USE OF FLY ASH IN CONCRETE: A REVIEW

Transcription

1 Journal of Latest Technology in Engineering & Management (IJLTEM) ISSN: USE OF FLY ASH IN CONCRETE: A REVIEW Abstract: Portland cement concrete industry has grown in recent years. The demand for Portland cement concrete material has increased due to increases in infrastructure. Fly ash concrete has economic and environmental advantage. It also makes concrete sustainable. This paper presents a general review of fly ash derived from the combustion of fossil coal for energy production. Fly ash is generally considered as a waste material and the physical, chemical properties of fly ash are similar to cement, which allows us to use in In India, less than 50% of fly ash is consumed and cement is responsible for 7% of total world carbon dioxide emissions. Carbon dioxide is the main threat in causing global warming and all attempts have been made to reduce carbon dioxide emission in environment but cement has not found a suitable replacement for it till date. Fly ash concrete is an effort in reducing cement content of construction. This paper presents a detailed review about fly ash in The effect of fly ash on compressive strength, tensile strength, surface tensile strength, flexural strength is discussed in this paper. Keywords - Concrete, Cement, Fly ash, Marine environment, Admixture, Polypropylene Fiber, Steel fiber. INTRODUCTION Fly ash is a by-product of coal-based thermal power plants. A Huge quantity of fly ash generated at coal based thermal power plant if not managed pollutes the air, water, and soil but fly ash is also a useful resource material. When pulverized coal is burnt to generate heat, the residue contains 80% fly ash and 20% bottom ash. The ash carried away by flue gas collected at economizer, air pre-heater and ESP hoppers. Clinker type ash collected in the water impounded hopper below the boiler is called bottom ash (Parisarmahiti.kar.nic, 2007). Thermal power plants in India consume about million tons of coal and produce near about MW power. This produces approximately million tons of fly ash out of which only 63.97% is being utilized for production of cement, construction of embankments and roads, mine filling, agriculture, making bricks, tiles and building materials, etc. (Central Electricity Authority ) [12] Besides that, other materials like fertilizers, steel, paper, chemical, etc. A major problem faced by many industries worldwide is the handling and disposal of fly ash which gets generated in uncontrollable volume. Table.1. Fly ash generation and utilization during the year 2011 to 2016 Description Some thermal power stations Installed capacity (MW). Coal consumed (Million tons). Average ash content (%). Fly ash generation (Million tons) Volume 2 Issue 2 page 27

2 Fly ash utilization (Million tons) % utilization (Source: Central Electricity Authority 2011 to 2016)[12] In the year of , it is expected that increase the production of fly ash around MT/year. A large amount of fly ash produced if not utilized in the right direction then it will be hazardous to the environment. Table.2. Fly ash utilization during the year ( ) S.Nu. Mode of utilization. Utilization (Million % utilization. tons). 1. Cement Mine filling Bricks and tiles Reclamation of low-lying area. 5. Ash dyke rising Roads and fly over Agriculture Concrete Hydropower sector Others Total (Source: CEA annual report )[13] Utilization (Million tons) Cement. Mine filling. Bricks and tiles. Reclamation of low lying area. Ash dyke rising. Roads and fly over. Agriculture. Concrete. Hydropower sector. Others. Fig.1- Utilization of fly ash Volume 2 Issue 2 page 28

3 % utilization Fig.2- %Utilization of fly ash Cement. Mine filling. Bricks and tiles. Reclamation of low lying area. Ash dyke rising. Roads and fly over. Agriculture. Concrete. Hydropower sector. Others. In the cement sector, the utilization is in the year In road and flyovers sectors the utilization is 3.32%. These two sectors increased a lot in last few years. Table.3. Fly ash generation and utilization during the period to S.Nu. Year. Fly ash generation Fly ash utilization % Utilization. (Million ton). (Million ton) Volume 2 Issue 2 page 29

