The normal
constituents of this Foaming Agent based technology from Germany are cement, Fly Ash (to the extent 1/4th to 1/3rd
of total materials constituent), sand, water and foam (generated from biodegradable foaming agent). Using CLC
walling & roofing panels can also be produced. Foaming agent and the Foam generator, if used for production of CLC
with over 25% fly ash content invites concession on import duty by Govt. of India.
Advantages of Cellular Light Weight Concrete;
Better strength to weight ratio
Reduction of dead load resulting in saving of steel & cement and reduction in foundation size
Better Acoustics and thermal insulation (Air conditioning requirement is considerably reduced)
Saving in consumption of mortar and Higher Fire Rating.
Development of Fly Ash Based Polymer Composites as Wood Substitute:
Fly ash based composites have been developed using fly ash as filler and jute cloth as reinforcement. After treatment,
the jute cloth is passed into the matrix for lamination. The laminates are cured at specific temperature and pressure.
Number of laminates is used for required thickness. The technology on fly ash Polymer Composite using Jute cloth as
reinforcement for wood substitute material can be applied in many applications like door shutters, partition panels,
flooring tiles, wall paneling, ceiling, etc. With regard to wood substitute products, it may be noted that the developed
components / materials are stronger, more durable, resistant to corrosion and above all cost effective as compared to
the conventional material i.e. wood. This technology has been developed by Regional Research Laboratory, Bhopal
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in collaboration with Building Materials & Technology Promotion Council (BMTPC) and TIFAC. One commercial
plant has also been set up based on this technology near Chennai.
Portland Pozzolana Cement (Fly Ash based): Up to 35% of suitable fly ash can directly be substituted for cement as
blending material. Addition of fly ash significantly improves the quality & durability characteristics of resulting
concrete. In India, present cement production per annum is comparable to the production of Fly Ash. Hence even
without enhancing the production capacity of cement; availability of the cement (fly ash based PPC) can be
significantly increased.
Ready mixed Fly Ash concrete: Though Ready Mix concrete is quite popular in developed countries but in India it
consumes less than 5 percent of total cement consumption. Only recently its application has started growing at a fast
rate. On an average 20% Fly ash (of cementitious material) in the country is being used which can easily go very
high. In ready mix concrete various ingredients and quality parameters are strictly maintained/controlled which is not
possible in the concrete produced at site and hence it can accommodate still higher quantity of fly ash.
Fly Ash- Sand-Lime-Gypsum (/Cement) Bricks /Blocks:
Fly Ash can be used in the range of 40-70%. The other ingredients are lime, gypsum (/cement), sand, stone dust/chips
etc. Minimum compressive strength (28 days) of 70 kg/cm2 can easily be achieved and this can go upto 250 Kg/cm2
(in autoclaved type).
Advantage of these bricks over burnt clay bricks:
Lower requirement of mortar in construction
Plastering over brick can be avoided
Controlled dimensions, edges, smooth and fine finish & can be in different colors using pigments Cost
effective, energy-efficient & environment friendly (as avoids the use of fertile clay).
Clay-Fly Ash Bricks:

