Partial Replacement of Cement with Fly Ash In Concrete And Its Effect

Authors: Vinod Goud, Niraj Soni

Corresponding Authors: Goutam Varma, Kapil Kushwah, Sharad Chaurasia, Vishwajeet
Sharma

ABSTRACT: Fly ash a waste generated by thermal power plants is as such a big
environmental concern. In modern decades, the industrialization and urbanization are the two
phenomena that are spreading all over the world. Apart from the requirement of these
phenomena, there should also be investigation into their negative impacts on the worldwide
environment and common life. Most important poor effect of these international processes
has been the production of large quantities of industrial wastes. Therefore, the problems
related with their safe management and dumping has turned into a major test to
environmentalists and scientists. Another problem is the stress on land, materials and
resources to sustain the developmental activities, including infrastructure. The thermal power
plants produce considerably large quantities of solid byproduct namely fly ash.

SUMMARY
Fly ash has many advantages which can be applied in other aspects but it has disadvantages
also. Worldwide Coal power plants produce a large amount of waste fly ash. It is produced
during combustion of coal, which not only causes environmental problems but is also a
serious threat to human health. This study revolves on the use of Fly Ash in concrete as
partial replacement and the need to develop effective technologies and actions for better
utilization of fly ash to assess the negative impacts of fly ash in the environment and in
people’s lives. In this work, the researchers studied the effects of different water cement ratio,
percentage of mineral admixture over the properties of concrete like workability & strength
furthermore the researchers studied the effect with age of concrete and slump loss. The
methods used in concrete preparation were performed such as Batching of materials, Mixing,
Compaction, Finishing, Curing and Demolding, and Cube testing.

At the end of the study, the researchers showed the variation of compressive strength of
concrete for different proportion of fly ash and for different age of concrete. The result of the
study shows that for 10% to 20% replacement of fly ash with weight of cement compressive
strength is increases and then if we further increases percentage of fly ash, compressive
strength decreases.
Study of Durability of Concrete with Fly Ash as Fine Aggregate under Alternative
Interactions of Freeze-Thaw and Carbonation
Authors: Mingjie Mao, Dongsheng Zhang, Qiuning Yang, and Wenbo Zhang

ABSTRACT: To study the durability of concrete with fly ash as fine aggregate subjected to
alternative attacks of freeze-thaw and carbonation, the appearance, mass loss, relative
dynamic modulus of elasticity, relative compressive strength, and carbonation depth of the
concrete are investigated using cyclic tests under single carbonation, single freeze-thaw, and
alternation of freeze-thaw and carbonation. In addition, microstructural analysis techniques
including scanning electron microscope and X-ray diffraction are adopted to reveal the
deterioration mechanism of alternating freeze-thaw and carbonation. Results show that
carbonation is beneficial for refining the pore structure and increasing concrete strength in the
initial alternative cycle, which delays the damage from freeze-thaw cycles. Damage from
freeze-thaw causes crack propagation in concrete, which leads to carbonation intensification.
Compared with other test modes, concrete under alternative freeze-thaw and carbonation
causes the greatest degree of deterioration during the initial freeze-thaw cycles. The
carbonation depth under alternative freeze-thaw and carbonation is positively correlated with
the carbonation time and the water-to-cement ratio. However, as the reactant is continuously
consumed due to the expansion of crystalline ice and CaCO3, alternative cycles result in the
appearance of more new cracks in the concrete.

SUMMARY
This study investigates the impact of freeze-thaw cycling and carbonation on the durability of
concrete in which fly ash was used as the fine aggregate. Carbonation is the process of
dissolving Carbon Dioxide in liquid. The Carbon Dioxide undergoes under high pressure.
The Carbon Dioxide is released from solution as small bubbles which causes the solution to
“fizz” when the pressure is reduced. This effect is seen in carbonated soft drinks; Freeze-thaw
is a process of erosion that happens in cold areas where ice forms. A crack in a rock can fill
with water which then freezes as the temperature drops. As the ice expands, it pushes the
crack apart, making it larger. When the temperature rises again, the ice melts, and the water
fills the newer parts of the crack. The water freezes again as the temperature falls, and the
expansion of the ice causes further expansion to the crack. This process continues until the
rock breaks.
The methods used were Freeze-Thaw Test, Carbonation Test, Compressive Strength Test,
Scanning Electron Microscope (SEM), and X-Ray Diffraction (XRD). Data analysis was
conducted to evaluate the concrete’s characteristics (including appearance, mass, relative
dynamic elastic modulus, relative compressive strength, and carbonation depth). This study
provides a fundamental basis for further investigating the durability of concrete with fly ash
as a fine aggregate when used in complex environments.
Comparative Study on Compressive Strength of Fly Ash Concrete
Authors: Krishna Hygrive, Siva Kishore, KJB Chari

