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Compressive Strength of Concrete Containing We Energies ASTM C618, Class C Fly Ash (Phase I Study) Concrete is used in several applications requiring different levels of strength. Most applications require concrete with a compressive strength in the range of 3,000 to 5,000 psi. Based on the type of application, engineers select a mixture design with a specified 28-day compressive strength. Other durability factors such as porosity or freeze-thaw resistance also influence the selection of a concrete mixture. With the introduction of fly ash concrete, the long-term (56 day or 1 year) properties of concrete have shown dramatic improvement. Since long-term properties of concrete are vital, most construction professionals are interested in understanding the performance of fly ash and the resulting concrete made using fly ash. The influence of We Energies fly ash on the quality of concrete has been studied for several years. Fly ash is used as a partial replacement for cement at various replacement levels. In order to understand the properties of We Energies fly ash and the short-term and long-term performance of concrete containing We Energies fly ash, a great amount of research work has been conducted. The following data is from a research project conducted at the Center for By- Products Utilization at the University of Wisconsin-Milwaukee for We Energies (24). This work was done with the objective of developing mixture proportions for structural grade concrete containing large volumes of fly ash. ASTM C618, Class C fly ash from We Energies Pleasant Prairie Power Plant was used in this research project. Preliminary mixture proportions were developed for producing concrete on a 1.25 to 1 fly ash to cement weight basis replacement ratio. The replacement levels varied from 0 to 60% in 10% increments. Water to cementitious materials ratios (w/c) of 0.45, 0.55 and 0.65 were used in this project to develop concrete with strength levels of 3,000 psi; 4,000 psi and 5,000 psi. It is interesting to observe that at fly ash utilization levels rising above 50%, Portland cement becomes the admixture or supplementary cementitious material. Actual concrete production was performed at two local ready mixed concrete plants utilizing different cement and aggregate sources. Three quarter inch maximum size aggregates were used in the mixtures and the slump was maintained at 4”± 1”. Entrained air was maintained in the range of 5-6% ± 1%. The concrete mixtures were prepared at ready mixed concrete plants using accepted industry practices. Six-inch diameter by 12” long cylinder specimens were prepared for compressive strength tests. The compressive We Energies 54 Coal Combustion Products Utilization Handbook
strength tests were performed at various ages in accordance with standard ASTM test methods. The chemical and physical properties of PPPP fly ash used in these tests are shown in Table 4-1. Tables 4-2 to 4-4 show the mixtures designed for concrete in the various strength levels and various percentages of cement replacement with fly ash. The compressive strength results are shown in Tables 4-5 to 4-7. Table 4-1: Chemical and Physical Test Data Pleasant Prairie Power Plant (PPPP) Fly Ash Chemical Composition Average (%) ASTM C-618 Silicon Oxide (SiO 2 ) 40.89 --- Aluminum Oxide (Al 2 O 3 ) 16.13 --- Iron Oxide (Fe 2 O 3 ) 6.01 --- Total (SiO 2 +Al 2 O 3 +Fe 2 O 3 ) 63.03 50.0 min Sulfur Trioxide (SO 3 ) 2.98 5.0 max Calcium Oxide (CaO) 25.30 --- Magnesium Oxide (MgO) 4.56 5.0 max Loss on ignition .45 6.0 max Available alkalies as Na 2 O 1.19 1.5 max Fineness % retained on #325 wet sieve 18.83 34.0 max Pozzolanic activity index with cement 28 days with lime 7 days Water requirement % of the control Soundness Autoclave expansion (%) 92.43 1805 75.0 min 800 min 91 105 max 0.15 0.8 max Specific gravity 2.58 --- Discussion of Test Results - 3,000 psi Concrete Compressive strength test results for the six different 3000 psi concrete mixtures are shown in Table 4-2. The specified strength for these mixtures is 3,000 psi. These test results show that with an increase in cement replacement levels with fly ash, the early age compressive strength decreases. The decrease is not significant for concrete with 20 and 30% replacement levels. At 7-day age, cement replacement with up to a 40% replacement level produces concrete with compressive strength comparable to that of the control mix. At 28-day age, all mixtures showed strength levels higher than the design compressive strength of 3,000 psi. However, concrete containing 40% replacement of cement with fly ash had the highest strength. 55 We Energies Coal Combustion Products Utilization Handbook
Page 1 and 2:
Ramme - Tharaniyil Second Edition A
Page 3 and 4:
This book is dedicated to all the i
Page 5 and 6:
Contents Chapter 5 Controlled Low-S
Page 7 and 8:
Contents Appendix A Product Data Sh
Page 9 and 10:
Chapter 1 Background and History o
Page 11 and 12: The United States is the world's se
Page 13 and 14: are currently installed on about 25
Page 15 and 16: problems. In the late 1920’s, cin
Page 17 and 18: Chapter 2 CCPs and Electric Power
Page 19 and 20: for loading dry bulk semi tankers o
Page 21 and 22: Figure 2-2: Basic Diagram of an IGC
Page 23 and 24: Properties of Fly Ash Fly ash is a
Page 25 and 26: for air entraining admixtures, maki
Page 27 and 28: Fly ash is an artificial pozzolan.
