STUDY ON DURABILITY OF FLYASH CONCRETE

By
A.L.DEEPAK
deepak_amerineni@yahoo.com

K.J.V.S.PRAVEEN
Praveen_satyakommuri@yahoo.com

ABSTRACT
Concrete, typically composed of gravel, sand, water, and Portland cement, is an

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extremely versatile building material that is used extensively worldwide. Reinforced

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concrete is very strong and can be cast in nearly any desired shape. Unfortunately,

significant environmental problems result from the manufacture of Portland cement.

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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

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cars driving 12,500 miles per year.

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Fortunately, a waste product can be substituted for large portions of Portland

cement, significantly improving concretes environmental characteristics. Fly ash,

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consisting mostly of silica, alumina, and iron, forms a compound similar to Portland

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cement. High volume of fly ash are used in concrete creates a stronger, more durable

product and reduces concretes environmental impact considerably. Due to its strength
and lower water content, cracking is reduced.
When the study deals with the durability of concrete like Acid attack, Alkaline
attack and Sulphate attack which results in volume change, cracking of concrete and the
deterioration of concrete has to be considered. The study reveals that high volume fly ash
concrete show that higher resistance against acid attack, alkaline attack, and sulphate
attack compared with conventional concrete.

1.0 INTRODUCTION
Fly ash is a byproduct of coal burning power plants - the ash that flies up their
smokestacks and gets captured in giant filters. It can be used to produce stronger, more
durable and more environmentally friendly concrete. When used in concrete, fly ash acts like
cement, and actually replaces a percentage of the Portland cement normally used. Concrete

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with high percentages of fly ash looks and finishes the same as regular concrete, with a few
minor adjustments. Fly ash already replaces around 15% of cement in much of the concrete

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used today, but we can do much better by using it to replace 50% or more.

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2.0 EXPERIMENTAL PROGRAMME

MATERIALS USED

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Ordinary Portland Cement (OPC) available in the market conforming to IS 12269 1987

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was used for casting the specimens. Locally available river sand in dry condition was

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used for the preparation of specimens. The grading of sand conforms to Zone-II as per IS
383 1970. The specific gravity sand was 2.61 and fineness modulus value was 2.642.

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The loose and compacted bulk density values of sand were 1633 and 1765 kg/m 3,
respectively.
Crushed granite aggregate conforming to IS: 3831970 was used for the
preparation of concrete. Coarse aggregate of size 20 mm down, having the specific
gravity value of 2.80 and fineness modulus of 6.59 were used. The loose and compacted
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bulk density values of coarse aggregates were 1598 and 1775 kg/m , respectively. Clean
potable water was used for mixing concrete.

Fly ash (Class F Type) having specific gravity of 2.15 obtained from Ennore
Thermal Power Plant at Chennai was used for the replacement of cement.
MIX PROPORTIONING

It is the process of selecting suitable ingredients of concrete and determining their

relative quantities with the purpose of producing economical concrete. The mix
proportion of 1: 1.49: 3.26 [W/C = 0.50] and 1: 1.36: 2.09 [W/C = 0.42], respectively

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for the controlled concrete of M20 and M40 grades were arrived as per the specifications

and used throughout the study. Fly ash concrete mixtures were then proportioned by

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replacing 10%,20%,30% and 40% of cement with Ennore fly ash ( Class F ) and the
volume of concrete was adjusted by reducing the sand content

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PREPARATION OF THE TEST SPECIMENS

A tilting type mixture machine was used to mix the ingredients of concrete mixtures.

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Steel moulds were used to cast the specimens and table vibrator was employed to

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compact the concrete in the moulds. Curing was started immediately after top surface of

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concrete in the moulds became hard and devoid of free water, by covering the moulds
with wet gunny clothes. At the age of about 24 hours after casting, the specimens were

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demoulded and kept submerged in water tank for curing till testing. 100mm cubes were

prepared for evaluating compressive strength, water absorption, acid attack, alkaline
attack, and sulfate attack and temperature effect on compressive strength. The cylinder
specimens of the size 100mm diameter and 200mm high. for split tensile strength,
150mm. diameter and 300mm. high for youngs modulus and 100 x 100 x 500mm
prisms for flexural strength specimens were cast.

