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Utilization potential of fly ash together with silica fume in autoclaved aerated

concrete production

Article  in  KSCE Journal of Civil Engineering · January 2013

DOI: 10.1007/s12205-014-0392-7

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KSCE Journal of Civil Engineering (2014) 18(1):47-52 Environmental Engineering
Copyright ⓒ2014 Korean Society of Civil Engineers
DOI 10.1007/s12205-014-0392-7 pISSN 1226-7988, eISSN 1976-3808
www.springer.com/12205
TECHNICAL NOTE

Utilization Potential of Fly Ash together with Silica Fume in

Autoclaved Aerated Concrete Production
M. Serhat Baspinar*, Ismail Demir**, Erhan Kahraman***, and Gokhan Gorhan****
Received December 2, 2011/Revised July 24, 2012/Accepted December 22, 2012

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Abstract

The increase in the number of thermal power plants has led to the production of an increasing amount of fly ash that causes high
environmental impact in Turkey. Many researchers around the world are looking at methods of gainful utilization and disposal of fly
ash. However, the construction materials industry is the most suitable way to mass consumption of the fly ash waste. In this study, the
utilization potential of fly ash and silica fume in Autoclaved Aerated Concrete (AAC) production were investigated. Optimum fly
ash/cement ratio was determined, and this composition was improved by the silica fume addition. Strength-Microstructure relations
of the products were investigated. Crystalline C-S-H phases of Tobermorite and Xonotlite were developed after autoclaving at 4 bar.
Silica fume addition was found to be useful for the prevention of the ettringite phase in the product. Silica fume addition improved
the hydrothermal conditions during the autoclaving of the mixtures.
Keywords: Fly ash, silica fume, AAC, microstructure, C-S-H phase development
··································································································································································································································

1. Introduction which were studied by several researchers.

Aerated concrete is classified as lightweight concrete. It is
kinds of either cement or lime mortar in which air-voids are
entrapped in the mortar matrix by a suitable aerating agent. The
important advantage of aerated concrete is its lightweight, which
economises the design of supporting structures. It has a high
degree of thermal insulation and considerable savings in energy
and the static loading of the building. Wide range of densities
(300-1800 kg/m3) can be produced for several applications such
as structural, partition and insulation purposes. Autoclaved Aerated
Concrete (AAC) is classified into cement or lime based depending
on the binder used. Autoclaved aerated concrete usually is made
from quartz-rich sand, lime, cement, and calcium sulphate with
traces of aluminium powder as a pore-forming agent. Silica based
filler is generally used in commercial aerated concrete production.
AAC is also a good alternative for the mass utilization of the
SiO2 and CaO rich industrial wastes. Several researchers investigated
the partial replacement of waste material instead of quartz rich
sand or lime in AAC production. Copper tailings, blast furnace
slag (Huang et al., 2012), gasification residues (Holt et al.,
2005), fly ash from the cellulose industry (Hauser et al., 1999)
and coal bottom ash (Kurama et al., 2009) are some examples
Fly ash is an important waste from Thermal Power Stations
that generates a great deal of pollution to the environment due to
its fineness and soluble ions. The growth of power plants around
the world results in an increasing amount of fly ash that causes
high environmental impact, especially in Turkey. Today, annual
fly ash generation reaches to 15 million ton in Turkey. Fly ash is
mainly utilized in the construction industry, concrete and cements
production as an additive material; however the utilization ratio
is still very limited. Attempts have also been made to use pozzolanic
materials such as pulverised fuel ash in AAC production.
Properties of lime based fly ash aerated concrete were studied
and cellular concrete production parameters were discussed in
detail (Verma et al., 1983). Density change-pore structure relations
were studied in cement based fly ash aerated concrete (Pospisil et
al., 1992). C-S-H gel structure and strength development was
studied in cement based fly ash aerated concrete under moist
curing conditions (Durack and Weiqing, 1998). CaO assisted
cement based fly ash aerated concrete was also extensively
studied (Sengupta, 1992, Ramamurthy and Narayanan, 1999).
Apart from the use of fly ash instead of silica based filler, high
volume partial replacement of fly ash was also studied (Kearsley
and Wainwright, 2001; Jones and McCarthy, 2005). Many of the

*Assistant Professor, Metallurgy and Material Science Dept., Afyon Kocatepe University, ANS Campus, Afyonkarahisar 03200, Turkey (Corresponding
Author, E-mail: sbaspinar@aku.edu.tr)
**Professor, Afyon Kocatepe University, Civil Eng. Dept., ANS Campus, Afyonkarahisar 03200, Turkey (E-mail: idemir@aku.edu.tr)
***Research Assistant, Construction Education Dept., Afyon Kocatepe University, ANS Campus, Afyonkarahisar 03200, Turkey (E-mail: ekahraman@
aku.edu.tr)
****Assistant Professor, Civil Engineering Dept., Afyon Kocatepe University, ANS Campus, Afyonkarahisar 03200, Turkey (E-mail: ggorhan@aku.edu.tr)

