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Silica Fume
Glass
Natural
Pozzalans
Type F Flyash
Clay
Metakaoli
n
Portland
Cement Class C
Flyash
GGBFS
CaO Al2O3
Pozzolanic Materials
• Concretes containing pozzolans have
different properties due to the chemical
and physical interaction
• Initial use of these materials was
economic
• The best argument for their use is the
technical aspects of the concrete
Fly Ash
• ASTM C618
– Class C – High Calcium
– Class F - Low Calcium
Premarc 1/18/07
Class C Flyash
• Class C ashes contain C2S and
•
• Will have some hydraulic action
• Can contribute Alkali (K+, Na+)
Class F Ash
• Pozzolanic action alone
• Longer term strength gain over Class C
• Retards more than class C
Setting
Effect Set Time of LMN Cement & ICF Ash
Replacements
Updated Data of New Lehigh Cement (8/1/03)
Laboratory Condition
LMN & 0% ash (3:45 / 5:40)
5000
4500
LMN & 10% ash (3:50 / 5:50)
+0:05/+0:10
Penetration Resistance, psi
4000
LMN & 20% ash(4:05 / 6:10)
+0:20/+0:30
3500
LMN & 30% ash (4:30 / 6:25)
3000 +0:45/+0:45
2500
2000
1500
1000
500
0
3:00 3:30 4:00 4:30 5:00 5:30 6:00 6:30 7:00
Age, hr:min
Fly Ash Manufacturing
Flyash is not a constant
Mortar Fraction, 6 1/4 Bag, 0.45 W/C, 1490 lb SSDLLFA per C.Y
LM1 standard & 20% , 40% Replacement
7000
6500
6000
5500
5000
4500
4000
3500
3000
R
,p
io
c
s P
n
tra
e
2500
2000
1500
1000
500
2:00 3:00 4:00 5:00 6:00 7:00 8:00 9:00 10:00 11:00 12:00 13:00 14:00 15:00
Age, hr:min
GGBFS
• Extracted from the non-ferrous product of
a Bessemer furnace
• Material is cooled rapidly to trap slag in
the glass state
• Consists mainly of aluminates and
silicates of Calcium
•
Slag Cement
Slag Cement
manufactured under
ASTM C 989
Hydraulic cement
Co-product of a highly
controlled metallurgical
process
Enhances concrete
properties
Environmentally positive
material
Slag Cement
Definition: Finely ground
granulated material
originating from an iron blast
furnace and consisting of
primarily calcium (CaO) and
aluminum (AL2O3) silicates
(SiO2) , used as a partial
replacement for portland
cement in concrete
hot slag
Slag is changed to glassy sand like
substance known as granulated blast
furnace slag - GBFS
Premarc 1/18/07
Premarc 1/18/07
Silica Fume
• Condensed molten siliceous material –
amorphous in nature
• Product of the silicon and ferrosilicon smelting
industries
• Mean Diameter of 0.15μm
• Specific Surface Area of 15000 – 20000 m2/kg
• At 10 percent, there are 50000 to 100000
particles present for each grain of cement
Silica Fume
• 350 kg of Cement 3000 m2/kg 105000 m2
• 8 percent silica fume 28 lb 560000m2
•
• Large Surface Forces result in very
cohesive mixture
• Large Surface area and high proportion of
reactive material makes it extremely
reactive
Properties of Materials
Property Silica Slag Fly Ash
Fume
Specific 2.2 2.85 2.6-2.75
Gravity
Specific Very Fine Varies Finer than
Surface cement
Reactivity Very Rapid Varies with Varies with
size and size and
Chemistry Chemistry
Cement Chemistry
• Chemically active
• Major and Minor Constituents
• Sulfate Form can be very important
• Solids must either dissolve in solution or a
surface reaction takes place
Major Components
• C3S
• C2S
• C3A
• C4AF
• CaSO4
Hydration
• Chemical reaction between individual
clinker minerals, calcium sulfate and
water
• Proceed at different rates – in series and
in parallel – and influence one another
Pozzolanic Reaction
• Cement + Water Glue and Ca(OH)2
•
• Ca(OH)2 + PozzolansMore Glue
•
High Volume Flyash Concrete
• Significant increases in ASR, sulphate and
thermal cracking resistance are possible
at 25 percent or higher flyash
replacement
• Problems with setting time and early age
strength gain
High Volume Flyash Concrete
• Minimum of 50 percent flyash by mass of
cementitious materials
• Low water content 130 kg/m3
• Low cement content 200 kg/m3
• Air entrained for freeze thaw
• 4500 psi, 6 inch or higher w/cm ~0.3
• Below 4500 psi , w/cm ~ 0.4
Comparisons to OPC Concrete
High Volume Fly Conventional
Ash Concrete Concrete
Less energy Energy intensive
intensive manufacture
manufacture Weaker ultimate
Higher ultimate strength
strength Less durable
More durable Uses virgin materials
only
Uses a waste by- More global warming
product gases created
Less global warming
gases created
Plastic Properties
• Low water content dictates use of
Superplasticizer So slump is available
as required
