Strategies of using fly ash and their effect on properties of cement mortar

Abstract

Three different ways of using fly ash, namely, partial replacement of cement, or sand, or both cement and sand in the cement mortar, were studied in this investigation. The replacement varied from 10 percent to 60 percent by weight. The effects of design parameters such as water‐cement ratio and curing temperature on the replacements were studied. In this paper, strategies of using fly ash in concrete construction were also proposed in order to conserve resources.     

Phosphate-activated high-calcium fly ash acid-base cements

Some fly ashes are used in the concrete industry but some are deemed unsuitable owing to their chemical compositions. This study investigated the use of such a high-calcium fly ash containing large amounts of anhydrite, free lime, and calcite, to produce room-temperature acid-base cements by activation with phosphate sources. Orthophosphoric acid solutions and potassium dihydrogen phosphate were used as activators. Paste microstructures were studied using x-ray diffraction, scanning electron microscopy, isothermal calorimetry, and pH measurements. These findings were related to strength development up to 28 d. Room-temperature cured pastes activated with a 60% H₃PO₄ solution and a solution-to-powder ratio of 1.0 gave the highest 1-d strength of 15 MPa and 28-d strength of 22 MPa. Partial replacement of the ash with glass powder further increased the 28-d strength. Crystalline calcium phosphates, Brushite and Monetite, were among the products of the solution-activated pastes, as well as some amorphous phases. Potassium salt-activated pastes did not contain the calcium phosphate crystals and gave lower strengths. The ultimate pH of well-reacted mixtures were close to neutral.     

Compressive strength and chloride resistance of self-compacting concrete containing high level fly ash and silica fume

The influence of high-calcium fly ash and silica fume as a binary and ternary blended cement on compressive strength and chloride resistance of self-compacting concrete (SCC) were investigated in this study. High-calcium fly ash (40–70%) and silica fume (0–10%) were used to replace part of cement at 50, 60 and 70 wt.%. Compressive strength, density, volume of permeable pore space (voids) and water absorption of SCC were investigated. The total charge passed in coulombs was assessed in order to determine chloride resistance of SCC. The results show that binary blended cement with high level fly ash generally reduced the compressive strength of SCC at all test ages (3, 7, 28 and 90 days). However, ternary blended cement with fly ash and silica fume gained higher compressive strength after 7 days when compared to binary blended fly ash cement at the same replacement level. The compressive strength more than 60 MPa (high strength concrete) can be obtained when using high-calcium fly ash and silica fume as ternary blended cement. Fly ash decreased the charge passed of SCC and tends to decrease with increasing fly ash content, although the volume of permeable pore space (voids) and water absorption of SCC were increased. In addition when compared to binary blended cement at the same replacement level, the charge passed of SCC that containing ternary blended cement was lower than binary blended cement with fly ash only. This indicated that fly ash and silica fume can improve chloride resistance of SCC at high volume content of Portland cement replacement.     

减水剂在水泥与粉煤灰表面的吸附行为研究

为了揭示水泥与粉煤灰对减水剂的竞争吸附规律,采用分光光度法研究了SMF、FDN和ASP三种减水剂在此两种颗粒表面的吸附行为.结果表明,三种减水剂在胶凝颗粒表面的吸附均符合Langmuir等温吸附方程,属单分子层吸附.吸附量顺序均为:SMF>FDN>ASP.20℃时,SMF、FDN、ASP减水剂在水泥表面的饱和吸附量分别为12.95、11.35、3.83mg/g,而在粉煤灰表面的饱和吸附量则分别为3.15、2.86、1.10mg/g,表明水泥对减水剂的吸附强于粉煤灰对减水剂的吸附.减水剂在胶凝颗粒表面的吸附动力学也遵循Lang-muir吸附速率方程,SMF、FDN在水泥表面的平均吸附速率大于在粉煤灰颗粒表面的平均吸附速率,而ASP在两种胶凝颗粒表面的吸附速率较为接近.研究表明SMF、FDN将优先吸附在水泥颗粒表面,而ASP在水泥和粉煤灰表面的吸附选择性不高.     

高铁粉煤灰对水泥基材料吸波特性的影响

采用X射线衍射(XRD)、扫描电子显微镜(SEM)、能量色散谱仪(EDS)分析粉煤灰中铁组分矿物组成和分布形态,对高铁粉煤灰颗粒电磁参数及复合高铁粉煤灰水泥浆体的吸波性能进行了试验研究.结果表明,粉煤灰中富集在球形颗粒表面的各种微细氧化铁晶体,是高铁粉煤灰产生电磁损耗的物质基础;高铁粉煤灰颗粒具有较高的介电常数和一定的磁导率,是以介电损耗型为主的电磁波有效损耗介质;高铁粉煤灰水泥基复合材料在2～8GHz波段范围内具有吸波性能,其最小反射率为-13.01dB,同时吸波能力可能与材料电导率有关.     

