Average Expansion at 1

(values extrapolated from expansi

15

BULLETIN
7
NUMBER
Class F Fly Ash Increases Resistance to Sulfate Attack
10

5
Expansion to failure

0
Type V Type V Type II Type II Type I Type I Type V Type V Type II Type II Type I Type I
+ Fly Ash Cement + Fly Ash Cement + Fly Ash Cement + Fly Ash Cement + Fly Ash Cement + Fly Ash Cement

Soluble sulfates in soils, ground waters, and sewage can destroyContinuous

portland Soaking, cement
21 pct. Na2SOconcrete unless
Accelerated Wet it is produced
and Dry, 21 pct. Na2 SO with fly ash

to provide sulfate resistance commensurate with the severity of the attack.

S
ulfate attack is a two-phased process. Sulfates combine with calcium As CaO calcium oxide increases and Fe2O3 decreases, sulfate resistance decreases
hydroxide generated during cement hydration to form calcium sulfate (gyp- due to fly ash chemistry.
sum). The volume of this gypsum is greater than the sum of its components
causing internal pressure and expansion, which fractures the concrete. Then
aluminate compounds from portland cement react chemically with sulfates and 0.005

calcium to form a compound called ettringite (calcium sulphoaluminate). Ettringite

formation destroys the concrete in the same manner as gypsum formation. 0.004

Percent Expansion
Fly ash effectively reduces this sulfate deterioration in three important ways: 0.003

1) Fly ash chemically binds free lime in cementitious compounds, rendering it

0.002
unavailable for sulfate reaction. High C
Low C
2) Fly ash activity reduces concrete permeability, keeping sulfates from Control
0.001
penetrating concrete. Class F Von Fay, Kurt and Pierce,
3) Replacing a portion of portland cement with fly ash reduces the amount of James S., “Sulfate Resistance
0 of Concrete with Various
reactive aluminates (tricalcium aluminate) available for sulfate reaction. 200 400 600 800 1000 1200 Fly Ashes”, ASTM
Standardization News,
-0.001 Dec. 1989.
Studies by the United States Bureau of Reclamation (USBR) show that properly
proportioned concrete utilizing up to 35 percent Class F fly ash will withstand
sulfate attack far better than conventional portland cement. Plain and fly ash R factor requirements are currently used in USBR concrete specifications. The
concrete mixes using Type I, moderate sulfate resisting Type II, and sulfate resisting limits established by the USBR requiring progressively lower R values as sulfate
Type V cements were compared under standardized conditions of exposure to attack severity increases are as follows:
sodium sulfate. In all instances, Class F fly ash concrete dramatically outperformed
conventional portland cement concrete.4,5 These tests clearly demonstrate that Type R Limits* Sulfate Resistance***
II cement with Class F fly ash was more resistant to sulfate attack than Type V <0.75 Greatly improved
cement alone. 0.75 to 1.5 Moderately improved
Further USBR work correlates the chemistry of a given fly ash with its ability to 1.5 to 3.0 No significant change**
resist sulfate attack through a mathematical equation called the R factor, formulated >3.0 Reduced
below:2,3
* R = (CaO-5)/ Fe2O3 percentage from fly ash oxide analysis; for very severe cyclic
conditions of wetting and drying or for MgSO4 reduce the R value by 0.50.
** Slightly improved to slightly reduced.
Average Expansion at 10,000 Days, pct

25
(values extrapolated from expansions obtained to date)

*** Compared to a Type II cement control at 0.45 w/c2.

The Portland Cement Association (PCA) reports the use of Class F fly ash improves
20
sulfate resistance, while Class C fly ash is less effective and may even accelerate
deterioration.4
15
ACI 232.2R-96 (Use of Fly Ash in Concrete) reports that fly ash with CaO content
less than 15% will generally improve sulfate resistance. Fly ash with greater CaO
10 content should be evaluated for use per ASTM C1012 or USBR test 4908.

Expansion to failure
5 ingredient when the project will be vulnerable to attack by sulfates or other
0
Type V Type V Type II Type II Type I Type I
+ Fly Ash Cement + Fly Ash Cement + Fly Ash Cement
Continuous Soaking, 21 pct. Na2SO
Reduced expansion of concrete containing 30 percent fly ash illustrates improved sulfate
resistance afforded by fly ash use.1
CaO-5
R=
Fe2O3
To ensure the most durable concrete possible, Class F fly ash is an essential
aggressive compounds.
Type V Type V Type II Type II Type I Type I
+ Fly Ash Cement + Fly Ash Cement + Fly Ash Cement 1. Dixeau, J.T., “Fly Ash Increases Resistance of Concrete to Sulfate Attack”, United
Accelerated Wet and Dry, 21 pct. Na2 SO States Department of the Interior, Bureau of Reclamation, Research Report No. 23,
US Government Printing Office, 1975.
2. Dunstan, E. R., “A Spec Odyssey-Sulfate Resistant Concrete for the 80s”, United
States Department of the Interior, Water and Power Resources Service, March 1980.
3. Dunstan, E. R., “Fly Ash and Fly Ash Concrete”, US Bureau of Reclamation, U.S.
Government Printing Office, May 1984.
4. Helmuth, R. “Fly Ash in Cement and Concrete”, Portland Cement Association, Skokie, IL,
1987.

0.005
For more information or answers to specific questions about the use of fly ash
for resistance
0.004
to sulfate attack, contact your nearest Headwaters Resources technical
representative, call 1-888-236-6236, or visit us online at www.flyash.com.
t Expansion

0.003
Rev. 3/05

0.002 High C