USE OF FLY ASH AS PARTIAL REPLACEMENT

OF FINE AGGREGATE IN CONCRETE

Submitted By:

MOAZZAM HUSSAIN (G.L) 1801-BECE-022

MUHAMMAD MEHFOOZ (A.G.L) 1801-BECE-026
ABID ALI 1801-BECE-004
AQEEL HYDER 1801-BECE-008
JAY KRISHAN 1801-BECE-018
SAJJAD ALI 1801-BECE-037

Supervisor:

ENGR. UROOSA MEMON

Co-Supervisor:

ENGR. IRFAN ALI SHAR

A Final Year Project Report submitted in partial fulfillment of the requirement

for the degree of Bachelor of Civil Engineering

DEPARTMENT OF CIVIL ENGINEERING

FACULTY OF ENGINEERING, SCIENCE &TECHNOLOGY
ISRA UNIVERSITY, HYDERABAD

January, 2022
USE OF FLY ASH AS PARTIAL REPLACEMENT
OF FINE AGGREGATE IN CONCRETE

Submitted By:

MOAZZAM HUSSAIN (G.L) 1801-BECE-022

MUHAMMAD MEHFOOZ (A.G.L) 1801-BECE-026
ABID ALI 1801-BECE-004
AQEEL HYDER 1801-BECE-008
JAY KRISHAN 1801-BECE-018
SAJJAD ALI 1801-BECE-037

Supervisor:

ENGR. UROOSA MEMON

Co-Supervisor:

ENGR. IRFAN ALI SHAR

DEPARTMENT OF CIVIL ENGINEERING

FACULTY OF ENGINEERING SCIENCE &TECHNOLOGY
ISRA UNIVERSITY, HYDERABAD

January, 2022

ii
 UNDERTAKING

I/We undertake that, the undertaken project titled “USE OF FLY ASH AS
PARTIAL REPLACEMENT OF FINE AGGREGATE IN CONCRETE” is
my/our own work. No portion of the work presented in this project has been
submitted in support of another award or qualification either at this institution or
elsewhere. Where material has been used from other sources it has been properly
acknowledged / referred.

(Signature of Student 1) (Signature of Student 2)

Moazzam Hussain (G.L) Muhammad Mehfooz (A.G.L)
1801-BECE-022 1801-BECE-026

(Signature of Student 3) (Signature of Student 4)

Abid Ali Aqeel Hyder
1801-BECE-004 1801-BECE-008

(Signature of Student 5) (Signature of Student 6)

Jay Krishan Sajjad Ali
1801-BECE-018 1801-BECE-037

iii
 CERTIFICATE

DEPARTMENT OF CIVIL ENGINEERING

The thesis report entitled “Use of Fly Ash as Partial Replacement of Fine Aggregate
in Concrete” written by the following students under the direction of their Supervisor
and approved by the members of the Evaluation Committee, has been presented to the
department of Civil Engineering, in partial fulfillment for the requirements of the
degree of bachelor of Civil Engineering.

Prof. Dr. Ghous Bux Khaskheli Engr. Uroosa Memon

(Chairperson) (Supervisor)

Prof. Dr. Naeem Aziz Memon Engr. Irfan Ali Shar

(External Examiner) (Co-Supervisor)

Dated:

iv
 ACKNOWLEDGEMENT

I am very thankful to Allah who gave me strength and showered His blessing over me
because of which I was able to complete this final Thesis of my Topic On time.

This report is dedicated to their counselors and facility associates for their constant
support and supervision in this research. Without their help, this project would not
have been possible. Firstly, we would like to thank ENGR: UROOSA MEMON,
who helped us at each and every step we took towards the completion of this report.
We are grateful to ENGR: IRFAN ALI SHAR as well, for his endless
encouragement and inspiration.

The authors would like to acknowledge and be thankful to the staff members of the
ISRA UNIVERSITY, HYDERABAD CAMPUS, for providing with necessary
details and facilities in order to precede this study in the correct manner.

v
 ABSTRACT

Because the building industry has used up all of the earth's natural materials (fine and
coarse aggregates), there is a scarcity of raw materials for the industry, and the price
of these commodities has risen. Researchers were forced to regulate these issues and
discover remedies due to a scarcity of raw materials and tonnes of waste materials.
Reusing such waste that would otherwise be disposed of in landfills is a green choice.
Hence, the major aim of this study was envisioned to evaluate the effective use of Fly
ash in concrete as partial replacement of fine aggregate. Considering this, concrete
specimens were prepared by replacing fine aggregate with fly ash (i.e. 10, 20 and
30%). Fresh and hardened properties of concrete were determined (such as:
Workability, Compressive and Tensile strength). Results show that there is increase in
compressive and tensile strength with replacement of fine aggregate with fly ash.
Replacement percentage were 10, 20 and 30% and the maximum strength was
obtained at 10%. Results obtained that concrete workability decreases when fly ash
content increased replacing fine aggregate. However, splitting tensile strength of
experimental mix at 28 days curing age surpassed that of conventional concrete in all
replacements. Taking into all these considerations along with substantial recompenses
both economically and environmentally, replacement of fine aggregate with fly ash
will prove to be most worthwhile and beneficial in construction industry at 10%
replacement.

vi
 TABLE OF CONTENTS

Description Page

UNDERTAKING ........................................................................................................ iii

CERTIFICATE ............................................................................................................. iv
ACKNOWLEDGEMENT ............................................................................................. v
ABSTRACT .................................................................................................................. vi
TABLE OF CONTENTS .............................................................................................vii
LIST OF NOTATIONS ................................................................................................. x
LIST OF ABBREVATIONS ........................................................................................ xi
LIST OF FIGURES .....................................................................................................xii
LIST OF TABLES ..................................................................................................... xiii
LIST OF PHOTOGRAPHS ........................................................................................ xiv

CHAPTER 1 INTRODUCTION ................................................................................ 1

1.1 BACKGROUND OF STUDY ........................................................................... 1
1.2 FLY ASH AS SUPPLEMENTARY CEMENTOUS MATERIAL................... 3
1.3 PROBLEM STATEMENT ................................................................................ 3
1.4 AIM AND OBJECTIVES.................................................................................. 4
1.5 SCOPE OF STUDY ........................................................................................... 4
1.6 LIMITATION OF STUDY................................................................................ 4
1.7 OUTLINES OF THESIS ................................................................................... 5

CHAPTER 2 LITERATURE REVIEW .................................................................... 6

2.1 INTRODUCTION ............................................................................................. 6
2.2 FLY ASH AS COAL COMBUSTION BY-PRODUCT ................................... 6
2.3 HISTORY OF USAGE OF COAL ASHES IN CONCRETE ........................... 7
2.4 PRODUCTION OF FLY ASH IN THAR COAL POWER PLANT ................ 7
2.5 ENVIRONMENTAL IMPACTS OF FLY ASH ............................................... 8
2.6 CHEMICAL COMPOSITION OF THAR COAL FLY ASH ........................... 8
2.7 USES OF FLY ASH IN CONSTRUCTION ..................................................... 9
2.8 CHEMICAL ACTION OF FLY ASH IN CONCRETE.................................. 10
2.9 EFFECT OF FLY ASH ON PROPERTIES OF CONCRETE ........................ 10
2.9.1 Workability .......................................................................................... 10

vii
 2.9.2 Compressive Strength .......................................................................... 11
2.9.3 Effect of Fly Ash on Other Properties of Concrete.............................. 12
2.10 CONCLUDING REMARKS ........................................................................... 13