ABSTRACT: We are vigilant that an intense damage is done to environment in the

manufacturing process of cement which involves emission of majority of carbon associated
with other chemicals. There are evidences from researches that every one ton of cement
manufactured releases half ton of carbon dioxide so there is an instant need to control the
usage of cement. On the other hand, material wastes such as fly ash is difficult to dispose
which in turn is an obstacle to the environmental safety. Fly ash is a finely divided d residue
resulting from the combustion of pulverized coal and transported by the flue of boilers that
carries gaseous combustion away from the point of combustion. The fly ash initially imparts
high strength to concrete and also reduce the permeability of concrete. It was obtained from
Thermal power station, dried and used. This project mainly deals with the substitution of
cement by Fly ash taken in fixed proportions and analyzing the effects of fly ash blended
concrete. The concrete mix is prepared by varying the proportions of fly ash for 30%, 40%
and 50% of cubes and prisms cured in normal water for up to 28 days and the properties like
Slump cone test, Compaction factor test for fresh concrete and Compressive strength for
hardened concrete are verified and the results are analyzed.

SUMMARY
Strength of hardened concrete measured by the compression test. The compression strength
of concrete is a measure of the concrete's ability to resist loads which tend to compress it. The
compressive strength is measured by crushing cylindrical concrete specimens in compression
testing machine. The objective of this study is to increase strength properties & durability of
concrete by reducing water content by using fly ash.

In this study, the researchers performed certain tests on cement, coarse aggregate and fine
aggregate. Tests performed on cement were Standard Consistency Test, Initial and Final
Setting Time, and Specific Gravity of Cement; Tests performed on fine and coarse aggregate
were Fineness Modulus of Fine and Coarse Aggregate and Specific Gravity of Fine and
Coarse Aggregate. Tests on workability were also performed such as Slump Cone Test and
Compaction Factor Test.
As a result, the incorporation of fly ash in concrete can save the coal and thermal industry
disposal cost and produce a “greener” concrete for construction.
Experimental Study on Use of Fly Ash in Concrete
Authors: Khushal Chandra Kesharwani, Amit Kumar Biswas, Anesh Chaurasiya, Ahsan
Rabbani
ABSTRACT: Fly ash utilization in concrete as partial replacement of cement is gaining
importance day by day. Technological improvements in thermal power plant
operations as well as collection systems of fly ash improved the quality of fly ash. To study
the use of fly ash in concrete, cement is replaced partially by fly ash in concrete. In this
experimental work concrete mix prepared with replacement of fly ash by 0%, 25%, 50%,
75% and 100%. Effect of fly ash on workability, setting, time, compressive strength and
water content are studied.

SUMMARY
Fly ash which shows Pozzolanic properties is being used as a partial replacement in concrete
and is produced as a waste material from pulverized coal manufacturing units which is then
grinded to the fineness less than that of cement for obtaining good bonding between cement
and fly ash. The impact of partial replacement of cement by different amount of fly ash on the
properties of concrete. In this experiment, test on ingredient of Fly Ash Concrete were
performed which are Sieve Analysis to determine the particle size distribution and Specific
Gravity to know how much heavy the material relative to water.