Fly Ash content can be 20 to 60% depending on the quality of clay. Process of manufacturing is same as for the burnt
clay bricks.
Advantages:
Fuel requirement is considerably reduced as fly ash contains some percentage of unburnt carbon
Better thermal insulation
Cost effective and environment friendly.
Durability of Fly ash based products:
Blended Cement (Fly Ash based)/Concrete using Fly Ash: Use of blended cement has now become quite popular
world over from durability and environmental benefits point of view. For example, blended cement constitutes 91%
of the total cement production in Italy. In India also 45% of total cement manufactured is fly ash based blended
cement. Now the advantages achieved with the use of blended cement in concrete quite well documented;
Reduced heat of hydration
Improved workability & Ease of pumping
Superior microstructure leading to lower permeability
Higher long term strength
Better performance in aggressive environment (Sulphates, Chlorides etc.)
Reduced risk of alkali silica reaction
Higher Electrical Resistively leading to lesser chances of reinforcement corrosion.
Fly ash bricks viz-a-viz clay bricks:
A lot of studies have been conducted on durability aspects of Fly Ash bricks in many CSIR Labs, IITs, etc. Recently a
study was sponsored by Fly Ash Mission, TIFAC and implemented by four CSIR Labs namely: CBRI - Roorkee,
RRL-Bhopal, ERADA-Vadodara and CFRI-Dhanbad to assess the durability of Fly Ash brick viz-a-viz clay brick. In
this study all kind of aggressive environment as acidic, saline etc. were quantified (in terms of its concentration and
exposure duration) to conduct accelerated tests on Fly Ash bricks and clay bricks both. The study has been completed
and it has concluded that Fly Ash bricks are as durable as clay bricks and in fact in certain aggressive environments
perform better than clay bricks.
Limitations on quantity of fly ash:
This is perhaps the most frequently applied restriction governing the use of fl y ash in a concrete specification. When
fl y ash was originally used in concrete in the 1970s, there was some basis for restricting its use. However, after
extensive research and several decades of successful utilization of fly ash, there is no basis for a restriction on the
quantity of fl y ash that should be permitted to be used in concrete. Some may say that the ACI 318 Building Code
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restricts fly ash use to 25% of total cementitious content. However, that is inaccurate. The e new ACI 318-08 Building
Code in Chapter 4 defines very severe freeze-thaw exposure (Exposure Class F3) as concrete exposed to freezing and
thawing cycles that will be in continuous contact with moisture and exposed to deicing chemicals. For concrete
structural members subject to Exposure Class F3, there is a limitation on the quantity of supplementary cementitious
materials, expressed as a percentage of the total cementitious materials, as follows:
1. Fly ash or other C618 pozzolans max: 25 percent
2. Total of fl y ash or other pozzolans and silica fume max: 35 percent
3. Combined fl y ash, pozzolan and silica fume max: 50 percent with fl y ash or pozzolan not exceeding 25 percent
and silica fume not exceeding 10 percent
4. Ground granulated blast-furnace slag max: 50 percent
5. Silica fume max: 10 percent the primary reason for these limits in the Building Code is to minimize the potential
for deicer-related surface scaling that can subsequently compromise the concrete cover over reinforcement and initiate
corrosion earlier than expected. There is no technical reason to extend this maximum 25% limit for other applications.
It is seen that for adequate resistance to alkali silica reaction (ASR) with some types of aggregate and for sulfate
resistance, more than 25% of fly ash frequently is required. Also, with greater quantities of fly ash, the durability of
concrete related to resistance to ASR, sulfate attack and chloride-induced corrosion is further enhanced. Further, the
use of fly ash in concrete supports sustainable construction. While it is true that greater quantities of fly ash can delay
setting and early strength gain, these could be addressed to a large extent through the effective use of chemical
admixtures. The concrete producer can evaluate the setting and early strength-gain characteristics of concrete
containing fly ash under varying ambient conditions to assure the contractor that these needs will be achieved. It
should be left to the concrete producer to optimize concrete mixtures to accommodate different quantities of fly ash.
Prescriptive limits on fly ash amounts do not help concrete performance in any way and may actually limit the
improvement in concrete durability
Limitations on the class of fly ash or supplementary cementitious material:
Some specifications only permit the use of C618 Class F fly ash. In many parts of the country, good quality Class C fl
y ash is also available. In some regions, a good quality Class N pozzolan, such as calcined clay, is also used. Slag
cement may be the preferred supplementary cementitious material in some markets.
INITIATIVES AND BENEFITS OF FLY ASH
Energy saving & environmental benefits:
Most of the developing countries face energy scarcity and huge housing and other infrastructure shortage. Ideally in
these countries materials for habitat and other construction activities should be energy efficient (having low energy
demand). The following table shows some examples of energy savings achieved through the use of Fly Ash in the
manufacture of conventional building materials. It should be noted that use of Fly Ash also improves the properties of
building material, as mentioned above:
