Study Of Properties Of Concrete Using Processed Flyash Engineering Essay

In visible radiation of increased consciousness towards environment, pollution and preservation it is high clip for Construction industry to integrate ways and means to cut down the pollution potency of assorted building activities. One major country where building industry is doing steady advancement is the usage of assorted industrial wastes and by merchandises generated in concrete and concrete based applications. One major industrial waste/by-product that is copiously used now a yearss is flyash.

This paper tries to show the trial consequences obtained at the terminal of experimental surveies on concrete manufactured utilizing Processed Flyash. Processed Flyash is a type of sub-bituminous fly ash that is self cementing and pozzolanic in nature. As per ASTM criterions Processed flyash is categorized as Class C flyash because of its high Ca content. In peculiar the choiceness and C content belongingss of the flyash have great influence on the air content and H2O demand of concrete. The air content and H2O demand of concrete greatly affect the lastingness and strength of concrete.

The experiments undertaken in this survey undertaking utilized the Processed flyash obtained from DIRK flyash processing works. The original flyash was acquired from local power works which was subjected to treating. Trial mixes for M-20 class of concrete were prepared by increasingly replacing cement with Processed flyash in phases with maximal replacing upto 35 % . Regular workability trials every bit good as compressive strength trials were performed on regular hexahedrons dramatis personae of normal concrete every bit good as concrete manufactured with Processed flyash with changing per centums.

The paper presents the consequences of above experimental trials performed and discusses possible applications of Processed flyash.

Cardinal Wordss: Environment, Pollution, Conservation, Concrete, Processed Flyash.


Flyash, a byproduct of coal fired power station, is now accepted on a world-wide footing as a concreting stuff but this acknowledgment has taken a long clip due to conservative attitude of building industry vis- & A ; agrave ; -vis flyash every bit good as variableness in the quality of flyash. The belongingss of flyash vary depending upon the coal that is burned and the furnace conditions. This paper focuses on survey of belongingss of flyash ensuing from coal burning and non with flyash from waste incineration or from heavy fuel oil. In general coal fired power Stationss usually use bituminous coal but can besides utilize brown coal, anthracite or a mixture of coal and other waste stuffs. Previously use of coal based flyash was restricted in mass concreting plants like dikes, where a high grade of variableness would non endanger structural unity.


Flyash is a byproduct of powdered coal blown into a fire furnace at a power generating works. Coal land to the consistence of flour ignites when blown into the furnace and a certain sum of non-burnable stuff residue remains as either scoria or air borne atoms known as flyash. These air borne atoms are removed by mechanical aggregators, electrostatic precipitators or wet scrubbers. Flyash looks really similar to cement in visual aspect. However when magnified flyash will look as spherical atom, similar to ball bearings, whereas cement appears angular, more like crushed stone coarse sums. Spherical form of flyash gives it a ball-bearing consequence in the concrete mix. One of the of import facets to be considered in pick of flyash is the Loss of Ignition ( LOI ) . LOI is the step of unburnt C. In modern twenty-four hours processes usage of powdered coal and improved efficiencies of burning mechanisms guarantee LOI within allowable bounds in most of the flyash.

The chemical composing of flyash depends on the beginning of coal and the operating conditions of the furnace2. As per ASTM pattern flyash is categorized as Type F or Type C. Type F flyash, besides called every bit low Ca flyash, is the burning merchandise of anthracite or bituminous coal and has a atom size in scope of 1? to 150? . In this type of flyash the sum of lime nowadays is less than 10 % . Type C flyash besides termed as high Ca flyash, is the burning merchandise of lignite or sub-bituminous coal. Class C flyash has a atom size in scope of 1? to 15? . In this type of flyash the calcium hydroxide content is more than 20 % . The category C flyash is more reactive than category F flyash. Both classs of flyash exhibit broad scope of belongingss. Concrete manufactured utilizing type C flyash has higher early strength and ensures early induction of pozzolanic action3. Type F flyash provides sulphate opposition equivalent to or at times superior to Type V Cement. It efficaciously moderates the heat addition during concrete hardening operation.







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The general components of flyash are glass ( 60 to 85 per centum ) and crystalline constituents ( 10 to 30 per centum ) and unburnt C ( upto 5 % ) . Silica and aluminum oxides are chiefly contained in glass, formulated into solid or hollow spherical atoms with some Fe oxide, calcium hydroxide, bases and periclase. In coal with high sulpher content, SO3 is present either as anhydrite or as gypsum or even associated with glass. Carbon is present in the signifier of cellular atoms larger than 45i?­ . More than 5 percent C in a flyash meant for usage as a mineral alloy in concrete is considered unwanted because the cellular atoms of C tend to increase both the H2O demand for a given consistence and the alloy demand for air entrainment.


