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Construction

and Building

Construction and Building Materials 21 (2007) 150–156


MATERIALS
www.elsevier.com/locate/conbuildmat

Hybrid fiber reinforced self-compacting concrete


with a high-volume coarse fly ash
Mustafa Sahmaran, I. Ozgur Yaman *

Department of Civil Engineering, Middle East Technical University, 06531 Ankara, Turkey

Received 25 November 2004; received in revised form 16 June 2005; accepted 30 June 2005
Available online 19 August 2005

Abstract

This paper presents a study on the fresh and mechanical properties of a fiber reinforced self-compacting concrete incorporating
high-volume fly ash that does not meet the fineness requirements of ASTM C 618. A polycarboxylic-based superplasticizer was used
in combination with a viscosity modifying admixture. In mixtures containing fly ash, 50% of cement by weight was replaced with fly
ash. Two different types of steel fibers were used in combination, keeping the total fiber content constant at 60 kg/m3. Slump flow
time and diameter, V-funnel, and air content were performed to assess the fresh properties of the concrete. Compressive strength,
splitting tensile strength, and ultrasonic pulse velocity of the concrete were determined for the hardened properties. The results indi-
cated that high-volume coarse fly ash can be used to produce fiber reinforced self-compacting concrete, even though there is some
reduction in the concrete strength because of the use of high-volume coarse fly ash.
Ó 2005 Elsevier Ltd. All rights reserved.

Keywords: Self-compacting concrete; Fiber reinforcement; High-volume coarse fly ash

1. Introduction two or more types of fiber into concrete, can offer more
attractive engineering properties as the presence of one
The term fiber reinforced concrete (FRC) is defined fiber enables more efficient utilization of the potential
by ACI 116R, Cement and Concrete Terminology, as properties of other fiber [2,3].
a concrete containing dispersed randomly oriented On the other hand, use of self-compacting concrete
fibers. Inherently concrete is brittle under tensile loading (SCC) in the construction industry has grown signifi-
and mechanical properties of concrete may be improved cantly due to its technical advantages [4]. Generally,
by randomly oriented short discrete fibers which prevent SCC is achieved using new generation superplasticizers
or control initiation, propagation, or coalescence of to reduce the water–binder ratio. In addition, supple-
cracks [1]. The character and performance of FRC mentary cementitious or inert materials such as lime-
changes depending on the properties of concrete and stone powder, natural pozzolans, and fly ash is also
the fibers. The properties of fibers that are usually of used to increase the viscosity and reduce the cost of
interest are fiber concentration, fiber geometry, fiber SCC. Among these materials fly ash, a by-product of
orientation, and fiber distribution. Using a single type thermal power plants, has been reported to improve
of fiber may improve the properties of FRC to a limited the mechanical properties and durability of concrete
level. However, the concept of hybridization, adding when used as a cement replacement material [5]. Con-
cretes having large amounts of fly ash are termed as
*
Corresponding author. Tel.: +90 312 210 5473; fax: +90 312 210
high-volume fly ash (HVFA) concrete. HVFA concrete
1262. was initially developed for mass concrete applications
E-mail address: ioyaman@metu.edu.tr (I.O. Yaman). to reduce the heat of hydration. Later on, it was used

0950-0618/$ - see front matter Ó 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2005.06.032
M. Sahmaran, I.O. Yaman / Construction and Building Materials 21 (2007) 150–156 151