4 Fly ash generation (Million ton). Fly ash utilization (Million ton). % Utilization Fig.3- Fly ash generation and utilization during the period to Since to increase in fly ash production observed so the consumption (9.63% in to 60.97% in ). Type of ash used (Mihirrathod et.al.)[18]:- i. Fly ash: - This kind of ash is extracted from flue gasses through electrostatic precipitator in dry from. This ash is fine materials and possesses good pozzolanic property. ii. Bottom ash: - This kind of ash is collected in the bottom of the boiler furnace. It is comparatively coarse materials and contains higher unburnt carbon. It possesses zero or little pozzolanic property. iii. Pond ash: - Both fly ash and bottom ash with a large quantity of water to make it in slurry form and deposited in ponds wherein water gets drained away. iv. Mound ash: - Fly ash and bottom ash or both mixed in any proportion and deposited in dry form in the shape of a mound is termed as mound ash. Physical properties of fly ash: - i. Very fine. ii. Light weight (Density: g/cc). iii. Spherical (Specific surface area, cm 2 /g with diameter= u). iv. FA is grey to blackish grey and is dependent on coal type and combustion process. v. FA has dielectric property. Chemical properties of fly ash: - i. Fly ash content Sio 2, Al 2 o 3, Fe 2 o 3, Cao, Mgo. ii. Fly ash is classified into two class- class C and class F. This class is based on the amount of lime. a. Class C- Lignite and sub-bituminous coal (>10% Cao). b. Class F- Bituminous (<10% Cao). Oxides of silicon, aluminum, calcium and iron in FA are responsible for pozzolanic activity which decreases by the loss of ignitions. Volume 2 Issue 2 page 30

5 Table.4. A typical chemical composition of fly ash: - Content % by mass CaO SiO Al 2 O Fe 2 O SO MgO TiO Na 2 O K 2 O Other alkaline & unidentified LOI Table.5. The effect of fly ash on the properties of (Norshahrizannordin et.al.)[17]:- Property. Effects of fly ash. Fresh concrete 1. Improved workability. 2. Reduced water demands for most fly ash. 3. Produced concrete with more cohesive and segregate less improved pump ability. 4. Reduced bleeding especially at high replacement level. Set time 1. Extended especially in cold water. 2. Can increase or retarded the setting time for the certain combination of fly ash. Heat of hydration 1. Reduced for class F fly ash at a normal level of replacement but class C fly ash at a higher level of replacement. 2. Increased in a reduction by using high levels of replacements. Permeability and chloride resistance 1. Reduced by time Expansion 1. Reduced. 2. Sufficient levels of replacement can completely suppress deleteriously. Resistance to carbonation 1. Decreased when a high level of fly ash are used in poorly curved, low strength Effluent and disposal of fly ash (Manoj Kumar Tiwari et.al.)[19]: - The high disposal cost is a Rs /MT and large area of land required for disposal of fly ash. This is the major problem with coal based thermal power plant. All elements below 92 atomic numbers are present in coal ash. According to the environmental agency of Japan [JEAN, 1973]. Shows that coal ash satisfies the criteria for landfill disposal. According to the hazardous waste management and handle rule of 1989, fly ash is considered as non-hazardous. Fly ash disposal in ash pond, the total land requires for ash disposal would be about 82,200 ha by the year 2020 at an estimated 0.6 ha per MW. Fly ash can be treated as a by-product rather than waste (Matani, 1982). Fly ash- Hazards to environment and life:- A. Contain toxic metal (U, Th, Cr, Pb, Hg, Cd, etc.) which may have negative effects on human health and plants. B. SO 2, NO 2 released from TPP causes acid rain. C. It may also affect agricultural by causing yellowing of green leaves. Volume 2 Issue 2 page 31