Energy Savings in the Manufacture of Building Materials through Use of Fly Ash
Composition
Material Compared
Energy savings (%)
75% Ordinary Portland cement
100% Ordinary Portland
Portland pozzolana cement
20
25% Fly Ash
Cement
25% Acetylene gas lime
25% Lime
Lime-pozzolana mixture
75
75% Fly Ash
75% Calcined brick
90% Fly Ash tailings
Calcium silicate brick
10% lime
Burnt Clay brick
40
(waste source)
75% Clay
Burnt brick
Burnt Clay brick
15
25% Fly Ash
Building Material
Source: Building Materials in India: 50 Years A Commemorative Volume, Building Materials & Technology
Promotion Council, New Delhi, India, 1998.
Initiatives taken by various Government departments of India:
Studies show that one ton of Portland cement production discharges 0.87 tonne of CO2 into the atmosphere. One
Japanese study indicates that every year barren land area approximately 1.5 times of Indian Territory need to be
afforested to compensate for the total global accumulation of carbon dioxide discharged into the atmosphere because
of total global cement production. Utilization of fly ash in cement/concrete minimizes the Co2 emission problem to
the extent of its proportion in cement. Use of Fly Ash Sand-lime-gypsum bricks also brings similar environmental
benefits if used in place of burnt clay bricks.
Initiatives by Ministry of Environment and Forest, Govt. of India
(This Ministry is primarily responsible for preserving environment and forest in the country)
MOEF recently issued notifications containing directive for greater Fly Ash utilization, some of which are as follows;
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Within a radius of 100 kms from coal or lignite based thermal power plants, manufacturers of bricks/blocks/tiles
would use at least 25% of ash in their product.
Every construction agency engaged in the construction of buildings within a radius of 50 to 100 kms of TPP have to
use 100% fly ash based bricks/blocks in their construction project by the end of August 2007. Within 50 kms of
radius of TPP the deadline for use of 100% fly ash based bricks/blocks is end of August 2005. It is pertinent to
mention here that any brick/block containing more than 25% fly ash is designated as fly ash brick/block.
Status of Standardization in the country:
Several initiatives taken by countrys standardization body (BIS) regarding higher utilization of fly ash are as follows:
Updation of Indian Standard on Portland Pozzolana Cement Specification Part 1 Fly Ash based( IS 1489 (Part 1):
1991): In the amended form, the Fly Ash constituent to be used shall not be less than 15% (from earlier 10%) and not
more than 35% (from earlier 25%) by mass of Portland Pozzolana Cement.
Revision of basic Indian Standard Design Code for Plain and Reinforced Concrete (IS 456:2000): This revised Code
lays emphasis on the use of PPC/Fly Ash in concrete in aggressive environmental conditions.
Revision of Indian Standard on Specification for Fly Ash for use as Pozzolana and Admixture (IS 3812-1981):
Updation of standard has been done keeping in view the change in technologies leading to generation of better quality
of Fly Ashes and wider applications of Fly Ashes. In the revised standard, the concept of improvement of Fly Ash
properties through beneficiation/segregation/processing has also been introduced.
Circular by Countrys Premier Govt. Construction Agency (CPWD): CPWD has taken a decision for use of fly ash
as part replacement of cement where concrete is obtained from RMC manufacturers for large projects in concrete
grade M30 and above.
Initiatives taken in the direction of creating Fly Ash Grading facility at Thermal Power Plant: As circular by CPWD,
IS 456:2000 etc. specifies certain grade of fly ash (conforming to IS 3812) for cement/concrete applications which is
not easily available at Thermal Power Plants. Even products like fly ash based bricks, blocks, tiles; pavers, etc. require
fly ash of graded quality. Therefore, it was felt necessary to create some fly ash processing facility at TPP so that
graded fly ash can be made available to end user. In this regard, letters have been issued to many Thermal Power
Stations detailed presentation has been made to Central Electricity Authority and discussions are in progress with
some of the TPPs.
High volume fly ash concrete:
The Indian standard IS: 456:1978 specify what essentially has existed for many years i.e. no more than 15%-25% fly
ash as a total of cementitious content. ACI 318, till recently, allowed up to 25% fly ash for all concrete, but the latest
ACI 318, just off the presses has since withdrawn this limit. Indian RMC Manufacturers I believe add 15-18% fly ash
to concrete but the common man here still does not comprehend the benefits derived from the usage of fly ash in
cement or in concrete. The table given below is a paper presented by Dr Wilbert Langley and Dr Gordon Lea man at
the sixth CANMET/ ACI / JCI International Conference, held May 31 - June 5, 1998. These are the actual mixes used
in demonstration projects throughout Canada to prove the practicality of using high-volume fly ash concrete for a
variety of projects. The Park lane Development in Halifax, Nova Scotia, Canada is a seven story structure and was
built with 55% high-volume fly ash concrete (high strength mix given in the table below). Cast-in-place columns and
beams were poured with concrete specified to meet design strengths of between 4,350 psi at 28 days and 7,250 psi at
120 days. Actual strengths developed exceeded required strengths by 30%-40% on an average.
HIGH VOLUME FLY ASH CONCRETE
All mixes contained air entraining admixtures and super-plasticizers
Usage of fly ash (55 %) with conventional mixes with Low, medium and high strengths
Contents
Conventional
Mix
Low Strength 55%