in structural and pavement applications, because of its Table 1


durability and good mechanical properties [6]. Fly ash Chemical composition of the Portland cement and mineral admixtures
is usually separated at the power plants and high quality Chemical Portland Fly ash Limestone
(fine) fly ash meeting the fineness requirement of ASTM analyses (%) cement powder
C 618 can be used in producing blended cements or CaO 61.94 11.31 54.97
added as a separate ingredient at the ready mixed SiO2 18.08 49.55 0.01
Al2O3 5.58 13.34 0.17
concrete batching plants. In addition to this fine fly Fe2O3 2.43 8.51 0.05
ash, there are vast amounts of substandard (coarse) fly MgO 2.43 4.10 0.64
ash that can be utilized in the concrete industry. A suc- SO3 2.54 1.70 0.00
cessful application of the coarse fly ash in producing K2O 0.99 1.99 0.00
blended Portland cements was published by the Na2O 0.18 3.08 0.00
LOI 4.40 2.74 43.66
researchers at CANMET [7]. Fly ash has also been
increasingly used in the Turkish concrete industry.
Recently, to increase the use of fly ash, investigations 2.2. Limestone powder
on HVFA in producing SCC are being performed [8,9].
In this paper, an application of a coarse fly ash will Limestone powder (LP) was used as a mineral viscos-
be presented on SCCs incorporating hybrid fiber rein- ity enhancing admixture. LP was a by product of marble
forcement. Previous investigations showed that the extraction with a CaCO3 content of 98% and a specific
use of steel fibers in SCC is feasible [10,11]. In these gravity of 2.70. The chemical composition of the lime-
mixtures, steel fibers can decrease workability of SCC stone powder is also presented in Table 1.
as the fiber amount and slenderness ratio (length/diam-
eter) increase. However, in case of well-proportioned 2.3. Fly ash
SCC the workability is not influenced by the steel fibers
[11]. The incorporation of fibers in concrete improves A fly ash (FA) from Çayırhan, Turkey was used in
mechanical properties of concrete such as ductility, this study. Its chemical composition is given in Table 1.
toughness, tensile strength, impact resistance and fati- The FA had a relatively low specific gravity and Blaine
gue. fineness of 2.01 and 2420 cm2/g, respectively. The per-
The objective of this study is to assess the effects of centage of fly ash retained when wet sieved on a 45-
HVFA replacement on the fresh and hardened proper- lm sieve was 46. Therefore, this FA failed to meet the
ties of SCCs incorporating different types of steel fibers. fineness requirements of ASTM C 618. To confirm the
Moreover, the fly ash used in this study was a coarse fly fineness of the FA, the particle size distribution of the
ash that does not meet the fineness requirements of FA was also determined. Fig. 1 shows the particle size
ASTM C 618. Even though, the suitability of using such distribution of the FA, as well as the LP, and PC used
a substandard fly ash needs much detailed investiga- in this study. As can be seen from that plot, FA was
tions, this study covers some fresh and hardened proper- much coarser compared to both PC and LP.
ties of such mixtures. In addition to the fly ash, two
different sizes of steel fibers were used at different 2.4. Fibers
proportions in making the concrete. Total mass of
cementitious materials is 500 kg/m3, in which 50% of Two cylindrical steel fiber types, one with hooked
cement is replaced by the coarse grained fly ash. For ends (SF1) and one straight (SF2) were used (Fig. 2).
comparison, a control SCC mixture without any fly
ash was also produced. The commercially available 100
chemical admixtures used in this study included a visco- 90
sity modifying admixture (VMA) and a polycarboxylic- 80
based superplasticizer (SP). 70
% Above

60

50
2. Materials
40
Fly ash (FA)
2.1. Portland cement 30
Portland cement (PC)
20
Lime stone powder (LP)
The cement used in all mixtures was a commercially 10
available Portland cement (PC), which corresponds to 0
0 1 10 100 1000
ASTM Type I cement. It had a specific gravity of 3.09
Particle Diameter (µm)
and Blaine fineness of 3030 cm2/g. The chemical compo-
sition of the PC is given in Table 1. Fig. 1. Particle size distribution of PC, FA and LP.
152 M. Sahmaran, I.O. Yaman / Construction and Building Materials 21 (2007) 150–156

Fig. 2. Steel fibers used for the production of SCC.

Table 2 seen from the gradation of the aggregates presented in


Aggregate grading Table 2, the maximum aggregate size was 19 mm. Both
Sieve size (mm) % Passing the coarse and fine aggregate had a specific gravity of
Fine Coarse 2.70, and water absorptions of 0.5% and 1.2%, respec-
19 100 100
tively.
12.7 100 58.6
9.5 100 35.8 2.6. Chemical admixtures
4.75 96.9 0
2.36 85.5 – A polycarboxylic type superplasticizer (SP) was used
1.18 68.3 –
0.6 42.3 –
in all concrete mixtures. In addition to the SP, a viscos-
0.3 17.4 – ity modifying admixture (VMA) was also used. The
0.15 3.7 – properties of both admixtures, as provided by their
manufacturers, are shown in Table 3.

