High Volume Fly Ash Concrete

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Lecture-7
High Volume Fly Ash Concrete
Dr. R.V. Ranganath

Professor & Head
Dept. Of Civil Engineering
BMS College of Engineering
Bangalore-560 019
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Lecture-7
Normal Concrete
IS-456: 2000 Provisions.
• Cement: 300-450Kg /m3
• Max.W/C Ratio: 0.55-0.4
• Grade of Concrete: M20 - M40
• Permits the use of :
o Mineral Admixtures (Fly Ash, Silica Fume, GGBS, Rice Husk Ash, Metakaoline)
o Chemical Admixtures
Eco-Smart Concrete (HVFC)
• EcoSmart or Green concrete uses large volumes of by-products to reduce green house
emissions for preservation of ecology
• Concrete optimally uses industrial and agriculture wastes in form of cementitious, pozzolanic
and or inert as its ingredients without scarifying its structural properties and imparting
improved performance and life.
Eco-Smart Concrete(HVFC)
EcoSmart or Green concrete uses large volumes of by-products to reduce green house
emissions for preservation of ecology
Concrete optimally uses industrial and agriculture wastes in form of cementitious, pozzolanic
and or inert as its ingredients without scarifying its structural properties and imparting
improved performance and life.
WHY HVFC
• Annually, more than 90 million tonnes of Fly Ash is being generated in India.
• Requires 65,000 acres of land for disposal
• By 2015, 1000 square Km of land required.
• Current production of Cement is about 70 million tonnes
HVFA Concrete
High volume fly ash concrete is designated as EcoSmart or Green concrete and have following
properties:
1. Structural capability
2. Durability
3. Cost efficiency
4. Aesthetics
5. Schedule of construction
Lecture-7
6. Better utilisation of large volume of co-product

7. Sustainability of depleting resources
Why use EcoSmart Concrete (HVFC)

• Adequate structural strength
• Improved flexural and tensile strengths
• Results in less bleeding
• Cohesive flow able concrete
• Improves resistance to sulphate and other chemicals
• Gives a superior appearance
• Costs less
• Is environmentally sound
HVFA Concrete
High volume fly ash concrete is defined as concrete with following attributes
1. Fly ash replacing cement by 30 – 60%
2. W/B < 0.40
3. Very low water, Chloride & oxygen penetrability
4. Almost double design life with least maintenance
5. Better fresh concrete properties
6. Better finishes and hence Aesthetics
7. Does not affects the schedule of construction
8. Economical than conventional concrete
9. Offers sustainability of depleting resources
HVFC
Disadvantages
1. All fly ashes can not be used in structural concrete
2. Replacement level depends on fly ash properties
3. Requires a good knowledge of mix proportioning
4. If not handled properly, may be dangerous
5. Requires better quality control at site
6. Slower rate of hardening and hence behaves differently to steam curing
7. Requires good curing for minimum 7 days
Lecture-7
E.A. Abdun- Nur, 1984.

“In the world of modern concrete, fly ash is as essential an ingredient of the mixture as are Portland
cement, aggregates, water and chemical admixtures. In most concretes, I use it in larger amounts ( by
volume) than Portland cement, and therefore it is not an admixture, i.e. an addition to the mixture.
Concrete without fly ash and chemical admixtures should only be found in museum showcases”.
Fly Ash
What is Fly ash?
• Fly ash is a fine powder, produced as a by-product of the combustion of coal in thermoelectric
power plants.
Types of fly ash

• Low-lime fly ash (CaO < 10% )
o Exhibit Pozzolanic properties produces cementitious properties with the help of an activator
(cement or lime).
• High-lime fly ash (CaO > 10% )
o Exhibit Cementitious properties itself.
Chemical Composition
• Major constituents of most fly ashes are
SiO2, Al2O3, Fe2O3 ,CaO and Loss on Ignition (LOI).
• Other elements are MgO, Na2O, K2O, SO3, MnO, TiO2.
Morphology
Smooth, glassy surface
Lecture-7
Properties of HVFC
FA absorptions, % 40 50 60
Total Binder, kg 435
Cement, kg 260 215 175
W/B 0.42 0.42 0.42
Slump, mm 75 85 95
Air content, % 3.5 3.8 4.0
Bleeding, ml/cm2 0.020 0.024 0.025

Density, kg/m3 2500 2495 2490
Hardened concrete properties
80
Compressive strength, MPa
70
60
50
40
30
20
10
0
40 50 60
0 50 100 150 200
Age, days
8
7
6
MOR, MPa
5
4
3
2
1 40 50 60
0
0 50 100 150 200
Age, days
Lecture-7
Water Permeability
50
Water penetration ,mm
40
30
20
10 40 50 60
0
28 60 90 180
Age, days
Chloride Permeability
Change passed, Coulomb
1000
800 40 50 60
600
400
200
0
0 50 100 150 200
Age, days
Lecture-7
Variety in HVFAC mixes
Fly ash %
Compressive strength, MPa 0 25 40 56
1 day 27.8 26.2 18.1 10.0
3 day 41.4 33.5 30.1 26.9
7 day 46.1 43.5 42.6 41.6

28 day 61.6 59.2 60.4 57.7
182 day 62.6 60.9 62.1 64.5
Sky Trains
• Work of Fast + Epp structural Engineers and Busby Architectural Associates in Vancouver.
• To construct two sky train stations, on elevated platforms with HVFA concrete with the support
of CANMET
Brentwood Station
Lecture-7
Precast Prestressed Platform Beams
South Concrete Frame
Gilmore Station
Lecture-7
Indian Case studies