The result of this study shows that cement replacement by fly ash is useful in lower grades of
cement such as M20. It can be stated that at 25% of replacement of cement by fly ash there is
considerable increase in strength properties; With the use of mineral admixture the cost is
considerably reduced due to no use of mechanical vibrators plus viscosity modifying
admixtures also avoided; The strength of concrete decreases with increases in percentage of
fly ash first and again increases as the percentage of fly ash increases.
Optimizing the Use of Fly Ash in Concrete
Author: Michael Thomas

Fly ash is used as a supplementary cementitious material (SCM) in the production of portland
cement concrete. A supplementary cementitious material, when used in conjunction with
portland cement, contributes to the properties of the hardened concrete through hydraulic or
pozzolanic activity, or both. As such, SCM's include both pozzolans and hydraulic materials.
A pozzolan is defined as a siliceous or siliceous and aluminous material that in itself
possesses little or no cementitious value, but that will, in finely divided form and in the
presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to
form compounds having cementitious properties. Pozzolans that are commonly used in
concrete include fly ash, silica fume and a variety of natural pozzolans such as calcined clay
and shale, and volcanic ash. SCM's that are hydraulic in behavior include ground granulated
blast furnace slag and fly ashes with high calcium contents (such fly ashes display both
pozzolanic and hydraulic behavior). The potential for using fly ash as a supplementary
cementitious material in concrete has been known almost since the start of the last century
(Anon 1914), although it wasn't until the mid-1900s that significant utilization of fly ash in
concrete began (for example, USBR 1948) following the pioneering research conducted at
the University of California, Berkeley (Davis 1937). The last 50 years has seen the use of fly
ash in concrete grow dramatically with close to 15 million tons used in concrete, concrete
products and grouts in the U.S. in 2005 (ACAA 2006). Historically, fly ash has been used in
concrete at levels ranging from 15% to 25% by mass of the cementitious material component.
The actual amount used varies widely depending on the application, the properties of the fly
ash, specification limits, and the geographic location and climate. Higher levels (30% to
50%) have been used in massive structures (for example, foundations and dams) to control
temperature rise. In recent decades, research has demonstrated that high dosage levels (40%
to 60%) can be used in structural applications, producing concrete with good mechanical
properties and durability (Marceau 2002). Increasing the amount of fly ash in concrete is not
without shortcomings. At high levels problems may be encountered with extended set times
and slow strength development, leading to low early-age strengths and delays in the rate of
construction. These drawbacks become particularly pronounced in cold-weather concreting.
Also, the durability of the concrete may be compromised with regards to resistance to deicer-
salt scaling and carbonation. For any given situation there will be an optimum amount of fly
ash that can be used in a concrete mixture which will maximize the technical, environmental,
and economic benefits of fly ash use without significantly impacting the rate of construction
or impairing the longterm performance of the finished product. The optimum amount of fly
ash will be a function of wide range of parameters and must be determined on a case-by-case
basis. This report discusses issues related to using low to very high levels of fly ash in
concrete and provides guidance for the use of fly ash without compromising the construction
process or the quality of the finished product. For the purposes of this document the
replacement levels shown in Table 1 will be used to represent low, moderate, high and very
high levels of fly ash.

SUMMARY
This publication discusses the impact of fly ash on the properties of concrete with a view to
optimizing the level of fly ash used for a given application. The optimum amount of fly ash
varies not only with the application, but also with composition and proportions of all the
materials in the concrete mixture (especially the fly ash), the conditions during placing
(especially temperature), construction practices (for example, finishing and curing) and the
exposure conditions. Thus, the optimum fly ash content will vary on a case-bycase basis. Fly
ash contents of up to 50% may be suitable for most elements provided the early-age strength
requirements of the project can be met and provided that adequate moist-curing can be
ensured. For flatwork, the level may be dictated by finishing requirements. If adequate curing
cannot be provided or if the concrete is exposed to freezing and thawing in the presence of
deicer salts, the amount of fly ash should be limited (for example, ≤ 25%).
Engineering Properties of Concrete Mixed with Varying Degrees of Fly Ash
Author: Akinola Johnson Olarewaju

