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    NONE - Soil Stabilization and Pavement Recycling With Self Cementing Coal Fly Ash-ACAA (2008) PDF

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    meh_ispas8011

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    Soil Stabilization and Pavement Recycling with Self-Cementing Coal Fly Ash ig cy ‘American Coal Ash Association Educational Foundation RE) Contributions Table of Contents Chapter 1: Background and General Information. 7 ‘Chapter 2: Slf-Cementing Goal Fly Ash Characteristics. 10 Hygraion of Sel Cementng Coal Fly Ash " [Chapter 3: Stabilization Applications... 18 (Current Use Drying Agent 15 Reducing Shrink-Swell Propares of Clay Seis 6 ‘Sol Stabiization o Increase Strength Properties. 16 Stabilized Aggregate Base. 7 Pavement Recycling - Ful-Dept Reclamation, Gravel Ross Recycling — In Sty Reciamation Chapter 4: Laboratory Mix Design... ‘Chapter 5: Stabilization of Clay Soils... ‘Srink- Sve Pototal Compaction Characteristics Caner Chapter 6: Stabilization of Granular Materials Stabilzed Aggregate Bases Recycling Existing Pavements Inuence of Recycled Materia Inuence of Ash Chemistry Influence af Construction Practice (Chapter 7: Construction Considerations Moisture Cont ‘Compaction Operations. 45 ‘curing, “6 ke Influence of Temperature. 46 oes (Chapter &: High Sulfate Ash. - penne Chapter 9 Environmental Considerations for Fly Ash Stabilization 52 Fugitive Oust 55 [chapter 10: Design Considerations neon 37 End Noten 58 BbtographY nan et Siate Specifications / Guidelines Standards 65 ‘Web Site Link re Appendix: Samp ofa Typical Stablization Spectoaton enn 67 1. Description. 67 2. Materials. 8 3. Equipment. or 4. Constueton Metiods 87 5. Measurement 63 6. Payment. 63 ‘Soa Stabiization and Pavement Recycling with Seif-Cementing Coal Fly Ash 3 Introduction Recent History |n 1999, when the Amerian Coal Ash Assocation first issued the “Manual on Soil and Pavement Base Stabilization with Set-Cementing Fy Ash,” this was a relatively new technology. The use of Class C fly ash n geotechnical applications vas growing as more electric utilities Were burning coal fom the Powder River Basin, Mr. Glen Ferguson of GeoSystems Engineering, Inc. (now Kleinfelder, In.), the primary author, was assisted by many others inthe industry. His erly research in the late 1980s and 1990s laid the groundwork fr any of today's Stabilization techniques." Sol stabilization has been defined 2s the “at and science” of improving eng neering properties of ols. Until he mid-1970s, stabilization snd dying of soils was achieved primarily with portland coment, i, and thee kiln dst, With passage of the Clean Air Act and lator amendments ne mattal became available for this purpose. Uilies in dhe west and adester regions ofthe United States begun burning lower-grade fel in ther powerplants —low-sulfr subbituminous coals — in onder to meat stricter US, Environmental Protection ‘Ageney sulfur emission standard New Type of Fly Ash ‘An unexpected benefit of burning tis lower sulfir coal was dhe production of a new ype of fy ash The new fly ash was intally viewed ws a problem material bocause ofits tendency to arden in inconvenient lations such a pus mixers and tucks when combined with water andthe requirement 1 keep absolutly ‘ry. Designated by ASTM International (former the American Sociey for Test= ing and Materials) a “Clas C” coal fly ash its selE-ementing because ofthe ‘presence of calcium oxide (CaO) in concenttions typically fons 10% 10 35%, ‘Today, subbituminovs cals are shipped by ral t power pnts throughout the United States, as faraway fom Wyoming 8 Alabama, George, ad the mid Allantic region. The largest concentration of subbituminous eol combustion con- tines tobe west of Ohio. Cass C fly ash i now shipped! by tuck and al into ‘many construction mackes throughout the United Sites for use alongside Class F fly ash a a partial replacement fr portland cement in concrete ‘Stabilizing ares of construction sites with sel-cementng fy ash ean be mach faster and more economical than removing and replacing low quality on-site soils such as soft compressible soils, wet sols, or hish-plastiiy clays witha tendeney 'o shrink and sell. Many ste are considered “unbuildabl” because of poor. ‘uality soils. In ation, the absence of mud allows consicucton season fo begin cartier in he spring and extend to fll at sits tha have been properly stabilize, The fc that sef-cementng fly ash can dry muddy areas within hours versus ‘weeks or months can esult in Tage energy savings, pollution prevention, and atual resource preservation ‘The primary focus ofthis manual is to diseuss practices for stabilization ap- 1. Ferguson, G, Use of Self Comenting Fly Ashes asa Sil Stabilization Agent: [ASCE Geotechnical