Fly Ash - Philippines

Designation: C 618 - 00
Standard Specification for

Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use
as a Mineral Admixture in Concrete
1
This standard is issued under the fixed designation C 618; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year oflast revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (E) indIcates an editorial change since the last revision or reapproval.
This standard has been approved {or usc by agencjes of the Dcparrmem of Defense.
1. Scope
1.1 This specification covers coal fly ash and raw or
calcined natural pozzolan for use as a mineral admixture in
concrete where cementitious or pozzolanic action, or both, is
desired, or where other properties normally attributed to finely
divided mineral admixtures may be desired, or where both
objectives are to be achieved.
NOTE I-Finely divided materials may tend to reduce the entrained air
content of concrete. Hence, if a mineral admixture is added to any
concrete for which entrainment of air is specified, provision should be
made to ensure that the specified air content is maintained by air content
tests and by use of additional air-entraining admixture or use of an
air-entraining admixture in combination with air-entraining hydraulic
cement.
1.2 The values stated in SI units are to be regarded as the
standard.
1.3 The text of this standard references notes and footnotes,
which provide explanatory information. These notes and foot
notes (excluding those in tables and figures) shall not be
considered as requirements of the standard.
2. Referenced Documents
2.1 ASTM Standards:
C 125 Standard Terminology Relating to Concrete and Con
crete Aggregates
2
C 311 Test Methods for Sampling and Testing Fly Ash or
Natural Pozzolans for Use as a Mineral Admixture in
Portland-Cement Concrete
2
3. Terminology
3.1 Definitions:
3.1.1 The terms used in this specification are defined in
Terminology C 125.
3.1.2 fly asfJ--the finely divided residue that results from
...()fground_()I .. and that is
! Tbis specification is under the jurisdiction of ASTM Committee C09 on
Concrete and Concrete Aggregates awl ;, the direct re5l'Msibility of Subcommittee
C09.24 on Ground Slag and Pozzolonic Admixtures.
Current edition approved Aug. 10,2000. Published September 2000. Originally
published as C618 68 T to replace C350 and C402. Last previous edition
C618 -99.
, Annual Book of ASTM Standards, Vol 04.02.
transported by flue gasses.
NOTE 2-This definition of fly ash does not include, among other
things, the residue resulting from: (1) the burning of municipal garbage or
any other refuse with coal; (2) the injection of lime directly into the boiler
for sulfur removal; or (3) the burning of industrial or municipal garbage
in incinerators commonly known as "incinerator ash."
4. Classification
4.1 Class N-Raw or calcined natural pozzolans that com
ply with the applicable requirements for the class as given
herein, such as some diatomaceous earths; opaline cherts and
shales; tuffs and volcanic ashes or pumicites, calcined or
uncalcined; and various materials requiring calcination to
induce satisfactory properties, such as some clays and shales.
ash normally produced from burning
anthracite or bituminous coal that meets the applicable require
ments for this class as given herein. This class fly ash has
properties.
4::'3 Class G---Fly ash normally produced from lignite or
subbituminous coal that meets the applicable requirements for
this class as given herein. This class of fly ash, in addition to
having pozzolanic properties, also has some cementitious
properties.
NOTE 3-Some Class C fly ashes may contain lime contents higher than
10%.
5. Ordering Information
5.1 The purchaser shall specify any supplementary optional
chemical or physical requirements.
5.2 The purchaser shall indicate which procedure, A or B,
shall be used when specifying requirements for effectiveness in
contribution to sulfate resistance under Table 4.
6. Chemical Composition
6.1 Fly ash and natural pozzolans shall conform to the
.requirementslls to chemical composition prescribed in Table 1.
Supplementary -optlona:lcnemicat-requirements .. are_..shownjg
Table 2.
7. Physical Properties
7.1 Fly ash and natural pozzolans shall conform to the
physical requirements prescribed in Table 3. Supplementary
Copyright ASTM. 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.
~ ~ I ~ C 618
optional physical requirements are shown in Table 4.
8. Methods of Sampling and Testing
8.1 and test the mineral admixturc in accordallcc
with the requirements of Test Methods C 31 J.
8.2 Use cemcnt of the type proposed for use in the work
and, if from the mill proposed as the source of the
cement, in all tests requiring the use of hydraulic cement.
9. Storage and Inspection
9.1 The mineral admixture shall be stored in such a manner
inspection and identification
Inspection of the material shall be made as agreed upon
and tbe seller as part of the Durchase contract.
10. Rejection
10.1 TIle has the right to reject material that fails
to conform to the of this specification. Rejection
shall be to the producer or supplier promptly and in
writing.
10.2 The purchaser has the right to reject packages varying
more than 5 % from tbe stated weight. The purchaser also has
the right to reject the entire shipment if the average weight of
the packages in any shipment, as shown by weighing 50
packages taken at random, is less than that specified.
10.3 The purchaser has the right to require that mineral
admixture in storage prior to shipment for a period longer than
6 months after be retested. The purchaser has the right
to reject such material if it fails to meet the fineness require
ments.
11. Packaging and Package Marking
11.1 'When the mineral admixture is delivered in
the class, name, and brand of the producer. and the weight of
the matelial contained therein, shall be
Similar infol1TIatlOn shall be
invoices the
mineral admixture.
12. Keywords
12.1 mineral natural poz
zolans
2
C 618
TABLE 1 Chemical Requirements
Mineral Admixture Class
N F C
.._-_._._--------------------
Silicon dioxide (SiD,) plus aluminum oxide (AI
2
0
3
) plus iron oxide (Fe203)' 700 70.0 500
min, %
Sulfur trioxide (S03)' max, % 4.0 5.0 5.0
Moisture content, max, % 3.0 3.0 3.0
Loss on ignition, max, % 100 S.OA
6.0
"The use of Class F pozzolan containing up to 12.0 % loss on ignition may be approved by the user if either acceptable performance records or laboratory test results
are made available.
TABLE 2 Supplementary Optional Chemical Requirement
NOT!' I--This optional requirement appJies only when specifically requested.
N F C
Available alkalies, as equivalent, as Na,O, max, %A 1.5 1.5 1.5
AAppiicable only when specifically required by the purchaser for mineral admixture to be used in concrete containing reactive aggregate and cement to meet a limitation
on content of alkalies,
TABLE 3 Physical Requirements
N F C
Fineness:
Amount retained when wet-sieved on 45 pm (No, 325) sieve, 34 34 34
max, %A
Strength activity index: S
With portland cement, at 7 days, min, percent of 75
c
75
c
75
c
control
With portland cement, at 28 days, min, percent of 75 75
c
75
c
control
Water requirement, max, percent of control 115 105 105
Soundness: D
Autodave expansion or contraction, max, % 0.8 0,8 0,8
Uniformity requirements"'
The density and fineness of individual samples
shall not vary from the average established by the
ten preceding tests, or by all preceding tests if the
number is less than ten, by more than:
Density, max variation from average, % 5 5 5
Percent retained on 45-flm (No. 325), max variation, 5 5 5
percentage points from average
ACare should be taken to avoid the retaining of agglomerations of extremely fine material.
"The strength activity index with portland cement is not to be considered a measure of the compressive strength the mineral admixture, The mass
of mineral admixture specified for the test to determine the strength activity index with portland cement is not considered to be the recommended for the concrete
to be used in the work. The optimum amount of mineral admixture for any specific project is detenmined by the of the concrete and other constituents
of the concrete and is to be established by testing. Strength activity index with portland cement is a measure a given cement and may vary as to the source
of both the mineral admixtUre and the cement.
the 7 day or 28 day strength index will indicate specification compliance.
admixture will constitute more 20 % by weight of the cementitious material in the project mix the test specimens for autoclave expansion
shall contain that anticipated percentage. Excessive autoclave expansion is highly Significant in cases where water to admixture and cement ratios are low, for
example, in block or shotcrete mixes.
3
C 618
TABLE 4 Supplementary Optional Physical Requirements
NUTI', 1-Thcsc optional requirements apply only when specIfically requested.
F c
AApp!icable only for Class F mineral admixtures since the loss on ignition limitations predominate for Class C,
BOetermination of compliance or noncompliance with the requirement relating to increase in drying shrinkage will be made at the request of the purchaser.
cMineral admixtures meetino this requirement are considered as effective in controlling alkali reactions as the use the low-alkali control cement used in
admixture shall be considered effective only when the is used at mass of the total cementitious
that used in the tests and when the alkali content of the cement to be used with the mineral not exceed that used in the
Appendix XI, Test Methods C 311.
"Fly ash or natural shall be considered effective only when the fly ash or natural pozzolan is used at percentages, by mass, of the total cementitious material
within 2 % of those are successful in the test mixtures or between two percentages that are successful, and when the CoA content of the project cement is less than,
or equal to, that which was used in the test mixtures, See Appendix X2 of Test Method C 311,
The American SOCiety for Testing and Materials takes no position respecting the validity of any patent rights asserted in connection
with any item mentioned in this standard, Users of this standard are expressly advised that determination of the validity of any such
patent rights, and the risk of infringement of such rights, are entirely their own responsibility
This standard is subject to revision at any time by the responsible technical committee and must be reviewed evel}' five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision ofthis standard or for additional standards
and should be addressed to ASTM Headquarters. Your comments will receive careful consideration at a meeting of the responsible
technical committee, which you may attend, If you feel that your comments have not received a fair hearing you shOUld make your
views known to the ASTM Committee on Standards, at the address shown below.
This standard is copyrighted byASTM, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
Individual (single or multiple copies) of this standard may be obtained by contacting ASTM at the above address or at
(phone), 610-832-9555 (fax), or service@astm.org (e-mail); or through the ASTM website (www,astmorg),
Multiple factor, calculated as the product of loss on ignition and fineness,
amount retained when wet-sieved on (No. 325) sieve, max, "loA
Increase of drying shrinkage of mortar bars at 28 days, max, difference, in %, 0.03
over control"
Uniformity Requirements:
In addition, when air-entraining concrete is specified, the of air- 20
entraining agent required to produce an air content of 18.0 vol of mortar
shall not vary from the average established the ten preceding tests or by all
preceding tests if less than ten, by more than,
Effectiveness in Controlling Alkali-Silica Reaction:
c
Expansion of test mixture as percentage of low-alkali cement control, at 14 100
days, max, %
Effectiveness in Contributing to Sulfate Resistance:
D
Proced u ro A:
Expansion of test mixture:
For moderate SUlfate exposure after 6 months exposure, max, % 0,10
For high sulfate exposure after 6 months exposure, max, % 0.05
Procedure B:
Expansion of test mixture as a percentage of sulfate resistance cement 100
control after at least 6 months exposure, max, %
255
0.03
20
0,10
0,05
100
0,03
20
0,10
0,05
100
4
FL'f A5;+) 1> 0 c"'u t--{ m
\ 3"1\>'\1, A6"", Xl 1:)1
r
aneon report fly ash in sulphate environment (1654x2340x2 tiff)
ANCON Beton Pty Ltd
ACN 076102<133 PO BO)(421
Practical Concrete Technology" Glenside SA 5065
Australia
Tel: +618837974
Fax: +61 88379 72
Mobile: +6141205661
[orrespondenc. 11m: POz003OC1.9SVld.dor
14 October 1998
ANtON REPORT
an
PQ2:zo1ank Philippines. Fly-ash Testing for its
Pel'fo.rnuulce in a 'E;nvuQnrnent
and fo1;' Other DmabiJity Critel'ia .
REPORT To: Mr. T. Schroeder Mcmage:r Pozzolanic Philipp:ines
PREPARED BY: Ian Burnett
UPDATED REpORT: 14 October 1998
Report Version 1d
Ot/11' Offices;
Sydney: Tel: +61293861470
Perth! 'reI, +61 8 94451435
Melbourne: Tel: +61397101820
Fax: +612 93861471
Fax: +61894451806
P"": +61397101811
JiV? 11Z.tJ S T.
m;:;hti,,;fh less effort, greater
more complete
FlY ASH
Hardened State
..
Fly ash COrrtinues tc Cl:lI'l1bine free lime,
ino\?asing s!rudural ova- lime.
PenoeabiJity.
The lubricating action of
reouces w$ter content for nf"r""""
density and reduces bleed channels.
This, coupled with long-term Pozzolanic
reaction which ties up free lime. lowers
permeability. (see chart).
Uil rability.
ash concrete is denser and less
permeable which keeps aggfessive
compounds outside the concrete where
their destructive action is lessened. Fly
ash concrete is.then more resistant to
attack by sulfate, mild acid, soft (time
hungry) water and sea water.
. . RellucedSnltateAtlack .
As Fly ash concrete is denser and less
permeable with chemically-bound free
lime; it keeps sulfate from getting inside
and crei3ting its destructive expansion.

With reduced permeability and
chemically-bound free lime and salts,
ash concrete reduced
efflorescence, causing
compounds are held inside the concrete.
BeducedShrinkage. .
The biggest contributor to drying
shrinkage is unit water content, The
lubricating action of fly ash spheres
reduces water content and with it. drying
shrinkage,
Reduced Heot01 HydraliOR,
The Pozzolanic reaction between fly ash
and lime generates less heat resulting in
reduced thermal cracking,
R-f'ACTOR
R = ~
F\O,
~ 0.75
ancon report fly ash in sulphate environment (1654x2340x2 tiff)
ANCON Beton Pty Ltd
ACN U761024a3
"Leading Practical Concrete Tecimology"
PO Box: 421
Glenside SA 5065
Australia
Tel: +618837974
Fax:: +61 8 8379 7Z
Mobile: +614120566'
C""""pornlenc. R.,;, p0z0030d98vld.dor
14 October 1998
,-
ANtON REPO:RT .
on
PQZzQ}i;lmc Philippines. Flyaah Test-ing for its,
Pe.riQ,t'lUaUce jn a 'En:v4'Ql1l:Uellt
and for Othe]' D1U'abUity Crite.xia
-----..
REPOR.T To: Mr. T. Mfma,gex Pozzolarric Philippines
PREPARED :6Y: Ian Burnett
UPDATED REPORT: 14 October 1998
Report Version 1 d
OtTmr Off'ias: . Sydney: Tel: +61 Z93861470 Perth! 'l:eh +61894451485 Melbourne: Tel: +61397101820
Fax: +6:1 Z93861471 Fax: +61 8 94451806 Fax: +61::; 9710 1811
Technical
Number 2
FLY ASH:
THE MODERN POZZOLAN
What Are Pozzolans? Pozzolans are sili
ceous or siliceous/aluminous materials which,
when mixed with lime and water, form
cementitious compounds.
What Is Fly Ash? Fly ash is the best known
- and one of the world's most commonly used
- pozzolans. Physically, it is a very fine pow
dery material, predom'inately silica, with par
ticles almost totally spherical in shape.
A Bilef History: Fly ash closely resembles
the volcanic ashes used in the production of the
earliest known hydraulic cements some 2,300
years ago-nearthesmall Italian town of Pozzuoli
(which later gave its name to our modern day
pozzolans). Predating portland cement by over
2,000 years, fly ash has significantly improved
the performance of concrete throughout its
history.
The Modern Pozzolan. Today's fly ash is
a by-product of burning finely ground coal in
electricity generating power plants. It is cap
tured from the exhaust gases of the plants by
electrostatic precipitators or bag houses which
leave relatively clean air to escape from the
smoke stacks. This accomplishes two objectives:
the fine fly ash is prevented from polluting the
ambient air and the collected material once
processed becomes a valuable resource for
industry.
Why Is Fly Ash Used In Concrete? Fly
ash is widely used today as a cementitious
material in the production of a great variety of
concrete mixes. The advantages of using fly
ash are detailed in Pozzolanic Technical Bul
letins. Briefly they include: *lncreased Com
pressive Strength * Increased Workability
*Increased Durability 'Decreased Permeabil
ity *Reduced Sulphate Attack *Decreased
Bleeding and Segregation *Reduced Shrink
age *Reduced Heat of Hydration *Reduced
Cement! Aggregate Reaction *Increased Flex
ural Strength.
The Fly Ash Advantage: The spherical
shape of fly ash particles and their extreme
fineness, has a beneficial effect on the work
ability of concrete. The shape allows the con
crete to move more freely ... and the fine par
ticle size allows better filling of the voids. The
slump test photograph shown below clearly
illustrates the improved cohesion of the fly ash
concrete mix.
I
I
Ordinary Concrete
Fly Ash Concrete
ALASKA. BRITISH COLUMBIA CALIFORNIA COLORADO IDAHO MONTANA
NEVADA. OREGON NEBRASKA WASHINGTON WYOMING UTAH
Technical IBllllIUL[illlW
Number 3
WHAT IS FLY ASH?
A&TM
The American So,ciety For Test
Type F
ing ancLMaterials defines pozzo!an
1, Most effectively moderates
as .-ra- siliceous or siliceous and
heat gain during concrete curing
aluminous material which in itself
- and is therefore considered an
possesses little or no cementitious
ideal replacementfor some cement
value, but will, in finely divided
in mass concrete, and high strength
form and in the presence of mois
mixes. For the same reason, Type F
ture, chemically react with calcium
is the solution to a wide range of
I
hydroxide at ordinary temperatures
j
summer concreting problems.
I
to form compounds possessing
2. Provides sulfide and sulfate
cementitious properties."
resistance equal or superior to
Types F and Cfly ash processed
Type V cement. Type F is often
and distributed by Pozzolanic are
recommended for use where con
by-products of the combustion of
crete may be exposed to sulfate
coal in large power plants. Pozzo
ions in soil and ground water.
lanic fly ash is collected in electro Type C
static precipitators or bag houses, 1. Most useful in "performance"
then claSSified by precise particle mixes, prestressed applications,
size, thus assuring a uniform, qual and other situations where higher
ity product. early strengths are important.
, I
Type F fly ash is available in the 2. Especially useful in soil
I
largest quantities. Produced when stabilization since TypeC may not
I
either anthracite, bituminous or require the addition of lime.
sub-bituminous coal is burned, For additional information or
Type F is generally low in lime, specific questions about fly ash.
usually under seven percent, and contact your nearestPozzolanic
contains a greater combination of
technical representative.
silica, alumina and iron (greater
than 70 percent) than Type C fly
ash.
Type C fly ash normally comes
from lignite or sub-bituminous
coal. These types of coal may
-prod-uceanashwlthhigher lime
contents - generally more than 15
percent - often as high as 30
percent This gives Type C unique
self-hardening characteristics.
Where as both types of fly ash
impart a wide range of qualities to
many types of concrete, they differ
chiefly in the following ways:
1\' l\eVA QOITICU f"r.H lUCIA. f"'1'l.11C"f""IOhlill nnl InAt-tn.