6 Table.6. Diseases due to presence of heavy metals in fly ash Metal Diseases Nickel (Ni) Respiratory problem, Lung cancer Cadmium (Cd) Anaemia Antimony (Sb) Gastroenteritis Arsenic (As) Skin cancer Chromium (Cr) Cancer Lead (Pb) Anaemia I. Compressive strength of fly ash S.Nu. Title Author Name of journal Materials used/ Grade 1. A research Alok Kumar, SSRG Ordinary Portland cement of paper on Shobha Jain, grade 43 is used to prepare the partial Shobha Gupta, civil mix design of M30 grade. W/Creplacement Sonaram, Sanjay 0.43 with cube size in M30 megawatt. [5] (SSRG-IJCE). 150MM*150MM*150MM. concrete from silica fume and fly ash 2. The Mr.Kamble Ordinary Portland cement of 43 compressive V.S., Prof. journal for grade with M40 cement strength of Nagendra M.V., research in concrete and cube of size fly ash based Dr.Shinde D.N. applied science 150MM*150MM*150MM. geopolymer [7] and technology. Curing Test result days 7, N/MM 2 was the compressive strength which is obtained at replacement level of 7.5% by weight of silica fume (SF) and replacement level of 20% by weight of fly ash with cement. 7,28. A concrete mix which is designed by using 85% fly ash has medium workability and For given replacement concrete giving about 67% result of the standard value of strength i.e Mpa. Also at 28 days, result are very good i.e. 100% average strength is Mpa. Hence, we can use in highway construction. 3. Experiment study on compressive strength of concrete with fly ash as a bonding layer. Journal on recent and innovation trends in computing and communicat i on. Priyankakamble, Dr.ShrikrishnaA.Dhak. [6] Journal on recent and innovation trends in computing and communication. A cube of 150MM*150MM*150MM with M20 and M30 grade of 7,14,28. The compressive strength of concrete with fly ash in powder form exceeded about 2% to 3% as compared to compressive strength of concrete with fly ash in paste form and also increases in compressive strength of concrete about 10% to 15% when fly ash in powder form is used as bonding layer as compared to strength of control mix. Volume 2 Issue 2 page 32

7 4. A study on fly ash concrete in the marine environment. 5. Effects of fly ash on compressive strength of M20 mix design 6. An experiment study on durability of concrete using fly ash and GGBS for M30 grade S. Bhanupravallika, V.Lakshmi. [4] Shantmurtiupad hyaya, Dr.R.Chandake. [15] S.P.S Ramya, A.M.N.Kashyap. [10] innovative research in science,, and technology. Journal of Advancements in research and technology. research and development. Portland pozzolana cement was made up of 53 grades and M20, M25 fly ash concrete was prepared using potable and sea water. Fly ash in powder form and replacement with 0%, 10%, 20% and 30%. M20 cement concrete cubes and W/C ratio= Ordinary Portland cement is used with 53-grade cement and ground granulated blast furnace slag (GGBS). The test is performed with normal water, sea water and 1% H 2 SO 4. 7,28,90. The compressive strength increases. 28. The addition of fly ash up to 10% there is negligible change in the strength of concrete, and up to 30% replacement, a fly ash block has shown very low compressive strength in comparison to concrete containing no fly ash. 7,28,60. GGBS gain in early strength as compared to fly ash. The result of fly ash and GGBS concrete when replaced with 20% cement are more than compared to control concrete at the end of 7, 28, 60 days in normal water where GGBS, when replaced with 20% cement, shows a good result for durability and 1% H 2 SO 4 when replaced with 20 % cement shows a good result for durability. 7. Fly ash as a partial replacement of cement in concrete and durability study of fly ash in acidic (H 2 SO 4 ) environment. T.G.G Kiran, M.K.M.R Ratnam. [2] and development. M35 grade concrete, different % of fly ash, sulphuric acid (1%), sulphuric acid (3%), sulphuric acid (5%) and different % of sulphuric acid. 28,60,90. The strength decreases in an acidic environment with age of concrete also with increases of fly ash content in In concrete cement can be replaced with 10% fly ash with maximum increases in strength beyond starts decreases due to slow pozzolanic reaction the fly ash concrete achieve significant improvement in its mechanical properties at a later age. 8. Effect of polypropylen K.Murahan, Rama Mohan journal of Ordinary Portland cement with 53 grades is used and fiber % is 28,56. The compressive strength of concrete gains Volume 2 Issue 2 page 33

