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Utilization of high-volume treated palm oil fuel ash to produce sustainable


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Article  in  Journal of Cleaner Production · July 2016


DOI: 10.1016/j.jclepro.2016.07.133

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Journal of Cleaner Production 137 (2016) 982e996

Contents lists available at ScienceDirect

Journal of Cleaner Production


journal homepage: www.elsevier.com/locate/jclepro

Utilization of high-volume treated palm oil fuel ash to produce


sustainable self-compacting concrete
Belal Alsubari a, Payam Shafigh b, *, Mohd Zamin Jumaat a
a
Department of Civil Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia
b
Department of Building Survey, Faculty of Built Environment, University of Malaya, 50603 Kuala Lumpur, Malaysia

a r t i c l e i n f o a b s t r a c t

Article history: Palm oil fuel ash is a supplementary cementitious material (SCM) generated from the combustion of
Received 13 January 2016 palm oil fibers and shells in palm oil mills to produce electricity, and One approach to reduce the carbon
Received in revised form dioxide emissions and increase the sustainability of concrete by substitute a significant amount of or-
20 July 2016
dinary Portland cement (OPC) with it. This study conducted laboratory investigations to evaluate the use
Accepted 21 July 2016
Available online 25 July 2016
of high-volume treated palm oil fuel ash (T-POFA) in producing economical and eco-friendly self-com-
pacting concrete (SCC). The concrete mixtures were prepared with 0%, 50%, 60% and 70% replacement (by
mass) of OPC with T-POFA at a constant water/binder ratio of 0.35. Self-compactability testing methods
Keywords:
Concrete cost
were also employed to evaluate the fresh properties of SCC. Compressive strength and drying shrinkage
Greenhouse gases tests were performed and investigated for up to 6 months and 1 year, respectively. An acid attack
Self-compacting concrete resistance test was also conducted on the concrete specimens. Results show that the substitution of OPC
Sustainability: treated palm oil fuel ash with high-volume T-POFA can improve the fresh properties of concrete. At an early age, SCCs containing
50%e70% T-POFA have lower compressive strength than the control SCC mix containing 100% OPC.
However, the concrete specimens attained a compressive strength equivalent to that of the control at an
age of 28 days and an even higher compressive strength at later ages. The specimens containing high-
volume T-POFA have lower drying shrinkage and exhibited better performance against aggressive
chemical attack. Cost analysis and carbon dioxide (CO2) emission calculation showed that the T-POFA
concrete specimens have 8%e12% lower cost and up to 45% lower CO2 emission than the control SCC mix.
The results suggest that T-POFA can be utilized as a cement replacement up to 70% in SCC to produce
low-cost and sustainable concrete.
© 2016 Elsevier Ltd. All rights reserved.

1. Introduction 2008). Globally, 40% of the energy consumption is attributed to


building operations, which contributes 40% of greenhouse gas
After water, concrete is the most widely used construction emissions (Lippiatt, 2007). The huge consumption of non-
material in the world (Gambhir, 2004), with a worldwide con- renewable natural materials and the greenhouse gas emissions
sumption rate of around 25  109 metric tons (25 gigatons) per year associated with concrete production exert substantial environ-
and an annual cement usage of about 3.3 billion tons (Celik et al., mental impact.
2015). Cement production processes contribute about 7% of the Having many advantages to conventional concrete, self-
global CO2 emissions, which cause environmental and greenhouse compacting concrete (SCC) is one of the most advanced de-
gas problems (Bouzoubaa and Lachemi, 2001; De Schutter et al., velopments in the construction industry (Nazari and Riahi, 2011;
Ouchi et al., 2003). SCC was developed to solve the problems of
conventional concrete (Sable and Rathi, 2012), such as the difficulty
Abbreviations: POFA, palm oil fuel ash; G-POFA, ground palm oil fuel ash; T-
of its compaction when the reinforcement is highly congested. SCC
POFA, treated palm oil fuel ash; SF, Slump flow; JF, J-ring flow; GCR, reduction in is a kind of concrete that has minimal resistance to flow and can
compressive strength reduction; ML, mass loss; Tv, V-funnel flow time; T50cm, T50cm therefore be casted and compacted under its own weight without
flow time. any external vibration, bleeding and segregation during casting
* Corresponding author. Tel.: þ60 172437383; fax: þ60 379675318.
(Aslani and Nejadi, 2013; Okamura and Ouchi, 2003). Given its easy
E-mail addresses: belalalsubari@gmail.com (B. Alsubari), pshafigh@gmail.com
(P. Shafigh), zamin@um.edu.my (M.Z. Jumaat). placement, SCC saves cost by reducing the construction period,

http://dx.doi.org/10.1016/j.jclepro.2016.07.133
0959-6526/© 2016 Elsevier Ltd. All rights reserved.
B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 983