I

I I
ASTM SPECIFICATIONs FOR FLY ASH Number 4 I
I
Like all materials used in the production of I
concrete, fly ash must meet the stringent require- ,
i
ments of ASTMsp. ec .. i.f. katio. nS.. f.. JY...ashsp...e.cific...a-l
tions are addressed under ASTMC-6 J8 "Fly
Ash and Raw orCalcinedNalural Pozzolan for \1
Use as a Mineral Admixture in Portland Cement.
Concrete.." While these standards are continu- i
ously under review and subject to change, a reP-i
resentation of this specification, current at the I
time of this writing follows this article.
The specifications are categorized by
chemical and physical pr9perties for standard
and optional requirements. Standard require
ments are imposed for alllly ash produced while
optional requirements are applied only when
certain conditions exist.
Standard Chemical Requirements:
Major Oxides. .summation of the major
oxides of Si0 , A 1
3
, and Fe 0 indicates the
2 2 2 3
amount of reactive material present and func
tions between class F
and class C llyash. Allhough not expressly ad
dressed, CaO fills in [or the reduced levels of
major oxides in class C ny ash.
Sulfur Trioxide. S03 content limitation is
based on minimizing expansion during hydra
tion.
.... ... M.?isture .. is

jty,Values as lowaSonepercent may cayseH9.,w
problems.
Loss On Ignition. Loss On (LOl)i
is a measure of unburned carbon remaining inl
the By ash. It is desirable to maintain the lowest
level of LOI possible, especially for air entrained I
concrete as carbon absorbs air-entraining agent!
rendering it unavailable for generation of an airl
void system. A low LOI is also desirable to pre-
v.... e....n....'.diSCOIO... rat.ion. O.....f. t.he ... co.fl .... I fOf.. class
FUy lirnitedloJypercent has
.
been lowered This was done to
improve Ily ash quality. 'I
Standard Physical Requirements: .
Fineness. The specilication places an up-I
per limit on coarseness of lIy ash at 34 percent
retained on the #325 sieve. Maintaining uniform, l
rin('! ness of tbe fly ash isirr1pgrtantj n producingl
quality concrete of consistent caliber. i
Strength Activity Index. Strength activi

weIght (JLce!'f1enUs r!'!placedwlthhke weight pJI
rlyas
n
.:jlhe test departs from the oid pozzolanl
test which was a 35% equivalent volume
ment o[ cement with fly ash. The current testlSj
felt to better simUlate the usefulness of [ly
lor strength in concrete. r
Lime Pozzolanlc Activity Index. Poz
zolanic activity with lime is again a measure 0,
I
the pozzolanic activity 01 the fly ash being tested
using a mortar mix composed of lime, fly ash
and sand.
Water Requirement. Water requirement
is an important tesLindicating the capacity of fly
ash to reduce water demand. Most active fly ashes
of good quality generate water demands of Jess
than 95 percent 01 the total cement control.
Autoclave Expansion. Autoclave expan
sion forces tota: cementitious hydration under
temperatures and pressures and gives an
accurate determination 01 long term expansion
characteristics cl fly ash concrete.
Uniformity requirements for
the specilic gravity and fineness of the lIy ash
ensure a level 0:' consistency of the fly ash en
abling unHorm production of concrete.
Optional Chemical Requirements:
Available Alkalies. Available alkalies are
measured as the amount available in a saturated
lime solution. Thi.s requirement is recommended
only where the threat 01 alkali-aggregate reac
tions my be encountered.
OpUooal Physlical Requirements:
Multlple Factor. Multiple factor is the
product of fineness and La!. The intent is to
prevent both fineness and La! lrom reaching
specification limits simultaneously and is a
method 01 maintaining uniformity.
Drying Shrinkage. The drying shrinkage
test measures increase in shrinkage of the
fly ash in a morta,r sample. Most high quality fly
ash will actually l;ed.uce the d(Yingshfinkage in
concrete. .
Air Entrain.ing Admixture Demand. Air
entraining admixture demand reflects the effect
of fly ash on air entraining admixture and en
compasses changes in fineness and La!. A high
LOI affects the ability to entrain air. Fly ashes
with LOI under one percent generally do
not affect admixture demand significantly.
Reactivity with Cement Alkalies. Ce
ment alkali reactlon indicates the elfectiveness
of fly ash in reducing alkali-aggregate reaction.
Due to the test method and the materials com
prising the test, it is only an indicator and cannot
.beidentifiedwith perlormance_olconcrele.This
test should only be used when alkaliaggregate
conditions are suspected.
ASTM specifications fully cover require
ments lor /Iy ash in Portland cement concrete
and provide [or the use 01 the uniform. well tested
materials for lly ash concrete production.
for further in/ormation Or specific questions
regarding ASTM specifications for fly ash. con
tact your neares!: Pozzolanic technical repre
sentative.
(specificaliOf/ chart 0(/ back)
ALASKA' BRITISH COLUMBIA iCALlFORNIA' COLORADO' IDAHO' MONTANA
. .... _..... _--. ......... . ........... ,
l
..
Technical
Number 5
WHY USE FLY ASH?
Concrete manufacturers. engineers,
architects, developers and contractors all
have an interest in specifying or using
ash on a routine basis to improve
quality of their project and toincrea'se
their cost effectiveness.
Ready Mix Producers. Aready mix
prod ucer has several reasons for using
ash in concrete.
1. Fly ash can compensate for fines
not found in some sands Clnd, thereby,
enhance pumpability and concrete
finishing.
2. Fly ash will result in a more pre
dictable and consistent finished product
which will ensure customer acceptance.
3. Fly ash offers flexibility in mix
design providing a greater range of mixes
from liquid soil at 100 p.s.i. to high
strength 8,OOO-plus p.s.i. concrete - pro
. duced by the same batch plant without
exotic equipment.
4. Fly ash improves the flowability of
the concrete which translates into less
wear and tear on alilhe producer's equip
ment from batching facilities to trucks.
5. Fly ash enables the producer to
customize designs to each customer's
needs. thus providing the producer who
uses it with a competitive advantage.
Engineers and Architects. Engi
neers and architects will find that fly ash
provides the following benefits:
1. It enables them to provide the
client with a superior and more durable
finished concrete.
2. Fly ash produces a high strength
concrete that accommodates the design
of thinner sections.
3. Fly ash permits design flexibility
acc()mmudating curves. arches and other
'pleasiilgarcliilecTufal eHects
4. The addition of fly ash to the mix is
a bu ilt in insurance lor later age strength
gain in concrete.
S. Fly ash ensures that the concrete
will qualify as a durable building material.
6. Fly ash contributes to the aesthetic
appearance of the concrete
Developers, Contractors, Owners.
ash concrete provides the following
advantages to developers, contractors and
owners:
J. The workability of fly ash concrete
generally ensures that the speed of con
struction is laster which translates into a
quicker return on investment.
2. Fly ash in the mix accommodates
more creative designs.
3. Since rJy ash concrete is not as
vulnerable to deterioration or disintegra
tion as rapidly as concrete without fly ash,
it ensures low-maintenance buildings
which will retain Iheirvalue over the long
term.
Fly ash definitely enhances concrete
construction and returns real benefits to
every member of the building team.
For further information or specific
questions about the use of Jly ash, contact
your nearest Pozzolanic technical
representative.
ALASKA' BRITISH COLUMBIA' CALIFORNiA' COLORADO' IDAHO' MONTANA
.......
NEVADA' OREGON' NEBRASKA' WASHINGTON' WYOMING' UTAH
TELEPHONE: LOCAL 2329320, (800) 426-5171 To A If. -20., '2
''-IT\U\\ /1 .;J
1:.
fbE"TOI'Ie 7vol : R.EA-l>Y Mix.
(f
oieal m\lllILILllilJ1JlNJ
Number 6
WHAT IS TYPE IP CEMENf?
Portland-pozzolan cements (Type I P)
are precise blends of portland cement
and fly ash (pozzolan). These cements
are manufactured to enhance concrete
products by introducing the properties
imparted by fly ash: increased compres
sive strength, increased workability, in
creased durability, decreased permeabil
ity, reduced sulphate attack, decreased
bleeding and segregation, reduced shrink
age, reduced heat of hydration, reduced
cemenVaggregate reactions, increased
flexural strength.
Specifications. Specifications lor
these cements are in ASTM C-595-81 and
cover the following cements:
1
L Types J(PM) & I (PM)-A pozzalan
modified portland cement for use in gen
eral concrete construction. Percentages
of fly ash included are up to 15 percent.
2. Types I P & 1 P-A portland-pozzalan
cement for use in general construction.
Percentages of fly ash range from 151040
percent.
3. Type P portland-pozzolan cement
for use in concrete construction where
high strengths at early ages are not re
quired. Percentage of fly ash is generally
ati,<!Oper(Jent.
TypelP cements are produced by
two methods, either by direct blending of
a specification fly ash or by intergrinding
ash with cement clinker in a finish
Intergrinding allows the use of coarse.
non-specification fly ash to be used since
grinding in the finish mill will reduce its
fineness.
Fly Ash Superior. Pozzolans nor
mally used include fly ash, diatomaceous
earth, shale, volcanic ashes or pumicites
as well as somecalci ned claysand shales.
gIves tfie-best results lor produc
tion of Type I P cement.
I. Fly ash consists of spheres which
enhance workability with a lubricating
action not given by high-surface area,
angular, natural pozzolan particles which
tend to yield sticky concrete mixes.
2. Fly ash spheres reduce water de
mand; thus improving concrete quality
white natural pozzolans increase water
demand. Upon intergri!)ding, the larger
ash spheres are crushed, releasing many
smaller spheres which were trapped in
side. Releasing these spheres can signifi
cantly increase the aCtivity of a fly ash.
Caution should be used, however,
with fly ashes of high carbon contents.
Upon intergrinding, the carbon particles
will be ground very fine exposing a high
surface area which can result in problems
in entraining air in concrete. Highcarbtm
ffy ash should not be used in this
uppltcati6n5
Although the use of Type I P cement
affords the user the advantages of fly ash
concrete, blended cements limit the flex
ibility of the concrete producer to vary
percentages of fly ash to meet different
needs. The best way to maintain flexibility
is to inventory fly ash in a silo of its own
and design the mixes as needed.
questions about 1 P cements, contact your
nearest Pozzolanic technical representative.
IASTM C-595-81: "Standard Specification For Blended Hydraulic CemenC. ASTM.Annua/ Book Of Standards.
Part 14. Concrete And Mineral Aggregates: 1981
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Technical [E)(U][LllIEmW
Number 7 CHEMICAL COMPARISON OF FLY ASH
AND PORTlAND CEMENT
The chemical composition of fly ash is
very similar to that of portland cement
The table below shows typical com.
pound#analyses for two fly ashes and a natural
pozzolan (Class F Fly Ash, Class CFly Ash and
Class N Natural) and ordinary portland
cemenl A glance at the table reveals:
I. The same compounds exist In fly ash
and portland cemenl Those of flv ash are
amorphous (glassy) due to rapid cooti ng;
those of cement are crystalline formed
slower cooling.
2. The major difference between fly ash
and portland cement is the relative quantity of
each of the different compounds. Portland
cement is rich in lime (CaO) while fly'ash is
low. Fly ash is high in reactive silicates while
cement has smaller amounts.
TI'PICAL CHEMICAL COMPOUNDS
IN POZZOIANS AND PORTlAND CEMENT
POZZOlAN TYPE
CHEMICAL
COMPOUND
ClASS F CLASSC ClASS N
CEMENT
SiO 54.90 39.90 58.20
22.60
25.BO AI
2
0
3 16.70 IB.40 4.30
6.90 5.BO 9.30 2.40
CaO B.70 24.30 3.30 64.40
MgO LBO 4.60 3.90 2.10
0.60 SOl 3.30 . LI0
2.30
Na,O & K
2
0 0.60 L30 1.10 0.60
The table illustrates the basic chemical
durable cementing compounds no different
difference. Portland cement Is manufactured
from those formed during hydration,of ordinary
with CaO some of which is released in a free
cement.
state during hydration. As much as 20
A review of the chemistry of both materials
of free lime is released during the hydration of
makes it quite apparent that a blend of the two
JOO pounds of cement. This liberated lime
will enhance the concrete product and effi
forms the necessary Ingredient for reaction ciently utilize the properties of both,
with fly ash silicates to form strong and
HYDRATION PRODUCTS OF CEMENTING BINDERS
PORTLAND CEMENT
PORTLAND, CALCIUM
CEMENT
(PC)
+
WATER -)
(H,Ol
,----__
SILICATE
HYDRATE
(CSH 1
PORTLAND CEMENT
T
FREE
LIME
(CAOH)
WATER
--ASH - -
PORTLAND FLY
CEMENT + ASH + WATER +
( PC) ( FA) ( H, 01
"'00'7
_ _
CALCIUM
SILICATE
HYDRATE
$Ot.;,UABLE,
(CSH)
FREE FLY
LIME + ASH
( CA OH) ( FA)
THROUGH POZZOLANIC ACTIVITY. FLY ASH COtotilNES WlTH FREE LIME TO PRODUCE THE
SAME CEMENTITIOUS COMPOUNDS FORMED BY THE HYDRATION OF PORTLAND CEMErIT.
For further information or specific questions about the chemistry or fly ash, contact your
nearest Pozzolanic techniCal representative.
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Technical WlliJILILill1J1]W
FLY ASH AND THE
. CONCRETE PRODUCER
During ,the past 20 years, the
producer of ready-mixed concrete
has experienced a number of chal
lenges in incorporating new tech
nology into day-to-day operations.