Replacement
Medium Strength
55%
Replacement
High Strength
55%
Replacement
Total Cementitious Content(c+fa)

(lb/cu.yd)
483
374
566
660
Cement (lb)
483
166
250
300
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Class F Fly Ash (lb)
208
316
360
Sand (lb)
1334
1467
1250
1266
Stone (lb)
1700
1834
1834
1850
Water (lb)
220
185
198
185
Water to Cement Ratio
0.46
0.49
0.35
0.28
3 day
4,600
1,250
2,320
3,190
Compressive Strength (psi)
7 day
5,000
1,750
3,040
4,900
28 day
6,500
3,350
5,500
8,300
91 day
7,100
4,050
7,700
10,900
365 day
7,550
7,400
10,000
Set Time (hours: minutes)

Initial
6:25
8:25
5:35
Final
7:50
11:15
7:40
In the US, the State of Wisconsin has been using a 60% Class F fly ash in concrete mix since 1989. HVFA concrete
has now found a commercial niche in the Sydney construction market and is being trialed for the Sydney Olympic
facilities. For the Crown Casino project, Connell Wagner required highly durable and low drying shrinkage concrete
for the construction of the 55,000 square meter basement that was located below the water table. Another benefit of
using fly ash in concrete is that fly ash makes beautiful, "architectural" concrete. Fly ash of today is light in color and
its extreme workability ensures smoother finishes.
Field performance of high volume fly ash concrete-Indian experience:
HVFAC a term coined by V.M. Malhotra of CANMET in late 1980s refers to a concrete having low water content
and in which at least 50% of the Portland cement is replaced by a good quality fly ash. This concrete also contains a
super plasticizer which helps reduce water while providing the needed workability. Lately, HVFAC has found use in
high-performance structural concrete in several projects in Canada and the U.S. HVFAC has excellent workability,
low heat of hydration, adequate early-age and high later-age strengths, reduced drying shrinkage, reduced micro
cracking, excellent durability characteristics while being more economical and environment-friendly when compared
to conventional concrete. Due to its superior performance and engineering properties the development of HVFAC has
opened new doors to sustainability of modern concrete construction.
PRESENT SCENARIO & HVFAC - PROJECT IN INDIA:
Presently in India, most ready-mixed concrete for private industry has fly ash between 20 to 30 % of the cementitious
material in it while many government departments still have reservations towards its use. Batching plants on large
construction sites are comfortable with fly ash up to about 25 30%. Much of the concrete mixed onsite with tilting
drum mixers does not use fly ash as a separate additive but blended cement use is common. As regards cement, nearly
60 to 70% of it being manufactured and sold is blended cement with 22 to 32 % of fly ash. It is still considered a
cheap, low grade replacement of cement. Often, higher cement content is associated with good concrete. Awareness
about High volume fly ash concrete (HVFAC) is still very dismal. It is imperative to improve this situation as the
threats of climate change and non sustainable construction practices get stronger.
CANMET-MTL in partnership with CII and other organizations in India had taken up the HVFAC technology
transfer project funded through Canadian International Development Agency. The aim was to develop Indias ability
to reduce GHG emissions, promote sustainable development of the construction industry by increasing use of fly ash
as cement replacement in concrete. In order to familiarize Indian practitioners with HVFAC, several demonstration
projects in the form of real life structures were taken up all over India and the concrete performance closely
monitored. The best example of HVFAC project is DELHI METRO RAIL CORPORATION PROJECT.
EXPERIMENTAL INVESTIGATION
Five different types of specimens are developed in the laboratory and Cubes of 150 mm size were cast for testing in
compression.
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Materials used:
1. Cement: Ordinary port land cement of 53 grade confirming to IS-12269 having specific gravity of 3.03
Physical properties of Cement