CHAPTER 3 MATERIALS & METHODOLOGY ............................................... 14

3.1 INTRODUCTION ........................................................................................... 14
3.2 EXPERIMENTAL PROCEDURE .................................................................. 14
3.3 MIX DESIGN AND MATERIALS CALCULATION ................................... 15
3.3.1 Mix Design........................................................................................... 15
3.3.2 Mix Design Table ................................................................................ 16
3.3.3 Materials Sourcing ............................................................................... 16
3.3.3.1 Cement ..................................................................................... 16
3.3.3.2 Aggregates ............................................................................... 16
3.3.3.3 Water ........................................................................................ 17
3.3.3.4 Coal Fly Ash ............................................................................ 17
3.4 MATERIALS TESTING ................................................................................. 17
3.4.1 Preliminary Tests on Cement ............................................................... 17
3.4.1.1 Normal Consistency Tests on Cement ..................................... 18
3.4.2 Tests on Aggregate .............................................................................. 19
3.4.2.1 Gradation of Fine Aggregate Test Results ............................... 20
3.4.2.2 Specific Gravity of Aggregates ................................................ 21
3.5 TESTS ON CONCRETE ................................................................................. 22
3.5.1 Workability of Fresh Concrete............................................................. 22
3.5.2 Compressive Strength of Concrete ...................................................... 23
3.5.3 Splitting Tensile Strength of Concrete ................................................. 24

CHAPTER 4 RESULTS AND DISCUSSION......................................................... 26

4.1 INTRODUCTION ........................................................................................... 26
4.2 WORKABILITY TEST RESULTS ................................................................ 26
4.3 COMPRESSIVE STRENGTH TEST RESULTS AND ANALYSIS ............. 28
4.3.1 7-Days Compressive Strength.............................................................. 28
4.3.2 14-Days Compressive Strength............................................................ 29
4.3.3 28-Days Compressive Strength............................................................ 31
4.4 COMPARATIVE ANALYSIS OF COMPRESSIVE STRENGTH ............... 32
4.5 TENSILE STRENGTH RESULTS AND ANALYSIS ................................... 35

viii
CHAPTER 5 CONCLUSION AND FUTURE RECOMMENDATIONS ............ 37
5.1 CONCLUSION ................................................................................................ 37
5.2 FUTURE RECOMMENDATION SUGGESTIONS ...................................... 38

REFERENCES ........................................................................................................... 39

ix
 LIST OF NOTATIONS

AI2O3 = Aluminum Oxide

Ca(OH)2 = Calcium Hydroxide

Co = Calcium Oxide

C-S-H = Calcium – Silicate – Hydrate

Co2 = Carbon Oxide

Fe2O3 = Iron Oxide

S-H = Hydrates

SIO = Silicon Dioxide

SIO2 = Silica

w/c = Water Cement Ratio

gm = Gram

mm = Millimeter

MPa = Mega Pascal

MW = Mega Watt

% = Percentage

x
 LIST OF ABBREVATIONS

ASTM = American Society for Testing Material

BA = Bottom Ash

BS = British Standard

CFA = Coal Fly Ash

CA = Coarse Aggregate

DoE = Department of Environment

FA = Fly Ash

FA = Fine Aggregate

FESEM = Field Emission Scanning Electron Microscopy

FM = Fineness Modules

HVFA = High Volume Fly Ash

OPC = Ordinary Portland Cement

UTM = Universal Testing Machine

xi
 LIST OF FIGURES

Description Page

Figure 2.1: FESEM image of coal fly ash (Rafieizonooz et al., 2016) .................... 6
Figure 2.2: Chemical composition of thar coal fly ash (nawaz abbasi et al.,
2010) ...................................................................................................... 8
Figure 2.3: Impact of fly ash on water demand of concrete. (M Thomas et al.,
2002) .................................................................................................... 11
Figure 2.4: Effect of fly ash on compressive strength development. (Dr. M
Thomas et al., 2002)............................................................................. 12
Figure 3.1: Schematic diagram of research study .................................................. 15
Figure 3.2: Penetration Curve of OPC ................................................................... 18
Figure 3.3: Gradation curve of coarse aggregate.................................................... 19
Figure 4.1: Relationship between slump and percentage fly ash replacement ....... 27
Figure 4.2: 7-days compressive strength results..................................................... 29
Figure 4.3: 14-days compressive strength results................................................... 30
Figure 4.4: 28-days compressive test results .......................................................... 32
Figure 4.5: Comparative results of compressive strength ...................................... 34
Figure 4.6: Splitting tensile strength results ........................................................... 36

xii
 LIST OF TABLES

Description Page

Table 2.1: Historical Uses of Coal Fly Ash in Construction................................... 7

Table 3.1: Concrete Mix Proportion ..................................................................... 16
Table 3.2: Normal Consistency of Cement Results .............................................. 18
Table 3.3: Sieve Analysis of Coarse Aggregate Result ........................................ 19
Table 3.4: Sieve Analysis of Fine Aggregate Result ............................................ 20
Table 3.5: Specific gravity and water absorption of coarse aggregate results ...... 21
Table 3.6: Specific gravity and water absorption of fine aggregate results .......... 21
Table 3.7: Workability Test .................................................................................. 22
Table 4.1: Slump test results for fly ash replacement ........................................... 27
Table 4.2: 7-days compressive strength results..................................................... 28
Table 4.3: 14-days compressive strength results................................................... 30
Table 4.4: 28-days compressive strength results................................................... 31
Table 4.5: Comparative results of compressive strength ...................................... 34
Table 4.6: Splitting tensile strength results ........................................................... 35

xiii
 LIST OF PHOTOGRAPHS

Description Page

Photograph 3.1: Slump cone testing for workability of concrete ................................ 23

Photograph 3.2: Cubes testing in UTM for compressive strength ............................... 24
Photograph 3.3: Splitting Tensile Strength test on UTM ............................................ 25

xiv
 CHAPTER 1

INTRODUCTION

1.1 BACKGROUND OF STUDY

"Time is not so far away that we should shield ourselves from ourselves," says the
author. "To survive on this holistic world, we must employ sustainability in every step
we take." In this context, the construction industry faces numerous significant
problems and challenges related to sustainable development around the world,
particularly in Pakistan, where these subpoenas are more severe due to the rapid
consumption of natural resources without regard for long-term development (Nawaz
Abbasi et al., 2010).

Sustainable development is a set of overarching aims for progressing humanity while

also fostering natural systems' ability to provide the natural resources and ecological
benefits that the economy and society rely on. The targeted goal is a state of society in
which everyday environments and assets are used to continue to support human needs
without jeopardizing the future generation's uprightness and privileges. Coal
combustion waste has existed since man discovered that burning coal produces
energy. Pakistan is rich in coal resources and has the capacity to power the country for
at least 200 years with 3377 Million tons of deposited coal fuel (MMst). Block Il
(with 1% of 175 trillion tons of coal and the capacity to create 5000 MW for 50 years)
just completed the construction of its two units, each capable of producing 2x330 MW
and consuming 280 tonnes of coal per hour (Nawaz Abbasi et al., 2010).