Special Publication 36: American Society of Civil Engineers, 1993, ‘Sol Stabilization and Pavement Recycling with Seif-Comenting Coal Fly Ash plications for ash produced during the combustion of subbituminous coals that net te casiiation ofa Cass C fly ash as defined by ASTM C68 (Standard Specification for Coal Fy Ash and Raw or Caleined Natural Pozzolan for Use asa Mineral Adminture). Selcementing fly ash that conforms to the “Class C fly ash” requirements of ASTM C618 are generally suitable forall stabilization applications. The relative degree of stabilization achieved wil be influenced by the chemical composition and mineralogy ofa specific ash and must be evaluated "rough laboratnry testing, Fly ash containing a sulfate content of about 8% i an excellet source of mate- rial for stabilization because ofits slower rate oF hydration. Fly ash witha sulfate content greater than 10% should be avoided because ots potential for expan sion, unless is suitability canbe demonstrated by means of thorough performance evaluation in both the laboratory and the fed. Only after a thorough | fn comprehensive evaluation should high-slfate ly ash be considered for use in specie projects According to ASTM D5239 (Standard Practice for Characterizing Fly Ash for Use in Soil Stabilization), the use of sef2cmenting fly ash cn result in in raved soil properties increasing sifness,suength, and freeze-thaw dail ity; reduced permeability plasticity and swelling; and increased contro of soil ‘compressibility and moisture Studios at Joa State University have confiemed Ferguson's early work end shown that Class C fly ash increases compacted dry density and reduces optimum moisture conten. Strength gain in soil-fly ash mixtures is dependent on cue time and temperature, compaction energy, and compaction delay. ‘This manusl provides design information for sel-cementing coal ly ash asthe soe stabilizing gent fora wide ringe of engineering applicstions. Although this ash hs properties simi to those of pordand cement, selfcementing coal fy ash slo bas unigue charactvstis that must he addressed by both the mix design and ‘onstruction procedars, ‘Asin any process the application of sound engineering practices, appropriate testing, and evaluation of fy ash quality and characteristics will end themselves to succesfil projects using the guidelines inthis manual. Beyond recognized performance atributes, using ly ash offers opportunites for envionment sustainably: Manufacturing porland cement creates about a ton of CO? for each on of cement produced, In general terms, contractors ean prevent the relaase ofa ton of tis greenhouse gas by using fly ash instead, The mount can represent significant savings that suppors project, community and government ssianable development goals. In 2006, more han 1S milion ons ‘of CO2 were avoided by using fly ash instead of portland cement. These savings 2, White, Dil: Harrington, D: Thomas, Z, Fly Ask Soil Stabilizarion for Nonuni {form Subgrade Sols: Volume I Engineering Properties an Construction Gulde- ‘nes lowa Highway Research Board Repost IHRB Project TR-461, FHWA Project 4: Hova State University Center for Transporation Research and Elation, April 2005 Introduction EE, oa ‘Soll Stobilizaiion and Pavement Rocydling with Saif Camenting Coal Fly Ash Introduction provide environmental benefis and can afer owners addtional project vale and savings. What's more, peal the cost of Class Cy ash sles than portland ‘cement, By using Cass C Ay ash for sol stabilization and pavement recycling, portland cement canbe used in other applications, extending the life af rw materials needed to produce cere. Some projects maybe linked to “green evelopment ntistives that come with tax and other economic inducements “These fio al offer the designer “green” incentives to use fly a in oi stabilization and other coastuction activities. “Soll Stabilization and Pavement Recycling with Self. Comenting Coal Fly Ash Background and General Information Coal combustion products (CCP) ae produced when cal is used to generate electricity. CCP include a range of materials. The materials produced ata speci: i coal-based generating station depend on the type of combustion (conversion) process Inthe uly industry, there are several basic types of boiler: pulverized coal-fueled (PC), sag tap, e¥clone, and Buiized-bed. Physically, the combustion ofthe coal crests two primary by-products, CCPs, ly ah and bottom ash, Fly ash consists ofa very fine, powdery material hat emains airborne afer burning, Bottom ash consists of heavier coal ash particles resembling coarse sand that fll to the bottom ofthe boiler and ae removed wet of dr. Bile slag ia specie type of bottom ash that is normally produced in PC, slag, or eyclone boilers, Boiler slag consists of lack, angular