The addition of air entraining
chemical admixtures to concrete
mixtures previously containing
only cement, water and aggregates
required increased production
equipment and controls to provide
satisfactory performance and
uniformity.
Chemical water reducing ad
mixtures further complicated con
crete production by opening a new'
range of product offerings with
varied properties depending upon
need and choice.
Conversion of concrete pro
duction from a sack content stand
ard to a compressive strength per
formance standard increased the
need for consistency in produc
tion and more testing to ensure
quality.
Meeting these technological
challenges and others have re
quired expertise and operational
changes which have resulted in
the production of better quality
concrete and a wider range of
concrete products.
Ely.asb.. presents a technical
challenge similar to the others and
also offers many benefits and
opportunities. Benefits to concrete
include:
Increased ultimate compressive
strength
Reduced water demand
Number 9
Improved workability
Better pumpability
Easier finishing
Reduced segregation
Increased density
Reduced permeability
Reduced bleeding
Reduced heat of hydration
Reduced drying shrinkage
Reduced thermal volume change
Increased early age extensibility
Decreased creep'
Increased flexural and tensile
strength
Increased ultimate modulus of
elasticity
Decreased leaching and
efflorescence
Decreased alkali-aggregate
reaction
Increased ultimate freeze-thaw
resistance
Increased sulfate resistance
For information about the prop
er handling and storage methods
for fly ash, see Technical Bulletin
Number 10.
For information about propor
tioning fly ash concrete mixes, see
Technical Bulletin Number 11.
For information about supply
of fly ash, see Technical Bulletin
Number 1.
For information about ASTM
specifications for fly a s h . ~ e e
For further information Or assis
tance, please contact your nearest
Pozzolanic technical representative .
TELEPHONE: LOCAL 2329320. (600) 4265171
() O .... ....... I_ ... ;"'" l .... t .... ....... 'll'>ro. ...1 f"'''' ...... " ......... 1eo:-....=
10 HANDLING FLY ASH
ash and cement are transported
and handled with common
ment but a similarity in appear-
has some different
that can affect its
FlowabUity.
reveal that fly ash particles
This rounded shape prevents the
from interlocking and restraining the flow.
"When aera.tedjflyashiscapapleof flo'ving
{ilrough openings where will not
flow.
More Abrasive. Fly ash consists,
basically. of particles of glassy silica
dioxide that have the abrasive qualities of
sandblasting grit. Fly ash flowing through
a small leak can rapidly enlarge it to
increase the rate of [low.
These two properties can cause prob
lems if there are leaks - even very tiny
ones- in either the storage orthe handling
equipment.
Therefore, if it's necessary to store fly
ash adjacent to cement in a split silo, the
partitioning must be carefully checked for
leaks to prevent seepage. Double partition
walls are recommended providing an
extra measure of safety.
Separate dust collection systems
must be used on split silos to avoid
contamination in compartments.
REMEMBER - FLY ASH WILL FLOW
WHERE CEMENT WILL NOT.
Highly Absorbent. Fly ash can be
handled equally well with either screw
systems or air-slide equipment, However,
some fly ash is in a sense "hydroscopic"
and it may readily absorb moisture.
Special precautions must be taken to
ensure that any equipment used to handle
ash has adequate water
_ Watershouldnol be'
allowed to collect on top of silos or above
C>nllipment that handles fly ash.
Alcohol traps have proven very effec
tive for removing moisture from the aera
tion source. Where boit-together equip
ment is
llli3illJILILlliUDW
Special Considerations. The fine
ness of the flv ash also reauirps that
screws or air-slides should contain posi
tive cut-off valves_ Certain air-slide designs
may be excepted from this, although
positive cut-offs are generally a good idea
for all fly ash systems: As a general ru Ie,
screws should be used for upslopes (max.
26 degrees) and air-slides should have a
down slope of 5 to 8 degrees.
Since dry fly ash is' generally less
dense than cement, tonnage capacity of a
silo will be less than for cement.
Unless fluidizing techniques are em
ployed, there is a danger of pa<;king in the
siJo and bridging may occur,ci3.
usin
g
difficultyof discharge. Do not use vibrators
to attempt to facilitate discharge Ofbihs.
Fly ash tends to "fly" more easily than
cement. The drop into the mixing hopper
should be kept to a minimul11 and an
enclosure provided if possible.
Most pollution equipment designed
for cement installations will work for fly
ash. However, should problems exist, it
may be that there is not a high enough
"c1oth-to-air" ratio in the dust collector.
Most older dust collectors have a 3 to 1
cloth-to-air ratio ... but since a high
quality fly ash is so fine. it may require a 7
to 1 ratio.
Fly ash may be handled with some
what lower air pressure than cement to aid
in the reduction of dusting problems. Fly
ash moves well at 10 from DnPll mrl t
discharge vehicles, and at I' to 6
to 10 c,Lm. for aeration and air-
slides.
in -" ...
)!'it";'
2. A\'oid 'II:' h. ,1<" II1l'l'.III'!l1t'nl
:1. A\'oid hi!!h ;,ir l'ro'" ,'" ll: Iht lli::ldlirJ:.!
equipment.
For further information or ti<.:
the
please contact your nearest Pozze;
Janic technical representatin:.
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PROPORTIONING FLY ASH
CONCRETE MIXES
Effects of Fly ProportIonIng
. Proportioning fly ash concrete mixtures
is only slightly more complicated than pro
portioning plain cement concrete mixtures.
The same solid tech
niques described in A'ef211 are employed
as are used with conventional concrete
mixtures.
AC! 211 gives theproportioner a series of
steps through which values are selected for:
cementitious materials content
water content
air content
coarse aggregate size and content
These ingredients are converted into
solid volumes. The difference between the
sum of the total volumes and 2.7 cubic feet
will determine the ilecessruy volume of sand.
Sand weight is then calculated to complete
the trial mix proportions. The accuracy of
this mix must be checked by physically
preparing a sample of the proportioned in
gredients and testing the mixture for yield.
While fly ash is a cementitious material
which greatly benefits concrete, the propor
tioning of concrete containing fly ash requires
adjustments due to the physical properties
of the ash. Viewed microscopically, fly ash
particles are found to be spherical in shape.
Because of this and other physical attributes
of fly ash, one can expect the following:
The ball bearing shape significantly
aids the workability of concrete. This allows
for lower sand content than conventional
mixes while handling remains similar. As
the propqrtion of sand is reduced, all pertor
anceaspects of llie concrete are enhanced.

plain con
crete, and this redud'lon can be further in
creased where high levels of fly ash are used.
The specific gravity of fly ash is much
lower than that of Portland cement; there-
TFI FPHnNF: I nr.AI
i
TechnicalIB3lliJIlJLlliUDINJ
Number 11
While ffy ash is generally
fore, 100# of fly ash has a much greater solid
volume than the same weight of Portland
cement. Past practice has dictated a cement
reduction when water-reducing admixtures
are used; however. in fly ash concrete the
(cefuentand flYa:sh)
/volume is not lower. ThiS higher
quantity of cementitious materials greatly
assists in the finishing process.
Air-entrainment is not affected ad
versely with high quality, low LOI fly ash
supplied by Pozzolanic, but one can expect
a need for a sligj:ltly higher dosage of air
entraining due to the increased solid volume
of cementitiousfines.

The of admixtures
is encouraged with fly ash concrete mix
tures; however, certain factors must be con
sidered:
temperatures, a nonnal
dosage of water-reducing admixture is cal
culated on the combined weight of cement
plus fly ash.
2. During periods temperatures, it
is advisable to use a conservative dosage of
normal set time water-reducing admixture
calculating the dosage based only on the
weight of cement. Under cool temperatures,
normal setting water-reducing admixtures
may cause retarded concrete set. Reducing
the dosage utilized during cool conditions
can help maintain proper concrete set times.
DeterminatIon of Fly Ash Content
Several methods exist for the selection
of the fly ash content in a mixture.
Spedftcatlon.:'ThespeciHcati0flS for
a particular project may define a required fly
ash
. ..
1:1\>00 the (:0ncetnsi)
(continued on back)
{ROm 4265171
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Technical J]3ill1ILllIETI1lW
Number 12
FLY ASH FOR
STRUCTURAL CONCRETE
A major use for fly ash in the construc
tion industry is in the production of high
quality structural concrete. Fly ash contrib
utes beneficial properties to the concrete
while helping to maintain economy. These
properties include compressive strength, lu
brication and increased durability.
CompressIve Strength. Specifica
tions for normal strength concrete generally
require a given level of strength in 28 days.
Fly ash concrete is easily proportioned to
meet strength requirements at this age or
any other age desired.
Fly ash concrete designed to be
equivalent in str ngth to ordinary concrete
at 28 days will normally exhibit slightly lower
strength at early ages. This slight early age
strength reduction does not adversely affect
job sequencing due to construction loading.
(See strength gain curves in Fig. 1).]
Fly ash concrete can be easily propor
tioned to meet strength specifications at early
ages (3 to 7 days). Economics, although still
attractive, will not be as great as when pro
portioning for of age orlater. Fly ash
has been.titilizedinrnany
proj ec!s.b8ause ofmanyheriefieiarleatllres
other than economy.
Later age strength gain after 28 days can
prove to be quite valuable. It may be used to
obtain required strengths at lower cost. It
may be relied upon in deciding structural
acceptability where compressive strength
tests indicate lower than specified strengths.
It also plays a key role in producing high
strength concrete.
High compressive strengths from 6,000
p.s.Lto... H,.oQOp,sJ, are.gflenrequ.ire<:l ... in
structural concrete. High quality fly ash
complying with ASTM C-618 is most advan
tageous in achieving these strength levels.
The strength gain derived from 10 to 25% fly
ash (by weight of cementitious materials)
cannot be equalled by adding cement.IJt has
also been found to produce the same high
strength levels in concrete as silica-fume
Fly Ash LubrIcates the MIx. Flyash
spheres impart a ball bearing lubrication to
plastic concreteenhancingw?rkabilityat the
same slump as ordinary concrete while re
rlucingwaterconvenience. Enhanced work
ability contributes increased quality to
structural concrete in several ways:
1. Concrete pumping is made easier.
Flow rate may be increased without in
creasing line pressure, and line blockages
are reduced. Record pumping time is
achieved as a result of the use of fly ash. The
technique of injecting concrete into the
bottom of the form from the pump hose is
made possible by the workability of the mix
from the fly ash.
2. Form filling becomes easier. Fly ash
concrete is more responsive to vibration,
enabling forms to be fully filled more quickly
and with less effort.
3. Segregation is reduced due to in
creased cohesiveness and workability as well
as resulting reductions in . s, rock

.

Janie activity which contributes cementitious
value to concrete also yields increased
density and reduced permeability. As a re
sult, penetration of aggressive media is
slowed or eliminated thereby increa:;ing
concrete durability.
Fly ash is especially effective in the ef
fort to restrict chloride ion penetration and
the accompanying disintegration it causes.
for parking structures, highway

. _
Pozzolanic activity afsOchemically binds
with cement alkalies, keeping them from
combining with reactive aggregates and also
acts to reduce internal expansion.
Reduced cement contents in lIy ash
concrete lowers the heat of hydration, which
is especially beneficial in mass concrete
without the high cost.
(continued on bock)
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FLY ASH IMPROVES WORKABILITY Number 13
Though it is neverspecifiecj, workability
is one 01 the most critical characteristics of
concrete. WorkabilitY refers to the of
handling, placing and finishing of fresh or
concrete. Slump is the general in
dicator of workability, yet different concretes
can have greatly different levels
with the same slump measurement.
Blemishes in concrete, typically called
rock pockets, are indicative of concrete
without suitable workability I even though the
slump may be judged to be acceptable. Rock
pockets indicate a separation of the paste
from the coarse aggregate in the concrete
mix. Concrete must be cohesive even at high
slumps to maintain its homogeneous char
acter and avoid segregation and costly rock
pockets. Fly ash offers this feature without
extra cost.
Reduced Water of Convenience.
25 pounds (three gallons) of
water are normally required to hydrate 100
pounds of cement
l
A normal concrete mix
will generally contain twice the required
amount of water to hydrate the cement
enough to facilitate handling and plaCing of
the concrete. This additional water, called
increases slump but
aHhe cost of decreased cohesiveness. Wa
ter of convenience is reduced when fly ash
is added to the mix because the plasticizing
action results in a two to ten percent water
reduction in the plastic concrete to produce
the same level of slump as plain concrete.
Reduced water of convenience at the same
level of slump makes for more cohesive
concrete and decreases the occurrence of
costly segregation.
Greater Consolidation. Fly ash
concrefeISadllaIlY-irioreworkablelhali p1<iili
cement concrete at equivalent slump. The
VEBE test measures the time and energy
necessary for consolidation of concrete un
der vibration. Figure 1 shows the remark
able difference in time and energy required
for consolidation of plain and fly ash con
cretes.
Great benefits can be obtained when
using the easier, more complete consolidat
fng .fly ash concrete in areas of difficult
placement where rock pockets and other
pJacing derects often occur. Engineers un
derstand the effectiveness or using fly ash
concrete in tall thin walls, such as those
used in water tanks. They know they have a
better chance of getting the dense, void free
concrete they have specified when fly ash is
included in the mix.
os
20
v

l5
:E
....
LIJ
0:0
wlO
>
"
o
TYPICAL
VEBE TIME
VS. SLUMP

P1.AIH
""
"

"'f '
v
"
in.
Paste Volume Increases. The spe
cific gravity of fly ash is lighter than cement.
When replacing cement with fly ash on a
pound for pound basis, the result is a greater
solid volume of cementitious fines. Propor
tioning concrete mixtures with only water
reducing admixtures results in a greatly di
minished volume of cementitious fines. In
16 lakihgcemefifahd
water out of the mix and replacing them with
sand and gravel. The strengths may be ac
ceptable, but the workability may not be.
Proportioning penormance concrete with
ash virtually guarantees a greater solid vol
ume of cementitious materials which in itself
helps promote cohesiveness and workability.
Cementitious fines are very important to
(continued on back)
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Technical IDOJILILlliUlJW
- 1
FLY ASH DECREASES THE
Number 15
PERMEABILITY OF CONCRETE
Permeability of concrete and the result
ing level of durability are matters of the
greatest concern as the infrastructure of our
nation disintegrates before our very eyes.
Our task now is to replace that which has
fallen apart and to do so in such a manner
that it will last. Attention to permeability and
durability then become our primary goals.
Permeability is defined as the coefficient
representing Uthe rate at which water is
transmitted through a saturated specimen of
concrete under an externally maintained
hydraulic gradientl," Permeability is in
versely linked to durability in that the lower
the permeability, the higher the durability of
concrete.
Permeability is most frequently being
described now by the chloride-ion perme
ability which measures the passage of
electrical current through a concrete speci
men exposed to a batch 01 sodium chlo
ride
2
, Limits 01 acceptability are as shown in
the table
Table 1. Chloride Permeablllty
Based on Charge Passed
Charge Pused Chloride
(coulombs) Permeability Typical 01
,. 4,000 High High walercemenl ratio
(>0.6), pee
2,000 4.000 Moderate Moderale walercement ralio
(OA 10 0.5), pee
1,000 2,000 Low Low water-cemenl ratio
004), PCC
100 1,000 Very Low Latex-modified concrele,
silca-lume collcrete
< 100 Negligible Polymer impregnated concrele,
polymer
It has been common thought that
latex modified and silica-fume concretes had
the ability to obtain permeabilities Jow
enough to pose long term durability lor our
highway system. Recent testing, however,
has shown that properly proportioned con
cretes using a combination 01 fly ash, nor
mal or high-range water reducing admixtures,
and air entraining admixtures have the abil
to produce the same low levels of perme
_________
the cementitiouS\
minimize water and
( reduce bleed channels all of which increase i
>concrete density. These factors yield con-
<-crete of low permeability with low internal \
! voids. Durability is increased to freeze-thaw /
damage (see Technical Bulletin #14) and (
( disintegration from attack by acids, salts or )
__ #!-Z)__
- Fly Ash llel.Psrrve"w(ys. Using
Pozzoianic fly ash in the concrete mixgreatly
aids permeability and durability in five ways;
1. Through poz:z.olanic activity fly ash
chemically combines with water and calcium
hydroxide forming additional cementitious
compounds which result in denser, higher
strength concrete. The calcium hydroxide
chemically combined with fly ash is not
subject to leaching thereby helping to
maintain high density.
2. The conversion of soluble calcium
hydroxide to cementitious compounds de
creases bleed channels, capillary channels
and void spaces and thereby reduces per
meapility.
3. At the same time, the above chemical
reaction reduces the amount of calcium hy
droxide susceptible to attack by weak acids,
salts or other sulfates4.
4. Concrete density is also increased by
the small, finely divided particles of fly ash
which act like micro-aggregates to help fill in
the tiniest voids in the concrete.
5. Fly ash provides a dramatic lubricat
ing effect which greatly reduces water de
mandTfW6-f6-1efipercent): -This--wafer-ie:
duction reduces internal voids and bleed
channels and keeps harmful compounds out
of the concrete.
For further information or specific ques
tions regarding the use 01 fly ash to decrease
the permeability 01 concrete, contact your
(continued on back)
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F FLY ASH DECREASES Number]6
POTENTIAL ALKALI/AGGREGATE REACTION
Theiunique properties of class F
it ot only beneficial, but
essentia in some cases for decreasing re
action b tween cement and aggregates dur
ing the ncreting process
l
(see Fig. 1).
Un er certain conditions and in certain
areas, re ctive silica in aggregates will react
with sol ble alkalies from any available
source, ausing excessive and deleterious
expansi n. A volume change will occur over
a period of time which causes the concrete
to "soaIl' at the surface. In addition to re
s rface ruptures, interior may
occur w ich cause cracking and seriously
impair s ructural integrity of the concrete.
The! use of low alkali (L.A.) cement
0.6% Ikalies) has become standard for
combatt ng reactive aggregates, although it
may by itself prove ineffective over time.
ASTM C 27 limits expansion at six months
to O.OID . While a mixture may prove ac
ceptabl in the test, it may well
expansion. Class C fly ash may not
control expansion as well as class F.
notes that CaO content may be a useful pa
rameter to indicate the effectiveness of an
ash to combat alkali/aggregate reaction
3
(see
Fig. 3),
The decrease in alkali/aggregate reac
tion comes from the fact that class F fly ash
reacts chemically with and absorbs alkalies
in the cement, thus making them unavail
able for reaction later with the reactive ag_
gregate.
One example of class F fly ash's unique
propensity to reduce alkali/aggregate reac
tions was documented by the State of Ala
bama. In 1960, the Alabama Highway De
partment specified fly ash in all concrete
pavement, bridges and culverts. Time-tested
results in hundreds 01 lane-miles of fly ash
concrete since then have been
tive according to department representatives.
Bridges more than 20 years old have exhib:
destruct' e expansion later 2). Al
kalies fr m other sources, including the ag
gregate, can fuel the expansion reaction.
Some . gregates may also be so reactive
that they expand to failure before six months
with low lkali cement. Stark reported failure
of a mix ure containing cement with as little
as .35% otal alkalies
2