Fly ash is the material collected in the dust-collection systems that remove particles
from the exhaust gases of power plants that burn pulverized coal. It is generally finer
than Portland cement and consists mostly of small spheres of glass of complex
composition involving silica, ferric oxide, and alumina. The composition of fly ashes
varies with the source of coal (Robert V. et al.., 2015).

At present two major classes of fly ash are related to the type of coal burned. These
are designated Class "F" and Class "C" by the American Society for Testing and
Materials (ASTM) and this differentiation is generally used in most of the current
literature. Class F is defined in ASTM specification C 618 as the fly ash normally

1
 2

produced from burning anthracite or bituminous coal. Under current conditions no

appreciable amount of anthracite coal is used for power generation. Thus essentially
all Class F fly ash now available is derived from bituminous coal. Class F fly ashes
are not self-hardening but generally have pozzolanic properties. This means that in the
presence of water the fly ash particles react with calcium hydroxide (lime) to form
cementitious products. The cementitious products so formed are chemically very
similar to those present in hydrated Portland cement. The pozzolanic reactions occur
slowly at normal atmospheric temperatures. Essentially all fly ashes in the United
States before about 1975 were of this type (Robert V. et al.., 2015).

Class C fly ashes normally result from the burning of subbituminous coal and lignite
such as are found in some of the western states of the United States. They have
pozzolanic properties but may also be self-hardening. That is, when mixed with water
they harden by hydration much the same way Portland cement hardens. In most cases
this initial hardening occurs relatively fast. These materials are referred to as being
cementitious and the degree of cementitiousness generally varies with the calcium
oxide (CaO) content of the fly ash. Higher values of CaO denote higher
cementitiousness. This type of fly ash has become available in large quantities in the
United States only in the last few years as the western coal fields have been opened
(Robert V. et al.., 2015).

Concrete is a flexible construction material that is usually made by combining cement

water with aggregate (sand and gravel) and contributes between 5% and 8% of global
greenhouse gas emissions (Nawaz Abbasi et al., 2010). Every year, around one ton of
conerete is generated for each person on the earth, according to estimates (Nawaz
Abbasi et al., 2010), that’s around 10 billion tons of concrete per year. Such a large-
scale use of traditional concrete would result in a serious depletion of naturally
available virgin resources, compromising the goal of sustainable development and
polluting the environment by contributing 6-7 percent to CO2 emissions. Previous
study has shown that coal combustion by-products may be used in concrete with good
results when fly ash is used as a supplemental cementitious material and BA is used to
partially or completely replace fine aggregate in concrete (Mangi et al., 2019). This
study looks into the viability of using coal by-products (fly ash and bottom ash) as
supplemental cementitious materials and fine aggregate in concrete to improve the
mechanical qualities of the material (Nawaz Abbasi et al., 2010).
 3

1.2 FLY ASH AS SUPPLEMENTARY CEMENTOUS

MATERIAL

The most common coal by-product is fly ash, which is produced when coal is burned.
It's a hazy, extremely fine particulate substance (made of small particles of burned
coal).

In coal-fired furnaces, it is created alongside flue gases. Non-burnable materials

accumulate in furnaces and settle to the bottom, generating bottom ash, while lighter
fine material reacts with gases and is released, forming fly ash, which is recovered
from coal-fired power plants' precipitators. In most cases, this coal by-product is
made up of around 70% to 85% fly ash, with the remainder being bottom ash or slag.
The mineralogy, physical properties, and chemical makeup of fly ash differ from one
source to the next. However, the content of silicon dioxide SIO, both in amorphous
and crystalline form, Alumina Oxide Al2O3, and, most crucially, calcium oxide CaO,
determines the overall composition of fly ash. Almost all fly ash contains these
chemicals as the major ingredients. These are non-energetic compounds that form as a
byproduct when coal is burned. Fly ash possesses pozzolanic and cementous qualities
due to its porosity, particulate size particles, and hazy texture (A.M Neville, and J.
Brook, 1990). Fly ash made from lignite or sub-bituminous coal has pozzolanic
characteristics and is particularly valuable. The majority of this form of fly ash is
categorized as C type by ASTM, meaning it contains more than 10% lime (A.M
Neville, and J. Brook, 1990).

1.3 PROBLEM STATEMENT

 Coal-fired power stations generate a large amount of waste products, such as

fly ash, flue ash, and bottom ash, which are difficult to handle and pose
serious environmental risks if left untreated.

 The typical concrete created from virgin ingredients depletes materials,

ultimately degrading the needs of future generations. We may orient ourselves
to reuse these waste items and more sustainable concrete to take into account
these excessive situations -environmental dangers and non-sustainability.
 4

 The waste obtained from coal power plants creating health problems for local
residents as such wastes are dumped inappropriately.

 There have been a slew of study articles published on concrete manufacturing

including coal plant fly ash from different power plants, all of which have
yielded positive outcomes.

1.4 AIM AND OBJECTIVES

The main goal of this study is to investigate the effects of utilization of fly ash in fresh
and hardened properties of concrete. The object of this research work is;

1. To determine the effects of fly ash on fresh property (i.e. Workability) of

concrete by partially replacing fine aggregate.

2. To determine the effects of fly ash on hardened properties (i.e. Compressive

and Tensile Strength) of concrete by partially replacing fine aggregate.

3. Comparative analysis of hardened properties of concrete.

1.5 SCOPE OF STUDY

In this study, concrete was developed with a 28MPa characteristic strength and a DOE
mix design method ratio of 1:1.89:3.56 was reached at a w/c ratio of 0.55. A total of
36 cubes with standard sizes of 150mm x150mm x150mm and 12 cylinders with sizes
of 150mm x300mm were cast for this mix. A total of four distinct fly ash percentages
used were 0, 10, 20, and 30% by weight of fine aggregate. 12 cubes and 3 cylinders
were casted for each blend. 3 cubes of each combination Compressive strength was
tested after 7, 14, and 28 days of curing. Workability for specific mix was determined
by Slump Cone test. The Compressive and Tensile strength were tested on UTM.

1.6 LIMITATION OF STUDY

Only two hardened properties of concrete, namely compressive and cracking tensile,
were seen in this study's laboratory tentative examination. All raw material and
concrete laboratory testing were carried out in accordance with British Standard (BS),
among other standards. Set of recommendations for fly ash concrete are based on a
 5

small number of data results produced experimentally in the lab and may have some
accuracy limitations.

1.7 OUTLINES OF THESIS

Thesis arrangement is organized as

Chapter No. 01: Introduction: In this chapter a momentary synopsis of entire research
is given.

Chapter No. 02: Literature Review: This chapter comprises of contours of prior study
done on fly ash in concrete is described.

Chapter No. 03: Materials and Methodology: This chapter incorporates the transitory
narrative of materials sourced and procedure implemented for recommended study.

Chapter No. 04: Results and Discussion: This chapter contains different laboratory
results compiled and data analysis.