equipment and skilled labor requirements. It also provides a better compatibility properties, compressive strength, drying shrinkage
working environment by eliminating the vibration and noise dur- strain and acid attack tests of SCC were studied. The k-value of SCC
ing its production (De Schutter et al., 2008; Sua-iam and Makul, containing T-POFA is also determined throughout its different ages.
2013). Furthermore, the improvement in the flowability of SCC can Moreover, the cost of concrete and that of carbon dioxide emissions
enhance the appearance and improve the durability of the finished are calculated.
element (Alsubari et al., 2014; Safiuddin et al., 2008). However,
producing SCC requires one or two types of chemical admixtures, 2. Experimental program
which are expensive. SCC has a lower aggregate content and a
higher volume of binder than vibrated concrete (Okamura and 2.1. Materials
Ouchi, 2003; Su et al., 2001), which in turn increases the cost of
construction. 2.1.1. Binder
An alternative to overcome the abovementioned problems is the OPC and T-POFA were used as binder. Raw POFA was brought
reduction of the OPC volume in SCCs using supplementary from a palm oil factory located in Selangor state, Malaysia. In order
cementitious materials (SCMs) as a partial replacement for OPC to dry the moisture of the raw POFA, it was placed in an electrical
(Sua-iam and Makul, 2014). The inclusion of SCMs in SCC improves oven at 105 ± 5  C for 24 h. To remove the coarse residues, the dried
concrete workability, enhances concrete characteristics, increases POFA was sieved through a 300 mm sieve. Sieved POFA was grinded
jobsite productivity and decreases cost (Sua-iam and Makul, 2015; using Los Angeles machine to reduce the particle size and increase
Uysal and Yilmaz, 2011). Moreover, the incorporation of SCMs re- the surface area. A total of 30 mild steel rods with a diameter of
duces the use of cement in concrete and therefore reduces green- 10 mm and length of 500 mm were placed in the rotating cylinder,
house gas emissions and energy consumption; as such, it saves together with 6 kg of the dried and sieved POFA. To grind the sieved
energy and natural resources and is a sustainable construction POFA, the machine was timed to run for 18 h using an electric motor
method (Alsubari et al., 2015; Persson, 2001). at a speed of 33.3 rpm. After that, the G-POFA was placed in an
Palm oil fuel ash (POFA) is a type of agro-waste generated from electrical furnace at 600  C for 2 h. The T-POFA was then ground
palm oil mills and dumped into open fields without any profitable again as in the first round to obtain a fine particle size. Scanning
return or recycling (Hussin and Awal, 1996; Mujah, 2016). Annually, electron microscope (SEM) was carried out to check the changes in
it was estimated that the total production of POFA was 2.6 million in the morphology of the POFA before heat treatment (G-POFA) and
Malaysia (Hassan et al., 2014). It was reported that POFA is a POFA after heat treatment (T-POFA) as shown in Fig. 1. The SEM
nuisance to the environment because of the method of its disposal results of G-POFA and T-POFA show that the particles were angular
in open areas. POFA includes large amounts of silica (44%e66%) and and irregular in shape and having porous texture. In addition, it can
has recently been used as a cement replacement to produce a be observed that there was no agglomeration of the particles after
different types of concrete (Safiuddin et al., 2011a). It has been the heat treatment. Additionally, X-ray fluorescence (XRF) tech-
utilized to produce normal and high-strength concrete (Awal and nique was performed to determine the chemical compositions of
Hussin, 1999; Sata et al., 2004). However, problems associated the OPC, G-POFA and T-POFA as shown in Table 1. The physical
with the reduction in its workability, its early-age compressive characteristics and chemical composition of the binder are shown
strength and its limited level of replacement have been encoun- in Tables 1 and 2, respectively. Moreover, The G-POFA and T-POFA
tered, as shown in previous researches (Alsubari et al., 2014; samples were subjected to X-Ray Diffraction (XRD) analysis to
Safiuddin and Jumaat, 2011; Tay, 1990). Recently, ground POFA check their silica structure. Fig. 2 shows that major phase of G-POFA
(G-POFA) was treated via heat treatment and being utilized to and T-POFA was Q ¼ Quartz (SiO2) and F ¼ iron oxide (Fe2 O3) and
produce high strength concrete (Johari et al., 2012). However, P ¼ Portlandite (H2CaO2) and as minor phases.
research on the use of high-volume T-POFA in SCC is lacking.
The efficiency factor (k-value) of POFA and T-POFA has not been 2.1.2. Aggregate
reported in previous studies. The concept of the k-value of SCMs has A natural crushed stone with a nominal maximum size of
been introduced in previous studies (Papadakis and Tsimas, 2002; 12.5 mm was used as coarse aggregate (BIBM and ERMCO, 2005;
Sethy et al., 2015). This factor is described as the part of SCMs in EFNARC, 2002). The specific gravity, fineness modulus and water
pozzolanic cement materials that can be considered comparable to absorption of the coarse aggregate were 2.62%, 6.3% and 0.44%,
OPC and therefore possesses the same characteristics as concrete respectively. Local mining sand with a grain size of 0e4.75 mm was
made with cement (Papadakis and Tsimas, 2002). Suvarna et al. used as fine aggregate. The fineness modulus, specific gravity and
(2012) defined this factor as the ability of SCM to function as a water absorption of the sand were 2.88%, 2.56% and 1.13%,
cementing material, given that the contribution of SCMs to con- respectively.
crete properties is mainly its ability to react with the free lime
Ca(OH)2 produced during cement hydration. The rate of this 2.2. Concrete mix proportions and mixing procedure
pozzolanic reaction when compared with cement hydration rate
determines the value of k. The pozzolanic reaction rate in concrete The materials and mix proportions in this study were generally
containing SCM is slower than the cement hydration rate without chosen according to the recommendations of EFNARC 2002 for self-
SCM when the k-value is less than 1.0. This normally occurs during compacting concrete (EFNARC, 2002). A suitable control mix that
the early age of the concrete specimen. The rate of pozzolanic re- satisfied the requirement for the fresh properties of SCC was
action and the rate of cement hydration are the same when the k- selected from different trial SCC mixes. A total of four different SCC
value is 1.0. The pozzolanic reaction rate is more efficient than mixes were produced with 0%, 50%, 60%and 70% T-POFA substitu-
cement hydration when SCMs are used to partially replace cement tion (by weight) of the total binder. Table 3 shows the mix pro-
in concrete and the k-value is greater than 1.0 (Suvarna et al., 2012). portions of all SCCs mixes. The binder content and water/binder
This study treats G-POFA and uses it in high volume to produce ratio were 480 kg/m3 and 0.35, respectively, for all mixes. A
cheap SCC with less effect on the environment. Heat treatment is modified polycarboxylate copolymers superplasticizer (EFNARC)
conducted to treat G-POFA and reduce its high content of loss of which is designed for the production of high flow concrete with a
ignition (LOI) and improve its chemical composition. T-POFA is used specific gravity of 1.09 ± 0.02 was used in SCC mixes to obtain the
as substitute cement by a mass of up to 70% of OPC. The fresh self- required fresh SCC properties. The superplasticizer met the
984 B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996

Fig. 1. SEM for G-POFA and T-POFA.

Table 1
Physical characteristics of aggregate, OPC, G-POFA, T-POFA.