Incl ding Class F fly ash in the mix de
sign inv riably reduces this reaction, pro
tecting he concrete (and the steel rein
forcem t) from the deterioration which
ited improved resistance to alkali/aggregate
reaction.
In addition to the use of pozzolanic ma
terial, it is recommended that low-alkali ce
ment (less than 0.6%) and acceptable aggre
gates be used in order to prevent alkalijag
gregate reaction
4

questions about the use of fly ash to de
crease alkali/aggregate reactions, contact
your nearest Pozzoianic technical represen
tative.
IEliert, R.I J., "Bureau 01 Reclamation with Fly Ash and Other Puzwlans in Concrete," Thirc
al Ash Utilization Symposium, 1973, p. 14.
2Stark, D.te.. "AlkaliSilica Reactivity: Some Reconsiderations," Research Development Bulletin RD07D.OlT
Portland ement Association, 1981.
'Dunstan, E. R., "Fly Ash and Fly Ash Concrete," Bureau of Reclumution, Denver, Colorudo, hlu)' 1984.
D. E., "Fly Ash and Its use in Concrete," NRMCA Publication No. 138, 1972, p. 10.
TELEPHONE: LOCAL 232-9320, (800) 426-5171
Technical [B)(l1]IULlliUDW
CLASS F FLY ASH INCREASES Number 17
RESISTANCE TO SULFATE ATTACK
Soluble sulfates in soils, ground waters,
and sewage waste destroy Portland cement
concrete unless it is designed with fly ash to
maximize sulfate resistance.
Sulfate attack is a two-phased pr.ocess:
I) Sulfates combine with calcium hydroxide,
forming calcium sulfate (gypsum). The vol
ume of this gypsum is greater than the sum
of its components, causingintemal pressures
which fracture the concrete. 2,) Aluminate
compounds from Portland' cement are at
tacked by sulfates forming a compound
called ettringite. Ettringite formation ruptures
the concrete in the same manner as gypsum
formation.
Fly ash effectively reduces this sulfate
deterioration in three important ways: I)
Class F fly a<;h chemically binds free lime in
cementitious compounds rendering it un
available for sulfate reaction. 2) Fly ash ac
tivity r e . d u c ~ concrete permeability (see
Bulletin #15) keeping sulfates from pen
etrating concrete. 3) Replacing a portion of
Portland cement with class F fly ash reduces
the amount of reactive aluminates available
for sulfate reaction.
Studies by the Bureau of Reclamation
show that properly proportioned concrete
utilizing up to 35 percent class F fly ash will
withstand sulfate attack far better than con
ventional Portland cement. Plain and fly ash
concrete mixes using Type I, moderate sul
fate resisting Type H, and sulfate resisting
Type V cements were compared under
standardized conditions of exposure to so
dium sulfate. In all instances, class F fly ash
concrete dramatically outperformed con
ventional Portland cement concrete. These
testsdearlydemonstratedcthat Type lIce
ment with class F fly ash was more resistant
to sulfate attack than Type V celtlent (see Fig.
1).
Further Bureau 01 Reclamation work
correlates the chemistI)' 01 a given fly ash
with its ability to resist sulfate attack through
a mathematical equation called the R factor,
formulated below '2:
R= CaO-5
FezOJ
AsCaO (calcium oxide increases and
Fep3 (iron oxide) decreases, sulfate resis
tance decreases due to fly ash chemistI)'
(see Fig. 2).
The limits established by the Bureau of
Reclamation requiring progressively lower R
values as sulfate attack severity increases
are as follows:
R Limits' Sulfate Resistance'" Class
<0.75
Greatly improved
F
0.7510 1.5 Moderalely improved
C
1.5103.0 No signilicanl change" C
>3.0
Reduced C
R - (CaO'5)!Fep, percentage from fly ash oxide
analysis; lor very severe cyclic conditions of wetting
and drying or lor MgSO. reduce the R value by 0.50.
Slightly improved to slightly reduced.
Compared 10 a Type" cement control at 0.45 w!c'.
The Portland Cement Association re
ports the use of class F fly ashes improves
sulfate resistance while class C fly ashes are
less effective and may even accelerate de
terioration
3

To ensure the most durable concrete
possible, class F fly ash is an essential in
gredient when the project will be vulnerable
to attack by sulfates or other aggressive
compounds.
For further information or questions re
gardiIT!;;-ny ashlorsullafeiesistance, cOntaCt
your nearest Pozzolanic technical represen
tative.
'Dunstan. E. R..A spec Odyssey - Sulfate Resistant Concrete lor the 80's," United States Department of the
Inlerior, Water and Power Resources Service. March 1980.
'Dunstan, E. R .. -Fly Ash and Fly Ash Concrele, U,S. Bureau or Reclamation, U.S. Government Printing Office,
May 1984.
3Helmulh. R. -Fly Ash in Cemenl and Concrele: Portland Cernenl Association, Skokie. IL. 1987
f;.'..
TELEPHONE: LOCAL 2329320. (800) 426,5171
- ......... Ll IJ L1'\J
FLY ASH HELPS MINIMIZE
Number 18
CONCRETE VOLUME CHANGE
It is natural that concrete changes volume
with changing environmental conditions. Three
primary factors are responsible for volume
changes in concrete: temperature, moisture, and
applied stress. Volume change becomes a criti
cal element when conqete is placed in a re
strained area ultimately resulting in high stresses
and failure. Fly ash can be instrumental in as
sisting to minimize the changes in volume and
the res\llting cracking associated with it.
same causing the edges to curl upwards.
ApplIed Stress. Applied stress (loading)
causes a change in concrete shape and dimen
sion called "delormation." Delormation can oc
cur rapidly caUSing a quick failure, Or it can begin
immediately and continue for as long as the load
is maintained on the concrete. Time dependent
deformation is called creep." (See Technical
Bulletin #37)
Fly Ash MinImIzes Change. Pozzolanic's
Temperature. Concrete volume changes
in a manner directly proportional to changes in
temperature Irom the time it first looses plasticity
t6when it gains its permanent set. High heat of
hydration in its early life causes great expansion
followed by great contraction as it cools back to
ambient conditions. Thermal cracking becomes
an issue as heat is retained inside the mass of
concrete more than at the edges_ This means the
outside shrinks faster than the inside with dif
ferential shrinkage accounting for
cracking. Concrete should be plated and I<ept as
close to ambient temperature as possible to
minimize thermal cracking.
MoIsture. Concrete volume change is also
directly proportional to changes in concrete
moisture. Concrete is produced with extra water
(water of convenience) beyond what is necessary
for the hydration of cementitious materials. The
greater the amount 01 extra water, the greater the
drying shrinkage potential of the concrete. At the
onset, the concrete has an initial volume. This
volume diminishes as water leaves the matrix
during setting. Resaturation with water will cause
the concrete to expand again. but it will never
reach its original capacity_ The concrete volume
will continue to change throughout it$ me as its
moisture content changes. the amount oC change
depending upon the original shrinkage potential
of the concrete.
An example of differential shrinkage in
concrete is "curling." This phenomenon is
characterized by the edges of a slab curling up
and orr the subgrade below. The predominanl
..reason fOf.lhis aredirrerential shrinkage fr()m l()p
10 bollom caused by improper finishing and
curing, and moisture difierenliallrom top to bot
tom. DiIIerential moisture becomes most appar
ent when the top surface is subject to very drying
conditions while the bottom remains moist Irom
capillary action through the subgrade $oils. The
surface shrinks while the bottom remains the
high quality fly ash vastly exceeds ASTM C-61B
specifications yielding a product that contributes
to minimizing volume change by'providing:
2%-10% water reduction thereby reducing
the potential for shrinkage in the plastic and
hardened states. This assists in reducing the se
verity of plastic cracking as well as cracking from
drying shrinkage. (See Technical Bulletin #11).
Superior workability at lower slumps allows
for the easier placement 01 concrete with low
water content Drying shrinkage is primarily al
e feeled by the unit water content q-f concrete.
(See Technical Bulletin #13).
. Lower concrete temperatures through gen
eration of lower heat of hydration than cement
alone generates. This reduced heat lessens
thermal cracking. (See Technical Bulletin #22).
For further information or specific questions
regarding the use of fly ash to minimize concrete
volume.change, contact your nearest Pozzolanic

IOU
E
w /00
'"
30n
u
. .(fkl

-Still
d
zA21b k ('\01 11'\1
ul
",eo )n pCI lIy a.1ih r('pla:Ct:'Mt"fH
bJ . No lepl.!ocemt'tll
(".!f . ]n pCI puml('t' tt'"lact'l11C'nI. b,," .... ('tg:hC
d.h :ttl i)("J ,.. Irlnf'd ..hale' tqllan'mt'nl b\ """,q:hf
curing
.. 214 lti5
..'
'''''
AGE. day" \ WG SCALE,
Drying shrinkage and autogenous length
change-or 4,by 4"by30--im::h-15ar:n5f Port
land cement concrete with various pozzo
Ian replacements.
Ellert, R. J., "Bureau of Reclamation Experiences
With Fly Ash and Other Pozzolans in Concrete:
Third International Ash Utilization Symposium 1973.
p. 14.

TELEPHONE: LOCAL 232-9320. (800) 426-5171
- - - --- '---" ""---"-' '------IL...--t L.=.1 Ll LJ L1 U
FLY ASH IMPROVES
FLEXURAL STRENGTH
Flexural strength of concrete is of
importance in highway and street
pavements, warehouses, parking
facilities - any area where concrete
must support vehicles. While the
flexural capacity of concrete may be
low in comparison with other
materials, such as steel, it can be
proportioned and its application
engineered to provide durable, 10ng
lasting service.
Concrete Capacity. The capacity
of a rigid concrete to support a given
dynamic. repetitious loading is basi
cally a function of concrete section
thickness, flexural strength and sub
grade stability. Many current specifi
_ cations caU for the flexural perform
ance of conventional concrete with
out realizing the benefits fly ash can
effect to achieve more durable, longer
lasting pavements at lower cost.
Fly Ash Advantages. The advan
tages offered by fly ash are both physi
cal and chemical in nature and posi
tively affect lIexural strengths.
Physical Advantages. Fly ash
consists of microscopic spheres
which interact in the concrete mix to
give the following benefits cement
. and other additives cannot.
1. Fly ash spheres impart a ball
bearing action that greatly increases
workability. This increased workabil
ity can be utilized to reduce sand
content which reduces aggregate sur
face area to be coated and increases
flexural strength.
Increased. densitylsachieved as
fly ash concrete is more easilyconsoli
dated and voids filled with the small
spherical particles.
Number 19
3. This ball bearing effect reduces
the resistance to flow that ordinarily
occurs between angular cement and
sand particles, reducing water of con
venience demand by two to ten per
cent and increasing both flexural
capacity and density.
4. More workable fly ash concrete
can be easily placed and consoli
dated at lower slump than can ordinary
portland cement concrete,' further
reducing water content.
Chemical Advantages. Fly ash is
a pozzolan and reacts with calcium
hydroxide generated by portland
cement. hydration to form stable,
durable cementitious compounds.
This pozzolanic activity is benefici.al
because:
I. Weak, leachable calciu m
hydroxide is chemically captured by
the fly ash and fixed in strong cementi
tious compounds, increasing flexural
strength and density, while decreasing
permeability.
2. Pozzolanic activity continues at a
high rate long after cement hydration
slows to provide higher flexural
strength.
Increased flexural strength derived
by the use of fly ash may be utilized to
decrease section thickness and save
money. H thickness is maintained,
longer useful (ife will result.
For additional information re
garding designing concrete mixes for
flexural strength, contact your nearest
Pozzolanic technical representative.
v.
NEVADA' OREGON' NEBRASKA WASHtNGTON WVo.MING UTAH
TELEPHONE: LOCAL 2329320. (800) 4265171
Technical
Number 20
FLY ASH FOR HIGH STRENGTH
CONCRETE
As recently as J960, concrete com
pressive strengths over 6,000 p.s.i.
were rarely achieved and seldom
used in the design and construction
concrete structures. By 1972,
Material Service Corp. in Chicago was
regularly producing 9,000 p.sj. con
crete for the construction of high-rise
concrete structures. High strength
concrete of 12,000 p.s. i. and above is
becoming fundamental to the archi
tecture and engineering of the ]980's.
Achieving high strength concrete
is a great deal more complex than
merely adding more cement to every
day concrete mixes. Decades of testing
and research have been required by
the finest technical people in the
world to achieve the kind of reliab!e,
consistent results required to make
high strength concrete a safe building
material.
.Attention To Mix. Research has
shown that careful attention must be
paid to all ingredients of the concrete
mix, choosing from among the many
to select those which produce the
best results. Careful appraisal of
available materials has shown that
"the use of a good quality fly ash is a
must in the production of high
strength concrete and a fly ash witb an
ignition loss under three percent or
less is preferable".' In terms of the
capacity for generating high strength.
'thestfehgtn gainacfiTeved fromihe
use of 1percent to 15 percent fly ash
(by weight of cement) cannot be
attained through additional cement."
Strength Requirement. In line
with the innovative thinking required
to develop high-strength concrete
comes a Change in the age at which
strength is commonly specified. It is
well known that the level of achieved
strength is time dependent. The older
the concrete, the stronger it will be
come. Delaying design strength re
quirements to later ages makes it
infinitely more practical to produce
high strengths. While fly ash concrete
is beneficial in many ways up to the
normally required 28 days, it has a
higher rate of strength gain at later
ages than portland cement. This later
age strength gain allows higher
strengths to be achieved than can be
achieved with portland cement alone.
High strength concrete requires
vel)' careful appraisal of available
materials, care in production and, of
course, the use of.a high quality fly.
ash.
Please contact your nearest
Pozzolanic technical representative
for more information or specific ques
tions about fly ash iii high-strength
concrete.
I Blick. R. L.. "Some Factors Jnil uencing High,Slrerlglh Concrele:' Modern COf1creh', VoL:lG. No. 12. April J!I7:l
. <r'
TELEPHONE: LOCAL 232-9320, (800) 4265171
o Pro' 7nl",nu": COOyflOm 199t:
Technical
Number 21
FLYASH FOR
PUMPED CONCRETE
Pumped concrete must be designed
so that il can be easily conveyed by
pressure through a rigid pipe or flexible
hose for discharge directly into the de
sired area. I
Changes in design mixes to improve
pumpability can enhance (he quality of
the concrete. These changes may result in
improved concrete strength and impron:d
concrete performance but they cdn be
more costly. However, by using Pozzo
Ian ic fly ash. pumpability can be ensured.
quality of the concrete impro\'ed and tile
costs controlled.
Mix Homogeneity. The designer
must be aware of the need to improve
gradation and maintain uniformity of 111('
various materials used in the pumped
mix in order to achieve greater homo
ge'neity of the total Three mix pro
portioning methods frequently \lsed to
produce pumpable cOllcrett' are:
Maximum Density 01 Combined
Materials
Maximum Density Least Voids
Minimum Voids Minimum Area
Mixes must be designed \\lith several
factors in mind:
J. Pumped concrete Illust be 111m\.'
with enough fine material and water
to fill internal voids.
2 .. Since the surface area and \'(Jiel
content of fine material below 300 microns
control the liquid under pressure, there
must be more of these .sizes than in iI
Illi ng..tJle. Ji It( '.I
the material, the greater the control.
. :3. The cuarse aggregal(' gradillg
should continuolls and often the .siliid
(:OI1I('llt mllst bt, increased by up to fi\'('
pern.'nl al the expense of the C()itrs('i'
aggregate so as to balance the sao micron
Smm fraction against the finer solids,
Fly Ash Effective. Unfortunately,
adding extra water and fine aggregate
leads to a weaker concrete. The usual
remedies for this are either to increase the
cement content, which is costly, or to use
chemical admixtures, which also can be
and may lead to segregation in
marginal mixes. There is another and far
1110re effective alternative: Pozzolanic fly
{lsi\.
There are many advantages 10 in
cluding Pozzolanic fly ash in concrete
mixes [0 be pumped. Among them are:
l. Particle Size. Fly ash rneeting
ASTM Specification G18 must have GG
percent passing the 325 (45 microll)sieve
and these fine particles are ideal for void
Just a small deficiency in the mix
fines can often prevent successful pumping.
2. Particle Shape. Microscopic
examination shows most fly ash particles
are spherical and act like miniature ball
bearings aiding the movement of the
concrete by reducing rriCtional losses in
Ilw pump and piping, Studies have shown
Ihilt fly ash can be twice as effective as
n'l1H:nl in improving workability ancl.
therefore, pumpability.:
3. P6zz.olanic Activity. This chem
ical reaction combines the fly ash particles
with the calcium hydroxide lii>t'rated
through tile hydration of cement to form
additional cemenlilious compoullds
\\1.1i5..I} jncrei,lsg..... I.U': r.eJe....!.ilw.nglll_
4. Water Requirement. Excess
walt'r in pumped mlxt's resulting in ()\'(:r
six illcil slumps \\'ill ollt'n Cill/St' Ilwtl'rial
(continued HI bock J
I:\("J :iU' -72 Fi('ld H{'ft'rt"tHT i\.liHIHal- .\fJrf lIlt fit" 1/1.' Ir II .';/IJ11 tllrlll ("HIIO('[('/UI ...... Pull SII.. -, 1 I' -; ....
:-'j'p 'portiUllilig C01H"rl'lp ',-\el 1'lIhltl Hilt/if .""" __/1" p. :!7.
J Missner. H.5.. "Eflecl of Inerl Mineral un \'urkabiJ.it:r," Significance of Tests and Propertie:i ,J!
Concrete ond Concrete Making MOleria/s. STP 169-A American Society iorTesling and X!alerillts. Phillldfclpitl<',
1966. pp. 404-'! 14.
V<
ALASKA' BRITISH COLUMBIA CALIFORNIA COLORADO IDAHO' MONTANA
NEVADA' OREGON NEBRASKA' WASHINGTON' WYOMING UTAH
TELEPHONE: LOCAL 232-9320, (600) 426-5171
b P",'r7.nI!'lnu- r:,...,nvt.nt'tt '1if4f1.
Technical [Q3(UJLLlL[El])JlM
FLYASH REDUCES HEAT OF HYDRATION
Number 22
Use of fly ash.in mass concrete has been
well documented by many sources, includ
ing the U.S. Army Corps of Engineers and
Bureau of Reclamation. Typical examples of
projects utilizing fly ash in mass concrete
include the Hungry Horse Dam, additions to
the Bonneville Dam, Hoover Dam repair, the
Canyon Ferry Dam, the 1-205 Bridge piers
and the Hood Canal Floating Bridge anchors.
Mass concrete is defined as [any vol
ume of concrete with dimensions large
enough to require that measures be taken to
cope with generation of heat from hydration
of the cement and attendant volume change
to minimize cracking. "1
Guidance is available in ACI 207-2R-73,
Effect of Restraint, Volume Change and
Reinforcement on Cracking of Mass Con
crete," to determine when existing condi
tions warrant mass concrete practices.
Smaller Rise. Replacement of cement
by pozzolanic fly ash results in a decreased
temperature rise in fresh concrete.
2
This is
especially important in massive structures
such as dams and large bridge piers where a
large temperature rise can lead to cracking.
Hydration of portland cement generates
heat very qllicklycausing the concrete tem
perature'to rise. This increase comes at an
early age where plastic strain capacity is high
and the concrete readily accepts expansion.
With age, the temperature falls to ambient.
This occurs where plastic strain capacity is
very low and may cause concrete to crack.
Criteria. Established criteria exists for
selecting proportions'for mass concrete in
ACI207-1R-70 "Mass Concrete for Dams and
Other Massive Structures" and are:
1. Utilize the largest maximum sized
aggregate possible while maintaining mini
mum sand contents, thereby requiring 'the
minimum amount of cementitious materials
[or a given strength level.
2. Maintairi slump at a minium to mini
mize water demand and cerrientitious mate
rials content.
3. Utilize low heat cement.
4. Make judicious
5.Pfoportion for Hie-highest fly ash con
tent within the constraints 01 time and
strength.
Fly Ash Benefits. Fly ash is a tremen
dous aid as it generates only 15 to 35 percent
as much heat as cement at early ages. This
coupled with long term strength gain and
physical fly ash characteristics benefit mass
concrete by:
1. Significantly reducing heat gain to re
duce thermal cracking. '
2. Functi0ning as a workability aid in
typically lean, coarse mass concrete mixes.
3. Acting as a water reducing agent by
allowing approximately two to ten percent
reduction in water content.
The rate and amount of heat generation
is dependent upon the fineness and qualily
of the fly ash and its proportion in the total
mix. When Type II cement is used with fly
ash, the heat generateq by the pozzolanic
reaction up to the age of approximately 28
days will be, on the avera,ge, about 50 per
cent less than the cement it replaced.
For large structures such as concrete
dams, not only is the possibility of thermal
shrinking and cracking reduced, but the low
ered, heat of hydration also decreases the
amount of artificial cooling required. Thus
larger placements can be made and con
struction expedited at lower cost.
3
For designers who want to minimize heat
problems in mass concrete, the following
caloric test results reflect the decreased heat
that can be obtained through the use of a
specification fly ash in concrete mixes.
SAMPLES CURED AT 73 F.
MIX DAY CALORIES
Type I Cement 3 67
Type I Cement 7 81
1 Part Type 1/
2 Parts Fly Ash 3 35
1 Part Type l/
2 Parts Type 1/
1 Part Fly Ash 3 48
2 Parts Type 1/
1 Part Fly Ash 7 61
'For fUrther Tnformaiiqri-or-speclflc' questions
regarding the use of fly ash to reduce heat 01
hydration, contact your nearest Pozzolanic
I CommiUee 116-1; and ConcreteTerminoiogy"; AC{ Manual of Cl?ncreie Practice, Part I; 1980.
2 Central Electricity Generating' Board; Applications of PFA In Concrete and Cement'; RIBA Product l)aICJ: London; March 1982.
l Abdum-Nur. Edward A.; "Fly Ash In Concrete"; /iigill1)ayResearch /3.oard; BulleJin No. 284; \961: p.28..
\1,1.:
TELEPHONE: LOCAL 232-9320, (800) 426-5171
echnical
FLY ASH IN PRECAST/PRESTRESSED
Number 23
CONCRETE PRODUCTS
Production of precast concrete products
involves intricate, difficult patterns. Precast
concrete products can be produced with or
without reinforcement, but units typically
consist of narrow, de'ep sections which are
heavily reinforced making concrete place
ment vel)' difficult. Reinforcement typically
includes the use of fibers, conventional re
inforcing steel" and prestressing steel ten
dons, either pretensioned or post-tensioned
or combinations thereof. Mixtures must have
enough workability to flow well under vi
bration and totally fHl the form without seg
regation. Hand finishing is often required
necessitating a mixture workable enough to
allow for this kind of manipulation.
By definition, precast concrete products
are cast and cured in other than their final
, position
l
. This enables the use of reusable
forms which, due to economic concerns,
are cycled as rapidly as possible. For this
reason, these concrete products generally
achieve their competitive position in the
marketplace by using a limited number of
forms with a rather short production cycle,
Normal production schedules allow for one
usage of forms per day; however, 10 to 12
hour schedules are common. Accelerated
curing, typically employed to enhance early
age concrete strength for handling, shipping,
and product utilization, accelerates the poz
zolanic reaction of fly ash to help develop
the necessary early strengths
2