− 47 −
 M. Serhat Baspinar, Ismail Demir, Erhan Kahraman, and Gokhan Gorhan

studies concluded on the variable nature of the fly ash and late and cement have Blaine fineness number of 2564 cm2/g and
hydration characteristics and its effect on the aerated concrete 3054 cm2/g respectively. Mineralogical analysis of the fly ash
properties. Conversely, very little studies have been conducted and silica fume are given in Fig 1. Fly ash mainly composed
on the phase stability and the microstructural development of from quartz phase and silica fume has an almost non-crystalline
cement based fly ash aerated concrete where sand is fully phase structure.
replaced by fly ash. Fly ash was first dried before mixing. Fly ash and cement were
The main objective of this study was to investigate the mass mixed with 2/3 of the required water. Then gypsum and lime
utilization potential of fly ash together with silica fume in AAC. were added. Finally, aluminum powder (as a foaming agent) was
In this study different fly ash/cement ratio mixtures were prepared. added with the rest of required water. Standard mixing time was
Mixtures were cured at different conditions. Low quality silica used until homogenous mortar was obtained. After mixing,
fume addition to fly ash/cement mixtures was also studied. samples were poured into plastic moulds which have 10 × 10 ×
Tobermorite phase development and density-strength relations 10 cm dimensions. Samples were then put into the ventilated
were investigated. Limitations on the use of fly ash in AAC were oven with the mould. The ventilated oven was set to 60-70oC.
also investigated. Filled moulds were held for 60 minutes in the oven. After the
expansion of the material, moulds were taken from the oven.
2. Materials and Methods Then the samples were subjected to different curing conditions;
24 hour vapour curing, autoclave curing at 1.15, 4 and 8 bar for 8
Fly ash was supplied from a thermal power plant in Turkey hour and industrial AAC curing conditions (11.5 bar, 12 hour).
(Seyitömer TPP). Silica fume was obtained from Antalya-Etibank Comparative results of the 1.15 and 4 bar autoclaving are given
Ferro-Alloy Production Plant in Turkey. Cement was appropriate in Table 2. However, result of the 24 hour vapour curing, 8 bar
to the TS EN 197-1 CEM I (42,5R). The chemical composition and industrial AAC curing conditions were discussed separately
of the fly ash and silica fume are given in Table 1. Fly ash was in the text on the base of C2 series which have optimal
classified as F type fly ash according to ASTM C-618. Fly ash properties. The bulk density of the samples were measured by
simply dividing the mass of the samples to their volumes. Eight
Table 1. Chemical Analysis of Fly Ash and Silica Fume different sample series were prepared with different cement/fly
Fly Ash Silica Fume ash ratio (Table 2). The first 2 series (A and C) were starting
Oxide Wt % Wt % mixtures for the determination of cement/fly ash ratio. C1, C2,
SiO2 46.300 94.50 C3 and C4 series were optimization series with lowered cement
Al2O3 19.20 00.88 amount. C2SF1 and C2SF2 are the Silica fume containing series
Na2O 0.51 --- of C2 series. For all series water amount kept constant. For the
Fe2O3 11.000 00.70 lower cement/fly ash ratio mixtures, the amount of gypsum and
CaO 6.34 00.80 lime were increased by 0,05% in order to compensate for the
MgO 4.76 01.25 decrease in the bonding ability of cement. The mineralogical
P2O5 0.10 --- structure of the samples was investigated by XRD technique.
SO3 1.54 --- SEM techniques were used to identify the microstructural
K2O 2.45 --- properties. Rheological properties of the mixtures were also
MnO 0.11 --- studied by rheometer. The hot wire method was used to measure
TiO2 0.87 --- the thermal conductivity of the samples having dimensions of
Cr2O3 0.12 --- 100 × 50 × 17 mm. A quick thermal conductivity meter (Shotherm
LOI 3.26 0.75 QTM-D2 Kyoto Electronics Manufacturing Co. Ltd., Japan)

Fig. 1. XRD Analysis of: (a) Fly Ash, (b) Silica Fume

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 Utilization Potential of Fly Ash together with Silica Fume in Autoclaved Aerated Concrete Production