Property Coarse aggregate Fine aggregate OPC G-POFA T-POFA

Maximum size (mm) 12.5 4.76 e e e


Water absorption (%) 0.43 1.13 e e e
Specific gravity 2.62 2.56 e e e
Fineness modulus 6.3 2.88 e e e
Color e e Grey Dark grey Grey
Passed on a 45-mm (No. 325) sieve (%) e e 92 96 100
Surface area, BET (m2/g) e e 3.05 4.9 7.4
Relative density e e 3.16 2.04 2.20

Table 2 from the moulds and completely immersed in water to cure until
Chemical composition of OPC, G-POFA, and T-POFA (%). the testing time. The temperature and relative humidity of the
Oxide composition OPC G-POFA T-POFA laboratory were 27 ± 3  C and of 80 ± 5%, respectively.
Silicon dioxide (SiO2) 17.60 59.17 69.02
Aluminum trioxide (Al2O3) 4.02 3.73 3.9
Iron oxide (Fe2O3) 4.47 6.33 4.33
2.4. Testing methods
Calcium oxide (CaO) 67.43 5.80 5.01
Magnesium oxide (MgO) 1.33 4.87 5.18 To evaluate the effect of high volume T-POFA on SCC, some
Sodium oxide (Na2O) 0.03 0.18 0.18 properties were investigated as following:
Potassium oxide (K2O) 0.39 8.25 6.9
Sulfur trioxide (SO3) 4.18 0.72 0.41
SiO2 þ Al2O3 þ Fe2O3 e 69.23 77.25
Loss on ignition (LOI) 2.4 16.1 1.8
2.4.1. Fresh properties
The fresh properties of SCC were determined according to
(EFNARC, 2002). The following three characteristics were checked
to fulfill the requirements of SCC:
requirements of ASTM C494-86 Type G and BS 5075: Part 3.
For the mixing of the constituent materials, the coarse and fine
 Filling ability was evaluated in terms of the slump flow, T50cm
aggregates were mixed for 1 min. About 10% of mixing water was
flow time and V-funnel flow time.
initially added and mixed for 5 min. The cement and T-POFA were
 Passing ability was determined by evaluating L-box and J-ring
later added to the mix. The SP was then dissolved into the
flow tests.
remaining water and was added to the mix. The mixing was
 Segregation resistance was assessed through visual observation
continued for 7 min. The mixing process for SCC was longer than
during the SF and JF tests. The GTM screen stability test was also
that for conventional concrete mixes.
determined to confirm the visual observation.

2.3. Sample preparation and curing methods

A variety of tests were conducted before casting to evaluate the 2.4.2. Compressive strength
fresh properties of the SCC. The mix was first subjected to a slump Three cubes of 100 mm were used to determine the compressive
flow test (SF) and T50cm flow time test (T50cm). When the mix passed strength of SCCs at the ages of 1, 3, 7, 28, 56, 90 and 180 days. The
both tests, after that, L-box, J-ring flow (JF), V-funnel flow time (Tv) compressive loading test on the cube concrete specimens was
and segregation tests were conducted. The fresh SCC mixes were conducted using a compression testing machine with a capacity of
finally cast into moulds and kept for 24 h. Then, they were removed 3000 kN, as per BS EN 12390-3:2002 (EN, 2002).
B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 985

Fig. 2. XRD for G-POFA and T-POFA.

Table 3
Mix proportions of SCC.

Mix no. Cement (kg/m3) Water (kg/m3) W/B ratio T-POFA (kg/m3) T-POFA (%) Fine aggregate (kg/m3) Coarse aggregate (kg/m3) S.P (% binder) Paste volume

SCC0 480 168 0.35 0 0 925 758.2 1.3 0.344


SCC50 240 168 0.35 240 50 925 758.2 1.3 0.367
SCC60 192 168 0.35 288 60 925 758.2 1.3 0.371
SCC70 144 168 0.35 336 70 925 758.2 1.3 0.375

2.4.3. Efficiency factor (k-value)


The following procedure was followed to calculate the k-value. fcu ¼ Kfð1=W=CÞ  0:5g (2)
The compressive strength fcu (MPa) of the control concrete can be
calculated using the following equation (Bolomey's equation): where “C” is the cement content (kg/m3), “W” is the water content
(kg/m3), “K” is a parameter that depends on the type of cement
(MPa) and “a” is a parameter that depends on curing time. Eq. (2) is
modified when SCM is used as cement replacement. The modified
fcu ¼ Kfð1=W=CÞ  ag (1) equation involves the concept of the k-value:

For structural purposes, Eq. (1) can be simplified as follows fcu ¼ Kf1=ðW=ðC þ k  PÞÞ  0:5g (3)
(Suvarna et al., 2012):
986 B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996