Hiranandani Builders, Mumbai
1. Frame structures with buildings up to 20 stories, both in Powai, Thane and other locations
2. Uses 30% fly ash in all structural concrete of grade M35
3. Uses 40% fly ash in non-structural concrete
4. Uses 50% Fly ash in Masonry
Hiranandani Builders, Mumbai

Typical concrete mix
Cement = 300 kg
FA = 130 kg
Water = 165 kg
W/B = 0.40
Aggregates = 1975 kg
Grade = M35
Other Builders
• Almost every builder in Mumbai uses fly ash based concrete, varying between 15 to 35 %
for various structural applications.
• Builders in Delhi have started using fly ash in structural concrete of residential and
commercial building
• Masonry and plasters uses about 60% fly ash as cement replacement
Delhi metro rail

Delhi metro rail under construction have about 100 km of underground portion, subjected to aggressive
environment
Lecture-7
Delhi metro rail

Used 30% fly ash in all structural concrete & 70% slag in underground sections
Concrete road in Ropar

700 m long, 7 m wide demonstration project undertaken under the guidance of CIDA
Concrete road in Ropar
Details Values
Grade of concrete M40
Cement 280
Fly ash 200
Water 180
Lecture-7
SP 2.8
Aggregates 1830
Compressive strength, MPa 7 day 27.0

28 day 40.2
90 day ?
Flexural strength, MPa at 28 days 6.4
Water permeability, DIN test, mm 17
RCPT, ASTM 1202, Coulomb 551
Concluding Remarks
It is possible in our country to have HVFAC structures
It is economically required for our country
Cooperative Owner/Contractor/Architect critical
Be Balanced – don’t “force it”
Ideal Conditions:
• warm weather
• large pours
• no schedule/form stripping constraints
Take higher strengths into consideration when designing
Concluding Remarks
Engineer’s of the future have to shoulder the additional responsibility of conserving the increasingly
depleting natural resources by adopting ECO-FRIENDLY technologies.
CONCRETE PUMPS
Pumps
• Pumps are available in different sizes
• Pipes diameter must be at least 3 times greater than max aggregate size
• A slump of 40 to 100 mm is generally recommended
Direct acting concrete pump
Lecture-7
Direct acting concrete pump

• Horizontal
Piston type with semi rotary valves
• Concrete
is fed by gravity and partially sucked during suction stroke
• Moved up
to 450m horizontally, 40 m vertically
• 60 cum of
concrete can be achieved per hour
Squeeze-type concrete pumps
Squeeze-type concrete pumps

• Concrete is placed in collecting hopper
• Used with small pipes (up to 100 mm dia)
• The vacuum inside the chamber is about 660 mm of Hg.
Lecture-7
• Two rotating rollers progressively squeeze the tube, thus pump the concrete in the suction
pipe towards delivery pipe.
• Moved up to 90m horizontally, 30 m vertically
• 20 cum of concrete can be achieved per hour
Advantages
• Concrete can be delivered to points over a wide area otherwise not easily accessible
• Pumping delivers the concrete direct from the mixer to the form and so avoids double
handling
• Placing can proceed at the rate of the out put of the mixer
• It is not held back by the limitations of the transportation and placing equipment
Limitation/ problems faced
• Unsatisfactory concrete cannot be pumped
• Control of mix is affordable by the force required to stir it in the hopper and by the pressure
required to pump it
• Blockage can occur
o Water escapes through the mix so that pressure is not transmitted to the solids,
therefore cannot move
o If the fines are very high, the friction resistance of the mix is so large that pressure
exerted by the piston is not sufficient to move the concrete, which becomes stuck
Moderon concrete pumps
• The first type of concrete pump is attached to a truck.
• It is known as a trailer-mounted boom concrete pump because it uses a remote- controlled
articulating robotic arm (called a boom) to place concrete with pinpoint accuracy.
• Boom pumps are used on most of the larger construction projects as they are capable of
pumping at very high volumes and because of the labour saving nature of the placing boom.
• They are a revolutionary alternative to truck-mounted concrete pumps.
Truck-mounted concrete pump

• The second main type of concrete pump is either mounted on a truck or trailer and are
called as truck-mounted concrete pump
• it is commonly referred to as a line pump or trailer-mounted concrete pump.
• This pump requires steel or rubber concrete placing hoses to be manually attached to the
outlet of the machine.
Lecture-7
• Line pumps normally pump concrete at lower volumes than boom pumps and are used for
smaller volume concrete placing applications
Under Water Concreting

• In the
tremie process, concrete is placed through a vertical steel pipe with an open, funnel-shaped
upper end. The lower end of the tremie is kept immersed in plastic concrete so that freshly
placed concrete doesn’t come into contact with the water.
Lecture-7

High Volume Fly Ash Concrete

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High Volume Fly Ash Concrete

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www.bookspar.

High Volume Fly Ash Concrete

Dr. R.V. Ranganath

6. Better utilisation of large volume of co-product

Why use EcoSmart Concrete (HVFC)

E.A. Abdun- Nur, 1984.

Types of fly ash

Bleeding, ml/cm2 0.020 0.024 0.025

Hardened concrete properties

Hardened concrete properties

Hardened concrete properties

Variety in HVFAC mixes

7 day 46.1 43.5 42.6 41.6

Precast Prestressed Platform Beams

South Concrete Frame

Indian Case studies

Hiranandani Builders, Mumbai

Delhi metro rail

Delhi metro rail

Concrete road in Ropar

Concrete road in Ropar

Grade of concrete M40

Fly ash 200

Compressive strength, MPa 7 day 27.0

Flexural strength, MPa at 28 days 6.4

Water permeability, DIN test, mm 17

RCPT, ASTM 1202, Coulomb 551

Direct acting concrete pump

Squeeze-type concrete pumps

Truck-mounted concrete pump

Under Water Concreting

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