Concrete mixtures for these products
are proportioned for high levels of perfor
'
of 3500 to 5000 psi (24 to 28 MPa) are typi
calty required at the time of form removal or
stripping. These early concrete strengths are
generally achieved with cementitious mate
rial contents of 600 to 750 Ib/cy (355 to 445
kg/cm). Conventional and highrange water
reducing agents are often employed to attain
workability at very low water content. Non
chloride accelerating admixtures are also
sometimes used. While the early strength
gain characteristics of fly ash has generally
been considered too slow for use in these
mixtures, conditions are changing toward
the use of fly ash in these applications. As is
true Qf all mixtures used in precast concrete
work, mixture proportioning and curing
procedures used must produce adequate
early strength or the turnaround time on
forms or molds will be increased
3
,
While early age strength levels are re
quired for stripping and handling, higher
strength levels are required for the ultimate
use of the products. The Use of quality fly ash
meeting ASTM C-618 (class f) spedfications
is a must in the production of high strength
concrete of 6000 p.s-i. and higher4. The
strength gain achieved from the use of 10 to
15 percent fly ash cannot be readily attained
through the addition of a proportionate
amount of cement.
Pretensioned hollow-core structural
slabs are produced with no-slump concrete.
It is consolidated and shaped as it passes
through an extrusion machine. The particle
shape of the coarse aggregate and the
amount of fine aggregate are very important
to workability. Fly ash is widely considered
as a beneficial ingredient to increase the
workability of these dl)', harsh mixes
s
. Early
strength performance of these mixtures us
ing class F fly ash closely parallel mixtures
without fly ash in terms of early compressive
strength. No early strength reduction is ap
parent.
Although most concern is directed at
obtaining desired early compressive
strengths,-meseconcrefe pCrocfuds must
possess durability to resist destructive attack
from numerous environmental factorsG. Class
F fly ash is seen as a major ingredient utilized
in the production of durable concrete and as
such should be included in any concrete
subject to severe environments. For further
information on the role of class F fly ash as
an aid to durability, see technical bulletins
#14 (freeze/thaw resistance), #15 (perme
ability). and #17 (sulfate attack).
(continued on back)
NEVADA' OREGON' .NEBRASKA' WASHINGTON' WYOMING UTAH
I
Number 24
FLY ASH FOR
CONCRETE PAVEMENT
ash has been used in road paving
for more than 2,000 years.
The Romans used naturally occurring
volcanic ash from Mount Vesuvius to cement
the paving stones in their roadways. Many
miles of this ancient roadway - although
rough by our standards - still exist as a
useable highway.
Today in Europe, paving stones have
been replaced by modern day pavement - but
a product almost identical to volcanic ash.is
still used. In fact, most European highways
have been constructed with fly ash in all
levels, including the wearing course.
On this side of the Atlantic, it has been
only in relatively recent years that we have
begun to recognize the value of fly ash in
concrete pavements.
Many States Use Ash. Roadways and
interstate highways in Alabama. California,
Georgia, Florida, Nebraska, Utah and approx
imately 20 other states and Canadian provinces
have been successfully constructed with
ash, many dating back to the early 50's and
60s. These roads are found in every type of
clImatological condition that exists - from
virtually subtropical to sub-zero.
In January of 1974. the Federal Highway
Administration encouraged the use of fly ash
in concrete pavement with its Notice N 5080A
.which urged the states to allow partial substi
tution of fly ash for cement whenever feasible'.
The FHWA indicated that the replacement of
cement with fly ash of the order of 10 to 25
percent can be made giving equal or better
concrete strength and durability. In addition,
in January, 1983, the Environmental Protection
Agency published federal procurement guide
lines for cement and concrete containing
ash which encourage the utilization of [Iv ash
and establish compliance deadlInes.
Co-mpressivestren-gths.-Highway
departments frequently specify a minimum
14-day flexural strength. These requirements
can readily be met through the utilization of
proper mix designs incorporating specifica
tion fly ash. Equal compressive strengths at all
ages can be readily attained providing specifi
cation fly ash, properly proportioned, is substi
tuted for up to 25 percent of the cement.
Some of the reasons that fly ash is used in
concrete paving have more to do with the
physical characteristics of fly ash than the
chemical and strength gain characteristics.
With modern construction techniques - such
as paving trains using slip form equipment
the fly ash facilitates placement of the con
crete at lower slumps while maintaining
excellent workability. This means less hand
work for the paving contractor. , . and better
surface texture and edge characteristics for
the design engineers.
Denser Concrete. Using fly ash also
results in a denser concrete, . _ and one that
will have much greater ultimate strength and
Paving contractors are increasingly
asking that Oy ash be used in their concrete
because they are able to place the pavement
or curb with less tearing and thus, a smaller
crew is required_
These are other advantages to using
ash which result in a stronger and more
durable pavement:
.. Fly ash concrete pavement will im
prove the resistance of the concrete to sulphate
attack,
.. The concrete will be more resistant to
road salts and freeze/thaw action as well as
reduced alka I 1/aggregate reaction.
.. In many areas of our C"ountry, fly ash
also can help keep the initial cost of concrete
pavement competitive with asphalt pavements_
Many Advantages. These are all valid
reasons - and time tested advantages for
producers and specifiers to request the use of
fly ash in their paving concrete. The fact that
the ancient Roman roadways still exist today
is profound testimony to the wisdom of using
bothJJy.ash.andconcfe.teiRwad<:--efls+ruction.
For further information or specific ques
tions regarding the use of fly ash in concrete
pavement, please contact you'r nearest Pozzo
janie techn ical representative.
l"Use of Fly Ash in Portland Cement Concrete and Stabilized Base Construction," Federal Highway
Administration (FHWA), Notice N 5080.4. p. 6, January 17. 1974.
........... ..... ',... ... r, I __ .. i "''"'''' ...... "' .... Ir., .......... ........... ...... _J
hnieal
Number 25
FLY ASH FOR SOILS WORK
Five basic types of soils work commonly
utilize Ily ash:
L Cement Treated Base (CTB) pro
duced through a mixing plant
2. Soil Cement- produced by disking the
cement and fly ash into in-situ soils.
3. Lime Treated Base/Type A- produced
through a pug mill.
4. Lime Treated Base/Type B - produced
by disking the lime and fly ash into in-situ
soils.
5. Flow Fill Placement - produced by
mixing large quantities 01 fly ash, sand and
waterwith minimal orzero quantity of cement.
Cement Treated Base (CTB). This
method most closely resembles normal con
crete work because of the gradation 01 the
malerial with which it is mixed. The mix is
designed to achieve a given strength p.s.i.
factor at a given age. . placed using a dump
type vehicle ... brought to grade with a scraper
... and compacted with either rubber tired or
steel drum compactors. Moisture is added
after the material has been placed and graded
and sometimes aller rolling.
This process makes replacement of ce
ment with fly ash feasible with 15 \025 percent
replacement common and up to 60 percent
representing close 10 the maximum.
Design strengths can be anticipated at
about the same ages as with straight cement
utilization.
Soil Cement The gradation of materials
used in the soil cement method resembles
block and pipe mixes. Basically. small aggre
gate is used with cementing materials at
minimum water contents and subjected to
compaction.
Large amounts 01 this type 01 work have
been done in the U.S. and Canada using lIyash
replacements of up to 33 percent and as low as
five percent.
With fly ash the soil cement surface will
exhibit greater strengths over a longer period
01 time. For that reason. it is often used in the
construction of road bases in housing
developments.
Lime Treated Bases. The practice 01
using lIy ash and lime to produce cementitious
bases is severa! centuries old, The process
utilizes limE and. for the most part. naturally
occurring water (either ground water or rain
water) to produce cement-like compounds.
Once the lime and flv ash have been
mixed together by means 01 (a) a pug mill or
(b) disking into the soil, the normal pozza.
lanic action between the lime and the fly ash
begins.
This process initially uses either water
introduced at the pug mill or applied to the
surface of the designated area by a water truck.
Over the long term, moisture from ground
water and rain will continue to supply adequate
moisture to sustain the pozzolanic activity of
these two materials and thus generate con
tinual strength gain.
Subgrade Application. This character
istic of slow strength gain usually is not
detrimental because, in most cases. the
material is being applied as a subgrade for
asphaltic concrete or to stabilize in-silu soils.
In these instances. high early strengths are not
necessary, and may, in facl, be undesirable.
It must be remembered. however. that
this is a soils product that becomes "concrete
like," rather than concrete. and cannot, there
fore, be expected to perform like concrete at
early ages. It will perform in early ages in a
manner very similar to normal, compacted
soils. At medium ages (90 to 120 days), it will
begin to acquire properties 01 low strength
concrete. At later ages. it will begin demon
strating the properties 01 normal concretes.
Several projects where lime and fly ash
have been used have shown extraordinary
strengths (3.625 p.s.i. to 5.800 p.s.i.) at five to
ten years.
Flow Fill Placement One of the more
recent uses of fly ash is as the binding medium
and auxiliary carrying medium.in a liquidly
placed soil !ill. This method uses somewhat
bighJ1Y.ash..contents.300 .\ol.DOOpocJndspe r
cubic yard and. low. 10 to 100 pounds per
cubic yard. or zero cement contents.
Zero Voids. This method is designed to
produce a soils product that has zero air voids
and high. inter- particle surface contact. Fly
ash has just the properties for achie\'ing both
criteria.
As a binding medium. fly ash partic:ies
mteracl wilh the chemicals in water to form
certain crystaline structures that i1ct a" a
source of- internal stabilization ill the soil
svstem.
. II more than 7:2:; p.:-;,i. tu 1.1:ill p.s.i. IS
required of the soil mass. il is recommendf::<l
COIUlInt,-I! 011 bOi'hi
lechnical
FLY ASH FOR ASPHALTIC CONCRETE
Number 26
The use of fly ash in asphaltic
concrete is common practice in
many parts of the United States and
Canada.
Fly ash is most commonly used
in this application where adequate
fines in the local sand -are not
available. However, even where
adequate sands do exist, including
fly ash in the mix design can
improve the quality of the asphaltic
concrete.
Fly Ash Ideal Choice. When
ever a mineral filler is required, fly
ash is the ideal choice for two
reasons:
1. The particle size of fly ash is
virtually 100 percent minus 200
sieve. This means less asphaltic
oil is required to fill the voids and,
therefore, the result is a less
expensive mix.
2. Fly ash promotes a denser
mix and surface which assures a
longer pavement life with less re
pair work required to maintain
satisfactory surface conditions for
traffic.
The tremendous increases in
the cost of asphaltic oil make the
use of fly ash extremely attractive
even in areas where sands normally
contain adequate fines for asphalt
work.
The round, hard, spherical
particle shape of the fly ash con
tributes a great deal to its ability to .
minimizethearnountofoiLrequired
for the mix ... and its ability to
produce greater density in the
asphaltic concrete. These round
pa.rticles act like little ball bearings,
much the same in asphaltic con
crete mixes as in portland cement
concrete - promoting flowability
and compactability of the mix.
Reduces On.Justas this lubri
cating characteristic reduces the
need for more water in portland
cement concrete, it reduces the'
need for oil in asphaltic concrete
with obvious cost savings resulting.
The surface of the fly ash par
ticles are generally very hard and,
therefore, will not absorb the oiL
They have few crevices or rough
points to retain or demand oiL
Others Porous. Neither of
these attributes is true of other
mineral fillers. In fact, other min
eral fillers have a porous surface
which causes them to soak up
more oil. They are also angular
with many crevices and peaks,
increasing the need for oil to assure
proper fluidity and compaction.
Another very important factor
to consider in selecting a mineral
filler is the cost, in energy, to
produce it. A ton of fly ash-since it
is the by-product of a power gener
ation facility - costs zero BTUs of
energy. Manufacturing a ton of
cement by comparison, consumes
7.3 millio"n BTUs of energy. Similar
comparisons are relevant for lime,
other manufactured fillers or
alphaltic oiL
Because of the fact that it is a
by-product and not the product of
an energy-intensive manufacturing
. Vefs.lJS
1
the cost of other fillers is generally
lower.
For further information or spe
cific questions about using fly ash
for asphaltic concrete, contact
represen tative.
ALASKA' BRITISH COLUMBIA' CALIFORNIA' COLORADO' iDAHO' MONTANA
Technical [B301l[L[LIETI1JWl
Number 28
FLY ASH
AND HOT WEATHER CONCRETE
Hot Mudl The statement is heard
often in the concrete industry.
Rapidly setting concrete is gen
erally considered a good thing.
However, when the mercury goes
above 80 degrees and as-placed
concrete temperatures rise above
85 degrees, a complex set of prob
lems must be solved.
Problems: Dehydration of
concrete due to high temperatures,
low humidity, wind and subsur
face wicking aggravates plastic
cracking and crazing. Increased
concrete water demand due to
high temperature and rapid ce
ment hydration increases drying
shrinkage and reduces strength.
Since cement generates 120
BTU's per pound of it is
important to reduce the amount of
cement-generated heat. This can
be done with fly ash which de
creases the heat of hydration in the
mix. During the first critical 24
hours, replacement of 100 pounds
of cement with the same amount of
fly ash reduces the heat of hydra
tion by 19 percent, but does not
sacrifice any strength or durability
features. Since fly ash minimizes
water requirements by two to ten
Other methods that the ready
mix producer and the contractor
use to keep concrete cool during
hot weather are:
Ready-mix Producer:
1. Design mixes for strength
using higher percentage of quality
fly ash and reducing cement.
2. Use a chemical retarder in
prescribed dosage to slow initial
heat build up.
3. Spray aggregate piles to cool
by evaporation.
4. Chill water or add shaved ice
to mix water.
5. Keep spray on cement silo.
6. Reschedule to night pours.
Contractor:
1. Soak subsurface for mini
mum of two hours before placing.
2. Keep spray on rebar ahead of
pour.
3. Erect wind screen.
4. Erect shade covering.
5. Don't allow ready mix trucks
to stand in the sun.
6. Screed immediately and
don't overwork the concrete. Spray
on surface evaporation retardant if
applicable.
7. Immediately after finishing,