Efficiency of fly ash in concrete

Earlier efforts towards an understanding of the efficiency of fly ash in concrete has led to the introduction of rational methods. Based on the results available on some of the more recent pulverised fuel ashes, the authors evaluated the efficiency of fly ash in concrete over a wide range of percentage replacements (15–75%). It was clearly shown that the overall efficiency of fly ash cannot be adequately predicted using a single efficiency factor at all percentages of replacements. The overall efficiency factor (k) has been evaluated at all percentages of replacements considering the general efficiency factor (k_e) and the percentage efficiency factor (k_p). This study resulted in a quantitative assessment of the behaviour of fly ash in concrete, especially for the 28 day compressive strength at different percentages of replacement.     

氯氧镁水泥对焚烧飞灰固化作用及影响因素

利用氯氧镁水泥对飞灰进行固化处理,研究了氯氧镁水泥对飞灰重金属离子的固化效果及影响因素。结果表明,氯氧镁水泥对飞灰固化存在一个最佳摩尔比,在最佳摩尔比条件下Pb浸出浓度最低,固化率达94%;随着活性氧化镁含量上升(由28.9%提高到60.56%),Pb浸出浓度显著降低,固化率提高23.9%,当活性氧化镁含量进一步增加时,Pb浸出浓度降低幅度减小;按摩尔比为10∶1,水灰比为0.3配制氯氧镁水泥,在掺量为20%的条件下,固化效果优于掺量为40%的P·O42.5水泥,且满足生活垃圾填埋标准的限值,具有很好的应用前景。     

Hydration of high-volume fly ash cement pastes

The hydration processes of high-volume fly ash cement paste were investigated by examining the non-evaporable water content, the CH content, the pH of pore solution and the fraction of reacted fly ash, curing at either 20°C or elevated temperatures after an initial curing at 20°C. The replacement percentage levels of fly ash were 40%, 50% and 60% by weight, respectively. The results revealed that the non-evaporable water content in high-volume fly ash cement pastes does not develop as plain cement pastes does, so it may be improper to apply the non-evaporable water content to evaluate the hydration process in high-volume fly ash cement matrix. The reduction in CH content increases with the progressing of hydration process and varies linearly with the logarithm of curing age. The addition of 3.0% of Na₂SO₄ could accelerate the pozzolanic reaction of fly ash at early ages. At 20°C, the pH of pore solution of high-volume fly ash cement paste was reduced to a great extent at early ages and it continued to decline at later ages due to the inclusion of large amount of fly ashes. At elevated temperatures, however, this trend was not found. The fraction of reacted fly ash directly reflects the pozzolanic reactivity of fly ash both at normal and elevated temperatures. There is some inherent correlation between the reduction in CH content, the pH of pore solution and the fraction of reacted fly ash. For specified matrix, the consumption of CH and the pH of pore solutions change linearly with the increase of the fraction of reacted fly ash.     

Influence of key cement chemical parameters on the properties of metakaolin blended cements

The use of metakaolin (MK) as a mineral admixture for cement and concrete is a well-documented practice. The properties of cement pastes and mortars containing MK have been investigated as a function of key cement chemical parameters recognized as potential activators of the MK. Rheological behavior, initial setting time and compressive strength development have been compared by varying the total sulfate content, the nature of the added calcium sulfate and the free lime content (in the form of portlandite) in the cement. The results obtained indicate that it exists a compromise for the ratio performance/consistency in term of sulfate content and nature. Concurrently, a small addition of portlandite improves the consistency of the properties investigated.     

空心粉煤灰对铁氧体-炭黑/水泥基复合材料吸波性能的影响

通过改变空心粉煤灰微珠、铁氧体、炭黑的配比,分析了影响混凝土电磁吸收效能的主要因素,并探讨了空心粉煤灰微珠、铁氧体和炭黑的加入对水泥基复合材料电磁吸收性能的影响机制。结果表明:8~18GHz频率范围内,空心粉煤灰微珠是影响水泥基复合材料吸波性能的最主要因素,最佳水平组合为20wt%铁氧体、20wt%粉煤灰、10vol%炭黑,-10dB吸收带宽可达10GHz且明显优于无粉煤灰样品,其机制在于空心粉煤灰微珠的掺入同时改善了材料表面透射性能和介电损耗。     