8 e fiber on the strength properties of fly ash-based Rao-p. [11] science invention. 0.15%, 0.20%, 0.25% and 0.30%, % of fly ash used 30%, 40% and 50%. maximum strength at an early age was observed for all fly ash and polypropylene fiber based concrete mix when compared to control It was found that compressive strength increases gradually by additions of polypropylene fiber from 0.15% to 0.30% also increases in compressive strength as compared with normal plain concrete (without fibers). 9. Fly ash (Fclass) opportunities for sustainable development of low-cost rural roads. 10. Combine effect of rice husk ash and fly ash on concrete by 30% cement replacement. 11. Utilization of fly ash as cement replacement to produce highperformance DarshBelani, Prof. JayeshkumarPitr odca. [9] Satish H. Sathawane, Vikrant S. Vairagade, Kavita S. Kene. [3] J.A. Peter, M Neelameyam, J.K. Dattatreya, N.P. Rajamane, S. Gopalakrishnan. [1] trends and technology. Sciverse science direct. Procedia Engineering 51(2013). Fly ash utilization for value added products. A cube of 150MM*150MM*150MM in N/MM 2 at 7, 14, 28 days for M25 grades. A cube of dimension 150MM*150MM*150MM was cast for an M25 grade of concrete with rice husk ash (RHA). Fly ash, high-performance concrete (HPC) mixes. 7,14,28. We can use fly ash (class- F) for sustainable development of Indian road network 7,14,28,5 6, % strength was increased as compared to target strength, and 8.73% strength decreased as compared to control concrete at 28 days. 7,28,90 The strength at seven days of the fly ash based HPC has marginally decreased whereas the strength at 28 days was observed to be greater than that of the reference HPC mix as compared with 90 days it is also greater than seven days, 28 days and reference HPC mix. 12. Use of high volumes of class C and class F fly ash in TarunR.Naik, Bruce W.Ramme, John H.Tews. [16] Authorized reprint from cement, concrete, and aggregate. Cement, MixS1 40% class f fly ash, MixS2 50% class f fly ash, MixS1 20% class f fly ash. 3,7,28,56. The concrete mixture had same compressive strength as we predict 3500 psi. High-class F fly ash content concrete gained strength a little more slowly than the 20% class Volume 2 Issue 2 page 34

9 C fly ash 13. Assessment of concrete strength using fly ash and rice husk ash. SatishD.Kene, PravinV.Domke, SandeshD.Desh mukh, R.S. Deotale. [8] research and application. Ordinary Portland cement with 43 grade and for compressive strength we use a cube size of 150MM*150MM*150MM and rice husk ash. 7,14,28,9 0. The compressive strength increases with the increases % of fly ash and rice husk ash up to replacement (21% fly ash and 9% rice husk ash) in II. Flexural strength of fly ash S.Nu. Title Author Name of journal Materials used/ Grade 1. A research paper on Alok Kumar, SSRG Ordinary Portland cement partial replacement in Shobha Jain, of grade 43 is used to M30 concrete from prepare the mix design of silica fume and fly M30 grade. W/C ash. Shobha Gupta, Sonaram, Sanjay me rawat. [5] civil (SSRG- IJCE). Curing Test result days 7, N/MM 2 was the flexural strength which is obtained at replacement level of 7.5% by weight of silica fume (SF) and replacement level of 20% by weight of fly ash with cement. 2. A study on fly ash concrete in the marine environment. 3. Fly ash (F-class) opportunities for sustainable development of lowcost rural roads. S. Bhanupravallik a, V.Lakshmi. [4] DarshBelani, Prof. JayeshkumarPit rodca. [9] innovative research in science,, and technology. trends and technology. Portland pozzolana cement was made up of 53 grades and M20, M25 fly ash concrete was prepared using potable and sea water. A beam of 100MM*100MM*500MM in N/MM 2 at 28, 90 days for M25 grades. 7,28,90. The result shows that flexural strength increases. 28, 90. We can use fly ash (class- F) for sustainable development of Indian road network. 4. Effect of polypropylene fiber on the strength properties of fly ashbased K.Murahan, Rama Mohan Rao-p. [11] science invention. Ordinary Portland cement with 53 grades is used and fiber % is 0.15%, 0.20%, 0.25% and 0.30%, % of fly ash used 30%, 40% and 50%. 28,56. The flexural strength of concrete gains maximum strength at an early age was observed for all fly ash and polypropylene fiber based concrete mix when compared to control It was found that flexural strength increases Volume 2 Issue 2 page 35