Page 29 and 30: Table 2-6: Geotechnical Properties
Page 31 and 32: Table 2-9 shows the chemical compos
Page 33 and 34: Table 2-12: Typical Chemical Compos
Page 35 and 36: The following coal fired power plan
Page 37 and 38: All bottom ash is removed as necess
Page 39 and 40: ottom ash is removed by a hydraulic
Page 41 and 42: Chapter 3 Properties of We Energie
Page 43 and 44: that distribute and test fly ash to
Page 45 and 46: Physical, Chemical and Mechanical P
Page 47 and 48: However, some engineering propertie
Page 49 and 50: ----------------------------U.S. ST
Page 51 and 52: Results of Testing to AASHTO Standa
Page 53 and 54: Table 3-8: Summary of We Energies B
Page 55 and 56: Chapter 4 Concrete and Concrete Ma
Page 57 and 58: alumina in the pozzolan may also re
Page 59 and 60: Dunstan summarized his work in term
Page 61: The level of shrinkage strains depe
Page 65 and 66: Discussion of Test Results - 4,000
Page 67 and 68: Other important observations from t
Page 69 and 70: Figure 4-3: Compressive Strength vs
Page 71 and 72: 300 290 AMOUNT OF WATER, lbs 280 27
Page 73 and 74: Table 4-8: PPPP ASTM C618 Class C F
Page 75 and 76: The final setting time for 5000 psi
Page 77 and 78: Table 4-12: Length Change* NON-AIR-
Page 79 and 80: Table 4-14: Freeze-Thaw Tests* (Air
Page 81 and 82: Abrasion resistance tests were perf
Page 83 and 84: Table 4-16: Compressive Strength Te
Page 85 and 86: 4 DEPTH OF WEAR, mm @ 60 Minutes 3.
Page 87 and 88: Table 4-19: Mixture Proportions Usi
Page 89 and 90: 12000 COMPRESSIVE STRENGTH, PSI 100
Page 91 and 92: Table 4-21: Air Permeability Test R
Page 93 and 94: Table 4-22: Water Permeability Test
Page 95 and 96: Table 4-23: Chloride Permeability T
Page 97 and 98: Tax Incremental Financing (TIF) was
Page 99 and 100: Figure 4-20 : Maple Avenue roadway
Page 101 and 102: Figure 4-22: Finishing touch to We
Page 103 and 104: Table 4-26: Concrete Mixture and Si
Page 105 and 106: 6. The high-volume Class C fly ash
Page 107 and 108: Table 4-31: Average Tensile Strengt
Page 109 and 110: Table 4-35: Changes in Ultrasonic P
Page 111 and 112: Table 4-38: Results of De-Icing Sal
Page 113 and 114:
Table 4-40: Abrasion Resistance of
Page 115 and 116:
Summary Based on the data recorded
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3.00 M 101.5 MM WRAPPED UNDERDRAIN
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mixture and concrete mixture. Also,
Page 121 and 122:
Testing Program The testing program
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Test Results Table 4-46 shows the c
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Fly Ash Concrete for Precast/Prestr
Page 127 and 128:
Table 4-49: Concrete Mixture Propor
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Figure 4-27: Electrical Resistance
Page 131 and 132:
Table 4-51: Electrical Properties o
Page 133 and 134:
fly ash by weight of total cementit
Page 135 and 136:
Table 4-53: Compressive Strength of
Page 137 and 138:
Chapter 5 Controlled Low-Strength
Page 139 and 140:
Table 5-1: Mixture Proportions and
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1800 COMPRESSIVE STRENGTH, psi 1600
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Table 5-3: Chemical and Fineness Te
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1800 COMPRESSIVE STRENGTH, psi 1600
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and corresponding compressive stren
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conductivity tests were conducted u
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It can be concluded from this resea
Page 153 and 154:
Table 5-13: Compressive Strength of
Page 155 and 156:
(4) Compatible with copper, aluminu
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Mechanical Properties The compressi
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Figure 5-10: Electrical permeabilit
Page 161 and 162:
Pilot Projects Using We Energies CL
Page 163 and 164:
WisDOT Low Permeability CLSM with W
Page 165 and 166:
material for foundations, changing