111ented) or pond IIle concrete.
pefcenf;ilisnofnecessary
the mix with water during placing
and thus strengths can be maili
tained.. Pumpability, placeability
and finishability also are improved
by adding fly ash to hot weather
mixes because they will more
fluidly throughout placmg and
finishing processes.
for hot weather concrete. contact
representative.
ALASKA- BRITISH COLUMBIA' CALIFORNIA -COLORADO' IDAHO' MONTANA
I
, '",.
--. ;,.':(5 :
"
Tech
IIB3CUJrL[L[gJ]]W
FLY ASH FOR CONCRETE
PIPE MANUFACTURING
Class F fly ash has been used success
fully il1 the manufacture of concrete pipe for
more than 30 years. It has become an almost
indispensable ingredient to the dry, harsh
mixes typically used in modern pipe manu
facture.
The manufacture of concrete pipe is
accomplished by two different processes,
one using extremely dry concrete mixtures
and the other using plastic concrete mix
tures. DI)' cast concrete pipe are produced
utilizing mechanical compaction and/or vi
bration to consolidate the dry concrete
mixture into a form which is removed as
soon as the casting is finished. With removal
of the form. the green pipe is carefully
transported to its place of curing. Acceler
ated, atmospheric curing is typically used to
obtain early age performance.
Wet cast concrete uses plastic concrete
placed and compacted in a form which re
mains around the pipe until certain levels of
performance are achieved. Wet cast pipe
may be manufactured by the spinning pro-
cess. to remove excess water and air to
produce great density and low permeability.
Fly ash has found widespread use in the
manufacture of concrete pipe as a cementi
tious material and as an aggregate mineral
filler to enhance quality and economy.
The major reasons for the use of fly ash
in concrete pipe are:
HostIle CondItions. Pipe is inevita
bly subject to hostile conditions. It is most
....oftenus.edto convey sewage . .to arid through.
sewage treatment plants. where hydrogen
sulfide attack may erode Portland cement
concrete as if it were butter. Properly pro-
portioned mixtures containing fly ash make
the concrete less permeable, and pipe con
taining fly ash may be more resistant to weak
acids and sulfates (Davis 1954; K. Mather
1982). Factors pertaining to the life 01 con
crete pipe exposed to.sulfate attack include
the type of cement, class of fly ash, quality of .
concrete, bedding and backfill used, ground
V:ater. arid sulfate
I
I
Number 30
/.
I
I
Reduced Cement. Dry cast concrete
pipe mixes without fly ash typically use
greatercement contents than necessary tor .
strength to obtain the required workability.
In a pipe casting operation.
concrete with a very dry consistency and
low water content is compacted into a verti
cal pipe form using a revolving compaction
tool. VibratoI)' pipe use mechanical vibra
tion to compact d.ry mix concrete into a form.
Fly ash allows the producer to remove as
much as 30 percent of the cement from a
mix without sacrificing strength while, at the
same time, reducing the ,amount of water in
the mix. Fly ash is then used as a cementi
tious material and aggregate mineral filler to
promote added workabllity and plasticity.
Workabillty. Pipe manufacturers
throughout the world recognize that the
spherical shape of fly ash makes very dry
mixes. as used in packerhead machines,
extremely workable. This added workability
reduces cycle type, wear on moving parts
and forms, and makes a denser, less per
meable and more airtight pipe. Equipment
used in pipe production may last longer due
to the lubricating effect of the fly ash. Use of
ash can increase the cohesiveness of the
no--slump, freshly placed concrete facilitat
ing early form stripping and movement of
the product to curing.
Fewer Rejects. The wet cast and
centrifuge process of pipe manufacture also
benefit from the workability and densifica
.tionthat fly ash GORtributes to each-mix;
Most manufacturers using fly ash in their
mix have found less reject pipe due to voids,
crazing or collapse after dry molding.
Other benefits attributed to the use of fly
ash include a reduction in the heat of hy
dration of concrete mixtures containing fly
ash which can reduce the amount of hair
line cracks on the inside surface of stored
pipe sections (Cain 1979). Concrete mixtures
containing flv ash also tend to bleed less
(continued on back)
ALASKA. BRITISH COLUMBIA CALIFORNIA COLORADO IDAHO' MONTANA
l\I<=vt.nt. nl:><=r,ON N<=R"A!';KA WYOMING UTAH
Technical rBWJIIILIEUlJIK!J
FLY ASH FOR BLOCK MANUFACTURING
Number 31
The manufacture of concrete masonry
units uses a dry . harsh concrete mixture
compacted into molds with great mechani
cal energy. When' demolded, these units
maintain their shape during handling and
transpoltation into a curing environment.
Curing methods consist of the high pressure
high temperature autoclave and the atmo
spheric pressure high temperature kiln. The
use of high quality class F fly ash has be
come accepted practice in the industry.
Class F fly ash improves block manu
facture in two basic ways. It gives producers
the strength required and, at the same time,
the added plasticity that fly ash contributes
(reported by Belot 1976) to the relatively
harsh block mixes assures improved finish
and texture. better mold life and better.
sharper corners. Additional benefits for fly
ash in block include reduced permeability
and shrinkage, increased durability and vir
tual elimination at efflorescence.
Fly Ash Chemical Activity. Fly ash
is produced by burning powdered coal 10
generate electricity. Fly ash is a chemically
active, finely divided mineral product high in
silica, alumina and iron. Type F fly ash that
has a low lime content and has been burned
in the process of manufacturing (in the same
sense that Portland cement clinker is
seeks lime. One hundred pounds
of Portland cement during hydration usually
liberates from 12 to 20 pounds or more of
free lime (calcium hydroxide). Fly ash then
chemically reacts with this free lime to form
additional stable cementitious compounds.
TheformatTo'nofhisoTublecemeniingcom
pounds is accelerated and can be secured in
a matter of hours in the steam curing cycle of
the concrete products plant (autoclave or
non-autoclave).
Steam CurIng. Autoclave curing.
though not as common as in the past, is still
used to mamifacture high qUCi!ity masonry
units. Concrete mascmry, units cured in high
pressure autoclaves shoVf early strength
. equivalent to that . of moist-cured
strength and reduction in y.olum<; change in
drying (Hope 1981). The process uses tem
peratures 0(275 to 375
0
F (135
0
to 190
0
C)
and pressures of 75 to 170 p.s.i. (0.52 to 1.17
MPa). These conditions allow for the use of
fly ash as a cement replacement up to 35
percent for class C and 30 percent for class
F fly ashes. Percentages greater than this
can result in efflorescence with class C fly
ash. Particular care should be taken to insure
that the fly ash. meets the soundness re
quirement of ASTM C-6I8, indicated in note
C. Table 2 especially where the fly ash will
constitute more lhan 20 percent of the total
cementitious materiaL
Low-pressure steam curing is usually
performed in insulated kilns at elevated
temperatures. The exact temperature used
being a function of the materials and op
eration of the specific plant. This process
allows for the use of fly ash as a cement
replacement up to 35 percent for class C and
25 percent for class F fly ash. Tests with 25
percent class F fly ash were successful with
a curing temperature above 160" F (71
0
C)
and indicate that drying shrinkage of low
pressure steam-cured concrete units can be
reduced by the addition of fly ash.
Accelerated curing techniques allow for
a period of preset before the concrete
products are subjected to elevated tempera
tures. The preset period may lengthen slightly
where cement is replaced with fly ash and if
so, it must. be allowed for.
Tests for resistance to freezing and
thawing of concrete masonry units contain
ing fly ash indicate that such units, in gen
eral, could be.
For the more se
vere condition of horizontal exposure, a
minimum compressive strength of 3000 p.sj.
(21 MPa) based upon the nel area ofthe unit
is recommended when normal weight ag
gregates are used. This is true il fly 'ash is
used or not.
Air-entrainment is not practical at the
extremely low or zero slumps used for con
crete block. It could be applicable to slump
blor;k pr quarry tile. To provide adequate
(continued on /;Jack)
ALASKA' BRITISH COLUMBIA' CALIFORNIA COLORADO' IDAHO' MONTANA
NEVADA OREGON' NEBRASKA' WASHINGTON' WYOMING' UTAH
" '
niml ]]3WJrLlIJEUlJW
.., . . .
Number 33
FLY ASH IN ROlLER COMPACTED
CONCRETE
Advances in technology are usually surging run-off sparked by thunderstorms
associated with sophisticated and compli and cloudbursts that .are historically in
cated processes that cany a correspond tense in the Blue Mountain foothills
ingly impressive price tag. But the Willow drained by Willow Creek.
Creek Dam constructed at Heppner, The cost of flood control in such a
Oregon is apt to go on the books as a remote use area had placed any pending
major step toward reversing the quality/ project at a low priority level. Now the
cost ratio in the matter of mass concrete roll crete dam will be completed for approx
construction. The aggressive efforts of the imately one-third the cost of the more
Army Corps of Engineers are resulting in massive earthfill structure that had been
what is the United States' first roller on the Corps' drawing board. The benefit
compacted concrete CRCC) dam. of the lower cost may result in stimulating
Rollcretels Born. "Rollcrete" is other activity as well. In April 1982, the
likely to become the more common term COE made a public announcement of a
for this simple process that compresses a $285,000 evaluation study that will encom
damp aggregate into an embankment pass some 80 new hydroelectric sites in
like fill with a resulting density greater the Northwest. Corps spokesmen say that
than conventional concrete poured wet design time for rollcrete structuring is
into forms. The additional density is attrib
relatively short. "From concept to con
utedto the use of fly ash and the new RCC
crete in less than two years;" is how one
process. This rollcrete mass cures more engineer described the designing of
quickly, and is stronger, yet contains a Willow Creek Dam.
smaller percentage of cement and fly ash The Eucon Corporation of Pasco,
than a conventional dam. The 9,000 tons
Washington, won a $14,000,000 contract
of fly ash needed for this job was supplied
to build the 1,700 foot long structure that
by Pozzolanic International which met the
topped out 218 feet above the excavated
rigid supply schedule from one of their
bedrock and contains over 400,000 cubic
class F sources meeting federal specifica
yards of concrete. Eucon's divisions were
tion SS-C-1960/5.
well suited for such a project. The
UseOf On-site Material. At Heppner,
Steelman-Duff Division based at
material standards allowed for use of all
Clarkston, Washington. was experienced
but the top soil of the overburden at the pit
and equipped for the rock and earth
excavation. The DeAtley Company of
site located just above the darn. Some
extra sand was mined out of the bottom of
Lewiston, Idaho, another division of
Eucon, produced the aggregate. Before
what will become the pool area. This
. the began,-,hal I .. lnemat.erial-was
added blendsCind allows ()f<ilLpit_
material without There is very
crushed and segregated into huge stock
piles lor feeding into a two drum noble
little material that is not useable in con
600 batch plant. A dozen or so subcon
crete if properly blended. The Heppner
tractors and suppliers drilled, fenced, and
project has no reject pile.
provided steel. pipe, concrete. cement, fly
The Willow Creek Dam has been
ash and many services.
designed and contracted by the Corps as
a 160 foot !Jigh flood control structure. It is
to act as a capacitor in absorbing the
I ,'utllil/lled ';/1 back)
References:
Klopfenstein, Don and Klopfensteif], Inez; "Rollcrete Dam - More Strength, Less Price".; Pacific Builder and
Engineer. July 5, 1982.
ALASKA' BRITISH COLUMBIA' CALIFORNIA COLORADO IDAHO' MONTANA
. NEVADA' OREGON' NEBRASKA' WASHINGTON' WYOMING' UTAH
I
I WUllLLLLllilJUlRl
FLY ASH IN MASONRY GROUT
Number 3"5
Hollow core masonry units form a sig
nificant portion of the building materials
used in housing and commercial projects.
Strength and stability of masonry construc
tion is often increased by encasing rein
forcing steel bars" in some, or all of the
cores with a concrete mixture. Difficulties
in placing and consolidating concrete in
side these long, small diameter cores re
quire the use of grout, an extremely fluid,
self consolidating mixture.
Ordinary Grouts. Ordinal}' grouts
use large quantities of sand and water to
achieve desired workability although they
create the following undesirable side-ef
fects:
1. Large voids will result from a high
sand content requiring large quantities of
portland cement to produce normally re
quired 2,000 p.s.i. to 3,000 p.s.i. compres
sive strengths at 28 days of age. High ce
ment contents result in very expensive
grouts.
2. Segregation frequently occurs as
these mixes often lack cohesiveness. As
the mix flows down the hollow core, seg
regation occurs yielding a variable, non
homogeneous core of poor quality.
3. Cracking is common due to the high
shrinkage characteristics of rich, sandy,
wet mixtures and segregation.
Fly Ash Improvements. Fly ash
utilized as an ingredient in grout mixtures
improves these undesirable aspects yield
ing a greatly improved product. Fly ash
affects grout mixtures in the following ways:
1. Fly ash particles are spherical in
shape which greatly increases workability
and cohesiveness, allowing complete core
filling with grouts of lower slump. The re
duced segregatianresultsin a more home
geneous core of uniform strength with a
reduced tendency to crack.
2. Spherical particles also reducewa
ter demand for a given degree of workabil
" ity which in turn reduces drying shrinkage
and propensity for cracking.
3. Fly ash is a pozzalan which chenli
cally combines with lime by port
land cement hydration to form durable,
strong cementing compounds similar to
those of portland cement. This reaction
provides higher 1,.Iltimate strength than can
be achieved with portland cement alone.
4. Efflorescence from grout is greatly
reduced as soluble compounds which form
efflorescence are chemically fixed inside
the mass by pozzolanic activity. This chemi
cal fixation renders these compounds nOD
soluble, preventing them from migrating to
the surface where they would form objec
tionable deposits.
5. Just as fly ash particles increase
workability, they increase pumpability, al
lowing grouts to be pumped farther, faster
and with less effort.
Grout Mixtures. Conventional
grout mixtures typically contain 800 to 950
pounds of portland cement, sand contents
of 60 percent of total aggregate and 40 to
50 gallons of water per cubic yard. Fly ash
contents of 200 pounds per cubic yard have
been used, replacing a like amount of port
land cement while reducing sand content
and water demand by 4 to 5 gallons.
With the benefits imparted by fly ash,
it is easy to see why fly ash is a desirable
component in concrete grout.
questions regarding fly ash in masonry
grout, contact your nearest Pozzolanic tech
nical representative.
NEVADA' OREGON' NEBRASKA' WASHINGTON' WYOMING- UTAH

Number 36
STRENGTH OF FLY ASH CONCRETE
Fly ash concrete can be designed to
achieve any level of strength obtainable
by concrete containing only portland
cement
Compressive Strength. Strength
gain contributed by portland cement
occurs very rapidly at early ages up to
about seven days, after which it slows
markedly. Strength development contrib
uted by fly ash occurs through chemical
combination of reactive fly ash glass with
calcium hydroxide generated by hydra
tion of portland cement This process is
called pozzolanic activity.
A fly ash concrete mix, designed for
equivalent performance to conventional
. concrete at normal ages, will generally
gain strength more slowly at early ages.
After about seven days, the rate of
strength gain of fly ash concrete exceeds
that of conventional concrete, enabling
equivalence at the desired age. This
higher rate of strength gain continues
over time enabling fly ash concrete to
produce significantly higher ultimate
strength than can be achieved with con
ventional concrete.
t
..c:
til
c