An application of blended fly ash and residual rice husk ash for producing green building bricks

The present study investigates the possibility of using a blended class-F fly ash (FA) and residual rice husk ash (RHA) in the production of green building bricks through the application of densified mixture design algorithm (DMDA) in order to provide a new use for solid waste materials. This study uses unground rice husk ash (URHA) as a partial fine aggregate substitution (10–40%) in the studied cementitious mixtures. Solid bricks of 220 × 105 × 60 mm in size were prepared under forming pressure of 25–35 MPa, a curing temperature of 90 °C, and a relative humidity of 50%, for tests that assessed: compressive strength, flexural strength, bulk density, void volume, and water absorption. The test results showed that all brick samples demonstrated excellent properties. Compressive strength and flexural strength ranged, respectively, between 20.2–33 MPa and 5.4–6.9 MPa. Additionally, up to 30% of URHA content, the values of water absorption and void volume ranged, respectively, between 8.8–15.7% and 1.5–2.1%. All of these values not only conformed well to the requirements of the Vietnamese codes but also demonstrated great potential for using a blended FA–RHA in producing green building bricks.     

Frost salt scaling resistance of concrete containing CFBC fly ash

The possibility for using coal combustion by-products in concrete exposed to frost-salt aggression was investigated. The research was aimed to assess an influence addition of circulating fluidized bed combustion (CFBC) fly ash on frost-salt scaling of air-entrained concrete. For evaluation of the resistance of concrete to frost salt scaling the test called “depth sensing indentation” (DSI) was applied. The DSI test method was implemented on a universal testing frame using a standard Vickers indenter. Experimental tests were performed on cement paste specimens and concrete specimens designed with partial replacement of cement with coal combustion by-products. The mass of scaled material in standard frost salt scaling resistance tests on concrete was inversely proportional to the Vickers hardness of the paste containing CFBC fly ash; the best-fit arithmetic relationship is provided.     

Influence of curing conditions on properties of high calcium fly ash geopolymer containing Portland cement as additive

This paper investigated the mechanical properties and microstructure of high calcium fly ash geopolymer containing ordinary Portland cement (OPC) as additive with different curing conditions. Fly ash (FA) was replaced with OPC at dosages of 0%, 5%, 10%, and 15% by weight of binders. Setting time and microstructure of geopolymer pastes, and flow, compressive strength, porosity and water absorption of geopolymer mortars were studied. Three curing methods viz., vapour-proof membrane curing, wet curing and temperature curing were used. The results showed that the use of OPC as additive improved the properties of high calcium fly ash geopolymer. The strength increased due to the formation of additional C–S–H and C–A–S–H gel. Curing methods also significantly affected the properties of geopolymers with OPC. Vapour-proof membrane curing and water curing resulted in additional OPC hydration and led to higher compressive strength. The temperature curing resulted in a high early compressive strength development.     

Fine limestone additions to regulate setting in high volume fly ash mixtures

High volume fly ash (HVFA) concrete mixtures are being considered more frequently due to their cost and sustainability advantages. While the long term performance of these HVFA concretes typically meets or exceeds that of conventional concretes, their early age performance is often characterized by excessive retardation of the hydration reactions, delayed setting times, and low strengths. Extending an HVFA mixture to a ternary blend that incorporates a fine limestone powder may provide a viable solution to these deficiencies, particularly the hydration retardation and setting issues. In this paper, a nano-limestone powder and two other limestone fillers of increasing median particle size (4.4 μm and 16.4 μm) are investigated for their propensity to accelerate early age reactions and reduce setting times in a Class C fly ash/cement blend. The fineness of the limestone has measurable effects on its efficacy in accelerating hydration and decreasing setting times. Companion specimens prepared with a fine silica powder suggest that the fine limestone may act favorably through both a physical and a chemical mechanism. Isothermal calorimetry and Vicat needle penetration measurements on pastes are accompanied by strength measurements on mortars, to verify that the limestone powder substitutions are not negatively impacting strength development. A linear relationship with a reasonable correlation is found to exist between 1 d and 7 d compressive strengths of mortars and their accompanying cumulative heat release values as determined using isothermal calorimetry.     

Research on the influence of the fly ash on the concrete carbonation

The influence of fly ash on the fresh properties, mechanical properties and carbonation properties were studied in this paper. The performance of a kind of curing agent which was applied to the hardened concrete surface was evaluated. Incorporating large volume of fly ash will risk the concrete carbonation. And the curing agent could prevent the concrete carbonation. And the mechanism was explained.     