10 gradually by additions of polypropylene fiber from 0.15% to 0.30% also increases in flexural strength as compared with normal plain concrete (without fibers). 5. Combine effect of rice husk ash and fly ash on concrete by 30% cement replacement. 6. Utilization of fly ash as cement replacement to produce highperformance 7. Use of high volumes of class C and class F fly ash in 8. Assessment of concrete strength using fly ash and rice husk ash. Satish H. Sathawane, Vikrant S. Vairagade, Kavita S. Kene. [3] J.A. Peter, M Neelameyam, J.K. Dattatreya, N.P. Rajamane, S. Gopalakrishnan. [1] TarunR.Naik, Bruce W.Ramme, John [16] H.Tews. SatishD.Kene, Pravin V.Do mke, SandeshD.Desh mukh, R.S. Deotale. [8] Sciverse science direct. Procedia Engineering 51(2013) Fly ash utilization for added products. value Authorized reprint from cement, concrete, and aggregate. research and application. A beam of 15CM*15CM*70CM was cast for an M25 grade of concrete with rice husk ash (RHA). Fly ash, high-performance concrete (HPC) mixes. Cement, MixS1 40% class f fly ash, MixS2 50% class f fly ash, MixS1 20% class f fly ash. Ordinary Portland cement with 43 grade and for compressive strength we use a beam size of 150MM*100MM*100MM and rice husk ash. 28. The flexural strength increased as compared to control 28. The tensile and flexural strength of mixes (except C5) with fly ash always a higher tensile strength than the control mix without fly ash. 3,7,28,56. Flexural strength was lower at all age for high fly ash content concrete mixture that is expected when compared with higher % Portland cement content mixture. 28. The maximum 28 days flexural strength obtains with 25% fly ash and 5% rice husk ash. III. Tensile strength of fly ash S.Nu. Title Author Name of journal Materials used/ Grade 1. A research paper Alok Kumar, Shobha SSRG Ordinary Portland cement on partial Jain, Shobha Gupta, of grade 43 is used to replacement in Sonaram, Sanjay prepare the mix design of M30 concrete from merawat. [5] civil M30 grade. W/C-0.43 with silica fume and fly cube size ash. (SSRG- 150MM*150MM*150MM. IJCE). Curing Test result days N/MM 2 was the tensile strength which is obtained at replacement level of 7.5% by weight of silica fume (SF) and replacement level of 20% by weight of fly ash with cement. 2. A study on fly ash S. Bhanupravallika, Portland pozzolana cement 7,28,90. The result shows that Volume 2 Issue 2 page 36

11 concrete in the marine environment. 3. Effect of polypropylene fiber on the strength properties of fly ash-based V.Lakshmi. [4] innovative research in science,, and technology. K.Murahan, Rama Mohan Rao-p. [11] science invention. was made up of 53 grades and M20, M25 fly ash concrete was prepared using potable and sea water. Ordinary Portland cement with 53 grades is used and fiber % is 0.15%, 0.20%, 0.25% and 0.30%, % of fly ash used 30%, 40% and 50%. tensile increases. strength 28,56. The tensile strength of concrete gains maximum strength at an early age was observed for all fly ash and polypropylene fiber based concrete mix when compared to control It was found that tensile strength increases gradually by additions of polypropylene fiber from 0.15% to 0.30% also increases in tensile strength as compared with normal plain concrete (without fibers). 4. Combine effect of rice husk ash and fly ash on concrete by 30% cement replacement. 5. Utilization of fly ash as cement replacement to produce highperformance 6. Use of high volumes of class C and class F fly ash in 7. Assessment of concrete strength using fly ash and Satish H. Sathawane, Vikrant S. Vairagade, Kavita S. Kene. [3] J.A. Peter, M Neelameyam, J.K. Dattatreya, N.P. Rajamane, S. Gopalakrishnan. [1] TarunR.Naik, W.Ramme, H.Tews. [16] Bruce John SatishD.Kene, PravinV.Domke, SandeshD.Deshmukh, Sciverse science direct. Procedia Engineering 51(2013) Fly ash utilization for value added products. Authorized reprint from cement, concrete, and aggregate. A cylinder is made with dimension 150MM, dia- 300MM high, for an M25 grade of concrete with rice husk ash (RHA). Fly ash, high-performance concrete (HPC) mixes. Cement, MixS1 40% class f fly ash, MixS2 50% class f fly ash, MixS1 20% class f fly ash. Ordinary Portland cement with 43 grades and for compressive strength, we 28. The tensile strength decreased as compared to control 28. The tensile and flexural strength of mixes (except C5) with fly ash always a higher tensile strength than the control mix without fly ash. 3,7,28,56. Tensile strength was lower at all age for high fly ash content concrete mixture that is expected when compared with higher % Portland cement content mixture. 28. The tensile strength obtains with 25% fly ash and 5% rice husk Volume 2 Issue 2 page 37