3.03
Specific Gravity of Cement
44 min
Initial Setting time
540 min
Final Setting time
31%
Normal Consistency
54.7 N/mm2
Compressive Strength
Chemical compositions of Cement as per manufacturers test report
1.
S.NO
Chemical property
Results
Limits as per IS
Lime saturation Factor (%)
0.78
0.66 min - 1.02 max
Alumina Iron Ratio (%)
1.2
Min 0.665
Insoluble Residue (%)
0.8
Magnesia (%)
2.1
Sulphuric Anhydride (%)
1.1
Loss on ignition (%)
2.0
Max 2%
Max 6%
2.5% to 35
Max 5%
Fine aggregate: Fine aggregate is natural and obtained from local market. The physical properties like
specific Gravity, bulk density, gradation fineness modulus are tested in accordance with IS 2386.
2.Coarse aggregate: The crushed coarse aggregate of 20 mm maximum size as well as 12mm size are obtained from
the local crushing plant, is used in the present study. The physical properties of the coarse aggregate like specific
gravity, bulk density, gradation fineness modulus are tested in accordance with IS 2386.
3.Fly ash: In the present investigation work, the fly ash used is obtained from Vijayawada Thermal Power Station in
Andhra Pradesh. The specific surface area of fly ash is found to be 4750 m2/kg by Blaines Apparatus. Fly ash
meeting specifications of IS 3812-1981& IS 456 can be used to produce good quality concrete. Typical
characteristics of good quality fly ash are as follows
a.
Fineness (Blaines): 475 m2/kg (Min.)
b.
Lime Reactivity
: 4.5 N/mm2 (Min.)
c.
Loss on ignition
: 5% (Max.)
Physical characteristics of VTPS fly ash
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Characteristics
Experimental results
Fineness, m2/kg (Blaines permeability)
475
Lime reactivity
Compressive strength, 21 days
>80% of the
Corresponding plain Cement mortar cubes
0.08
Drying shrinkage, %
4. Water
Confirming to IS 456:2000
5. Mix proportion
: M25 grade Concrete and M30 grade concrete
Specimen preparation :
The above specified Concrete grade was poured in cube moulds. Specimens are prepared with varying percentages of
fly ash.
30 Specimens namely:
Plain concrete
: 12 specimens for M25
Plain concrete
Plain concrete
Plain concrete
Plain with admixture (0% Fly ash)
: 3 specimens for M25 (7, 14, 21, 28 days)
Plain with admixture (0% Fly ash)
: 3 specimens for M25 (7, 14, 21, 28 days)
Plain with admixture (30% Fly ash) : 6 specimens for M25 (7, 14, 21, 28 days)
Casting: Standard cast iron Cubes of dimensions 150mm X 150mm X 150mm are used to cast the specimens for
compression test. The side plates of the mould where sufficiently stiff to eliminate spreading and warping. Before the
concrete was placed in the mould, all the joints were checked thoroughly for any leakage. A thin film of grease was
applied to cover the joints between the halves of the mould at the bottom surface of the mould and its base plate in
order to ensure that no water escapes.
Curing: After casting, the specimens are stored in the laboratory at room temperature for 24 hours. After these
periods the specimens are removed from the moulds and immediately submerged in clean, fresh water of curing tank
and specimens are cured for 7, 14, 21 and 28 days in the present investigation work.
Compressive strength: Of the various strengths of concrete the determination of compressive strength has received a
large amount of attention because the concrete is primarily meant to withstand compressive stresses. Generally cubes
are used to determine the compressive strength. In the present investigation the size of 150 X 150 X 150 mm are used.
In the compressive test, the cube while cleaned to wipe of the surface water, is placed with the cast faces in contact
with the planes of the testing machine, i.e. the position of the cube then tested is at right angles to that as cast. The
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ISSN: 2319 1058
specimens were removed from the moulds and submerged in clean fresh water until just prior to testing. The
temperature of water in which the cylinders were submerged was maintained at
27o C+2o C and 90% relative
humidity for 24 hours. The specimens were cured for 28 days.