3.0 RESULTS AND DISCUSSIONS

3.1 ACID RESISTANCE OF CONCRETE

The tests results of the M20 and M40 have summarized in Tables 3.1.1 and 3.1.2
respectively. The loss of compressive strength in all cases ahs been expressed as a

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percent of the strength of concrete at 60 days immersion in the Hydrochloric acid (HCl)

solution. It was found that under HCl attack, the percentage loss of compressive strength

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was 20.9%, 20.5%8, 16.7%, 12.7% and 11.8% at the flyash content of 0, 10, 20, 30 and
40% respectively for the M20 mix without superplasticizers, 20.0%, 14.3%, 13.1%,

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7.69% and 5.90% respectively. For M20 mix with naphthalene based superplasticizers
and 25.0%, 24.6%, 19.5%, 17.5% and 14.6% respectively for the mix with melamine-

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based superplasticizers.

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Table 3.1.1 Effect of Acid Attack on Compressive strength of M20 Concrete mixtures

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Mix

Flyash

0%

AFA10

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content

Dosage of
SP

Loss in Compressive strength at 60 days curing in acid

solution( % )

(by weight

Without

With Naphthalene

With Melamine based

of binder)

SP

based SP

SP

0.9%

20.9

20.0

25.0

10%

1.1%

20.5

14.3

24.6

AFA20

20%

1.3%

16.7

13.1

19.5

AFA30

30%

1.5%

12.7

7.69

17.5

AFA40

40%

1.7%

11.8

5.90

14.6

Note: * All the values are the average of the three identical specimens
** SP - Superplasticizers

Table 3.1.2 Effect of Acid Attack on Compressive strength of M40 Concrete mixtures

Mix

Flyash

Dosage of

content

SP

Loss in Compressive strength at 60 days curing in

acid solution (%)

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(By weight
of binder)

With Naphthalene

With Melamine

SP

based SP

based SP

0%

0.9%

41.0

BFA10

10%

1.1%

40.7

BFA20

20%

1.3%

BFA30

30%

1.5%

BFA40

40%

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29.8

23.5

27.9

20.4

24.0

13.3

38.6

23.1

13.9

35.0

15.4

4.2

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1.7%

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Without

38.9

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Note: * All the values are the average of the three identical specimens

** SP - Superplasticizer

In M40 concrete mixtures the loss of compressive strength at 0, 10, 20, 30 and 40 percent
fly ash are 41.0%, 40.7%, 38.9%, 38.6% and 356.0% respectively for the mix without
superplasticizers, 29.8%, 27.9%, 24.0%, 23.1% and 15.4% respectively for naphthalene
based mix and 23.5%, 20.4%, 13.3%, 13.9% and 4.2% respectively. For M40 concrete
mixtures with melamine based superplasticizers. The loss of compressive strength

attributed to the presence of greater amount of Calcium hydroxide, Ca (OH) 2, in both the
mixes without and with lower quantity of fly ash content in concrete mixtures.
3.2.ALKALINE RESISTANCE OF CONCRETE
The results of alkaline resistance of concrete are in graphs 3.2.1 and 3.2.2.
WSP

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NSP

MSP

Loss in Compressive strength (%)

30

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25

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20

15

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10

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0
A

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AFA10

AFA20

AFA30

AFA40

Flyash content (%)

Fig. 3.2.1 Effect of Alkaline Attack on Compressive strength of M20 Concrete mixtures

Loss in Compressive strength (%)

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40

WSP

NSP

MSP

BFA10

BFA20

BFA30

30

20

10

0
B

Flyash content (%)

BFA40

The addition of fly ash content of 10, 20, 30 and 40 percent to the concrete mix of M20
shows the percentage loss of compressive strength of 20.9%, 21.8%, 22.2%, 12.7% and
2.9%, respectively for the mix without superplasticizers. The addition of both types of
superplasticizers not showing much resistance against the strength loss of concrete cubes.

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But, higher amount of fly ash content shows higher resistance against alkaline attack than
the smaller quantity of fly ash.