where “k” is the efficiency factor and “P” is the replacement level of ability and segregation resistance. The fresh properties of SCC
OPC by SCM. incorporating T-POFA were investigated, and the results are sum-
marized in Table 4.
2.4.4. Drying shrinkage strain
Prismatic concrete specimens with a dimension of 3.1.1. Slump flow and T50cm flow time tests
100  100  500 mm3 were used to measure the drying shrinkage Fig. 3 shows the relationship between the replacement level of
strain. The samples were removed 24 h after casting and kept in T-POFA and slump flow. The SFs for all SCCs mixes are in the range
moist curing for 7 days. The samples were then taken out from the of 700e740 mm, which is well within the values specified by the
water. Demec points were placed at three sides of the sample at a EFNARC (2002). The mixes containing T-POFA could improve the SF
distance of 200 mm. The initial reading (zero reading) was then in comparison with to the control mix. The enhancement of the SF
measured and recorded. The concrete samples were then left to dry can be attributed to several reasons: (1) As shown in Table 2, the LOI
in a laboratory at a temperature of 27 ± 3  C and a relative humidity content of the T-POFA is reduced from 16.1% to 1.8%, which in turn
of 80 ± 5%. decreases the unburned carbon content. The reduction in the LOI
content reduces the amount of SP absorbed by T-POFA (Chandara
2.4.5. Chemical attack test et al., 2010), and this in turn improves the fluidity of SCC. Previ-
Chemical resistance of SCCs specimens was evaluated by con- ous studies show that the use of G-POFA, which contains signifi-
ducting acid attack test. A total of six cubes with the dimension of cantly higher LOI than T-POFA, reduces the workability of concrete
100  100  100 mm3 were used for each mix after 7 days of water as the replacement level increases (Alsubari et al., 2014; Safiuddin
curing. The cubes were kept in water mixed with 3% hydrochloric et al., 2011a). This is because of the nature of the G-POFA contain-
acid solution (HCL) with a pH concentration of about 2. This solu- ing a high amount of LOI, which absorbs more SP and water,
tion was replaced at regular intervals time of 14 days to keep a thereby decreasing the flowability of concrete (Chandara et al.,
constant pH value throughout the immersion time. The reduction 2010).
in compressive strength (fCR) and mass loss (ML) of the SCC speci- (2) The substitution of OPC with T-POFA is in terms of mass.
mens were determined after 75 days (1800 h) of immersion time Hence, the binder volume increases as the replacement level in-
(Budiea et al., 2010; Hussin et al., 2008). creases. This is because T-POFA has specific gravity of less than that
of cement. Table 3 shows that the excess amount of paste volume
3. Results and discussion for the SCC50, SCC60 and SCC70 mixes are 6.4%, 7.7 and 8.9%,
respectively, compared with the mix made from OPC only. This
3.1. Fresh properties extra paste can improve the packing between the aggregates. The
paste fills the gaps and spaces between the aggregate particles,
The fresh SCC mixes were tested according to the recommen- provides better coating for them to move during the SF test, and
dations of (EFNARC, 2002) to assess their filling ability, passing improves their flowability. (3) Given the high fineness of T-POFA,

Table 4
Fresh properties of SCC.

Mix no. Filling ability Passing ability Segregation resistance

Slump flow (mm) T50cm spread time (s) V-funnel time (s) J-ring (mm) L-box Segregation Index (%)

Difference in heights (mm) Flow spread (mm)

SCC0 700 3.5 6.6 9.0 690 0.94 6.7


SCC50 730 2.9 5.8 5.0 710 1.0 8.2
SCC60 730 2.8 5.6 5.0 720 1.0 9.8
SCC70 740 2.5 5.5 4.0 730 1.0 10.7

750

740

730
flow value (mm)

720

710

700

690

680
J-ring flow (mm)
670
Slump flow (mm)
660
0 50 60 70
T-POFA content (%)
Fig. 3. slump flow and J-ring flow for SCCs mixes.
B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 987

the fine particles of the T-POFA are adsorbed on the surface of the 3.1.5. Segregation resistance tests
oppositely charged cement particles. This prevents the flocculation The visual observations on the mixes during the SF and JF tests
of OPC particles, which are dispersed and do not trap more water indicate no bleeding or segregation in any of the mixes as shown in
(Alsubari et al., 2015). (Malhotra and Mehta, 2002) reported similar Fig. 4. The values of the segregation ratios of the different SCC mixes
conclusions on high-performance concrete incorporating high- are presented in Fig. 5. The values of the segregation ratios of the
volume fly ash. concrete mixtures containing 0%, 50%, 60% and 70% are 6.7%, 8.2%,
The T50cm flow time values are measured in combination with 9.8% and 10.7%, respectively. The results show acceptable resistance
the SF test. Table 4 shows that, as the T-POFA content increases, the for segregation, and all the values are within the range stated in
T50cm decreases. This is due to the decrease in the viscosity of fresh (EFNARC, 2002), that is, less than 15%. The segregation values in-
SCC as the level of substitution increases. A low T50cm indicates crease as the substitution level increases because the replacement
good filling ability. The results for T50cm are in line with previously of cement with T-POFA is by mass. Thus, the volume of paste in T-
reported results on the SCC incorporating fly ash up to 50% cement POFA concrete mixes is higher than that in the control mix (SCC0),
replacement (Dhiyaneshwaran et al., 2013). which increases the mortar volume in the mix and the paste
The results and discussion in the above sections indicate that the passing through the sieve.
replacement of OPC with T-POFA in SCC reduces the amount of
water needed to obtain a given consistency. Another advantage of 3.1.6. Correlation between the slump flow and J-ring flow tests
using high-volume T-POFA is that, given the increase in the SF and The slump flow test and J-ring flow tests were used to evaluate
T50cm compared to the plain mix at the same mix proportions, the flow ability and passing ability of fresh SCC. Fig. 6 shows the rela-
water content in the T-POFA mixes can be reduced to obtain similar tionship between the SF and JF results for the different SCC mixes.
values for the fresh properties of the control and T-POFA mixes, Fig. 6 shows that the SF and J-ring spread flow of the SCC mixes
which in turn improves the quality in the hardened state. have a strong linear relationship. This strong correlation is
observable because both the SF and JF vary with the T-POFA content
3.1.2. V-funnel flow time test in a similar way. The SF and JF increase as the content of T-POFA
The filling ability of the fresh SCC was evaluated by conducting increases. The filling ability and passing ability of SCC are interre-
V-funnel flow time test. The time values of the Tv are in the range of lated. Thus, the results for the filling ability can be used to predict
5.5e6.6 s. Table 4 shows that the Tv decreases as the content of the the passing ability of SCC.
T-POFA increases. Shorter flow times indicate better filling ability.
The improvement in the mixes containing T-POFA can be credited 3.1.7. Correlation between the slump flow, J-ring flow and
to greater paste volume of the SCCs especially at higher T-POFA segregation ratio tests
content leading to enhance the fluidity and made the concrete less The relationship between the SF and segregation ratio for fresh
viscous (Dhiyaneshwaran et al., 2013) showed that the inclusion of SCC mixes is shown in Fig. 7. A strong relationship is found between
up to 50% fly ash in SCC improves the Tv. The tests results lead to the both tests and T-POFA content. The segregation ratio increases as
conclusion that T-POFA enhances the flowability in terms of slump the SF increases. Hence, the SF results indicate the segregation
flow, T50cm spread time and V-funnel flow time in comparison with resistance of fresh SCC.
the SCC made with OPC only.
3.1.8. Correlation between the T50 cm flow time and V-funnel flow
time tests
3.1.3. J-ring flow test The flow time of the fresh mix can be used to evaluate the vis-
The J-ring flow test involves measuring the difference in the cosity and cohesiveness of SCC. Fig. 8 shows the relationship be-
height of the concrete inside the ring and that just outside the bars tween the T50cm flow time and V-funnel flow time. The Tv and T50cm
of the ring (h1eh2). The average diameter of the spread fresh mix is of the fresh mixes have a strong linear relationship. The flow time
also measured. The results of the J-ring flow are shown in Table 4. decreases as the T-POFA content increases because of the high SF of
The differences in the height of the all mixes vary within the range SCC with higher T-POFA. Such strong correlation is observable
of 4e9 mm. No visible blocking occurs during the test. The higher because both the T50cm and Tv vary almost similarly with the
content of T-POFA (SCC70 mix) shows the lowest value. This is different T-POFA contents. This also suggests that the flow time of
because the high paste volume helps the concrete to flow and fresh SCC can provide a good indication for the assessment of the
spread more easily than the control mix. The values of the J-ring viscosity and cohesiveness of fresh SCC.
flow are shown in Fig. 3. The difference between the slump flow
and J-ring flow (SFeJF) should be less than 50 mm for SCC to obtain 3.2. Compressive strength development
good passing ability and cohesiveness of the fresh concrete without
blockage (Safiuddin et al., 2011b). Hence, all the SCC mixes have a The results of compressive strength of SCC containing high
good passing ability. The results obtained are in line with the pre- volume T-POFA were divided into two parts; early-age and later-age
vious findings on SCC containing up to 30% rice husk ash (Safiuddin compressive strength as follow:
et al., 2012). They concluded that the SF increases as the content of
RHA increases. 3.2.1. Early-age compressive strength
Fig. 9 shows the development of the compressive strength of
3.1.4. L-box test SCC mixes containing T-POFA. All the SCC mixes containing high-
The results of the L-box test are shown in Table 4. The blocking volume T-POFA at the early ages of 1, 3 and 7 days exhibit lower
ratios of all the SCC mixtures are between 0.94 and 1.0, which compressive strength than the control concrete. The main reason
meets the acceptance criteria specified by the EFNARC (2002) for the low compressive strength at an early ages is attributed to the
standard. This indicates the good passing ability of fresh SCC less hydration product, namely, calcium hydrate silicate (CeHeS),
when it is subjected to small openings and heavily reinforced caused by the huge dilution of the cement content. CeHeS is the
blocks. The test results indicate that the L-box value also increases main component that contributes to the strength of concrete. The
as the replacement level increases because of the same reasons as results obtained are in agreement with the results for normally
in the case of the SF and J-ring. vibrated concrete with high-volume G-POFA (Awal and Abubakar,
988 B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996