Characterization of carbonation behavior of fly ash blended cement materials by the electrochemical impedance spectroscopy method

The carbonation behavior of fly ash blended cement materials is studied by the electrochemical impedance spectroscopy (EIS) method, and a novel equivalent circuit model R_s(Q₁(R_ct1W₁)) (Q₂(R_ct2W₂)) is proposed to investigate the influence of fly ash on the carbonation process in the cementitious materials. The experimental results demonstrate that the diameter of the impedance arc in high frequency region increases as carbonation progresses. Increasing the amount of fly ash incorporated in the cement paste is also found to enlarge the high frequency arc. The carbonation process can be quantified by the parameter R_ct2 extracted from the equivalent circuit model R_s(Q₁(R_ct1W₁)) (Q₂(R_ct2W₂)). It is found that the R_ct2 value increases with increase in fly ash content. A linear relationship between the R_ct2 value and the carbonation time is also observed. As a consequence, prediction of the carbonation depth of fly ash bended cement materials can be achieved through knowledge of the R_ct2 value.     

粉煤灰陶粒混凝土的抗盐冻性能

为了评价桥面铺装中应用的轻骨料混凝土长期耐久性,利用R ILEM推荐混凝土抗盐冻性能试验标准(CDF)研究了粉煤灰陶粒混凝土与普通混凝土的抗盐冻性能.结果表明:相同强度等级的掺加矿物掺合料的粉煤灰陶粒混凝土的抗盐冻性能明显优于普通混凝土的抗盐冻性能.复掺矿物掺合料混凝土的抗盐冻性能优于单掺矿物掺合料混凝土的抗盐冻性能.与普通混凝土相比,通过SEM-EDXA的分析,掺与未掺矿物掺合料陶粒与水泥石之间的界面过渡区的范围明显变小,这是粉煤灰陶粒混凝土抗除冰盐性能优良的重要原因.     

Characterization of the high-calcium fly ash geopolymer mortar with hot-weather curing systems for sustainable application

Fly ash geopolymers are an alumino-silicate material and thus enable the utilization of waste containing alumino-silicate effectively. Geopolymeric reaction occurs as a result of the activation of fly ash with alkali solutions. In Thailand, a large amount of high-calcium fly ash is available due to the use of low-grade lignite coal feedstock for pulverized coal combustion process and the calcium content becomes very high. In this study, heat curing at 35 °C as a representative of a high ambient temperature (hot weather) and low cost was investigated. Curing at temperature of 65 °C and room temperature of 25 °C were also conducted to compare the results. Geopolymeric products were tested for compressive strength and characterized by XRD, IR, SEM and TGA techniques. The results showed that heat curing enhanced the geopolymerization resulting in the formation of network product. Heat curings at 35 °C and 65 °C led to the formation of calcium silicate hydrate (C-S-H) and alumino-silicate (geopolymer bonding). Without heat curing, the product was predominantly C-S-H compound and the matrix was as strong as the heat-cured product. The immersion of samples in 3% sulfuric acid solution revealed that the performance of the heat-cured samples were better than those cured at room temperature. In addition, application of research results was to produce the geopolymer brick with outdoor heat exposure of 35 °C. Pedestrian pathway was demonstrated.     

Characterization of mine overburden and fly ash as a stabilized pavement material

Mine overburden removed during surface mining is considered as “waste” or “spoil” that is consuming a vast tract of land for storage. Due to high ash content (30–50%) of Indian coals, 130 million tons of fly ash per year is generated with less than 50% of it is being used. Many a time thermal power plants are close to coal mines. Hence, in the present study it is proposed that a mixture can be prepared using fly ash and coal mine overburden with or without cement, which can be used as a stabilized pavement material. The present study deals with characterization of cement stabilized mine overburden fly ash mixture as a pavement material. Mixtures with varying cement percentage of 4–7% were prepared. Based on the unconfined compressive strength and California Bearing ratio values of the stabilized mixture, it was observed that it can be used as a stabilized pavement material.     

Utilization of coal fly ash in the glass-ceramic production

Manufacturing the glass-ceramic has been proposed as a useful choice to recycle coal fly ash from power plants. In this work, a glass-ceramic of SiO2-Al2O3-Fe2O3-CaO family was synthesized by mixing 90 wt% of coal fly ash, from a power plant in west of China, with Na2O, and then melted at 1350 degrees C. The ceramization of the obtained glass was carried out at 770 degrees C for 2h. Esseneite and nepheline were found present as major crystal phases. The produced glass-ceramic exhibited good chemical durability as well as good mechanical properties. The toxicity characteristic leaching procedure (TCLP) method found that the glass-ceramic was non-hazardous.