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In M40 concrete mix without superplasticizers shows the percentage loss of

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compressive strength are 18.0%, 23.7%, 25.2%, 11.4% and 0% at 0, 10, 20, 30 and 40
percent of fly ash content, respectively. The additions of melamine-based mixtures are
showing the percentage of loss of strength of 28.3%, 20.4%, 16.8%, 8.3% and 0%,

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respectively. The naphthalene-based superplasticizers shows nearly same performance of

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melamine based mix up to 20% of fly ash content.

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3.3 SULFATE RESISTANCE OF CONCRETE

The effect of fly ash content on the sulfate resistance of concrete was studied using fly

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ashes at 10% to 40% replacement of cement. Percentage loss in strength decreases with
increase of fly ash contents.
In M40 concrete mixtures also the increase in fly ash content shows the decrease in
percentage loss of compressive strength. In the case of alternate wetting and drying of
specimen (cyclic attack) the 30% and 40% of fly ash content show the full strength of
M20 specimens without any losses. In M40 concrete mixtures the same trend was
observed at 40% fly ash content.

The percentage loss in compressive strength at 0, 10, 20, 30 and 40 percent fly ash
content are 6.9%, 5.1%, 2.8%, 2.5% and 0% for M20 concrete mixtures without
superplasticizers. From the tables, it is observed that the additions of superplasticizers
show the good resistance against sulfate attack for both the concrete mixtures. The
naphthalene based superplasticized M20 concrete showed the greater loss of compressive
strength compared with the concrete mixtures with and without melamine based

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superplasticizer.

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Table 3.3.1 Effect of Sulfate Attack in cyclic on Compressive strength of M20

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Concrete mixtures

Mix

Flyash

Dosage of

content

SP

Loss in Compressive strength at 60 days curing ( % )

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(by weight

Without

With

With Melamine

SP

Naphthalene

based SP

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0%

0.9%

12.5

7.8

15.4

AFA10

10%

1.1%

10.1

5.6

8.7

AFA20

20%

1.3%

5.1

5.5

6.8

AFA30

30%

1.5%

AFA40

40%

1.7%

of binder)

based SP

Note: * All the values are the average of the three identical specimens
** SP - Superplasticizers

Table3.3.2 Effect of Sulfate Attack in cyclic on Compressive strength of M40

Concrete mixtures

Mix

Flyash

Dosage of

content

SP

Loss in Compressive strength at 60 days curing ( % )

(By weight

Without

With

With Melamine

of binder)

SP

Naphthalene

based SP

based SP
0%

0.9%

16.4

10.5

BFA10

10%

1.1%

7.6

BFA20

20%

1.3%

3.7

BFA30

30%

1.5%

BFA40

40%

1.7%

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2.3
0

7.3
1.5

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9.7
4.4
0

Note: * All the values are the average of the three identical specimens

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** SP - Superplasticizers

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In M40 concrete mixtures the addition of melamine based superplasticizer with

30% and 40% fly ash content show the zero percentage of loss of compressive strength.
Due to the alternate wetting and drying of specimens the percentage loss of compressive
strength is more than the continuous sulfate attack. When fly ash content increases the
losses are decreases.

Melamine based superplasticized concrete is showing higher

resistance in M40 concrete mixtures for both the cases. But, in M20 concrete mixtures
without superplasticizer performing well compared with superplasticized concrete. In

cyclic test, the concrete mixtures of M20 with naphthalene base show higher resistance to
sulfate attack.
CONCLUSIONS
1. In M20 mix both the types of superplasticizers are not showing much
resistance against the strength loss compared with M20 mix without
superplasticizers. Between the two types of superplasticizers used the

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melamine based M40 mix shows good resistance even at 30% and 40% of fly
ash content.

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2. The replacement of cement with fly ash content of would render both concrete

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concrete mixtures more durable. This observation is more than the maximum
limit of 25 percentage of class F fly ash in concrete mixes recommended by
the ACI committee.
References

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1. Shikoku Island Concrete Research Association: Report by Self-Compacting

Concrete Research Committee, "Self-Compacting Concrete in Shikoku Island"
2000 to 2002, 2002

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2. MASTER BUILDER MAGAZINE

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3. INDIAN CONCRETE JOURNAL

4. Websites referred:
i.

www.thecivilengineer.com

ii.

www.concrete.com