Tests of concrete cubes with and without fly ash:
Compressive strength tests were carried out on cubes of 150 mm
size using a compression testing machine of 1000 KN capacity as per IS 516:1959.
Compressive strength properties of M25 grade concrete with and without fly ash
Sl. No
%fly ash
No of days
1.
0%
7,14,21,28
2.
10%
7,14,21,28
3.
20%
7,14,21,28
4.
30%
7,14,21,28
5.
40%
7,14,21,28
Compressive strength properties of M30 grade concrete with & without fly ash
Sl. No
%fly ash
No of days
1.
0%
7,14,21,28
2.
10%
7,14,21,28
3.
20%
7,14,21,28
4.
30%
7,14,21,28
5.
40%
7,14,21,28
Experimental Data: For M25 grade concrete at 7 days

S. no
Curing days
(normal curing )
Compressive Strength (N/mm2)
1.
7 days
0%
16
2.
7 days
17
Avg
15
10%
13
11
Fly ash content by weight of cement

Avg
20%
Avg
30%
09
07
12
8
07
05
151
Avg
6
40%
04
Avg
5
06
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S. no
Curing days
(normal curing )
1.
7 days
0%
23
2.
7 days
19
S. no
Curing days
(normal curing )
Avg
21
10%
19
17

Avg
20%
Avg
30%
15
13
18
14
13
9
Avg
11
40%
08
Avg
7
06

0%
Avg
10%
Avg
152

20%
Avg
30%
Avg
40%
Avg
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1.
14 days
22
2.
14 days
18
13
20
15
13
14
11
07
12
11
08
9
06

S. no
1.
Curing days
(normal curing )
14 days

0%
27
Avg
28
2.
14 days
S. no
Curing days
(normal curing )
29

10%
Avg
20%
Avg
30%
21
15
13
20
16
19
17
Avg
40%
08
Avg
10
14
15
12

0%
Avg
10%
Avg
153

20%
Avg
30%
Avg
40%
Avg
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1.
21 days
27
2.
21 days
15
S. no
Curing days
(normal curing )
18
26
22
19
20
15
13
17
10
09
12
07