• Concrete is readily air entrained using
conventional admixtures
• Workability is high, and fines content
promotes cohesion
Plastic Properties
• Bleeding - Negligible to very small
• Time of set – may be significantly
increased – depends on flyash being
used
• Autogenous temperature rise – peak
temperature is lower
Hardened Concrete Properties
• Strength
– Early age and later age strength
dependent on choosing the right cement
and flyash
– 1 day strength 900 to 1200 psi
– 28 day strength 4000 to 8000 psi routinely
available
• Accelerators or type III Cement will give 1
day strengths of 2500 psi or more
Hardened Properties
• Tensile strength and flexural strength are
the same as OPC Concrete
• Modulus of Elasticity is high – 35 GPa
(~107psi)
• Caused by infilling of the ITZ – flyash as
microfine aggregate
Hardened Properties
• Creep and Shrinkage
• Drying strains are lower than conventional
concrete
• Creep is lower than conventional concrete
• Likely due to denser microstructure
Durability
• Water Permeability Low
• Freezing and Thawing – Behaves as
conventional air entrained concrete
• Scaling resistance Some sidewalks have
been constructed in Canada with good
reported performance. Others have not
seen the same results. Should be
avoided in deicer exposure
Durability
• Penetration of Chloride Ions
• Rapid Chloride Permeability
– 28 days 2500 coulombs passed
– 90 days 1000 coulombs passed
– 365 days 150 coulombs passed
Durability
HVFA
2000
Charge Passed ,
Coulombs
1000
Silica Fume
Log Time
Mixture 5 100% OPC
Mixture 2 Slag: OPC
Mixture 3 Flyash:OPC
00
. 16 Mixture 1,10 FA:Slag:OPC
00
. 14
Mixtu re No5
.
00
. 12
00
. 1 Mixtu re No.2
00
. 08 Mixtu re No.3
00
. 06
00
. 04
Mixture No1
.
em
00
. 02
kg
,/ icalS
rn C
h
Mixtu re No1
. 0
0
00
. 45
00
. 4 M ix 1
00
. 35 M ix 2
00
. 3 M ix 3
Shrinkage %
00
. 25 M ix 5
Increasing
00
. 2 Pozzolan Log. (M ix2 )
Content Log. (M ix1 )
00
. 15
00
. 1 Log. (M ix5 )
00
. 05 Log. (M ix3 )
0
0 5 10 15
Time, Days
Hydration
• Chemical reaction between individual
clinker minerals, calcium sulfate and
water
• Proceed at different rates – in series and
in parallel – and influence one another
Hydration Curve
Heat
Evolv
ed,
dH/dt
Time
Hydration
• Progress dependent on
• Rate of dissolution
• Rate of Nucleation and Crystal growth
• Rate of Diffusion of reagents through
hydration products
Hydration
• Water/Cement Ratio
• Curing Conditions and Humidity
• Hydration Temperature
• Presence of Admixtures
Mixture Proportioning and
Adjustment
Water Content
• Water can be expressed in many ways:
Viscosity is slope of
line
Shear
Stress
Shear Rate
Viscosity Models
Bingham
Plastic
.
τ =τ0 + µ γ
Bingham Model
Shear
Stress
Shear Rate
Viscosity Behavior
SCC
Viscosity is slope of
line
Shear
Stress
WRDA
HRWRDA
Water
Shear Rate
Mixture Design - Rheology
20 Silica Fume
Air
τ0
1
VMA
0
2
Viscosity
Dispersion – the water
reduction trick
Capillary
Pores
Gel
Pores
Water:Cement Ratio
• Controls the pore space –
•
• Lower w/c = fewer pores=less water
How to Change Viscosity
• Alter the properties of the particles, the
fluid or their interaction
•
• Admixtures
•
• Geometry (particle packing)
Life-Cycle Costing
Case Studies
Great River Energy
Freeze-Thaw Resistance
• Freeze thaw resistance is imbued by air
entrainment
• Pozzolans do not change this
– low permeability
– ASTM C666 testing
– Very high class C – may be detrimental
secondary crystallization
Drying Period
• Water in concrete can fill pores that once
dried cannot be refilled
•
• So concrete may be more saturated
before drying than after immersion
following drying
Scaling Resistance
• Making the skin of concrete – because
concrete beauty is skin deep
•
•
Modified Pore Structure
OPC
Gel pores Capillary Pores
Intruded Volume
OPC +
GGBFS
60 %
Hydration
0.001 0.01 0.1 1
10
Pore diameter, μm
Modified Pore Structure
OPC +
GGBFS
28
days
60 %
Hydration
0.001 0.01 0.1 1
10
Pore diameter, μm
Platinum LEED 45 percent
reduction in cement content
• Flyash replacement of 60 percent
• Total cementitious content increased
• Net reduction 45 percent
•
I 35 W St. Anthony Falls Bridge
• All concrete in foundation and
substructure is High Pozzolan Content
• Conventional cementitious contents –
less than 625 lb per cubic yard
•
756
783
319
Thank You!
This concludes the American Institute of Architects
Continuing Education Systems Program.
Any Questions?
Kevin A. MacDonald
1-800-CEMSTONE