Chapter No. 05: Conclusions and Future Recommendations: It is a last chapter and it
contains the validation of the study and study findings also further recommendation is
prescribed.
 CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

This chapter comprises of previous research outcomes correlated to norm of fly ash
used in concrete.

2.2 FLY ASH AS COAL COMBUSTION BY-PRODUCT

After coal incineration, fly ash is the scum of organic and inorganic affluences that
remain in the coal. Fly ash and bottom ash are the two types of ash produced from
coal ash. Fly ash is a fine powdered particle with a grey hue that is produced as a
waste product in coal-fired power plants. Fly ash (also known as flue ash) is created
when non-burnable elements in coal manifest themselves. All combustible substances,
such as carbon, burn when coal is burned in boilers, whereas non-combustible
materials result in coal ash (M.D. A. Thomas, n.d.). Gases produced in furnaces carry
very fine and lighter ash particles to the chimney outlet. Previously, electrostatic
precipitators were put on the stacks to catch ash particles in the flue gases. (Nawaz
Abbasi et al., 2010). This non-combustible residue produced from the electrostatic
precipitators known as fly ash, whereas the un-brunt matter that is left at the bottom of
furnace is characterized as bottom ash (Nawaz Abbasi et al., 2010).

Figure 2.1: FESEM image of coal fly ash (Rafieizonooz et al., 2016)

6
 7

2.3 HISTORY OF USAGE OF COAL ASHES IN CONCRETE

Since over 1,000 years, concrete made from ashes and other pozzolans elements has
been utilised in civil engineering projects. Certain volcanic elements, today called as
pozzolans, were pulverised and blended with sand and lime to form a putty material
(mortar) that appeared to be cementations, water resistant, and exceedingly strong,
according to the Greeks and Romans. As an example, The Pantheon in Rome was
erected in 128 A.D. Today, ashes produced by coal thermal plants have similar
properties to the volcanic ashes used by The Romans.

Table 2.1: Historical Uses of Coal Fly Ash in Construction

Name of Project Construction Period

The Pantheon of Rome 128 A.D

Hoover Dam spillway tunnel, USA 1942

Horse Dam at Montana, Hungary. 1948-52

Portland cement replaced about 35%
With coal fly ash.

Metro subway system Washington, D.C, 1980s

USA.

Summer Olympics Stadium in Atlanta 1996

2.4 PRODUCTION OF FLY ASH IN THAR COAL POWER

PLANT

Pakistan is rich in coal resources and has the capacity to energise country for at least
200 years, with 185 billion tonnes of coal deposited over an area more than 9100
square kilometers. Tharparkar coal is a high volatile Lignite "B" class coal with 6.83
percent Ash and 29.55 percent volatile stuff (Nawaz Abbasi et al., 2010). Block IL
(which has 1% of 175 trillion tons of coal and can create 5000 MW for 50 years) just
started up its two units, each of which generates 660 MW and consumes 13440 tons
of coal per day at full capacity, producing 1344 tons of ash per day (Mott Mac
Donald, 2017).
 8

2.5 ENVIRONMENTAL IMPACTS OF FLY ASH

Coal mining and burning have a major impact on the ecosystem around it, especially
where mining is taking place. Mining activities have an impact on ground water, land
siting, water blocking due to ash dumps, ecosystems beneath water, and air pollution
as a result of coal exploration activities (Engro Report, 2014). Coal combustion in
power plants has a slew of negative consequences for the environment and human
health. When ashes from coal burning are disposed of on the ground under leaching
action, the ashes will make their way into underground water, producing pollution
(Mareal Pires et al; 2000; Liuguijian, 2000 a).

2.6 CHEMICAL COMPOSITION OF THAR COAL FLY ASH

Thar Coal fly ash is C type -ASTM classification- with high calcium content. (Nawaz
Abbasi et al., 2010) analyze the Thar Coal and found the ash composition as shown
below in chart.

Composition of Fly Ash

0.32
2.7
S iO 2
3.6 3
3 A l2 O3
F e20
4.5 27.15 C ao
4.8 MgO
SO3
5
K 2O
Na2O
MnO
18.5 17.5
P205
TiO2

Figure 2.2: Chemical composition of thar coal fly ash (nawaz abbasi et al., 2010)
 9

The chemical composition of fly ash is mostly determined by the coal source's
makeup. As a result, attributes differ from one source to the next. The qualities of fly
ash may be influenced by the coal plant's burning conditions, as well. The coal fly ash
is divided into two groups by the ASTM C618 Standard Specification for Coal Fly
Ash, which is based on the origin and composition of the ash. As a result, coal ash
produced from lignite or sub-bituminous coals that meets the chemical requirement
(SI02 + A12 03 + Fe2 03 2 70%) is classified as class F fly ash, while fly ash
containing Si02 + AI2 03 + Fe2 03 2 50% and produced from lignite or sub-
bituminous coal is classified as class C fly ash.

2.7 USES OF FLY ASH IN CONSTRUCTION

Below are the possible uses of fly ash Jamshoro Power Generation Project-18 Ash

Management Plan, 2016).

1) Concrete production, as a substitute for Portland cement and sand

2) Embankments and other structural fills (usually for road construction)

3) Grout and Flowable fill production

4) Grout and Flowable fill production

5) Cement clinkers production - (as a substitute material for clay)

6) Stabilization of soft soils

7) Road subbase construction

8) Aggregate substitute material for brick production

9) Mineral filler in asphaltic concrete

10) Ash brick manufacturing at location of Thermal Power Plant itself. Usually,
topsoil is used for brick manufacture. Topsoil is suitable for Irrigation. The
uses of Fly ash brick stop the depletion of topsoil.
 10

2.8 CHEMICAL ACTION OF FLY ASH IN CONCRETE

Coal fly ash is a pozzolanic byproduct of coal combustion. It comprises alumino-

silicate with varying percentages of calcium content when finely spread. When
calcium-silicate hydrate (C-S-H) and calcium-aluminate hydrates are mixed with OPC
(Ordinary Portland Cement) and water, they begin to react with Calcium Hydroxide
(Ca (OH)2) generated by the hydration of OPC to form calcium-silicate hydrate (C-S-
H) and calcium-aluminate hydrates. In the absence of a supply of calcium hydroxide,
however, fly ash with a higher calcium concentration appears to have cementitious
qualities when it combines with water and creates calcium-silicate-hydrate.

Because of pozzolanic reactions, the quantity of cementitious binder phase i.e.

calcium- silicate-hydrate (C-S-H) and to small extent calcium aluminate that could
enhance the long term strength and increase the density and minimize the
permeability of system.

2.9 EFFECT OF FLY ASH ON PROPERTIES OF CONCRETE

The impact of fly ash on concrete structural characteristics are mostly positive. There
have been a slew of studies on concrete with fly ash as a cement substitute that have
yielded a variety of results. The findings of such a replacement, which include the
impacts of fly ash on hardened and fresh characteristics, are as follows.

2.9.1 Workability

Siddique (2004) investigated the partial substitution of cement with fly ash and
discovered that by replacing up to 55 percent of the binder with CFA, concrete
workability improves.