Fig. 4. Visual appearance for Slump flow (1 and 2) and J-ring flow (3 and 4).

18

15
Segregation ratio (%)

12 Maximum limit

0
0
SCC0 50
SCC50 60
SCC60 70
SCC70
T-POFA content (%)
Fig. 5. Segregation resistance for SCC with T-POFA.

2011). The reductions in the compressive strengths of the mixes difference at 7 days is significantly reduced. The concrete mixes
containing 50%, 60% and 70% T-POFA at 1 day are 29%, 56% and 65%, containing high-volume fly ash with a 1-day compressive strength
respectively. Those at 3 days are 21.8%, 43% and 49%, respectively. of 10 MPa are considered to be early-age high-strength concrete
Those at 7 days are 9.5%, 13.03% and 18.2%, respectively. The dif- (Malhotra and Mehta, 2002). All the concrete mixes containing T-
ference between the compressive strength of the control concrete POFA in this study have considerably higher 1-day compressive
and POFA concretes at 1 and 3 days is significant, whereas the strength than the requirement. Thus, the concrete mixes even at an
B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 989

735
730 JF = 0.9444(SF) + 27.778
R² = 0.9175
725

J-ring flow, JF (mm)


720
715
710
705
700
695
690
685
695 700 705 710 715 720 725 730 735 740 745
Slump flow, SF (mm)
Fig. 6. Correlation between slump flow and J-ring flow of SCCs mixes.

Fig. 7. Correlation between slump flow, Segregation ratio and T-POFA content of SCCs.

6.8

6.6
Tv = 1.1611(T50) + 2.4787
V-funnel flow time, Tv (s)

6.4 R² = 0.9514
6.2

5.8

5.6

5.4

5.2

5
2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6
T50cm slump flow time, T50 (s)

Fig. 8. Correlation between V-funnel flow time and T50cm slump flow time of concrete.

early age of 1 day can be categorized as high-strength concrete. As 3.2.2. Later-age compressive strength
shown in Table 5, the 7- to 28-day compressive strengths of SCC50, Fig. 9 shows that the compressive strength continues to increase
SCC60 and SCC70 mixes are about 90%, 86% and 81%, respectively. with an increase in the curing period of up to 180 days. The
Thus, the strength of the concrete is satisfactory. reduction in the compressive strength of SCC is overcome by
990 B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996

90

80

Compressive strength (MPa)


70

60

50

40

30

20
SCC0 SCC50 SCC60 SCC70
10

0
0 20 40 60 80 100 120 140 160 180 200
Curing time (days)

Fig. 9. Compressive strength development of SCCs.

Table 5
Compressive strength and the relative compressive strength for SCCs.