iii
7 -Day Performance
/'"
/'"
Fly Ash concrete>./'
/.
A
.0
Plain Concrete
7 Age (Days) --to-- 28
Rates of strength gain of conven
tional concrete and fly ash concrete
based on equivalent performance at
7 days.
Fly ash concrete designed lor equ iva
lent performance at seven days or earlier,
will yield practically the same strength
gain, prior to the design age. At all ages
thereafter, fly ash concrete will exhibit
much higher strength gain than' conven
tional concrete.
Concrete made with Type C fly ash
(as opposed to Type F) has higher early
strengths because it contains its own
lime. This allows pozzolanic activity to
begin earlier. At later ages Type C behaves
very much like Type F - yielding higher
strengths than conventional concrete at
56 and 90 days.
Uniformity. Statistical analyses of
compression tests have shown that the
use of fly ash often lowers the variability
of strengths (lower coefficient of varia
,tion). This can result in a reduction in
"overdesign" yielding adirect cost savings
to the concrete producer.
Flexural Strength. In general, a
relationship exists between the compres
sive and flexural strengths of concrete.
Coricrete, which has a higher compres
sive strength, will have a correspondingly
higher flexural strength. This holds true
for fly ash concrete. However, in many
fly ash concrete has demonstrated
flexural strength exceeding that of con
ventional concrete when compressive
strengths were roughly equal.
High StrengthConcrete. In instances
I
where high strength concrete has been
specified (above 7,000 p.s.i.), fly ash has
consistently proven its usefulness. After a
certain amount of cement has been added
to a mix (usually about 700 pounds), the
I
I
addition of fly ash usually results in
higher strengths than an equal amount of
, added cement. This is especially true for
I
i
56 and 90 day strengths. Production of I
high strength concrete requires the use of
high quality fly ash at a minimum of 15
percent by weight of total cementitious
materials. ' j
For further information regarding the
strength of fly ash concrete, contact your
(continued Oil DaL'k)
ALASKA. BRITISH COLUMBIA CAUFORNIA COLORADO IDAHO' MONTANA
NEVADA' OREGON NEBRASKA WASHINGTON WYOMING' UTAH
lechnlcal
FLY ASH AND CREEP
IN CONCRETE
Creep of concrete is defined as
"time dependent deformation due
to a sustained load"l. Creep can be
a serious problem when long term
building loads cause concrete
members to change dimension
and impact the quality of their
function. Excessive deformation
can cause beams to sag with re
sulting difficulties in the function
of a structure.
The rate of creep is dependent
upon elastic modulus and ulti
mately upon compressive strength.
High quality fly ash used in con
crete mixes affects compressive
strength in a positive manner.
During the early construction
period where settlement and con
struction practices cause unusual
loadings, fly ash concrete has a
lower elastic modulus which
accommodates slightly greater
creep. This early age extensibility
allows fly ash concrete to accept
unusual loading without cracking.
When a structure is completed and
creep is undesirable, the later age
strength gain of fly ash concrete
gives significantly higher elastic
modulus than in concrete without
fly ash and results in less creep.'
The use of fly ash in structural
concrete is a great benefit in con
trolling deformation to work for
rather than against the integrity of
the structure.
'.-\CI i 16R78: "Cemei1t and Concrete Terminology"'
cific questions regarding fly ash
for the control of creep, contact
representative.
Manual Of Concrele Pracilce. Part I: 19&'
Number 37
i
,
I
cGosh, R, S, and Timu sk. 1. "Creep of FII' Ash Concrete: ACI Journal; September - October 198 I.
,"'t:\lid')" nRt:r-nrv WA<:HINr-TON WYOMING. t ITAH
echnical IfuM1UL@:lTIlW
Number 38
OIL WELL CEMENfING WITH
. . . .
FLY ASH/CEMENT SLURRIES
Cement slurries have been
Compressive Strength. High
used to support and protect well
. c9mpressive strengths are not
casings and prevent vertical migra- .
necessary in oil well cementing,
tion between strata since the early
but the waiting period during
1920's. In the oil well environment, strength development must be
the slurry may be subjected to
kept to a minimum. In most cases
temperatures ranging from below
the compressive strength of fly
freezing to as much as 700 degrees ..
ash/ cement mixtures is com
Fahrenheit, while having to remain parable to neat cement mixtures.
flowable for several hours under Accelerating admixtures are some
pressures ~ s high as 10,000 p.s.i. times used in low temperature
T h ~ use of fly ash in these mix situations to control strengths
tures has significantly improved the desired range.
the ability of the well drilling indus Corrosion. Low permeability,
try to cope with such harsh condi which is typical of fly ash concrete,
tions while cutting material costs is also a beneficial characteristic
well below those of the previous of hardened fly ash grout. Cor
100 percent cement technology. rosive water zones may cause
Slun-yWeight. The lower spe deterioration in neat cement grout
cific gravity of fly ash makes it leaving the well casing exposed
possible to cut the weight of the to corrosive attack. Fly ash mix
slurry by approximately ten per tures are an industry wide solution
cent. Thjs can lower the total to this problem.
column weight of the slurry in the For further information or spe
well- easing the stresson weaker cific questions concerning oil well
subsurface formations.
cementing, contact your nearest
ThickeningTime. Fly ash per Pozzolanic technical representative.
I
mits greater control of thickening
time (set) which ensures that
placement can take place with
I
ample time for minor breakdowns I
in equipment
Increased Flow i).ates. The
fmproved workability imparted by
the fly q.sh lowers the' energy costs
during placement and decreases
the total time necessary to corn;
plete the job.!
I Smith, D, K.. "Utilization of Fly Ash in !he Cementing 01 Oil Wells:' Sixth Inlernalional Ash Utilization
Symposium Proceedings, Reno, 1982.
, I"':'nut"'H.tt::. J n,....'d . ....,1;)1'). O., ..../'l lonn\ A#'),c hi "71
GUIDE SPECIFICATION
FOR
Number 39
STRUCTURAL CONCRETE
Technological advancements in the con
crete indusny have made available a wide new
range of products at heightened perforrnance
levels. Increased perlorrTIance, while bringing
benefits to the engineer and contractor in terms
of capabilities and economy, can be confusing
for the specifier dealing with recipe specifica
tions. This complexity makes it advantageous
for the specifier to draft perlormance specifica
tions which assLrre desired results without re
sponsibility for error.
Perlormance concrete can best be de
fined by referring to ASTM C-94 Standard Speci
fication for Ready Concrete, Section 5.3,
"Where the purchaser requires the manufac
turer to assume full responsibility for the selec
lion of proportions for the concrete mixture."
The specifier must then specify requirements
for strength, workability, placeability, durabil
ity, surface texture or other pertinent perlor
mance parameters. The combination of ingre
dients used and their relative proportions are
then left to the producer (or a testing agency
representing the producer) as is the responsi
bility for their perlormance. Testing procedLrres
and methods of interpreting data are fully cov
ered in existing documents for resolution of
disagreement.
Pozzolanic provides this specification
guideline utilizing the performance specifica
lion approach. It may be inserted in specifica
tions as is or may be adjusted to meet indi
vidual needs and situations:
A. Materials
1. Portland cement conforming to ASTM
C-lSOorASTMC-595 for blended cement.
2. Fly ash pozzolan conforming to ASTM
0618, loss on ignition ((:0.1.) maximum '1
percent.
3. Aggregate conforming to ASTM C-33.
4. Water
to ASTM C494 .
5. Air entraining admixtures conforming
to ASTM ,C-260
B. Composition ,of Concr.ete
1. Concrete miXtures shan consist of the
aDQropriate proportions ofportland cement,
ash, water. coarse and fine aggregate, air en

training agent and water reducing agent for the
intended application.
2. Concrete furnished under this
cation shall be provided under alternate 2 of
ASTM C-94. Concrete mixes shall be propor
tioned for each type and strength of concrete
specified. Mixes shall be selected by either the
laboratory trials batch method or the field ex
perience methods specified in ACI301 current
revision.
a. All concrete classes induding, but not
limited to, structural, architectural, paving and
tremie shall be covered by these specifications
b. Minimum fly ash content is 10 percent
by weight of total cementitious material in all
classes of concrete where fly ash is used.
Cementitious material is defined as portland
cement and fly ash.
c. Special Aggressive Environments:
1. RefertoACl318-83, Section 4.5, Table
4.5.2 for maximum allowable water
cementitious material ratio, Table 4.5.1 for rec
ommended air content and Table 4.5.3 for
cement type, for thespeda1 aggressive envi
ronment encountered.
2. For sulfate environments refer to ACI
318-83. Section 4.5, Table 4.5.3 and Com men
tal)' Section 4.5.3 for cement type and maxi
mumwater-cementitious material ratio. Water
cementitious materials ratio shall be equal to
water-cement ratio W/C=W/C+P. Class F fly
ash with acceptable R value may be used to
obtain sulfate resistant concrete. R value is
determined as:
. ....,.,.-
The recommended URn value for respective
degrees of sulfate resistance are listed
LIMITS FORA RESISTANCE FACfOR (R) FOR
CONCRETES CONTAINING Fl.Y ASH*
R Limits*
0.75
imnrti\fpr!
0.75 to 1.5
Moderately improved
1.5 to 3.0
No significant change **
3.0 Reduced
'continued on back
Technical
Number 2
FLY ASH:
THE MODERN POZZOLAN
What Are Ponolans1 Pozzol.ns are sili
ceous 0' siliceous/aluminous materials which,
when mixed with lime and water. fonn
cememitlous compounds.
What 10 Fly Ash7F1y ash is the best known
. and one of the world's most commonly used
pozzoiaas. PhysicaliYt it is a very fine pow
del)' material, predominately silica, wHh par
ticles almost :o:ally spherical in shape.
A BrIef HI.tory: Fly ash closely resembles
the voleanic ashes used in the production of the
earliest known hydraulic cements some 2,300
years ago - near the small Italian !own 01 pozzuoli
(which later gave its name to our modern day
p=ol.ns). Predating portland cement by over
2,000 years, fly ash has significantly improved
the performance of concrete throughout its
histOlY
The Modern Pozzolan. Today'. fly ash is
a by-product of burning finely ground co.1 in
electricity generating power plants. It is cap
tured from the exhaust gases of the plants by
elecJrOstatic precipilalors or bag bouses which
leave relatively clean air to escape from the
smoke stacks. This accomplishes two objectives:
the fine fly ash is prevented from polluting the
ambient air and the material once
precessed becomes a vah,labie resOlJrce for
industry.
Why Is Fly Ash Used In Concrete? Fly
ash is vndely uSed today as a cementitious
matena! in the production of a great variety of
mixes. The advantages of using fly
ash are detailed in Pozzolan;c Technical Bul
letins. Brieily they include: 'Increased Com
pressive Strength Increased Workability
'Increased Durability 'Decreased Permeabil
ity "Reduced Sulphate Attack -Decreased
Bleeding and Segregation *Reduced Shrink
age 'Reduced Heat of Hydration 'Reduced
Ceme!lVAggregate Reaction 'Increased Flex
ur.1 Strength.
The Fly Ash Advantage! The spherical
shape of fly ash particles and Iheir extreme
fineness. has a beneficial effect on the work
ability of concrete. The shape allows the con
crete to mOVe more freely.. and the fine par
ticle size allows better filling of the voids. The
slump test pbotograph shown below clearly
iIIustrales the improved cohesion of the By ash
concrete mix,
Ordinary Concrete
fly A.eh Concrete
ALASKA' BRIilSH COlUMBIA' CALIFORNIA' COLORADO' IDAHO' MONTANA
NEVADA' OREGON' NEBRASKA' WASHINGTON' WYOMtNG' UTAl1
TELEPHONE: LOCAL 23NI320. (800) 4265171
(I Pru:%olan>e lmemtition;;tf
Technical

Number 3
WHAT IS FLY ASH?
ALASKA' BRITISH COLUMBIA' CALlf'OANIA - COLORADO - IOAHO MONTANA
NEVADA' OREGON' NESRASKA WASHIN(ITON WYOMING' UTAH
TELEl'HONE: LOCAL 232-9320, (600)426-5171
CI F'o;:.zolan; InternmiONltl '9$
The American Society ForTest
ing and Materials deiines pozzolan
as "a siliceous or siliceous and
aluminous material which in itself
possesses little or no cementitiollS
value, but wili, in finely divided
form and in the presence of mois
ture, chemically react with calcium
hydroxide at ordinarytemperalures
to form compounds possessing
cementitious properties."
Types Fand Cfly ash processed
and distributed by Pozzoianic are
by-products of the combustion of
coal in large power plants. Pozzo
lanic fly ash is collected in electro
static precipitators or bag houses,
then classified by precise particle
size, thus assuringa uniform, qual
ity product.
Type Ffly ash is available in the
largest quantities. Produced when
either anthracite, bituminous or
sub-bituminous coal is burned,
Type F is generally low in lime.
usually under seven percent, and
contains a greater combination of
silica, alumina and iron (greater
than 70 percent) than Type C fly
ash.
Type C fly ash normally comes
from lignite or sub-bituminous
coal. These types of coal may
produce an ash with higher lime
contents - generally more than 15
percent - often as high as 30
percent. This gives Type C unique
self- hardening characteristics.
Where as both types of fly ash
impart a wide range of qualities to
many types of concrete, they differ
chiefly in the following ways:
TypeF
i. Most effectively moderates
heal gain during concrete curing
and is therefore considered an
ideal replacemenffor some cement
in mass concrete, and high strength
mixes. Forthe same reason, Type F
is the solution to a wide range of
summer concreting problems.
2. Provides sulfide and sulfate
resistance equal or superior to
Type V cement Type F is often
recommended for use where con
crete may be exposed to suliate
ions in soil and ground water.
TypeC
1. Most useful in "performance"
mixes, prestressed appiications,
and other situations where higher
early strengths are important.
2. Especially useful in soil
stabilization since Type C may not
require the addition of lime.
For additional information or
specific questions about fly ash,
contact your nearest Pozzolanic
-"::r.
II
[I Like all materials used in the production of
concrete, fly ash must meet the stringent requir",
ments of ASTM specifications, Fly ash specifica
tions are addressed under ASTM CGIS "Fly
II Ash and Raw or Calcined Natural Po=lan lor
Use as a Mineral Admixtur. in Portland Cemenl
Concrete" While these standards are
II
ously under review and subjecl to change. a rep
resentation of this specification, current at the
time of this writing Joliows this article.
II
The specifia::ations are by
chemical and physical properties ler standard
l'
and optional requirements. Standard require
ments Ne imposed for ail fly ash produced while
oplion.1 requirements are applied only when
certain conditions exist.
Standard Chemical RequIrements:
Major Oxides. Summation 01 the
oxides 01 SiD,. Al,O,. and Fe,O, indicates
amount of reactive malerial present and.
lions as the major dilference between class F
and class C fly ash. Allhough not expressly ad
dressed, caO mls in for Ihe reduced levels 01
major oxides in class C Ily ash,
Sulfur Trioxide. SO, conlent limitation is
based on minimizing expansion during hydra.
non.
Moisture Content. Moislure conlent is
primarily limited due to concerns over flowabil
ity. Values. as low &sane percent may cause flow
problems.
Lost; On Ignition. Loss On Ignition (LOI)
is a measure of unburned carbon remaining in
!he fly ash. It is desirable to maintain the lowest
level ofLOl possible. especially lor air entrained
concrete as carbon absorbs air-enlraining agent
rendering it unavailable lor generatiOl"i of an air
void system. A low LOI is also desirable to pre
vent discoloration althe concrete. LOt (or class
F lly ash previously limited 10 12 percent has
been lawered to 6 percenl. This was done 10
improve fly ash quality.
Standard Phy.kal Requirement.,
Flneneas. The specification places an up
per on coarseness of fly ash at 34 percent
retained on the N325 sieve. Malntainingunilorm
fineness of the Oy ash is importanl in producing
quality concrete of consistent caliber.
Strength Activity Index. Strenglh acliv
ity with cement is " measure of lhe reactivity of
fly ash in a mortar mix where 20 percent by
weight of cement is replaced with like weight of
.. fly ash. The test departs Irom the old pozzolan
test which was a35% equivalent volume repface.
ment of cement with ny ash. The currenllesl is
lelt 10 better simulate the of fly .,h
[or strength in concrete.
ltme Pozzo!anlc Activity Index.
zoianic activity with lime is again ameasure 0'
ji
Ii
il
Technical wUllrLILrn:1J1JJN]
II
II
II
J':lulTlb!!L't .
ASTl\!$PECIFICAIIONS ..EOR FLY ASH-
the pozzolank. activity oIlh. IIy ash being tested
using a mortar mix composed of lime. fly ash
and sand.
Water Requirement. Waterreguirement
is an Importantlesl)ndicating the capacity 01 fly
ash:o reduce water demand. Mast aclive fiy ashes
of .good quality generate water demands of less
than 95 percent of the total cement control.
Autoclave Expansion.
sion forces lotal cementiti()U.S hydration under
high temperatures and pressures and gives an
accurate determination of long term expansion
c:haractetistics of fly ash concrete.
Uniformity. Uniformity requirements Cor
the specific gravily and fineness 01 the fly ash
ensure a level of consistency 01 the fly ash en
abling uniform production of concrete.
Optlonal Chemical Requirements:
Aval.lable Alkal.le Available alkalies are
measured as the amount available in asalurated
limesolution. This requirement is recommended
only where !he !hreat of alkali""8!lfl'1l.te reac.
tions my be encountered.
Optional Pltyslc.al Requu-ements:
Multiple Fador. Multiple factor is the
produc! of fineness and LO!. The intent is 10
prevent both fineness and Lot (rom reaching
specification limits simultaneously and is a
method of maintaining uniformity.
Drying Shrinkage. The drying shrinkage
test measures the increase in shrinkage of the
fly ash in a mortar sample. Most high quality lly
ash will actually reduce the dl)'lng shrinkage in
cOncrete.
Air Entraining Admixture Demand. Air
enlraining admixture demand reflects tbe effect
of lly ash on air enlraining admixture and en
compasses changes in fineness and LOI. A high
LOI allects the ability.lo entrain air. Fly ashe..
wltb LOI under one percent generally do
not affect admixture demand significantly.
Reactivity with Cement Alkalie.. Ce
ment alkali reaction indicates the effectiveness
of fly ash in reducing alkali-aggregate reaction.
Due to the test method and the materials com
prising the test. illS only an indicator and cannot
be identified with performance of concrete. This
tesl should only be used when .lkali.,aggregate
conditions are suspected.
ASTM specifications fully cover require.
rnents for fly ash in Portiand cement c.oncrete
and provide lor the U'S'e oflhe uniform, wen te...led
materials for Hy ar::h concrete production.
For further information or specific questions
regarding ASTM specifications for fly ash.
lact your nearest Pozzolanic technkal repre
sentative.
(spl!d/i'co1icm dUJI! or; Dock)
AU.SI<:A BRITISH COLUMBIA' CALIFORNIA' COLORADO' IDAHO' MONTANA
NEVADA' OREGON' NEBRASKA' WASHINGTON' WYOMING UTAH
TELEPHONE: LOCAL 232932G. IBOO) 4265111
... P'o'Z2o.Iank: 31'1!f!rnaIlQI\;Io'i Copytil1m 1996