Table 2. Fractional (by Unit Weight) Constituents of the Mixtures, Their Mechanical and Physical Properties (F : Fly Ash, C : Cement,
G : Gypsum, L : Lime, W : Water, SF : Silica Fume, Al : Aluminum)
Seri D σ λ
F C G L W SF Al
No gr/cm3 MPa W/m.K
A 1.0 1.0 0.25 0.25 2.0 --- 0.001 0.66 (1) 2.10(1) 0.145
C 1.0 1.5 0.25 0.25 2.0 --- 0.001 0.76 (1) 3.72(1) 0.201
C1 1.5 0.9 0.3 0.3 2.0 --- 0.001 0.63 (2) 3.20(2) 0.128
C2 1.5 0.8 0.3 0.3 2.0 --- 0.001 0.64 (2) 3.70(2) 0.156
C3 1.5 0.7 0.3 0.3 2.0 --- 0.001 0.59 (2) 3.70(2) 0.123
C4 1.5 0.6 0.3 0.3 2.0 --- 0.001 0.65(2) 1.91(2) 0.142
C2SF1 1.5 0.8 0.3 0.3 2.0 0.02 0.001 0.74(3) 3.90(3) 0.135
C2SF2 1.5 0.8 0.3 0.3 2.0 0.04 0.001 0.78(3) 5.10 (3) 0.135
(1): 1.15 bar, (2):4 bar autoclave pressure, (3): 8 bar

based on ASTM C 1113-90 hot wire method was used to
measure the thermal conductivity.
3. Results and Discussion
The constituents of the different mixtures, bulk density,
strength and thermal conductivity values are given in Table 2.
First studies (orientation studies) show that higher cement/fly ash
samples (C series) have higher strength than lower ratio samples
(A series).
Higher cement amount means higher cement paste which is
responsible for strength development. However, an important
amount of ettringite phase was observed after the early hydration
period of the C mixture. Although ettringite phase is believed to
be useful for early strength development, it may cause cracks and
decreases the durability later. Fly ash contains anhydrite (CaSO4)
and cement contains 3CaO.Al2O3 (C3A) and 4CaO.Al2O3.Fe2O3
(C4AF) phases. Enough sulphate potential in the pore solution
results in the reaction of C3A phase and CaSO4 to form ettringite
phase. Therefore series with reduced cement amount were

Fig. 2. Microstructure at: (a) Low Autoclaving Pressure, (b) Prolonged Steam Curing, (c) EDX Analysis from the Needle Shape Forma-
tions

Vol. 18, No. 1 / January 2014 − 49 −

 M. Serhat Baspinar, Ismail Demir, Erhan Kahraman, and Gokhan Gorhan

produced. Fig. 2. shows the microstructure of the two different
series of the sample at prolonged (24 hour) steam curing (for C2
series) and at low pressure autoclaving condition (for C series).
A high amount of cement paste surrounding the fly ash particles
was observed in Fig. 2(a) with a small amount of ettringite
needles. XRD studies showed that there was not any tobermorite
phase which is the main crystalline phase responsible for
strength development for aerated concrete, in the structure at low
pressure autoclaving conditions. Instead, the highest peaks of
CSH(I) phase due to hydration of cement phases were observed
with high amount of unreacted Ca(OH)2. A very high amount of
ettringite phase was observed when the C2 mix was cured at
prolonged vapour curing condition (Fig. 2b). Undissolved reactive
fly ash particles were still observed in the structure.
Increasing the autoclaving pressure to 4 bar resulted in the first
formation of tobermorite crystals in the structure. Hydrothermally
more favourable conditions at higher autoclaving pressure increased
the tobermorite formation. Further increment in the autoclave
pressure to 8 bar resulted in higher amount of tobermorite phase
development with other crystalline CSH phases like xonotlite.
Increasing the autoclaving pressure from 4 bar to 8 bar resulted
in good development in the tobermorite phase formation (Fig. 3).
In spite of an increase in the tobermorite phase formation by
increasing the autoclaving pressure from 4 bar to 8 bar, strength
of the series increased only 14-16%. Compressive strength of the
C1, C2, C3 and C4 samples were measured as 3.70, 4.20, 4.10
and 2.10 MPa respectively after autoclaving at 8 bar. The first
tobermorite formations with an intensive CSH gel structure at 4
bar autoclaving conditions are shown in Fig. 3(a).
In the cement chemistry, it is generally accepted that the
principle products of the hydration of Portland cement are
amorphous calcium-silica-hydrate (C-S-H) (60-70%), portlandite
Ca(OH)2 20-25% and other minor phases, such as calcium
carbonate (Chan and Mitsuda, 1978).
Fly ash has a pozzolanic activity. Hence, during the hydration
of cement, it easily reacts with Ca(OH)2 and converts into the
compounds that possess cementitious properties. As a result, the
strength of hardened concrete improved. Decreasing the cement
amount in the mixtures reduced the amount of Ca(OH)2 that
formed after the hydration of cement. When comparing the C1
and C4 series, this effect is more visible. There was an excess
Ca(OH)2 in C1 composition and deficient amount of Ca(OH)2
C4 composition. XRD studies also proved that free Ca(OH)2
peak was reduced by decreasing the cement content by keeping
the fly ash amount constant. Therefore C4 series has the lowest
strength. Under similar conditions, decreasing the cement amount
while keeping the fly ash amount constant resulted in an increase
in the strength values. C2 composition was found to be optimum.
C3 series were suitable to the bulk density-strength requirements
stated in the TS 453 (Turkish standards on group definitions for