The choiceness of flyash is one of the of import belongingss which governs the belongingss like lime responsiveness and part in compressive strength. In instance of a thermic power station, flyash gets trapped in between figure of rows of electrostatic precipitators. About two-third of entire flyash is by and large trapped in the first row of electrostatic precipitator whereas the balance gets trapped in subsequent rows. The coarsest atoms are trapped in the first row and finer atoms are trapped in subsequently rows. It is this flyash which meets the choiceness demands as prescribed by IS 3812:2003. nevertheless the measure of this type of flyash is less and its belongingss and choiceness has to be checked before use in concrete. To guarantee significant measure of flyash the coarser atoms need to be land, but due to the crunching action the flyash atoms loose their perfect spherical form thereby the advantage of improved workability is lost. The best possible option in the scenario would be subjecting the flyash to mechanical air clear uping procedure which segregates the flyash on the footing of size. This is known as processing of flyash where by no change in chemical belongingss and physical visual aspect takes topographic point merely the coarser atoms are segregated from the finer atoms.

The atom size of flyash has important function in strength part every bit good as pozzolanic action. The atom size of natural flyash scope from 1? to 100?3. Atoms under 10? , irrespective of type of flyash are the 1s that contribute to the 7 and 28 twenty-four hours strengths. Particle size of 45? and more are considered as inert and make non take part in any pozzolanic reaction. A typical flyash should fulfill commissariats of IS 3812: 2003 with regard to following parametric quantities:

Table 1: Trial Parameters for flyash as prescribed by IS 3812: 2003 ( Part 1 ) 4

Sr. No.


IS Code proviso



Specific Surface Area = 320m2/kg

Max. bound of 45? atom = 34 % by wet sieve analysis.


Lime Reactivity

Minimum compressive strength after 10 yearss for fly-ash calcium hydroxide howitzer regular hexahedron should be 4.5N/mm2


Compressive Strength

28 twenty-four hours compressive strength of cement-flyash howitzer regular hexahedrons should be 80 % of the corresponding field cement howitzer regular hexahedron.


SiO2 Content

Minimum SiO2 in per centum by mass should be 35 % .



Max. allowable bound is 5 % .


The survey undertaking focused on proving basic belongingss of concrete – workability and compressive strength- utilizing Processed flyash by replacing cement from the concrete mix with 0 % replacing to 35 % replacing. The trial process parametric quantities are as follow:

Beginning of flyash: Dirk Flyash Processing Plant, Nashik – Dirk Pozzo 60.

Specific Gravity of Flyash: 2.3

Class of concrete: M20.

Specified minimal strength: 20 MPa.

Target strength: 27 MPa.

Water cement ratio adopted 0.52.

Batching procedure: Weigh Batching.

Blending Procedure: Mechanized utilizing pan sociables.

Workability measured instantly after blending procedure was over every bit good as after 30 proceedingss, 60, 90 and 120 proceedingss.

Workability measurement trial: Slump Cone Test.

Compressive strength measured at interval of 1, 3, 7 and 28 yearss.

Table No. 2: Properties of Processed Flyash used in the survey:

Sr. No.

Test Parameter

IS 3812:2003 ( Part 1 ) Recommendation

Test Consequence


Fineness Specific Surface by Blaine ‘s Permeability Method ( Min. )

320 m2/kg

378 m2/kg


Loss of Ignition ( Max. )

5 %

0.90 %


Residue on Sieve ( Wet Sieve analysis ) 45µ atom ( Max. )

34 %

16.33 %


Chemical Analysis Test


SiO­2 + Al2O3 + Fe2O3 ( Min. )

70 % by mass

92.84 %


MgO ( Max. )

5 % by mass

2.14 %


Na2O ( Max. )

1.5 % by mass

0.56 %

Sr. No.

Test Parameter

IS 3812:2003 ( Part 1 ) Recommendation

Test Consequence


SO3 ( Max. )

3 % by mass

0.88 %


Entire Chlorides ( Max. )

0.05 % by mass

0.029 %

Table No. 3: Detailss of the Concrete Mix.



0 % Replacement

20 % Replacement

25 % Replacement

30 % Replacement

35 % Replacement



340 kilogram

264 kilogram

255 kilogram

238 kilogram

221 kilogram


Dirk Pozzo – 60


66 kilogram

85 kilogram

102 kilogram

119 kilogram

River Sand


772 kilogram

772 kilogram

772 kilogram

761 kilogram

750 kilogram

Crushed Rock Fines

Dindori Sinner

365 kilogram

360 kilogram

357 kilogram

362 kilogram

355 kilogram

10 millimeter CA

Dindori Sinner

242 kilogram

237 kilogram

233 kilogram

240 kilogram

248 kilogram

20 millimeter CA

Dindori Sinner

692 kilogram

686 kilogram

683 kilogram

697 kilogram

705 kilogram


176 kilogram

168 kilogram

165 kilogram

162 kilogram

160 kilogram


Sikament 610 Greenwich mean time

1.5 %

1.45 %

1.45 %

1.40 %

1.35 %

The trial consequences are tabulated below:

Table No. 4: Trial Consequences on Workability and Compressive Strength.