12 rice husk ash. R.S. Deotale. [8] research and application. use a cylinder size of 150MM and 300MM and rice husk ash. ash. REFERENCE [1] J.A. Peter, M Neelameyam, J.K. Dattatreya, N.P. Rajamane, S. Gopalakrishnan. Utilization of fly ash as cement replacement to produce high-performance Fly ash utilization for value added products, 1999, Jamshedpur, page number [2] T.G.G Kiran, M.K.M.R Ratnam. Fly ash as a partial replacement of cement in concrete and durability study of fly ash in acidic (H 2 SO 4 ) environment. and development. e-issn: x, p-issn: x, volume-10, issue-12, December 2014, page number [3] Satish H. Sathawane, Vikrant S. Vairagade, Kavita S. Kene. Combine effect of rice husk ash and fly ash on concrete by 30% cement replacement. Sciverse science direct. Procedia 51(2013) [4] S. Bhanupravallika, V.Lakshmi. A study on fly ash concrete in marine environment. innovative research in science, and technology. Issn: , volume-3, issue-5, May [5] Alokkumar, Shubhamjain, Shubhamgupta, Sonaram, Sanjay merawat. A research paper on partial replacement in M30 concrete from silica fume and fly ash. SSRG civil (SSRG-IJCE). Volume-3, issue- 5, May [6] Priyankakamble, Dr.ShrikrishnaA.Dhak. Experiment study on compressive strength of concrete with fly ash as a bonding layer. journal on recent and innovation trends in computing and communication. Issn: , volume-3, issue-2. [7] Mr.Kamble V.S., Prof. Nagendra M.V., Dr.Shinde D.N. Compressive strength of fly ash based geoplymer journal for research in applied science and technology. Volume-4, issue-6, June 2016, Issn: [8] SatishD.Kene, PravinV.Domke, SandeshD.Deshmukh, R.S. Deotale. Assessment of concrete strength using fly ash and rice husk ash. research and application. Volume-1, issue-3, Issn: , Page number [9] DarshBelani, Prof. JayeshkumarPitrodca. Fly ash (F-class) oppertiunities for sustainable development of low cost rural roads. trends and technology. Volume-4, issue-5, May [10] S.P.S Ramya, A.M.N.Kashyap. An experiment study on durability of concrete using fly ash and GGBS for M30 grade concrete. research and development.,e-issn: X, p-issn: X, volume-10, issue-11, November 2014, page number [11] K.Murahan, Rama mohanrao-p. Effect of polypropylene fiber on the strength properties of fly ash based concrete. science invention. issn (online): , issn(print): , volume-2, issue-5, May 2013, page number [12] Central electricity authority. [13] CEA annual report. [14] MoEF notification, 3,November,2009. [15] Shantmurtiupadhyaya, Dr.R.Chandake. Effects of fly ash on compressive strength of M20 mix design concrete. advancements in research and technology. issn: , volume-3, issue-9, September [16] TarunR.Naik, Bruce W.Ramme, John H.Tews. Use of high volumes of class C and class F fly ash in concrete. Authorized reprint from cement, concrete and aggregate, June [17] Norshahrizannordin, Muhammad faheemmohdtahir, Andrei victor sandu, Kamarudinhussin. Utilization of fly ash waste as construction materials. conservation science. volume-7, issue-1, January-March [18] Mihirrathod, Shiprasharma. Use of both fly ash and pond-ash in concrete mix design. journal for scientific research and development. issn: , volume-2, issue-12, [19] Manojkumartiwari, Dr. Samir bajpal, Dr. Umeshkumardewangan. Fly ash utilization: A brief review in India context. research and technology. e-issn: , p-issn: , volume-3, issue-4, April Volume 2 Issue 2 page 38