particles with «smoot, glassy appearance, ‘aging in size from coarse sand to fino gravel Definitions for these CPs and ‘others canbe ound on the American Ceal Ash Association (ACAA) website and in ASTM International Standard E2201, ‘The Clean Air Act (CAA) and later amendments, the Clean Air Intestate Rule (CAIR), and the Cean Ait Mercury Rule (CAMR) have suited in major ‘changes in the operation of generating facilis and in the CCPs progiced. The ‘CAA imposed set imi on sulfur dioxide (S02) emissions. To comply withthe regulations, many generating plants throughout the United States were converted to low-sulfur subbituminous coals that could achieve emission standards without additional treatment or additives. In addition to converting subbituminous coals {0 reduce sulfur oxide (SOx) emissions, sltemate combustion procedures bave been developed to allow the se of high-sulfir bituminous cols, Products from clean coal technology plants such as Nudized-bed combustion (FBC) unis, ue gas desulfurization (FGD) systems, and gasification Tailties Produce various types of material similar wo fy ash, bottom ash o slag, FBC ash s typically a mistureof unreacted lime, calcium suite (CaSOS), anhydrous caleium sulfate (CaSO4), and ash that is highly alkane in nature. Even though Aly ash produced by FBC and FGD processes may exhibit self-cementing char acteristics, such ly ash may contain sufficient quanites of slate compounds to produce highly expansive reactions. This expansion can result in damage to pave- ‘ments and buildings located on the materials, For more information on the CCPs produced by FBC and FGD processes, see Chaptcr 8 of this manual (CCPs have beon used effectively ina wide range of uilzation applications, The research, development, demonstration, and commerialization ofthese applica tions have been well-documented since the organization of ACAA in 1968, The ACAA Web ste (wwwu.acau-usa.org) has much data available concerning the se ‘of CCPs ina variety of applications as well sth characteristics ofthe materia, Coal combustion fly ash isthe most brodly used CCP in the United Stats. Fly ss is used in numerous application, including concrete and concrete products, ‘he production of portland cement, uctura ls and fr soil modification, An ACAA annual production and use survey estimates the quantities of By ash produced and used: In 2006, fy ash comprised approximately 38% of all CCPs ‘produced inthe United Sates and is readily available throughout the county. fei ORES ; ‘So Subtkeaion and Pavement Recgding off Goll Genera Goal Paar Chapter 1: Background and General Information Fly ash isthe CCP that is most commonly used in soil applications for constus- tion activites. Fly ash hasbeen effectively used inet fil, for sol drying, and for soil and base applications. ditional examples of fy ash lization in soi, stabilization applietions canbe found on the U.S. Environmental Protston ‘Agency (EPA) Coal Combustion Products Partnership (C2P2) Web sit at -swunugpa govepaoswer/sw/conservee2p2. ‘As already noted, ly ah x produced and realy available throughout the United States; however, the characteristics of fy ash ftom coal-hase electric generating facilites vary based on sever! factors: [Because of these factors, fy ash characteristics andthe resulting performance in uilization applications ean vary. Coal used inthe United States includes primar- ly bituminous (from the easter and southwester United States), subbituminous {primarily from the Montana and Wyoming Powder River Basia [PRB)}, and Uigite (fom the Fert Unioa lignite basin in North Daketa and the Gulf Coast region. Properties of these coal are described in mare dealin US. Geological Survey Circular 1143, “Coal ~ Complex Natural Resource”? ‘The inorganic constituents in the coal used for combustion in oiler impact the properties ofthe resulting CCPS including the ly ash. Is generally tue that fy sh produced from bituminous col comprises pinay silicon and aluminum, ‘with minor amounts of iron, calcium, magnesium, sodium, potassium, and suf Fly ash produced from subbituminous coal generally comprises silioa,alumi- ‘um, and caleiam, with minor amounts of ren, magnesium, sodium, potassium, and sulfur. Fly ash produced from lignite typically contains primarily silicon, aluminum, and fon and may contain moderate to high levels of elem. The re- ‘maining elements noted forthe fly ash from te oer coal types are also present as minor components of lignite Aly ash Inthe United States, ly ash sequently categorized based on the ASTM C618. This standard defines two classes ofl ash: Cass F and Clas C. Tho Ammricas Association of Sate Highway and Transportation Officials (AASHTO) has a Similar classification fr fy ash In onder for Ay as to be classified under ASTM (Co18 or AASHTO, the