According to Dr. Michael Thomas' findings, a good quality fly with a high level of
fineness and low carbon content reduces water demand, allowing concrete with the
same workability to be produced with less water. In addition, as compared to a
Portland cement concrete of the same slump, a well-proportioned fly ash concrete
mixture will have better workability.
 11

Figure 2.3: Impact of fly ash on water demand of concrete. (M Thomas et al., 2002)

2.9.2 Compressive Strength

Tariq (2017) conducted an experimental study on strength and durability of cement

and concrete by partial replacement of fine aggregate with fly ash. Results showed
that, Addition of fly ash as an admixture in replacement of cement enhanced strength
properties of cement and concrete up to a limit. At 10% fly ash cured for 28 days
maximum compressive and tensile strength was achieved.

From (Dr M Thomas et al., 2002) research finding it is concluded that with increasing
the level of replacement of fly ash the early-age strength decreases. But long-term
strength almost same as that of Portland cement concrete. It is also found that the
ultimate strength achieved by the concrete increases with increasing fly ash content, at
least with replacement levels to 50%.
 12

Figure 2.4: Effect of fly ash on compressive strength development. (Dr. M Thomas
et al., 2002)

2.9.3 Effect of Fly Ash on Other Properties of Concrete

At low and medium levels of replacement, the presence of fly ash has no significant
effect on the relationships between tensile strength, flexural strength, and elastic
modulus, as well as compressive strength of concrete (Kesharwani, and Kumar
Biswas, 2017).

The long-term flexural and tensile strength of HVFA concrete may be greatly
improved, according to (Malhotra and Mehta et al., 2005), due to the continual
pozzolanic response increasing the binding between paste and aggregates. They
further suggest that because of the limited porosity of the interfacial zone, the elastic
modulus of HVFA concrete could be increased by using large volumes of unreacted
fly ash flakes as fine aggregate.
 13

2.10 CONCLUDING REMARKS

Following the conclusion, a review of the literature is conducted.

Good grade flies with high fineness and low carbon content save water consumption
and boost workability by up to 55 percent as compared to binder.

Early age strength diminishes as percentage replacement increases up to 50%, but

long-term strength is the same as OPC.

Flexural strength grew up to 50% replacement over time. Due to the presence of
unreacted fly ash, which acts as a fine aggregate and reduces porous gaps, the elastic
modulus increased.
 CHAPTER 3

MATERIALS & METHODOLOGY

3.1 INTRODUCTION

This chapter describes materials and methodology that is adopted in this research to
ascertain the behavior of fly ash as replacement of fine aggregate in concrete.

3.2 EXPERIMENTAL PROCEDURE

In this research, methodology adopts to discover the behavior of fly ash as a

replacement of fine aggregate in concrete, to test the mechanical properties of
concrete i.e. Splitting Tensile Strength of Concrete and Compressive Strength of
Concrete. The concrete mix design for target compressive strength of 28 MPa
(allowance for safety) is chosen for the present study. For checking these properties,
12 number of cement concrete standard cylinder of dimensions 150mm x300mm were
cast for splitting tensile strength and total 36 cubes of dimension 150mm x150mm
x150mm were cast for compressive strength. These two types of specimens were cast
by using different percentage of mix ratios at water cement ratio of 0.55. All
specimens were cast by using four proportions of fly ash i.e. 0%, 10%, 20% and 30%
by weight of fine aggregate. Curing age selected for cubes are 7, 14, and 28 days.

During each curing age 3 cubes tested for a given mix (i.e. total 12 cubes- 3cubes of
each fly ash percentage- were tested on each curing age) were tested for compressive
strength. Curing age selected for cylinder testing are 28 days. Further, this research
methodology is described in flow diagram given below.

14
 15

Figure 3.1: Schematic diagram of research study

3.3 MIX DESIGN AND MATERIALS CALCULATION

3.3.1 Mix Design

In this research we design the concrete mix for compressive strength of 28 MPa and
for the following typical specification. DOE mix design used for this purpose.

1) Cement OPC-42.5

2) Max. Aggregate size =20mm crushed

3) Fine aggregate = uncrushed 40% passing from 600-micron sieve

4) Assumed density of concrete = 2410 Kg/m3

5) Considering 5% defective rate

6) Target slump 50 mm

Designed concrete specification from DOE mix design are

1) Taken ratio of ingredient - 1:1.89:3.56

2) w/c-ratio-0.55
 16

3.3.2 Mix Design Table

Table 3.1: Concrete Mix Proportion

MIX PROPORTION (KG/CU.M)

CEME
TRI DESIGN
NT FINE COARSE
AL W(W/C= ED
AGGREG AGGREG
COD 0.55) SLUMP(
CFA% CF CEME ATE ATE
E MM
A NT

M-0 0 0 345 685 189.75 1228.2 50

M-
10 68.5 345 616.5 189.75 1228.2 50
10

M-
20 137 345 548 189.75 1228.2 50
20

M-
30 205.5 345 479.5 189.75 1228.2 50
30

3.3.3 Materials Sourcing

Two categories of samples were made for evaluating the hardened properties i.e.
splitting tensile and compressive strength of concrete. For casting of specimens
following materials were used.

3.3.3.1 Cement

In this study Ordinary Portland Cement -OPC- of grade 42.5 was used, which is being
manufactured under the product name of falcon Cement. Cement obtained from the
local market.

3.3.3.2 Aggregates

Coarse aggregates were taken from Al-saudia Crusher Plant kotri near M-9 motorway,
with maximum size of 19.5mm. Fine aggregate was acquired from well-known
resource of hill sand in Bolahari. Both fine and coarse aggregates were splashed with
drinking water, for detaching the dust, prior to applying in concrete.
 17

3.3.3.3 Water

Drinking quality water from concrete workshop was applied in producing the
concrete.

3.3.3.4 Coal Fly Ash

Fly ash was taken from trade worth certified supplier in Karachi.

3.4 MATERIALS TESTING

All primary tests on cement, aggregates were conducted out in Structural and
Concrete laboratory of Civil Engineering Department. All tests are performed by
following the international code of practice like AST and BS methods.

Description and procedure of material testing is given below.

3.4.1 Preliminary Tests on Cement

Below are the number of tests which conducted on cement for qualifying the
properties of cement and to authorize the obligation of standard code of practice for
OPC.

1) Normal consistency

2) Initial setting time final setting time

3) Fineness of cement
 18

3.4.1.1 Normal Consistency Tests on Cement

This test is done on Vicat’s Apparatus. Following results obtained. It shows that
normal consistency of cement achieved at 0.30 W/C-ratio.

Table 3.2: Normal Consistency of Cement Results

W/C
S.NO CEMENT(gram) WATER(ML) PENETRATION(mm)
RATIO

1 300 0.39 160 40

2 300 0.38 152 40

3 300 0.37 148 40

4 300 0.35 140 40

5 300 0.32 128 35

6 400 0.30 120 5

Figure 3.2: Penetration Curve of OPC

 19

3.4.2 Tests on Aggregate

Aggregate is filler materials in concrete that occupy almost 70 %2 of the concrete

volume. Here in this study we conducted different tests on the aggregate to qualify it
standard code requirement. 3.4.3.1 Gradation of Coarse Aggregates (ASTM C33-921)
Weight of coarse aggregate taken is 4 Kg. sieve analysis done according to ASTM
code guidelines. Following are the test results of gradation of coarse aggregate.