Page 167 and 168:
Chapter 6 Commercial Applications
Page 169 and 170:
The report also evaluated frost sus
Page 171 and 172:
Field Study Following the initial s
Page 173 and 174:
Figure 6-3: Bottom ash base course
Page 175 and 176:
Table 6-2: Permeability and Drainag
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Bottom Ash as an Aggregate in Aspha
Page 179 and 180:
Table 6-4: Total Elemental Analysis
Page 181 and 182:
We Energies Bottom Ash as a Soil In
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The coal combustion materials landf
Page 185 and 186:
The only other compounds detected t
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affect combustion. The resulting fl
Page 189 and 190:
Table 6-7: Dry-Cast Concrete Block
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Table 6-10 Compressive Strength of
Page 193 and 194:
Chapter 7 Fly Ash Stabilized Cold
Page 195 and 196:
Using the back-calculated SN values
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Falling Weight Deflectometer tests
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unconfined compressive strength of
Page 201 and 202:
Chapter 8 Fly Ash Metal Matrix Com
Page 203 and 204:
The green density of the aluminum f
Page 205 and 206:
Table 8-1: Alloy Samples Tested in
Page 207 and 208:
Cenospheres Cenospheres are hollow,
Page 209 and 210:
Chapter 9 Environmental Considerat
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judgment is required for new applic
Page 213 and 214:
Table 9-2: NR 538 Fly Ash Analysis
Page 215 and 216:
Table 9-3: NR 538 Fly Ash Analysis
Page 217 and 218:
Table 9-4: NR 538 Bottom Ash Analys
Page 219 and 220:
Table 9-5: NR 538 Bottom Ash Analys
Page 221 and 222:
Table 9-7: ASTM D3987 Extraction An
Page 223 and 224:
Table 9-8: Typical Heavy Metals Fou
Page 225 and 226:
The voluntary C 2 P 2 Challenge Pro
Page 227 and 228:
General Usage - NR 538 Applicabilit
Page 229 and 230:
* Use Property Owner Notification -
Page 231 and 232:
Mercury Removal-Ash Beneficiation (
Page 233 and 234:
the air slide inlet was set at 538
Page 235 and 236:
equired removal temperatures of 813
Page 237 and 238:
Chapter 10 Minergy LWA - Structura
Page 239 and 240:
Chapter 11 Sample Specifications
Page 241 and 242:
Part 2 - Products 2.01 Concrete Mat
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3.02 Embedded Items A. All sleeves,
Page 245 and 246:
C. Provide adequate number of units
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B. Reinforce or replace deficient w
Page 249 and 250:
show the strength of masonry strong
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3.02 Bottom Ash Placing and Compact
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3. The CLSM shall meet the followin
Page 255 and 256:
3.02 CLSM Depositing A. CLSM shall
Page 257 and 258:
11.5 Sample Specification for We En
Page 259 and 260:
D. Basis of Payment This item, meas
Page 261 and 262:
If the reprocessed asphaltic base-f
Page 263 and 264:
Chapter 12 References 1. American
Page 265 and 266:
33. University of Wisconsin-Milwauk
Page 267 and 268:
69. Naik, T.R., Kraus, R.N., and Si
Page 269 and 270:
Appendix A Product Data Sheets Min
Page 271 and 272:
Personal Protective Equipment Speci
Page 273 and 274:
FirstAid Eyes Inhalation Ingestion
Page 275 and 276:
Appendix B Radioactivity in Coal a
Page 277 and 278:
annual number of curies of each of
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is divided among cosmic (30 mrem),
Page 281 and 282:
constructed with fly ash building m
Page 283 and 284:
Appendix C Field Guide for Recycli
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‣ Blend the fly ash and prepared
Page 287 and 288:
Index AASHTO See American Associati
Page 289 and 290:
Index Backfill material, 6, 43, 138
Page 291 and 292:
Index Disposal costs, 5 See also La
Page 293 and 294:
Index Pavement, 26, 109, 187; botto
Page 295 and 296:
Index Size, boiler slag, 22; bottom
Page 297:
About the Authors Bruce W. Ramme B
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