Curing time (days) Item SCC0 SCC50 SCC60 SCC70

1 Compressive strength (MPa) 39.0 28.0 17.0 14.0


Relative strength 100.0 71.7 43.5 35.0
R1/28cr (%) 58.1 41.7 25.3 20.8
3 Compressive strength (MPa) 51.2 40.0 29.0 26.0
Relative strength 100.0 78.1 56.6 50.7
R3/28cr (%) 76.3 59.6 43.2 38.7
7 Compressive strength (MPa) 57.5 52.0 50.0 47.0
Relative strength 100.0 90.4 86.9 81.7
R7/28cr (%) 85.7 77.4 74.5 70.0
28 Compressive strength (MPa) 67.1 69.0 68.0 65.5
Relative strength 100.0 102.8 101.3 97.6
R28/28cr (%) 100.0 102.8 101.3 97.6
56 Compressive strength (MPa) 70.5 75.2 74.7 72.9
Relative strength 100 106.6 105.9 103.4
R56/28cr (%) 105.1 112.7 111.3 108.6
90 Compressive strength (MPa) 72.0 78.4 76.6 74.5
Relative strength 100.0 108.8 106.3 103.4
R90/28cr (%) 105.1 116.8 114.1 111.0
180 Compressive strength (MPa) 74.0 83.0 81.4 78.8
Relative strength 100.0 112.2 109.8 106.5
R180/28cr (%) 110.0 123.6 121.3 117.6

Rx/28cr is the relative compressive strengths with regard to 28 days compressive strength for control SCC.

continuing the curing time. In contrast to their early-age increasing the compressive strength. However, previous research
compressive strengths, the later-age compressive strengths of all (Alsubari et al., 2014; Safiuddin et al., 2011a) shows that the
the mixes containing high-volume T-POFA are higher than those of replacement level in concrete should not be more than 30% because
the SCC made with OPC only. The compressive strengths of the of the high LOI of G-POFA (i.e., more than 10%). The main reason for
SCC0, SCC50, SCC60 and SCC70 mixes at 28 days curing are about this limitation is the significant reduction in workability and
67, 69, 68 and 66 MPa, respectively. Thus, the compressive strength compressive strength when the replacement level is more than 30%
of the SCC concrete containing T-POFA is similar to that of the (Awal and Abubakar, 2011; Safiuddin et al., 2011a). The results
control mix at the age of 28 days. With prolonged curing time, the obtained in the present study are in line with those of the study of
increments in the strengths of the SCC50, SCC60 and SCC70 mixes (Johari et al., 2012) on high-strength concrete that contains T-POFA.
are 12%, 11% and 8% at 56 days, respectively, and 16%, 15% and 11% at The results of this study lead to the conclusion that T-POFA can be
90 days, respectively. The main factor contributing to the late-age utilized up to 70% to replace OPC and produce an SCC with high
strength is the pozzolanic reaction of T-POFA. Calcium hydroxide strength at early and later ages. The performance of T-POFA is
(CH), which results from primary cement hydration, reacts with T- compared with that of other types of supplementary cementitious
POFA. The silica and aluminum in T-POFA combine with CH to materials in terms of the development of compressive strength. The
produce secondary hydration products (additional CeSeH). This SCC70 mix in this study, which has almost the same cement con-
process densifies and improves the micro-structure of SCC and tent, W/B ratio and fresh properties as the self-compacting concrete
increases its compressive strength. Moreover, T-POFA has signifi- containing 70% type-F fly ash reported by (Dinakar et al., 2008), has
cantly lower LOI than G-POFA (Table 2). The reduction in LOI con- a significantly higher later-age compressive strength. The
tent enhances the chemical composition, especially SOi2, from compressive strengths of the present mix at 28-, 90- and 180-day
59.17% to 69.02%. This improves the pozzolanic activity, thereby ages are about 88%, 64% and 38%, respectively, which are higher
B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 991