Table 3.3: Sieve Analysis of Coarse Aggregate Result

Weight Percentage Cumulative

SIEVE Cumulative
S.NO retained weight percentage
SIZES wt. retained
(gram) retained wt. passing

1 37.5 0 0 0 100

2 19.5 2761 30.67 30.67 69.33

3 9.5 4866 54.1 84.77 15.263

4 4.75 1261 15.2 99.97 0.03

5 PAN 0.0 0 99.97 0

120

100

80

60

40

20

0
0 5 10 15 20 25 30 35 40

Figure 3.3: Gradation curve of coarse aggregate

 20

3.4.2.1 Gradation of Fine Aggregate Test Results

Sieve analysis of fine aggregate is done to find out its fineness modulus (FM) using
ASTM code guideline. Following table shows the calculation of FM. The weight
taken is 1000 gm. of fine aggregate. Test is carried out using standard methods
according to ASTM code guideline. Results reveals that FM of aggregate is 3.11.

Table 3.4: Sieve Analysis of Fine Aggregate Result

Weight Percentage Cumulative

Cumulative
S.NO Sieve sizes retained weight percentage
wt. retained
(gm.) retained wt. passing

1 4.75 38 3.8 3.8 96.2

2 2.36 55 5.5 9.3 90.7

3 1.18 100 10 19.3 80.7

4 600um 135 13.5 32.8 67.2

5 300um 155 15.5 48.3 51.7

6 100um 492 49.2 97.5 2.5

7 PAN 33 2.5 100 0

 21

3.4.2.2 Specific Gravity of Aggregates

Specific gravity is bulk property of material in which it is density is compared with

that of water. Generally, it the ratio of weight of aggregate to weigh of water of
volume equal to that of aggregate. Sp. Gravity of CA is finding out by Wire basket
Method whereas for FA density bottle method is used. Both tests carried out
according to ASTMIC127=93 code guide line.

Table 3.5: Specific gravity and water absorption of coarse aggregate results

Wight of sample taken 3000gm

SSD weight of sample 3010gm

Weight of netted basket in water 622gm

Wt. of netted basket +sample in water 2477gm

Oven dried sample 2990gm

Water absorption of aggregate 0.67%

Specific gravity of coarse aggregate 2.58

Table 3.6: Specific gravity and water absorption of fine aggregate results

Weight of empty density bottle 165gm

Weight of bottle +SSD fine aggregate sample 665gm

Wt. of bottle + sample +water 975gm

Wt. of bottle + water 665gm

Oven dried soil sample 497gm

Wt. of SSD sample for water absorption 500gm

Water absorption of aggregate 1.02%

Specific gravity of fine aggregate 2.6315

 22

3.5 TESTS ON CONCRETE

In this study tests are conducted for fresh concrete as well as hardened concrete.
Merely one property of green concrete is taken i.e. Workability test is carried on green
concrete.

For hardened concrete two mechanical properties checked out.

1. Compressive strength

2. Splitting tensile strength

Following testing procedures illustrates the testing method for examining the
overhead properties of concrete,

3.5.1 Workability of Fresh Concrete

Workability is the extent of valuable internal work that is necessary to give complete
compaction. In other it is the ease or homogeneity to handle the green concrete. In this
research only slump test is carried out for workability. Test is done on standard size
cone of dimension 200 mm x 100mm x 300mm. Following table will describe the
different values of slump achieved at different replacement percentage of fly ash.

Table 3.7: Workability Test

FLY ASH
MIX CODE SLUMP (mm)
PERCENTAGE

M-0 0 32

M-10 10 18

M-20 20 12

M-30 30 8
 23

Photograph 3.1: Slump cone testing for workability of concrete

3.5.2 Compressive Strength of Concrete

Concrete is represented by compressive strength. Compressive strength is one of the

important properties of harden concrete, which gives overall picture of quality of
concrete.

For compressive strength of concrete, we cast cubes of 150mm x150mm x150mm

size were tested in UTM following the standard procedure. Compressive strength of
concrete is calculated by following the equation.

Fc’=P/A

Whereas P= Maximum crushing load and

A = cross-sectional area of cylinder or contact area fc' = characteristics compressive

strength of concrete.
 24

Photograph 3.2: Cubes testing in UTM for compressive strength

3.5.3 Splitting Tensile Strength of Concrete

Splitting tensile is indirect way of determining the tensile strength of concrete by

using diagonal crushing strength of standard size cylinder. In this research we use
cylinder of size 150mm × 300mm". Cylinder was tested in UTM on 28 days curing
age. The splitting tensile strength (fst) is then calculate using equation.

𝟐𝑷
Fst= 𝝅𝒅𝒍

Where, P= Maximum load

I= Length of cylinder and d= diameter of cylinder

 25

Photograph 3.3: Splitting Tensile Strength test on UTM

 CHAPTER 4

RESULTS AND DISCUSSION

4.1 INTRODUCTION

This chapter describe the material testing results. The results are analyzed to obtain
the effects of fly ash as partial replacement of fine aggregate in concrete, compare to
conventional concrete.

For this act, concrete is design for characteristics strength of 28 MPa and DOE mix
design procedure ratio achieved is 1:1.89:3.56 @ W/C ratio of 0.55. For this mix
cumulative of 36 cubes with standard size of 150mm x 150mm x 150mm and 12
cylinders of size 100mm x 300mm were casted. Total 4 mixes of different percentage
of fly ash of 0, 10, 20 and 30% of concrete were prepared. For each mix 12 cubes and
3 cylinders were prepared. 3 cubes of each mix compressive strength were tested on 7,
14, and 28 days of curing age. 3 cylinders of each mix were tested for indirect tensile
strength at curing age of 28 days only. Workability for each mix was obtained by
slump cone test. The compressive and tensile strength were tested on UTM at Isra
University Hyderabad.

4.2 WORKABILITY TEST RESULTS

For determining the workability of concrete slump test is performed on every mix
design. Total 3 tests were carried out for slump test of each fly ash percentage
replacement. Slump test was done using standard method with slump cone of
dimension 200mmx100mmx300mm. Table 4.1 show the slump test results at different
percentages of fly ash replaced with fine aggregate. Maximum slump difference
obtained is 32 mm at 0 % fly ash replacement. However, the different percentage
design slump was assumed as 18 mm at 10%, 12 mm at 20% and 8mm at 30% at 0.55
W/C-ratio. It is a clear evident from the above tabulated data that there was a trend
appeared in the concrete mix when fine aggregate is replaced with Fly ash. Figure 4.1
shows that with increasing fly ash percentage the workability of concrete decreases.
decrease in slump is 43.75%, 62.5% and 75% at 10%, 20% and 30% replacement of
fine aggregate with fly ash, respectively. The decrease in workability might be due to
amount of fine aggregate is reduced and fly ash content increment so does the amount

26
 27

of water need for hydration. In addition to it, the shape of fly ash particles is spherical
generally, due to this reason particles creates balling action (i.e. easily rolling of
spherical particles over one another). Thus, the balling action reduces the friction
between particles of cement and aggregates as well which results in increased
mobility of concrete to flow easily.