chemical composition, several physical properties, nd performance in prescribed concrete-related tests must be determined and results ‘compared othe C618 requirements. . al Watitaeton aud Pavemncl nani wth Salt ennai Goel Pac es Chapter 1: Background and General Information (Class F ly ash is pozzolaic, indicating thatthe ly ash wil ract with water nd 5 calefum ftom another source such as cement, lime, or lime kiln dust) to harden or Yeement." Class C fly ash contains enough calc soit will reac with water 3 without cement. lass C fly ash is frequently refered to as secementing oF cementitious ly asb. Inthe United States, significant quantities of ly ash pro ‘duced meet the requirments for either Class F of Class C; however, not ally ash produced moets one ofthese specifications Fly ash tha doesnot meot either the Class Fo¢ Class C specifications can sti ‘exhibit pozzolanic or selfementing properties, Since ASTM C618 isa specifica. tion for ly ash for use in concrete, fy ash hat doesnot meet these specifications can be used for other beneficial applications Fly ash produced from coals of the same source, which have very similar chemi= «al compositions as detenmined by elemental analysis, an have very diferent mineralogies depending on the combustion technology used. Hence, ash hydra ‘tion characteristics can vary significantly between generating fie, The relative proportions af spherical glassy pase and crystalline materials, the size distribution of the ash, the typeof erystalline material, the chemical nature ofthe las phase, and te nature and percentage of unburned carbon are some ofthe ‘characteristics tht can differ, ‘Both pozzoanic (not sef-cementing) and self-cementing fly ash can be used in soil stabilization applications. This manual provides a summary of curren design and construction practices for stabilization applications using selcemeating My sh Selfscementing fy ash is further defined in Chapter 2 ‘Sol Stablization and Pavement Racycling with SalfCamenting Coal Fly Aah 7 Chapter 2 Self-Cementing Coal Fly Ash Characteristics “Most coal-based electric generating fciites inthe United Sats currently use PC combustion, The coal is pulverized (ypically to 70% passing 200 mesh) be- fore introduction into th bile Inthe bole, the coal reaches temperatres up to 1583°C 2900}, The erganic portion ofthe coal is combusted, ad the inorganic portion ofthe coal ether agglomerates or fall othe bottom af tho boiler, fom= {ng bottom ashor boiler slag, o is carried by the ue eases through the system (oa paniculate contro device, usually a fabric fer baghouse or an electrostatic rcilafor (SP). Tho ash ht scared ough th Mu as ten ado lected in the parculate contol device is Ny a, As already noted ly ash consists ofthe ine particles that didnot combust in the boiler, Sel-cementng fly ash exhibits the property of hardening and gaining strength overtime when combined with wator. Fly ashi produced daring coal ‘combustion. Since the inorganic components ofthe coal are exposed to elevated temperatures during the combustion process, hig peteentage of that material, becomes molten, and some constituents volatilize. As the molten ash and vola- tle components travel tough the system, they col, and slasy or amorphous spheres are formed incorporating some ofthe volatile elements. Crysaline ‘compounds also can be carried through the system (some enstalin components Fsuch as quartz} passthrough the high-temperature zone unchanged or form from the molten ash andr volatile elements. Fy ash usually comprises a east 70% glassy material, Fly ash is generally very fine, with atypia! particulate size -anging from less than I ym to geatr than 1 am. ‘As the wse of subbituminous and some lignite coal was initiated for elocie generation, selF-eementing fly ash was produced and research and development ‘nits properties and uiliztion potential bogan,Sel-cementing Ay ash exhibited diferent chemical composition than ly ash derived frm bituminous coal. The primary compositional difference was in the caleum content ofthe Ay ash. Se ‘cementing fly ash generally basa calcium content 10% when reported as ime (CaO) (se Chapter | Toran explanation of porting conventions for enced ‘composition ofthe fy ash. Using advanced characterization techniques, it was also determined that sel-cementing fly ash contained diferent crystalline com- pounds than pozzolanic ash, Sel-cementng fy ash usally contains CaO and ther crystalline compounds such asthe following ‘Sal Sakae eed Paced Ronin ott, Oelt Gareten Gad PAs Chapter 2: Self-Cementing Coal Fly Ash Characteristics Ti shouldbe noted thatthe lime content refers to he crystalline compound CxO 23 and doesnot equate othe percentage of Ca sed to report he ttl alum ne

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