Sr. No.

Test Parameter

Time interval

0 % Replacement

20 % Replacement

25 % Replacement

30 % Replacement

35 % Replacement




170 millimeter

180 millimeter

180 millimeter

180 millimeter

180 millimeter

After 30 min.

160 millimeter

160 millimeter

170 millimeter

170 millimeter

170 millimeter

After 60 min.

150 millimeter

150 millimeter

160 millimeter

150 millimeter

150 millimeter

After 90 min.

130 millimeter

140 millimeter

150 millimeter

140 millimeter

140 millimeter

After 120 min

130 millimeter

130 millimeter

130 millimeter

130 millimeter



Compressive strength

1 twenty-four hours

9.11 N/mm2

8.45 N/mm2

8.35 N/mm2

8.22 N/mm2

8.14 N/mm2

3 yearss

19.31 N/mm2

14.51 N/mm2

12.64 N/mm2

12.22 N/mm2

12.06 N/mm2

7 yearss

27.59 N/mm2

24.64 N/mm2

22.08 N/mm2

23.92 N/mm2

24.34 N/mm2

28 yearss

28.39 N/mm2

32.89 N/mm2

32.6 N/mm2

31.68 N/mm2

31.56 N/mm2

Fig No. 1: Graph demoing fluctuation in compressive strength with regard to changing % of flyash.


From the above observations and the graphs plotted we observe that, as more flyash is added to the concrete mix, a lessening in the rate of strength addition is observed. Early strength addition within 3 – 7 yearss by and large decreases as more flyash is added in the concrete mix. Flyash affects the early strength addition likely due to free calcium hydroxide that is still responding during the hardening procedure. As concrete is adequately cured the 28 twenty-four hours compressive strength is more than the mark strength projected. Further it can be stated that concrete mix with 20 % – 25 % flyash content gives optimum compressive strength. It can besides be observed that all the mixes achieved 70 % – 80 % of the its strength in first seven yearss of hardening.


Pozzolanic Chemical reaction: Due to hydration of cement the alkalinity of mix ranges upto 12.55. The glassy construction of flyash gets dissolved due to high alkalinity and single flyash atoms are free to respond. The handiness of free silicon oxide and aluminum oxide in Ca hydrated oxide gel leads to pozzolanic reaction which consequences in formation of stable crystalline compounds thereby increasing the denseness of the binder matrix.

Contribution to chemical stableness: Pure Ca hydrated oxide is an unstable compound easy soluble in H2O. If this Ca ( OH ) 2 is exposed to acidic elements there will be leaching action doing debasement of concrete and increased permeableness through the binder matrix. However due to add-on of flyash there will be pozzolanic reaction wherein the unstable Ca ( OH ) 2 is stabilized due to formation of stable crystalline construction with silicon oxide and aluminum oxide.

Improvement in workability: Due to take down specific weight of flyash the entire volume of adhering matrix additions well which improves workability taking to ease in managing and compression. Due to hone spherical form of single flyash atom they act as ball bearings and consequence equal lubrication in the binder matrix.

Influence on heat of hydration: Replacement of cement by flyash non merely reduces the entire sum of heat of hydration developed and released, but besides delays upto certain extent the heat release cut downing the extremum temperatures that may do thermic shrinking.

Contribution to lastingness: Due to utilize of flyash the H2O cement ratio is significantly lower. The binder matrix is denser and less pervious to H2O and other environmental agents.

Ecofriendly: Use of flyash as replacing of cement to some bound can assist in decrease of Green House Gas emanations.

Versatile Applications: Flyash has versatile applications apart from concrete applications such as usage in Cellular light weight concrete blocks, flyash based complexs reinforced with jute can move as wood replacement, in brick industry, in route building.

7.0 Decision:

For a assortment of grounds concrete industry is non sustainable. It consumes big sum of virgin stuffs, industry of Portland cement – chief binder stuff in concrete – emits significant sum of green house gases and in conclusion most concrete constructions fail in lastingness due to inauspicious consequence of altering environment.

Use of flyash can assist in get the better ofing these restrictions and turn to the sustainability issues besides.

Processed flyash can be used as a replacing for Portland cement to bring forth high public presentation concrete.

Use of Processed flyash benefits one and all by bettering the lastingness of the construction, giving better workability of fresh concrete and most significantly helping in doing our planet Earth a better topographic point for the following coevals to populate in.

In decision usage of Processed flyash offers a holistic solution to the job of run intoing the increasing demand for concrete in future in a sustainable mode and at a decreased or no extra cost and at the same clip cut downing the environmental impact if two industries that are critical to economic development viz. cement industry and coal fired thermic power works.