ABSTRACT: The rate of carbon dioxide emission is on the high side globally and very few of
this emission are being used. Bulk of this emission comes from cement manufacturing
industries. There is urgent need to look for alternatives to cement in other to preserve natural
resources globally. This study is aimed at determining the possibility of fly ash as substitute
for cement in concrete production. In this study, ordinary Portland cement (OPC) and fly ash
were obtained from Lafarge Group Nigeria Limited, Ewekoro Cement Plant, Itori, along
Lagos-Abeokuta Express way, Ogun State, Nigeria. Cement was replaced with fly ash at 5%,
10%, 15%, 20% and 25% to determine the workability characteristics, with 0% serving as
control. Concrete cubes in ratio of 1:2:4 were prepared in accordance with BS 1881 parts 1-4,
1970, part 6, 1971 and crushed at 28 days and 90 days to determine the compressive strength.
From the result of this study, the fly ash of about 20% showed similar characteristics to that
of normal concrete. It shows the possibility of using up to 20% fly ash in concrete for normal
concrete works. It is therefore evidently clear that cement could be replaced with fly ash in
engineering construction works. Therefore, environmental risks and hazard associated with
cement production would be greatly reduced.

SUMMARY
In this study, it tells us that production of cement has a great impact and contribution in
destroying the environment because it is one of the negative contributions of human activity
that causes pollution. According to another study, every ton of production of cement releases
approximately 7% carbon dioxide to environment. In many industries, including power
plants, coal is used as fuel. This generates tones of coal ash, which is very difficult to dispose
off, which in turn causes pollution
The Effect of Properties of Fly Ash on Strength and
Microstructure Development of Mortars
Author: Amarpreet Kaur

ABSTRACT: Supplementary cementitious materials such as fly ash are currently used as
clinker replacement to reduce costs and environmental pollution associated with the
production of cement. The objective of this study was to understand the effect of physical and
chemical properties of fly ash on strength development and hydration kinetics of mortars and
cement pastes. Ten different fly ashes, collected from northern and central parts of India,
were used. All the fly ashes and cements were characterised using X-ray diffraction (XRD)
and X-ray fluorescence (XRF). The chemical composition of fly ashes shows that all the fly
ashes fall under category Class F as per ASTM C-618 that have pozzolanic properties and
react with water and calcium hydroxide produced by cement hydration. Two cements,
obtained from two different cement plants, were used to eliminate effects that may be
associated with one particular cement. The mortar mixes were prepared by replacing 25% of
cement with fly ash, using three different water to binder ratios viz. 0.4, 0.45, 0.5, which were
cured under water at a temperature of 27°C. The compressive strength of mortars was
measured at 1, 3, 7, 28 and 90 days. The hydration kinetics were measured using isothermal
calorimetry and chemical shrinkage. Sorptivity was measured on mortar discs after 90 days of
hydration to study the effect of fly ash on the pore-structure. Advanced techniques such as
scanning electron microscopy (SEM) were used to understand the effect of fly ash on the
morphology of the cement paste. The results from experiments show that the early strength of
mortars with fly ash is lower than cement mortar but most of the mortars recover strength by
28 days. Finer fly ashes show higher or equal strength as compared to OPC after 28 days. It is
also observed from sorptivity and SEM (Scanning electron microscopy) images that the iv
finer fly ashes improve the microstructure and porosity. A linear correlation was found
between degree of hydration and strength. Modelling of the strength development on the
basis of the particle size distribution was carried out. It was found that it is possible to predict
the strength development of the mortars using only the particle size distribution of the fly ash
as the input. It was found that for the fly ashes studied, there is little effect of the chemical
composition of the fly ash on hydration and strength development. It was also found that the
existing test for reactive silica in the Indian standard is not suitable to assess the reactivity of
a fly ash.

SUMMARY
Performance of Concrete with Fly Ash and Kaolin Inclusion
Authors: Afaf Ghais, Duaa Ahmed,Ethar Siddig,Isra Elsadig, Samah Albager

ABSTRACT: Waste materials of environmental risks, costly landfill disposal can be utilized in
cement and concrete applications. Partial replacement of cement in engineering projects
reduces the cost of construction with ecological benefits. The type and mix ratio affects the
strength and workability of cement-concrete matrices. This research deals with the
replacement of Class F fly ash and kaolin with cement used in concrete. Replacement of 10%
fly ash with cement improves the comprehensive strength of concrete in 28 days period, and
the workability is increased by 53.8%. The kaolin replacement reduced both the strength and
workability of concrete.
Experimental Study On Partial Replacement Of Cement With Fly Ash And Complete
Replacement Of Sand With M sand
Authors: T.Subramani , K.S.Ramesh