1.
21 days
0%
31
2.
21 days
33
Avg
32
10%
21
23

Avg
20%
Avg
30%
19
16
22
18
17
14
Avg
15
40%
11
Avg
12
13

S. no
1.
Curing days
(normal curing )
28 days

0%
31
Avg
10%
24
29
2.
28 days
27
Avg
23
21

20%
Avg
30%
Avg
20
14
19
15
18
154
16
40%
10
Avg
11
12
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S. no
Curing days
(normal curing )
1.
28 days
0%
36
2.
28 days
40
Avg
38

10%
Avg
20%
Avg
30%
25
23
19
26
22
27
21
17
155
Avg
18
40%
14
Avg
15
16
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CONCLUSION
In this paper an attempt is made for assessment of compressive strength of Fly ash cement concrete.
Concrete mixes M25, M30, are designed as per the Indian standard code (IS-10262-82) by adding, 0%, 10%, 20%,
30% and 40% of fly ash. Concrete cubes of size 150mm X 150mm X150 mm are casted and tested for compressive
strength at7 days , 14 days,21 days and 28 days for all mixes and comparing the results of the cubes containing fly ash
and the pure concrete . The compressive strength of all mixes is tabulated. The compressive strength of fly ash cement
concrete is assessed for concrete mixes M25 and M30 grade concrete with 0%, 10%, 20%, 30% and 40% of fly ash. It
is found that there is a decrease in compressive strength for M25 and M30 grade concrete with increase in the
percentage of fly ash.
REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
IS 3812-2003, Pulverized Fuel Ash specification, part 1 for use as pozzolana in cement, cement mortar and concrete.
IS 456-2000 Plain & Reinforced Concrete Code of Practice.
IS: 269 -1989 - Ordinary Portland Cement - 33 Grade (Reaffirmed 2004)
IS: 8112-1989 - 43 Grade Ordinary Portland Cement (Reaffirmed 2005)
IS: 12269-1987 - 53 Grade Ordinary Portland Cement (Reaffirmed 2004)
IS: 1489 part-1 1991 - Portland Pozzolana Cement fly ash based (Reaffirmed 2005)
IS: 1489 part-2 1991 - Portland Pozzolana Cement calcined clay based (Reaffirmed 2005)
IS: 455-1989 - Portland Slag Cement (Reaffirmed 2005)
ASTM International C: 618-03 Standard specification for coal Fly ash and Raw or Calcined Natural Pozzolana for use in Concrete.
V. M. Malhotra and AA Ramezanianpour March 1994, Fly Ash In Concrete
Fly ash in concrete (Properties and Performance) - Report of Technical Committee 67-FAB (RILEM)
Souvenir & Seminar Document, May 1996 Maharashtra India Chapter of ACI, Use of Fly ash in concrete.
156
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International Journal of Innovations in Engineering and Technology (IJIET)

Compressive Strength of Fly Ash Based Cement Concrete

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Total CI, Max

Loss on Ignition, Max

Moisture content, Max

Not less than 80% of the

Reactive SiO2 Min

Total S as SO3, Max

Alkali as Na2O, Max

Drying shrinkage, Max

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Clay-Fly Ash Bricks:

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Low Strength 55%

Total Cementitious Content(c+fa)

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Class F Fly Ash (lb)

Water to Cement Ratio

Compressive Strength (psi)

Set Time (hours: minutes)

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Specific Gravity of Cement

Initial Setting time

Final Setting time

Chemical compositions of Cement as per manufacturers test report

Lime saturation Factor (%)

0.66 min - 1.02 max

Alumina Iron Ratio (%)

Insoluble Residue (%)

Sulphuric Anhydride (%)

Loss on ignition (%)

Fineness (Blaines): 475 m2/kg (Min.)

: 4.5 N/mm2 (Min.)

Volume 4 Issue 4 December 2014

ISSN: 2319 1058

International Journal of Innovations in Engineering and Technology (IJIET)

Fineness, m2/kg (Blaines permeability)

Compressive strength, 21 days

: M25 grade Concrete and M30 grade concrete