than the strengths reported by (Dinakar et al., 2008) for SCC fly ash role in the pozzolanic reactions act as a micro-filler; thus, more
concrete. Moreover, the SCC70 mix, which has the same cement POFA replacement leads to more restraints to paste shrinkage
content and W/B ratio as the SCC containing 70% fly ash reported by (Altwair et al., 2013). Moreover, SCC had better compaction, less
(Wongkeo et al., 2014), has about 65% and 49% higher 28- and 90- empty voids on the surface and lower porosity than normal con-
day compressive strengths, respectively. Moreover, a reported SCC crete (Alsubari et al., 2015; Safiuddin et al., 2008). These charac-
containing 60% fly ash has almost the same cement content and W/ teristics reduce the water evaporation and drying shrinkage of
B ratio as the SCC60 mix in the present study (Khatib, 2008). concrete. These results are in line with those of the previous studies
However, the 28-day compressive strength of this fly ash SCC is conducted by (Mehta, 2004) and (Altwair et al., 2013) on SCMs,
about 26% lower than the SCC60 mix in this study. such as fly ash (FA) and G-POFA, which can be used to reduce the
drying shrinkage of concrete. Altwair et al. reported that the drying
shrinkage decreases as the POFA content increases. Moreover,
3.3. Efficiency factor (k-value) of T-POFA
(Ayub et al., 2014) reviewed the effect of mineral admixtures, such
as FA and GGBS, on drying shrinkage. Authors concluded that the
The k-value was calculated using a modified Bolomey's strength
use of SCMs refines the pore configuration by reducing the size of
equation. k-values are normally used to describe the effect of SCM
pores. Thus, the shrinkage of concrete incorporating mineral ad-
replacement on the enhancement of the strength and durability of
mixtures is lower because of the reduced diameter compared with
concrete (Papadakis and Tsimas, 2002; Suvarna et al., 2012). Eqs.
concrete made with OPC only. The results therefore suggest that the
(1e3) were used to calculate the k-values. For the OPC utilized in
use of high-volume T-POFA in SCC can reduce drying shrinkage.
this study, K was calculated as 28.5 MPa using Eq. (2). The “A”
values were calculated as 1.48, 1.06, 0.857, 0.5, 0.383, 0.33 and 0.26
for 1, 3, 7, 28, 56, 90 and 180 days, respectively, using the mean 3.5. Acid attack
measured values of the compressive strength of the control spec-
imen. The k-values of the concrete mixes containing high-volume The results of acid attack are reported in terms of weight loss,
T-POFA are presented in Table 6. The k-value mainly depends on reduction in compressive strength, degradation at corners and
the age of concrete and the percentage of replacement. The k-value faces and change in the color of the specimens. Studies on acid
for all the mixes at an early age (i.e., 1 and 3 days) are less than 1.0. attack are conducted to evaluate the performance of SCC with and
This is because of the slow pozzolanic reaction rate compared with without T-POFA against aggressive chemical attack. The tests were
the hydration reaction of cement. However, the k-values exceeded conducted after immersing the specimens in 3% HCL solution for a
1.0 with prolonged time of curing. Increasing the curing time in- period of 1800 h.
creases the rate of pozzolanic reaction and results in more CeSeH,
which enhances the paste structure and increases the compressive 3.5.1. The mechanism of acid attack
strength of the specimens. These results agree well with those of Concrete is alkaline in nature. Any environment with a pH less
the previous research conducted by (Suvarna et al., 2012) on high- than 12.5 is considered to be destructive and harmful to concrete
volume fly ash (HVFA) of up to 70%. Authors concluded that the k- because a reduction of the alkalinity can eventually cause the
values for 50% FA at 90 and 180 days are between 1.45 and 2.14. decomposition of cement hydration products. Acid attack occurs as
a result of the reaction of aggressive acid ions with calcium hy-
3.4. Drying shrinkage strain droxide Ca(OH)2, which forms highly soluble calcium salt, as shown
in Eq. (4) and Eq. (5) (O'neill et al., 2001; Zivica and Bajza, 2001).
The effect of incorporating T-POFA on the drying shrinkage of The calcium salts can be easily leached away from the cement paste,
SCC mixes is shown in Fig. 8. Most of the shrinkage occurred within which weakens the paste's structure. Thus, exposure to acidic en-
90 days after casting the specimens. The drying shrinkage strain vironments reduces the alkalinity of concrete (Siad et al., 2010),
values of the all SCC samples were low and did not exceed 400 thereby rendering its whole structure unstable and weak.
microstrain at 360 days of drying. All the SCC mixes with T-POFA
Calcium silicate þ water/calcium silicate hydrate
showed lower drying shrinkage than the SCC made with OPC only.
Fig. 10 shows that utilization of T-POFA up to 70% as a cement þ calcium hydroxide (4)
replacement (by mass) could reduce the drying shrinkage of SCC.
The reductions in the drying shrinkage of the SCC50, SCC60 and Acid þ calcium hydroxide/calcium salt þ water (5)
SCC70 mixes in 6 months are 7%, 11% and 13%, respectively,
compared with that of SCC0. The average reductions in the three
SCC mixes containing 50%, 60% and 70% T-POFA are 14%, 12%, 11%
and 12% at 56, 90, 180 and 360 days, respectively. The reduction in 3.5.2. Mass loss
the drying shrinkage of SCC incorporating T-POFA content can be The relationship between weight loss and T-POFA content is
accredited to the good pozzolanic activity and high packing effect. presented in Fig. 11. The reductions in the mass of SCC0, SCC50,
The high fineness of the T-POFA particles promotes pozzolanic re- SCC60 and SCC70 are 2.8%, 1.83%, 1.75% and 1.92%, respectively. The
actions and micro-filler effects, which cause pore refinement and results reveal that the mass losses of all the specimens containing
structure densification, which in turn reduce the loss of water and T-POFA are lower than those of plain concrete. This is because acid
decrease drying shrinkage. Moreover, POFA particles that have no attack is mainly associated with the cement content in concrete. As
the cement content increases, the calcium hydroxide Ca(OH)2
content increases, which makes the concrete highly susceptible to
Table 6
Efficiency factor (k-value) of SCC containing T-POFA.
chemical attack. Thus, when T-POFA is used as cement replacement,
Ca(OH)2 is consumed during pozzolanic reactions to form CeSeH,
Mix no. 1 day 3 days 7 days 28 days 56 days 90 days 180 days
thereby resulting in a denser concrete with higher resistance
SCC50 0.72 0.73 1.01 1.05 1.12 1.16 1.22 against acid attack. The higher mass loss of the plain SCC is pri-
SCC60 0.54 0.55 0.86 1.02 1.08 1.10 1.15 marily attributed the formation of weak and soluble calcium salt,
SCC70 0.55 0.56 0.83 0.98 1.05 1.05 1.09
which can be easily removed from the specimen's surfaces and
992 B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996

450
400
350

Drying shrinkage (με)


300
250
200
150
100
50 SCC0 SCC50 SCC60 SCC70
0
0 50 100 150 200 250 300 350 400
Time (days)

Fig. 10. Drying shrinkage strain of SCCs containing T-POFA.

3.7

3.2 Result of this research

Hussin et al., (2008)


Mass loss (%)

2.7

2.2

1.7

1.2

0.7

0.2
0 10 20 30 40 50 60 70 80
POFA content (%)
Fig. 11. Relationship between mass loss and T-POFA content.

corners. (O'neill et al., 2001) recommends the use of pozzolanic ions into the inner part the specimen. This result suggests that the
materials to enhance the performance of concrete against aggres- use of high-volume T-POFA produces SCC with high resistance
sive chemical attack. (Dinakar et al., 2008) reported a similar against aggressive chemical attack. Siad et al. (Siad et al., 2010)
conclusion in the case of SCC containing up to 85% HVFA. Dinakar made similar observations in using natural pozzolan to produce
et al. investigated the effect of 3% H2SO4 acid on SCC containing SCC. They reported that the use of natural pozzolan improves the
HVFA and concluded that the weight loss of SCC decreases as the fly resistance of SCC against acid attack. Dinakar et al. (Dinakar et al.,
ash percentage increases. Hussin et al. (Hussin et al., 2008) reported 2008) and Verma et al. (Verma et al., 2013) studied the effect of
that utilization of 20% G-POFA in aerated concrete results in good acid attack on SCC and normal vibrated concrete containing HVFA.
resistance against aggressive chemical attack. They showed that They reported that the inclusion of HVFA in concrete improves the
only 0.9% mass reduction occurred in specimens immersed for resistance against destructive chemical environment.
1800 h in 5% HCL. This is due to the pozzolanic reaction and low
content of CaO of concrete containing POFA compared with the 3.5.4. Relationship between the reduction in compressive strength
control concrete. and mass loss
Fig. 13 shows the relationship between the reduction in
3.5.3. Residual compressive strength compressive strength (fCR) and mass loss (ML) of SCC after being
All the SCC specimens suffered a reduction in compressive immersed in hydrochloric acid. A strong linear relationship is found
strength after being immersed in hydrochloric acid solution for 75 between both results. Compressive strength is reduced as the mass
days (1800 h). The relationship between the residual compressive loss increases. Exposing SCC to hydrochloric acid results in the loss
strength (fCR) and T-POFA content can be seen in Fig. 12. The highest of cement paste and its structural integrity, which weakens the
strength loss is found in the SCC0 specimens compared with SCC concrete matrix.
incorporating T-POFA. The reductions in the compressive strengths
of SCC0, SCC50, SCC60 and SCC70 are about 18%, 12.8%, 12.4% and 3.5.5. Visual observations
13.3%, respectively. The improved resistance of SCC containing Specimens with and without T-POFA exhibited a change in color
high-volume T-POFA is mainly attributed to the consumption of and degradation in the faces and corners after being immersed in
Ca(OH)2, which reduces the porosity and increases the imperme- HCL acid, as shown in Fig. 14. SCC without T-POFA suffered from
ability of SCC specimens. This prevents the penetration of the acid more changes and degradation than SCC with T-POFA. The higher
B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 993