SF1 type had a tensile strength and a specific gravity of


1100 MPa and 7.85, and SF2 type had a tensile strength 3. Experimental procedures
and a specific gravity of 2000 MPa and 7.17, respec-
tively. The length and aspect ratio of the SF1 was 3.1. Mixture proportions
30 mm and 55, respectively, compared to 6 mm and
37.5 for SF2. The SF2 type was made of high strength Five concrete mixtures, with the proportions pro-
steel with a brass coating providing the fiber a relatively vided in Table 4, are prepared. The two control mixtures
smooth surface. For all the mixtures, the total fiber did not contain any steel fibers. As a binder one of the
content was kept constant at 60 kg/m3. control mixture included PC (Control_PC) and the
other one had FA replacing 50%, by weight, of PC
2.5. Aggregates (Control_FA). All of the remaining mixtures had the
same amount of FA as in Control_FA. These were
As for the aggregates, crushed limestone and crushed named as FA_SF1, FA_SF1&SF2, and FA_SF2 indi-
sand from the same local source were used. As can be cating the type of steel fiber incorporated in the mixture.

Table 3
Properties of chemical admixtures
Chemical admixture Specific gravity pH Solid content (%) Main component
SP 1.08 5.7 40 Polycarboxylic ether
VMA 1.00 5.8 20 Aqueous dispersion of microscopic silica
M. Sahmaran, I.O. Yaman / Construction and Building Materials 21 (2007) 150–156 153

Table 4
Mixture proportions
Mixture ID Ingredient (kg/m3)
Water PC FA LP Aggregate Steel fiber SP VMA
Fine Coarse SF1 SF2
Control_PC 250 500 0 70 905 539 0 0 5.5 6.25
Control_FA 230 250 250 70 888 529 0 0 5.5 6.25
FA_SF1 226 250 250 70 889 530 60 0 5.5 6.25
FA_SF1&SF2 205 250 250 70 925 550 30 30 5.5 6.25
FA_SF2 205 250 250 70 924 549 0 60 5.5 6.25

For all the mixtures, the total amount of binder the slump flow diameter (D). According to Nagataki
(PC + FA), the amount of chemical admixtures, and and Fujiwara [12], a slump flow diameter ranging from
the amount of LP were all kept constant. Water was 500 to 700 mm is considered as the slump required for
added to the mixture until the SCC characteristics were a concrete to be classified as SCC. According to Specifi-
observed; therefore, the water/powder ratio (w/p) was cation and Guidelines for SCC prepared by EFNARC
not kept constant and was observed to change between [13] (European Federation of National Trade Associa-
0.35 and 0.44. tions), a slump flow diameter ranging from 650 to
800 mm can be accepted for SCC. In the slump flow test
3.2. Preparation and casting of test specimens concreteÕs ability to flow and its segregation resistance
can also be measured. To measure these properties,
The mixtures were prepared at about 5 min with a the time it takes for the concrete to reach a 500-mm
70-liter rotating planetary mixer. The sand, coarse spread circle and any segregation border between the
aggregate and fibers were first dry-mixed followed by aggregates and mortar around the edge of spread are
the addition of fine materials and 1/3 of water. Finally, recorded. EFNARC [13] suggests a slump flow time
water and chemical admixtures were pre-mixed and (t500) of 2–5 s for a satisfactory SCC.
added to the mixture. In addition to the slump flow test, V-funnel test is
After the mixing procedure was completed, tests were also performed to assess the flowability and stability of
conducted on the fresh concrete to determine slump flow the SCC. The funnel is filled completely with concrete
time and diameter, V-funnel flow time, and air content. and the bottom outlet is opened, allowing the concrete
Segregation and bleeding were visually checked during to flow. The V-funnel flow time is the elapsed time
the slump flow test and was not observed in any of the (tV-f) in seconds between the opening of the bottom
mixtures. From each concrete mixture, six 150-mm outlet and the time when the light becomes visible from
cubes and six cylinders 100 mm in diameter and 200 the bottom, when observed from the top. Good flowable
mm high were cast. All specimens were cast in one layer and stable concrete would consume short time to flow
without any compaction. The cubes were used for the out. According to Khayat [14], a tV-f which is less than
compressive strength and ultrasonic pulse velocity tests 6 sec. is recommended for a concrete to qualify as a
and the cylinders were used for the splitting tensile SCC. According to EFNARC [13], tV-f ranging from 6
strength tests. After demolding, all specimens were to 12 s is considered adequate for a SCC.
stored in a curing room at 21 ± 2 °C, and 95 ± 5%
relative humidity until testing. 3.4. Tests on hardened concrete