ABSTRACT: Due to rapid growth in construction activity, the available sources of natural
sand are getting exhausted & also, good quality sand may have to be transported from long
distance, which adds to the cost of construction. In some cases, natural sand may not be of
good quality. Therefore, it is necessary to replace natural sand in concrete by an alternate
material partially, without compromising the quality of concrete. Quarry sand is one such
material which can be used to replace sand as fine aggregate. The present study is aimed at
utilizing Quarry sand as fine aggregate replacing natural sand and also the compressive
strength of the water cured specimens is measured on the 7,14,28 Days. Split Tensile
strength, Flexural Strength, Here we have conducting a test on concrete by using fly ash and
m sand. By using these materials we have find out strength on a concrete by adding partial
replacement on cement with fly ash and complete replacement of sand with m sand.
Study of Fly Ash Cement Concrete Pavement
Authors: Anjali Yadav , Nikhil Kumar Yadav

ABSTRACT: This experiment study is aimed to investigate the physical, chemical and
mechanical properties of fly ash cement concrete for road construction. From research, it has
been observed that the use of 30% of fly ash and 70% of cement possess a superior
performance. Moreover, in construction, the use of fly ash would result in the reduction of the
cost of materials and the reduction of greenhouse gas emission. High strength of concrete can
be prepared and the incorporation of admixture or substitute to improve the properties of
concrete. Test result of specimens indicates the bonding strength of properties, workability,
and different reaction when the water ratio a change its content. Slump test having an
appropriate workable mixing the slump of a concrete, gave sufficient compressive strength.
Now a day’s concrete pavements are achieving popularity for its own good paving properties,
as such consumption of cement is increased to a great. As cement demand increases,
production also increases. Every ton of production of cement releases approximately 7%
carbon dioxide to environment. In many industries, including power plants, coal is used as
fuel. This generates tones of coal ash, which is very difficult to dispose off, which in turn
causes pollution. Thus the production of cement and electricity contributes huge amount of
carbon dioxide emissions and coal ash causing environmental pollution. Fly ash contains
reactive constituents and unreactive crystalline matter. Reactive constituents reacts with lime
and offers hydrated minerals to impart strength and un reactive matter gives packing effect to
the concrete, filling up of pores and thus increases the strength. Here an attempt is being
made to consume this pollution causing material to a utility by using it in concrete.
Performance of Light Weight Concrete using Fly Ash Pellets as Coarse Aggregate
Replacement
Authors: Dr. M.Vijaya Sekhar Reddy, Dr. M.C. Nataraja, K.Sindhu, V.Harani and
K.Madhuralalasa

Abstract Many researchers have been carried out in the area of fly ash utilization in the past.
It mainly concentrated on replacement of cement with fly ash but production of artificial
aggregates with fly ash helps in utilizing large volume of fly ash in concrete. In the present
scenario the world is much interested in this part recently due to this large scale utilization
which also reduces environmental pollution and dwindling of natural resources. The
production of concrete requires aggregate as an inert filler to provide bulk volume as well as
stiffness to concrete. Crushed aggregates are commonly used in concrete which can be
depleting the natural resources and necessitates an alternative building material. This led to
the widespread research on using a viable waste material as aggregates. Fly ash is one
promising material which can be used as both supplementary cementitious materials as well
as to produce light weight aggregate. This paper mainly focuses on manufacturing process of
fly ash light weight aggregates using pelletizer and curing has been done in cold bonded 96
Dr. M. Vijaya Sekhar Reddy et al. technique. The properties of these fly ash aggregates have
been tested and the results indicated that cold bonded fly ash aggregates can be effectively
used as a coarse aggregate replacement material in concrete. Artificial manufactured
lightweight aggregates can be produced from industrial by-products such as fly ash, bottom
ash, silica fume, blast furnace slag, rice husk, slag or sludge waste or palm oil shell, shale,
slate, clay. The use of cost effective construction materials has accelerated in recent times due
to the increase in the demand of light weight concrete for mass applications. The present
experimental investigation aimed in studying workability, strength properties of M40
lightweight concrete made with artificial fly ash aggregates as replacement of coarse
aggregates with addition of superplasticizer.