of concrete, as shown in Fig. 15. The reductions in the cost of the


50%, 60% and 70% mixes are 7.9%, 9.6% and 11.3%, respectively. The
utilization of high-volume T-POFA considerably reduced the cost of
concrete. Aside from producing cheaper SCC, the utilization of this
waste as cement replacement improves mechanical properties and
durability and reduces potentially risky effects on the environment.

5. Carbon dioxide (CO2) emissions

About 2.3 gigatons of CO2 were emitted globally in 2011 because


of the production of about 3.3 gigatons of Portland cement (Celik
et al., 2015). Hence, the substitution of Portland cement, which is
produced from non-renewable raw materials with wastes, leads the
production of sustainable and eco-friendly concrete and reduces
greenhouse gas emissions.
In this research, the system boundary approach is used to assess
the environmental impact of concrete material extraction, trans-
Fig. 12. Relationship between residual compressive strength and T-POFA content.
portation and treatment. The total energy consumed during prep-
aration, grinding and heat treatment for POFA was measured. In
degradation of SCC0 is primarily due to the formation of calcium addition, the total CO2 emitted due to transportation for materials
salt, which can be easily removed. Alsubari et al. (Alsubari et al., was calculated. The calculations for CO2 emission are based on the
2014) and Budiea et al. (Budiea et al., 2010) studied the effect of conversion factors obtained from the Department for Environment,
acid attack on SCC and high-strength concrete degradation. They Food and Rural Affairs, and the factors of electricity and transport
concluded that concrete containing G-POFA showed less degrada- emissions are based on the Department of Energy and Climate
tion and color changes. Change (DECC). The calculations are based on the information
presented in Table 7. The relationship between the estimated CO2
and cement replacement level is presented in Fig. 16. A significant
4. Cost analysis reduction in CO2 emissions is observed when T-POFA is used to
replace OPC. With the decreasing amount of Portland cement and
The cost of concrete is one of the important factors that should increasing amount of T-POFA, the CO2 from SCC50, SCC60 and
be considered during its production. Table 7 indicates the approx- SCC70 concrete mixes can be as low as 32%, 39% and 45%, respec-
imate prices of various materials used to produce SCC. The price tively, compared with SCC0 mixture made of OPC only. This
value of Portland cement is 8, 6 and 1.76 times more than those of reduction in CO2 is due to huge cement dilutions, which is the main
coarse aggregate, sand and T-POFA, respectively. Hence, cement is source of CO2 in concrete production. A similar result was reported
the main material that contributes to the cost of concrete. The raw by (Celik et al., 2015) on SCC containing fly ash (FA) and limestone
POFA was subjected to dying in oven, sieve, grinding and heat powder (LP). The replacement of OPC with 50% FA results in a
treatment processes to obtain the final product of T-POFA. The cost reduction of about 47%, while a combination of 60% FA and 15% LP
of G-POFA resulted from the preparation and grinding processes. cement replacement produces concrete with about 67% less CO2-eq
However, the cost of T-POFA is higher than that of G-POFA as a emission compared with the control concrete. The significant
result of the further energy consumption for the heat treatment reduction in CO2 emission and cost because of high-volume cement
processes. The cost of producing 1 kg T-POFA is calculated to be RM replacement with T-POFA can positively contribute to the envi-
0.25. Thus, the replacement of cement with T-POFA reduces the cost ronment and the economy.

19
Reduction in compressive sterngth, ƒ (%)

ƒCR= 5.3439(ML) + 3.0364


18 R² = 1

17

16

15

14

13

12
1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9
Mass loss, ML (%)

Fig. 13. Relationship between reduction in compressive strength and mass loss.
994 B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996

Fig. 14. Change in color and corner losses for SCCs with and without T- POFA. (For interpretation of the references to colour in this figure legend, the reader is referred to the web
version of this article.)

Table 7
Price and CO2 emission for the main constitutes of concrete.

Item Unit Price (RM)/unit CO2/unit Reference


DECC (2011)
Electricity kWh 0.21 0.25
DECC (2011)
Distance (medium car) km e 0.18
Celik et al. (2015)
Cement kg 0.44 0.91
Purnell and Black (2012)
Aggregate kg 0.055 0.005
Purnell and Black (2012)
Superplasticizer kg 38 0.01
G-POFA kg 0.19 0.23 From this research calculation
T-POFA kg 0.25 0.31 From this research calculation

RM is Ringgit Malaysia, 1 USD ¼ RM 3.25 (As of 1 September 2014).

Fig. 15. Cost of concrete based on T-POFA content.


B. Alsubari et al. / Journal of Cleaner Production 137 (2016) 982e996 995

Fig. 16. Relationship between the carbon dioxide (CO2) emission and T-POFA content.

6. Conclusions References

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