3.3. Tests on fresh concrete Tests performed on cured concrete specimens consist
of the specimen compressive strength, the splitting ten-
Deformability and viscosity of fresh concrete is eva- sile strength, and the ultrasonic pulse velocity. For each
luated through the measurement of slump flow time mixture, cubic specimens were loaded under compres-
and diameter, and V-funnel flow time (Fig. 3). The sive load to failure (ultimate load) at 28 and 56 d. The
slump flow is used to assess the horizontal free flow compressive strength was computed from the average
(deformability) of SCC in the absence of obstructions. of three specimens. The ultrasonic pulse velocities
The procedure for the slump flow test and the com- (UPV) of all six cubic specimens were measured on the
monly used slump test are almost identical. In the slump two smooth sides of the specimen at 7, 14, 28, and 56
test, the change in height between the cone and the d. The UPV test was conducted with direct transducer
spread concrete is measured, whereas in the slump flow arrangement using a pair of narrowband 54 kHz trans-
test the diameter of the spread concrete is determined as ducers with a commercially available PUNDIT system.
154 M. Sahmaran, I.O. Yaman / Construction and Building Materials 21 (2007) 150–156

Fig. 3. Workability tests on the HVFA–SCC.

4. Results and discussion smaller w/p. Therefore, using a coarser FA with higher
volumes naturally decreased the water demand of a
4.1. Fresh concrete properties SCC mixture for similar workability measures.
The steel fibers also affected the fresh properties of
The results of fresh concrete tests are shown in the concrete mixtures. The addition of SF1 type steel fi-
Table 5, which included the w/p of the mixture, slump bers did not affect the water requirement of the mixture
flow diameter and time, V-funnel flow time and air for the same workability. However, addition of SF2 type
content. As seen in that table, the slump flow diameters fibers which had smaller diameters and sizes reduced the
of all mixtures were in the range of 560–700 mm. The amount of water. This could be explained by the geo-
slump flow times were less than 2.9 s, and the V-funnel metry of the fibers as well as the surface characteristics
flow times (tV-f) were in the range of 2.4–4.3 s. There- of these fibers. SF2 fibers had smaller dimensions when
fore, all concrete mixtures were considered as SCC. compared to SF1 fibers, thus had less potential to
In all of the SCC mixtures, there was no segregation prevent the movement of aggregates. In addition, SF2
of aggregate near the edges of the spread-out concrete fibers were coated with brass and had smooth surface
as observed from the slump flow test. characteristics as compared to SF1 fibers. Therefore,
Also observed in Table 5, is the change in w/p for the these characteristics of SF2 type of fibers reduced the
same workability measure, i.e. the same D, t500, and tV-f. energy loss during the movement of concrete ingredients.
The Control_PC mixture had the highest w/p, but as part
of the PC was replaced by FA the w/p of all mixtures 4.2. Hardened concrete properties
decreased. This phenomenon was also observed by other
researchers [7,15]. In such studies, even though finer FAs The results of hardened concrete tests are presented in
were used, which is expected to increase the water Table 6, which included the 28 and 56 d compressive and
requirement of a concrete mixture, the smooth surface splitting tensile strength tests in addition to 7, 14, 28, and
characteristics and spherical shape of the FA improved 56 d ultrasonic pulse velocity tests. To evaluate the effect
the workability characteristics of concrete mixtures, of fibers on the hardened properties, the 56-d properties
and similar workability properties was achieved by a are normalized with respect to the Control_FA mixture

Table 5
Fresh properties
Mixture ID w/pa Fiber factor Slump flow V-Funnel tV-f (s) Air content (%)
D (mm) t500 (s)
Control_PC 0.44 0 560 2.9 4.3 2.5
Control_FA 0.40 0 690 <2.0 2.4 1.8
FA_SF1 0.40 42 660 <2.0 2.8 4.2
FA_SF1&SF2 0.36 35 630 <2.0 4.0 4.5
FA_SF2 0.36 29 700 <2.0 2.7 3.6
a
p (powder) = PC + FA + LP.
M. Sahmaran, I.O. Yaman / Construction and Building Materials 21 (2007) 150–156 155