Fig. 3. Microstructure at Higher Autoclaving Pressure: (a) 4 Bar, (b) 8 Bar, (c) EDX Analyses of 8 Bar Samples

− 50 − KSCE Journal of Civil Engineering

 Utilization Potential of Fly Ash together with Silica Fume in Autoclaved Aerated Concrete Production

Fig. 4. (a) Microstructure of the Commercial AAC Microstructure, (b) C2 Samples after Autoclaving under Industrial Autoclaving Condi-
tions, (c) EDX Analysis of C2 Composition after Industrial Autoclaving

Fig. 5. XRD Patterns of C2 and C2SF2 Compositions at Different Autoclaving Conditions: (a) 1.15 bar, (b) Industrial Curing at 11.5 bar,
(c) 8 bar, (d) 8 bar for C2SF2 Sample

Vol. 18, No. 1 / January 2014 − 51 −

 M. Serhat Baspinar, Ismail Demir, Erhan Kahraman, and Gokhan Gorhan
aerated concrete). G3 class aerated concrete has minimum strength
of 3.0 MPa with densities between 510 and 600 gr/cm3. C2 series
samples were also cured under commercial autoclaving conditions
(11.5 bar, 12 hour). Fig. 4(a) shows the microstructure after the
highest pressure autoclaving. Well developed and defined
tobermorite platelets are shown in the microstructure. Aside
from the very well defined tobermorite morphology, compressive
strength was not changed extensively. More advanced tobermorite
phase development obtained in fly ash/cement based composition
when compared with the commercial (sand/lime/cement based)
aerated concrete microstructure (Fig. 4b).
Crystalline CSH phase (tobermorite and xonotlite) formations
were increased by the increase in autoclaving pressure. Industrial
autoclaving resulted in the highest crystalline peaks in C2
samples (Fig. 5b). Silica fume addition to the C2 composition
resulted in an increase in the compressive strength of autoclaving
at 8 bar. 5% Silica fume addition gave the same mineralogical
structure (Fig. 5d.) as in the case in industrial autoclaving conditions.
Low pressure autoclaving at 1.15 bar was not effective for the
tobermorite formation (Fig. 5a). Silica fume addition was found
to be useful for the prevention of the ettringite phase in the early
hydration period of the fly ash/cement based aerated concrete
compositions. 5% silica fume additions stopped the formation of
ettringite phase after 24 hour vapour curing. However, further
addition over the 5% decreased the workability of the mixtures.
The optimum amount of the silica fume addition was determined
using a shear type rheometer.
4. Conclusions
Defect free standard aerated concrete samples were produced
from fly ash/cement mixture. A high amount of cement in the
mixture resulted in an extensive ettringite formation during the
early hydration period. Decreasing the amount of cement
resulted in an increase in the compressive strength at autoclaving
curing conditions. Increasing the autoclaving pressure resulted in
better tobermorite phase development. However, increasing the
pressure higher than 8 bar was found not to be useful for
compressive strength. Although a well defined tobermorite phase
was observed after autoclaving the samples at commercial curing
conditions, compressive strengths were measured at lower levels
than the samples cured at 8 bar pressure. This showed that apart
from the mineralogical structure, macrostructure such as cell
wall thickness plays an important role in the strength of aerated
concrete. Five percent silica fume addition to C2 composition
was found to be useful in both prevention of the ettringite phase
formation at the early stage of hydration and the strength
development at higher autoclaving pressures. In conclusion, fly ash/
cement based AAC is a good alternative for the mass utilization
− 52 −
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of fly ash. Silica fume can be used as a functional additive to the
fly ash/cement based AAC systems.
Acknowledgements
Authors wish to thanks to Tübitak (Turkish National Scientific
Research Council) which allows the financial support under
project number 109M245.
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