Table 4.1: Slump test results for fly ash replacement

Fly ash Slump

S.NO Mix LD (%) (mm)

1 M-0 0 32

2 M-10 10 18

3 M-20 20 12

4 M-30 30 8

Slump vs % Fly ash replacement

35 32
30
25
SLUMP (mm)

20 18

15 12

10 8

5
0
0 5 10 15 20 25 30 35
% of FA replaced with fly ash

Figure 4.1: Relationship between slump and percentage fly ash replacement
 28

4.3 COMPRESSIVE STRENGTH TEST RESULTS AND

ANALYSIS

4.3.1 7-Days Compressive Strength

Compressive strength test results at 7 days curing age are listed in Table 4.2 and plotted
in Figure 4.1. It is clearly seen that concrete mix with FA replacement with fine
aggregate has a bit higher compressive strength than the conventional mix. The
compressive strength of concrete (with design mix of 1:1.89:3.56) increases to 18% at
10% and then decreases to 18.8% and 16.11% at 20% and 30% replacement of fine
aggregate with FA, respectively. This increase in compressive strength at 10%
replacement may be due to vary in chemical and physical characteristics of FA to that
of typical cement composition. Improvement in strength can also be due to the
improved density of concrete, as size of fly ash grains is generally smaller than the fine
aggregate particles. However, this increment is up to certain amount of replacement, if
FA increased more than 10% the strength decreases. Moreover, adding more fly ash in
concrete the free water content in mix raises further which cause decrease in strength.

Table 4.2: 7-days compressive strength results

Max. Avg. Avg.

Fly ash Strength
S.NO Batch ID load Strength Strength
(%) (MPa)
(KN) (MPa) (Psi)
1 M-0-7 431.5 19.17
2 M-0-7 0 431 19.11 19.335 2804.3
3 M-0-7 443 19.68
4 M-10-7 514.2 22.85
5 M-10-7 10 527.6 23.44 22.82 3309.7
6 M-10-7 498.7 22.16
7 M-20-7 383.4 17.02
8 M-20-7 20 315.1 14.1 15.7 2277.1
9 M-20-7 362.3 16.1
10 M-30-7 408.6 18.16
11 M-30-7 30 443.35 19.7 16.22 2352.8
12 M-30-7 468.1 20.8
 29

7 Days Compressive Strength Results

25 22.82

Compressive strength (MPa)

19.32 19.55
20
15.7
15

10

0
0 10 20 30
% Fly ash replacement

Figure 4.2: 7-days compressive strength results

4.3.2 14-Days Compressive Strength

Compressive strength results of 14 days are tabulated in table 4-3 given below.
Generally, 14 days strength testing is sufficient for analysis and indicative of early age
strength of concrete, used for quality assurance for removing formwork. 14 days
strength check done to indicate the strength gain rate of concrete specimen.
Compressive strength tested on 14 days curing age are listed in Table 4-3 and plotted
in Figure 4.3 against percentage replacement with Fly ash, that show a mixed trend. It
is clearly seen that concrete mix with FA replacement have a bit higher compressive
strength than conventional mix. 14 days compressive strength of concrete, when
tested at designed ratio of 1:1.89:3.56 mix ratio; increases 25.27% 4.82%, at 10% and
20% replacement of cement with fly ash respectively and decreases 2.32% at 30%.
While strength gain rate for conventional mix is more than that of other Fly ash
replaced mix. 14 days strengths increase are 28.2%, 36.1%, 65.47%, 49.3% for 0%,
10%, 20%, 30% replacement with FA mix, respectively as compared to strength at 7
days. This indicate that strength gain rate for conventional is more than that of other
FA replaced mix.
 30

Table 4.3: 14-days compressive strength results

Max. Avg. Avg.

Fly ash Strength
S.NO Batch ID load Strength Strength
(%) (MPa)
(KN) (MPa) (Psi)

1 M-0-14 556.1 24.72

2 M-0-14 0 574.1 25.51 24.79 3594.9

3 M-0-14 542.8 24.12

4 M-10-14 695.6 30.92

5 M-10-14 10 690.95 30.7 31.05 4503.4

6 M-10-14 709.65 31.54

7 M-20-14 572 25.42

8 M-20-14 20 581 25.82 25.98 3768.1

9 M-20-14 601.3 26.71

10 M-30-14 548.8 24.39

11 M-30-14 30 531.35 23.62 24.21 3511.4

12 M-30-14 554.75 24.65

14 Days Compressive Strength Results

35
31.05
Compressive strength (MPa)

30
24.78 25.98
24.21
25
20
15
10
5
0
0 10 20 30
% Fly ash replacement

Figure 4.3: 14-days compressive strength results

 31

4.3.3 28-Days Compressive Strength

Compressive strength test results at 28 days curing age are tabulated in table 4-4 and
shown in figure 4.4. The strength at 28 days curing age is critical and standard for
indication of long-term strength of the structures. From testing it was observed that
the mix containing 10%, 20% and 30% FA improves compressive strength over
conventional mix about 31.2% and 3.41% and 2.21% respectively as compared to
conventional mix.

Table 4.4: 28-days compressive strength results

Max. Avg. Avg.

Fly ash Strength
S.NO Batch ID load Strength Strength
(%) (MPa)
(KN) (MPa) (Psi)

1 M-0-28 624.2 27.74

2 M-0-28 0 619.6 27.54 27.53 3992.9

3 M-0-28 614.7 27.32

4 M-10-28 826.5 36.73

5 M-10-28 10 790.8 35.15 36.13 5240.2

6 M-10-28 813.4 36.15

7 M-20-28 616.2 27.4

8 M-20-28 20 661.8 29.4 28.47 4168.4

9 M-20-28 643.6 28.6

10 M-30-28 616.1 27.4

11 M-30-28 30 681.25 30.3 28.14 4080.8

12 M-30-28 601.95 26.75

 32

28 Days Compressive Strength Results

40 36.011

Compressive strength (MPa)

35
30 27.53 28.47 28.136

25
20
15
10
5
0
0 10 20 30
% Fly ash replacement

Figure 4.4: 28-days compressive test results

4.4 COMPARATIVE ANALYSIS OF COMPRESSIVE

STRENGTH

Figure 4.5 show all compressive strength results and indicate the basis for comparison
of 7,14- and 28-days results. A mixed trend is observed for the different fly ash
replacement percentage. This comparison is done with the mix of no-fly ash content
or conventional mix. Generally, it shows increase of compressive strength with
addition of fly ash and this increment is maximum for 10% replacement. At the other
hand, the trend of strength gain rate observed is; for early 7 days curing the strength
gain rate for fly ash content is fast as compared to conventional mix that might be due
to high calcium content in fly ash that may cause increase hydraulic reactivity of fly
ash and produce hydrates (-S-H) in the absence of a source of calcium hydroxide
which give more strength to fly ash content mix as compared to conventional mix. At
the other hand for other curing age strength gain might be due to pozzolanic behavior
and these reactions are gradual, so strength gain rate is slow as compared to
conventional mix.