Table 6
Hardened properties
Mixture ID Compressive strength Splitting tensile strength Ultrasonic pulse velocity (m/s)
(MPa) (MPa)
28 da 56 da 28 da 56 da 7 db 14 db 28 db 56 da
Control_PC 40.7 (0.5)c 41.7(0.4) 3.58 (0.3) 3.68 (0.1) 4562 (22) 4570 (45) 4578 (35) 4609 (7)
Control_FA 23.3 (1.0) 28.6 (1.2) 2.82 (0.4) 3.34 (0.5) 4161 (31) 4260 (51) 4436 (74) 4564 (29)
FA_SF1 19.6 (0.1) 24.5 (0.6) 3.10 (0.2) 3.69 (0.6) 3963 (10) 4007 (44) 4157 (45) 4317 (28)
FA_SF1&SF2 22.8 (0.5) 26.1 (2.0) 3.40 (0.0) 3.82 (0.3) 3970 (42) 4100 (41) 4249 (40) 4383 (88)
FA_SF2 22.5 (2.9) 31.8 (0.8) 3.08 (0.1) 3.23 (0.2) 4142 (109) 4224 (109) 4359 (82) 4506 (114)
a
Tests are performed on three specimens.
b
Tests are performed on six specimens.
c
Numbers in parenthesis are the standard deviations.

and the results are presented in Fig. 4. As seen from that 35


figure, the most significant changes were observed on the 56 day
2
30 28 day R = 0.89
compressive strength and later on splitting tensile

Compressive Strength (MPa)


strength. The effects of high-volume FA replacement 25
and fiber inclusion on the ultrasonic pulse velocity 2
R = 0.70
(UPV) seemed to be negligible. 20

Substitution of PC with a coarse FA resulted in lower 15


compressive and splitting tensile strengths both at 28
and 56 d, even though the w/p of the mixture was 10
reduced. The reduction in compressive strength was
5
43% at 28 d and 31% at 56 d. This reduction could be
attributed to the low pozzolanic activity of the coarse 0
FA. Fiber inclusion did not significantly affect the mea- 0.0 0.2 0.4 0.6 0.8 1.0
Vf, SF2 / Vf, SF1+SF2
sured mechanical properties. However, as seen in Fig. 5,
as the volumetric ratio of the SF2 type fibers increased Fig. 5. Effect of steel fibers on the compressive strength.
the compressive strength increased. This was due to
the relatively small dimensions of SF2 type fibers, which
gave these fibers the ability to delay the micro-crack 4.5
formation and to arrest and prevent their propagation 4.0
afterwards up to a certain extent. Another explanation
Splitting Tensile Strength (MPa)

3.5
to the increase in the compressive strength could be
the decrease in w/p which decreased as the amount of 3.0

SF2 type fibers increased. However, when the splitting 2.5


tensile strengths were examined (Fig. 6), it could be seen 2.0
that there was a reduction in the splitting tensile
1.5
strengths as the volume of SF2 type fibers were increa- 56 day
sed or the w/p decreased. The reduction in the splitting 1.0 28 day

tensile strength was explained by the loss of the presence 0.5

0.0
0.0 0.2 0.4 0.6 0.8 1.0
Vf, SF2 / Vf, SF1+SF2

Fig. 6. Effect of steel fibers on the splitting tensile strength.

of longer SF1 fibers that also had hooked ends. There-


fore, SF1 fibers were mainly responsible for the increase
in tensile strengths.
As presented in Fig. 4, the UPV of the SCC mixtures
seemed to be unaffected by the steel fiber inclusion.
However, the UPV could be used to assess the harden-
ing of the SCC mixtures. It was clear from Fig. 7 that
Fig. 4. 56-d hardened properties of the HVFA–SCC. as hydration continued, the UPVs increased for all the
156 M. Sahmaran, I.O. Yaman / Construction and Building Materials 21 (2007) 150–156

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R = 0.99
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