After analysis of results that depicts in above figure it can clearly indicates that with
adding fly ash in concrete as partial replacement of fine aggregate the 7 days
compressive strength of concrete increases about 18% at 10% and then decreases to
18.8% and 16.11% at 20% and 30% replacement of fine aggregate. At 14 days curing
the mixes with 20% and 30% fly ash show almost same strength to that of
 33

conventional concrete but mix that contain 10% fly ash show 25.27% more strength
than that of conventional mix at 14 days. Strength gain rate is highest for 0% fly ash
concrete mix and lowest of 30% fly ash concrete mix. This show with increasing fly
ash content the strength gain rate is slow. This slow rate of strength is due to
pozzolanic activities in concrete due to fly ash. Strength indicative at 28 days curing
show all mixes show nearly the strength same with some variability up or down. At
28 days curing the highest strength achieved is 36.011 MPa for 10% fly ash
replacement mix which is about 30.8% more than that of conventional mix strength
(27.53 MPa), for mixes with 20% fly ash show 28.47 MPa which is about 3.41%
more than that of conventional mix strength at 28 days. And 30% fly ash content mix
show almost same strength of 28.136 MPa that is 2.21% more strength than that of
conventional mix. All results reveal a mixed trend, by adding fly ash in concrete up to
10% replacement of fine aggregate the compressive strength of concrete improved.
This mix trend strength variation is might be due to following reasons:

1. As fly ash contains high calcium content that may cause both hydraulic and
pozzolanic behavior of fly ash in concrete and improve early age compressive
strength.

2. Long term compressive strength increases might be due to continuing

pozzolanic reactions and presence of significant amount of unreacted fly ash
particles which act as fine aggregate cause very low porosity on interfacial
regions.

For the sole purpose of generating a more economical concrete mix that is more
suitable for use in the construction industry, curing time is important from
construction point of view and must be kept to the standard 28 days. This curing time
for concrete is powered by the strict deadline and timeframe that must be met during
the construction without delaying the whole work schedule. For the mix, the strength
gain may be expected to enhance well beyond 28 days and continue past the
compressive strength of the no fly ash mix.
 34

Table 4.5: Comparative results of compressive strength

7-days 14-days 28-days % increase

Fly ash
Mix LD strength strength strength of 28 days
(%) strength
(MPa) (MPa) (MPa)

M-0 0 19.32 24.78 27.53 100

M-1 10 22.82 31.05 36.011 30.8

M-2 20 15.7 25.98 28.47 3.4144

M-3 30 19.55 24.21 28.136 2.17

Comparison of the compressive strength

40 36.011
Compressive strength (MPa)

35 31.05
27.53 28.47 28.136
3024.78 25.98
22.82 24.21
2519.32 19.55
20 15.7
15
10
5
0
0 5 10 15 20 25 30 35
% Fly ash replacement

7 Days Curing 14 Days Curing 28 Days Curing

Figure 4.5: Comparative results of compressive strength

 35

4.5 TENSILE STRENGTH RESULTS AND ANALYSIS

Tensile strength of concrete was determined by splitting tensile test. The standard
cylinders were tested at 28 days curing age. Concrete cylinders were tested in
universal testing machine and failure load was observed than splitting tensile strength
was obtained by formula given below:

𝟐𝑷
T= 𝝅𝒅𝒍

The tensile strength results of conventional concrete and FA substituted concrete were
tabulated in Table 4-6 and Figure 4.6. Tests results revealed that the splitting tensile
strength of concrete after 28 days curing age with 10, 20 and 30% replacement of fine
aggregate with fly ash increased up to 35.2% and 22.9% and 18.24% respectively as
compared to the conventional concrete. This increase in tensile strength may be due to
ongoing pozzolanic reactions that strengthening the bond between paste and aggregate
and denser concrete.

Table 4.6: Splitting tensile strength results

Max. Avg. Avg.

Fly ash Strength
S.NO Batch ID load Strength Strength
(%) (MPa)
(KN) (MPa) (Psi)
1 M-0-28 153.7 3.26
2 M-0-28 0 149.3 3.168 3.18 460.93
3 M-0-28 146.5 3.11
4 M-10-28 202.1 4.29
5 M-10-28 10 200.3 4.25 4.3 624.38
6 M-10-28 206.8 4.38
7 M-20-28 182.3 3.87
8 M-20-28 20 178.4 3.78 3.91 566.6
9 M-20-28 192.2 4.07
10 M-30-28 197 4.18
11 M-30-28 30 174.4 3.7 3.76 545.34
12 M-30-28 160.55 3.4
 36

28 Days indirect tensile Strength Results

5
4.5 4.31
3.91 3.76

tensile strength (MPa)

4
3.5 3.18
3
2.5
2
1.5
1
0.5
0
0 10 20 30
% Fly ash replacement

Figure 4.6: Splitting tensile strength results

 CHAPTER 5

CONCLUSION AND FUTURE RECOMMENDATIONS

The aim of this research is to study the behavior of conventional concrete when fine
aggregate is partially replaced with fly ash. For that workability and mechanical
properties of concrete were examined in laboratory and based on experimental
investigation following conclusion can be drawn:

5.1 CONCLUSION

After analysis of the tests results and their comparison with conventional concrete
following conclusions could be drawn.

1. Addition of fly ash in concrete as partial replacement of fine aggregate

degrade the consistency (workability) of concrete. Test results clearly indicate
that there is an indirect relationship between percentage of fly ash content and
slump value (workability).

2. It was observed that maximum value of compressive strength occurred at 10%

replacement of fine aggregate with fly ash for all curing age.

3. It was observed that partial replacement of fine aggregate with 20 and 30%
comparatively same with each other and slightly less difference to that of
conventional concrete.

4. For optimum replacement of fine aggregate for both early and long-term
strength, it is commended to use 10% fly ash. However, in cases where early
strength is not significantly important and if minor compromise in 28-days
strength is accepted, then 30% fine aggregate with fly ash is recommended.

5. Likewise, Optimum value of splitting tensile strength of concrete at

1:1.89:3.56 mix ratio; is increase of 31.2% at 10% addition of fly ash.
Therefore, 10% addition of fly ash in concrete as partial replacement of fine
aggregate can enhance splitting tensile strength.

37
 38

6. Moreover, the results have clearly revealed that fly ash can increase the
compressive strength and enhance several other mechanical properties of
concrete as compared to conventional concrete. Taking into all these
considerations along with substantial recompenses both economically and
environmentally, replacement of fine aggregate with fly ash will prove to be
most worthwhile and beneficial in construction industry.

5.2 FUTURE RECOMMENDATION SUGGESTIONS

To recommend fully the use of fly ash as partial replacement of fine aggregate still
require detailed investigations with wider scope. However, under the scope of this
study, test results show considerable improvement in mechanical properties of
concrete. As, fly ash source is not much explored yet and very limited number of
studies are available, so there is a strong need of detail testing and analysis of
mechanical properties by varying the percentage replacement at different mix
proportions and W/C ratio. In addition to mechanical properties, durability is one of
the critical problems when conventional fine aggregate is replaced with any type of
fly ash. Therefore, durability properties should also be investigated to know the long-
term behavior of fly ash in structural concrete.
 39

REFERENCES

Ahmed Memon, F., Ahmed Memon, N., All Memon, R., Professor, A., & Professor,
A. Study of Compressive Strength of Concrete with Coal Power Plant Fly Ash as
Partial Replacement of Cement and Fine Aggregate.

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