Number 5
WHY USE FLY ASH?
Concrete manufacturers, engineers.
architects. developers and contractors all
have an interest in speeifyingor using fly
ash on a routine basis to improve the
quality of Iheir project and to increase
their cost effectiveness_
Ready Mix Producers. A ready mix
producer has several reasons for using fly
ash in concrete.
1. Ply ash can compensate for fines
no! found in some sands and, thereby.
enhance pumpability and concrete
finishing.
2. Fly ash will result in a more pre
dictable and consistent finished product
which wilt ensure customer acceptance.
3. Fly ash offers flex ibility in mix
design providing a greater range of mixes
- from liquid soil at 100 p.s.i. to high
strength a,OOO-plus p.5-!. concrete - pro
duced by the same batch plan! without
exotic equipmenl
4. Fly ash improves the flowability of
the concrete which translates into less
wear and tear on all the producer's equip
ment from batching facilities to trucks.
5. Fly. ash enables the producer to
customize designs to each customer's
needs, thus prOViding the producer who
uses it with a competitive advantage.
Engineers and Architects. Engi
neers and architects will find that rty ash
provides the following benefits:
I. It enables them to provide the
client with a superior and more durable
finished concrete.
2. Fly ash produces a high strength
concrete that accommodates the design
of thinner sections.
3. Fly ash permits design flexibility
accQITI!Oodaling curves_ arches and other
arChitectural effects.
addition 01 fly ash to the mix is
a bu il!- in insurance for later- age strength
gain in concrete.
ash ensures that Ihe concrete
a durable building material.
Fly ash contributes \0 the aesthetic
aPDe.!ralnce the concrete.
Developers, Contractors, Ownenl.
Fly ash concrete provides the following
advantages to developers. contractors and
owners:
1. The workability of fly ash concrete
ensures that the speed of con
SITU ction is faster which translates into a
quicker return on investment
2. Fly ash in the mix accommodates
more creative designs.
3. Since fly ash concrete is not as
vulnerable to deterioration or disintegra
tion as rapidlyas concrete without fly ash,
it ensures low-maintenance buildings
which will retain theirvalue over the long
term.
Fly ash definitely enhances concrete
construction and returns real benefits to
every member of the building leam
questions about the use of fly ash, contact
representative.
ALASKA - BRITISH COLUMBIA' CALIFORNIA - COLORADO' IDAHO' MONTANA
NEVAOA' OREGON NESRASKA' WASHINGTON' WYOMING' UTAH
TELEPHONE: LOCAL 232-'320, [800) 426-S,71
I) Po:i:zd8nic: 1l)1O:tn:r.I.iOflal cOPyright 1
Technicall]3(u][LILIE1Tnw
Number 6
WHAT IS lYPE IP CEMENf?
'ASTM 'Slandard Specification For Blended Hydraulic CemenC: ASTM Annual Book orStandards.
Part 14. Concrete And Mineral Aggregates: 1981
ALASKA - BRmSH COLUMBIA - CALIFORNtA COLORAOO 10AHO - MONTANA
NEVADA' OREGON' NEBRASKA' WASHINGTON - WYOMING' UTAH
TELEPHONE; LOCAL2S2-9320. {eOol.26S!?1
o Poz2llInic )nlefl"l&I;OrUIJ :opy!...;".
are precise blends of
and fly ash (pozzolan). cements
are manufactured to enhance concrete
products by introducing the properties
imparted by fly ash: increased compres
sive strength, increased workability, in
creased durability. decreased permeabil
ity. reduced suiphate attack, decreased
bleeding and segregation, reduced shrink
age, reduced heat of hydration, reduced
cemenl/aggregate reactions. increased
flexural strength.
Specifications. Speciflcations ior
these cements are in ASTM C-59581 and
cover the following cements:'
1. Types I (PM)& 1 (PM)-APozzolan
modified portland cement for use in gen
eral concrete construction. Percentages
of fly ash included are up to 15 percent
2. Types I ? & 1 P-A portiand-pozzolan
cement for use in general construction.
Percentages of Ily ash range from 15 t040
percent
3. Type? portland-pozzoJan cement
for use in concrete construction where
high strengths at early ages are not re
quired. Percentage of fly ash is generally
at 40 percenl
Type I P cements are produced by
two methods. either by direct blending of
a specification fly ash or by intergrinding
fly ash with cement clinkerin a finish
Intergrinding allows the use of coarse.
non-specification fly ash to be used since
grinding in the finish mill will reduce its
fineness.
Fly Ash Superior. Pozzo lans nor
mally used inClude Oy ash. diatomaceous
earth, shale. volcanic ashes or pumicites
as well as some calcined clays and shales.
Fly ash gives the best results for produc
tion of Type I P cement
I. Fly ash consists of spheres which
enhance workability with a lubricating
action not given by high surface area.
angular. natural pouoian particles which
tend to yield sticky concrete mixes.
2. Fly ash spheres reduce water de
mand. thus improving concrete quality
while natural pozzoians increase water
demand. Upon intergrin;;!ing. the larger lly
ash spheres are crushed. releasing man,
smaller spheres which were trapped in
side. Releasing these spheres can signifi
increase the activity 01 a fly ash.
should be used. however.
with fly ashes of high contents.
Upon intergrindins, the carbon particles
wi!! be ground vel)' fine exposing a high
surface area which can result in problems
in entraining air in concrete. High carbon
fly ash should nol be used il7 this
application.
Although the use of Type I P cement
a!fords the user the advantages of fly ash
concrete. blended cements limit the flex
ibility of the concrete producer to vary
percentages of fly ash to meet different
needs. The best way to maintain flexibility
is to inventol)' fly ash in a silo of its own
and design the mixes as needed.
questions about 1 P cements. contact your
nearest Pozzolanic technical representalive.
Technical rnmILllilT1JIl\IJ
-,
Number 7
CHEMICAL COMPARISON OF FLY ASH
1+-AND... POR1lAND-CEMENF
The chemical of fly ash is amorphous (glassy) due to ;apid COOling;
very similar to thaI of portland cement those of cement are crystalline formed by
The table below shows typical com slower co oling.
pound... analyses [or two fIyashes and a natural 2. The major diUerence between fly ash
panolan (Class l'1'ly Ash, Class CFly Ash and and portland cement 1S the relativequanttty of
Class N . Natural) and ordinary portland each of the differenl compounds. Portland
cement A glance at the table reveals: cement is rich in lime (CaO) while fly'ash is
1. The same compounds exist in low, Fly ash is high in reactive sUi cates whiie
and portland cement Those of ny ash are portland cement has smaller amounts.
TYPICAL CHEMICAL COMPOUNDS
IN POZZOlANS At'ID PORTlAlIlD CEMENT
CHE.WCAL
POZZOlAN TYPE
CEMElIoT
COMPOUND
CLASSF CLIISSC CLASSN
SiO 54.90 39,90 58.20 22.60
25.80 16.70 18.40 4.30
Fe,O, 6.90 5.80 9.30 2.40
CaO 8.70 24.30 3.30 64.40
MgO 1.80 4.60 3.90 2.10
SO, 0.60 3.30 1.10 2.30
Na,O& K,O 0.60 1.30 1.10 0.60
The lable illustrates the basic chemical durable cementing: compounds no different
dille renee. Portland cement is manuraclured from lhose formed during hydration of ordinary
with Cao some of which is reJeased in a free portland cement
state during hydration. As much as 20 pounds A oIthechemistryof both materials
of free lime is released during the hydration of makes it Quite apparent thaI a blend 01 the two
100 pounds of This liberated lime wiJI enhance the concrete product and effi
forms the necessary ingredient for reaction ciently utili.e the properties of both.
with fly ash silicates to form strong and
HYDRATION PRODUCTS OF CEMENTING BINDERS

POfITlANO,
CEMENT +
WATER (CSH I
(PC) ( H, 0 I HYORAl"E
IT: (C.OH)
PORTLAND CEMENT

+ FLY ASl:L
PORTLAND FLY
CALCIUM
SILtCATE (CSH 1
fM)RATE + ('t:) + ""'"7
'- FLY
LIME + ASH
(C,OH) (I'll)
THROUGH POZZOtANIC ACTIVrlY. FLY ASH CO_NES WI11i FREE LIME TO PRODUCE THE
SAME cr;Memnous COMPOUNDS FORMED BY TIlE HYORAnON OF PORn..ANO CENl'rr.
For further information or specific questions abou! the chemistry of fly ash, conlact ;.'our
nearest POZ2olanic technical representative.
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.. PotZOiank: It\tornational Copyrigh1 19!
Technical IBllllIJlLmW
Number 9
FLYASH AND TIlE
CONCRETE PRQPJJCER.
During ,the past 20 years, the
producer of ready-mixed concrete
has experienced a numberof chal
lenges in incorporating new tech
nology into day-to-day operations.
The addition of air entraining
chemical admixtures to concrete
mixtures previously containing
only cement, water and aggregates
required increased production
equipment and controls to provide
satisfactory performance and
uniformity.
Chemical water reducing ad
mixtures further complicated con
crete production by opening a new
range of product offerings with
varied properties depending upon
need and choice_
Conversion of concrete pro
duction from a sack content stand
ard to a compressive strength per
formance standard increased the
need for consistency in produc
tion and more testing to ensure
quality.
Meeting these technological
challenges and others have re
quired expertise and operational
changes which have resulted in
the production of better quality
concrete and a wider range of
concrete products.
Fly ash presents a technical
challenge similar to the others and
also offers many benefits and
opportun ities. Benefits to concrete
include:
Increased ultimate compressive
strength
Reduced water demand
Improved workability
Better pumpability
EaSier finishing
Reduced segregation
Increased density
Reduced permeability
Reduced bleeding
Reduced heat of hydration
Reduced drying shrinkage
Reduced thermal volume change
Increased early age extensibility
Decreased creep
Increased flexural and tensile
strength
Increased ultimate modulus of
elasticity
Decreased leaching and
efflorescence
Decreased alkali-aggregate
reaction
Increased ultimate freeze-thaw
resistance
Increased sulfate resistance
For information about the prop
er handling and storage methods
for fly ash, see Technical Bulletin
Number 10. .
For information about propor
tioning fly ash concrete mixes, see
For information about supply
of fly ash, see Technical Bulletin
Number L
For information about ASTM
specifications for fly ash, see
For further information or assis
tance, please contact your nearest
Pozzolanic technical representative .
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I) ?onolal'lic 100ernl.lHonai Copyr.-,fl\ 19
Technical
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ii Pozzolanir:: Jf'!lernaticr.... Coc:.:t.: -"
HANDLING FLY ASH
Fly ash and cement are transported
1*- __
, ment but deSpite a similarily in appear
ance. fly'ash has some different character
istics from cement that can affect its
handling.
Flowablllty_ Photomicrographs
reveal thai fly ash particles are spherical.
This rounded shape prevents the particles
from interlocking and restraining the flow.
When aerated. fly ash is capable ofUowing
through opE'nings where water will not
flow.
More Abrasive. Fly ash consists.
basically, of particles of glassy sil ica
dioxide thaI have the abrasive qualiti"'-S of
sandblasting grit. Fly ash !lowing through
a small leak can rapidly enlarge it to
increase the rate of flow.
These two properties can cause prob
lems if there are leaks even very tiny
ones- in either the storage or the handling
equipmenl
Therefore. if ifs necessary to store fly
ash adjacent to cement in a split silo, the
partitioning must be carefully checked for
leaks to prevellt seepage. Double partition
walls are recommended p,oviding an
extra measure of safety.
Separate dust collection systems
must be used on split silos to avoid
contamination in compartments.
RF.MEMBER - FLY ASH WILl.. FLOW
WHERE CEMENT WrLl.. NOT.
Highly Absorbent. Fly ash can be
handled equally well with either screw
systems or air-slide equipment. However,
some fly ash is in a sense" hydroscapic"
and it may readily absorb moisture.
Special precautions must be taken to
ensure thatanyequipment used to handle
or store fly ash has adequate water traps
and is watertight. Water shou Id not be
allowed to collect on top of silos or above
equipment that handles Ily ash,
Alcohol traps have proven very elfec
tive for removing moisture from the
lion source. Where bolt-together equip
ment is used. a high qualily caulking
compound should be applied liberal Iv. A
silicon based compound lends to
longer than conventional compounds.
Number 10
Special Considerations. The fine
ness of the fly ash also requires that
-'speciaJprecautirlns-be-la'kelf'inllY,,' de;'
sign of the handling eQu ipment.
For example, all negatively sloped
screws or air-slides should contain posi
tive cut-off valves. Certain air-slide designs
may be excepted from this. although
positive cut-offs are generally a good idea
lor all fly ash systems. As a general rule,
screws should be used for upslopes (max.
26 degrees) and air-slides should have a
down slope of 5 to 8 degrees.
Since dry fly ash is generally less
dense than cement, tonnage capadly of a
silo will be less than lor cemenl
Unless fluidizing techniques are em
ployed, there is a danger of packing in the
silo and bridging may occur, causing
difficultyof discharge. Do not use vibrators
to attempt to facilitate discharge of bins.
Fly ash tends to "fly" mOre easily than
cement. The drop into the mixing hopper
should be kept to a minimum and an
enclosure provided if possible
Most pollution equipment designed
for cemem installations will work for Fly
ash. However, should problems exist. it
may be that there is not a high enough
"cloth-toalr" ratio in the dust collector.
Most older dust collectors have a 3 to I
cloth-ta-air ratio .. _ but since a high
is SO fine. it may require a 7
to I ratio.
Flv ash rna\' be handled with some
what than cement to aid
in the reduction of dusting problems. Fly
ash moves well at [0 p.s.i, from pneumatic
discharge vehicles. and at 1 to 6 p.s.i. and 4
to 10 d.m. [or aeration pads and air
slides.
Remembning these three simple
rule:;; can in
Fully handlin" flv.isll:
1 A\"ui,! .lil m"bllp,' : 'l:" "':"[.1":' ,)n'l
:1. Avoid hi;!h .til'" I,r,'''''' It. lilt "T;'O:ldliM'

for further inroTllm(ion or specific
questions regardinf\ the handling .of iI;'
1:tsh. please contacl your nearest
lanic technical represent3ti\-.,.
Technical IIDlUJIlJLIETI1J1NJ
PROPORTIONING FLY ASH
Number 11
ALASKA' BRITISH COLlJMBIA CAUFORNlA COLORAOO IDAHO, MONTANA
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bPo:t1tllanie INOfM:.:;nal C:<!'>frign:
---CONCRETEcMIXES
Effects or Fly Ash .on ProportIonlng
. Proportioning fly ash concrete mixtures
is only slightly more complicated than pro
portioning plain cement concrete mixtures.
The same solid volt:me proportioning tech
niques desc:nbed in ACI 211 are employed
as are used with conventional c:oncrete
mixtures.
AC!211 givestheproportioneraseries of
steps through which values are selected !or:
cementitious materials content
water content
air content
coarse aggregate size and content
These ingredients are converted into
solid volumes. The difference between the
sum 01 the total volumes and 27 cubic feet
will determine the necessruy vo!wne of sand.
Sand weight is then calculated to complete
the trial mix proportions. The accurac;y of
this mix must be cbeclred by physically
preparing a sample of the proportioned in
gredients and testing the mixture for yield.
While By ash is a cenentitious material
which greatly benefits concrete, the propor
tioning ofconcrete containing fly a'lh requires
adjustments due to the physical properties
01 the ash. Viewed microscopically, fly ash
particles are found 10 be spherical in shape.
Because of this and other physical attributes
of fly ash. one can expect the following:
The baH bearing shape significantly
aids the wO!kabilily of concrete. This allows
lor lower sand content than conventional
mixes while handling remains similar. As
the proportion 01 sand is reduced, aI! perlor
mance aspeds 01 the conc:rete are enhanced.
Again, because of fly ash's spherical
particle shape, less water is required to
achieve the same level of slump as in the
control concrete. The addition 01 fly ash in
conventional mixtures typically reduces the
water needed by S to 10% over plain con
crete, and this reduction can be further in
creased where high levels of fly ash are used.
The specinc gravity oilly ash is much
lower than thai of Portland cement; there
fore, 100#01 fly ash has a muchgreatersoHd
volume than the same weight of Portland
cement. Past practice has diclated a cement
reductlon when water..reducing admixtures
are used; however, in fly ash concrete the
cementitiousmaterlals (cement and fly ash)
volume is higher, not lower. This higher
quantity 01 cementitious materials greatly
assists in the finishing process.
Air-entralnrnent is not affected ad
versely with high quality, low 1..01 fly ash
supplied by Pozzolanic, but one can expect
a need for a higher dosage of air
entraining due 10 the increased solid volume
of c.ementilious fines. This increase in dos
age typicallyamounls to lessthan 0.25 ounces
per 100# of cementitiollS materials.
The use of water-reducing admixtures
is encouraged with fiy ash concrete mix
tures; however, certain lactOts must be con
sidered:
1. Duringwarrn temperatures. a normal
dosage of VIaIer-reducing admixture is cal
culated on the combined weight of cement
plus fly ash.
2. Duringperiods allow temperatures, it
is advisable to use a conservative dosage of
normal set time water-reducing admixture
calculating the dosage based only on the
weight ofcement. Under cool temperatures,
noma! setting water-reducing admixtures
may caUSe retarded concrete set. RedUCing
the dosage utilized during cool conditions
can help maintain proper concrete set times.
Determination or Fly Ash Content
Several methods exist for the selection
of the fly ash content in a mixture.
SpeclfIcation. The specifications lor
a particular project may define a required fly
ash content. The percentage 01 fly ash re
quired may range from as little as 10% to as
high as 40% depending upon the concerns
of the engineer. While fly ash. is genera!Jy
limited to 20% in most structural concrete
applications. the engineer may have certain
durability concerns in mind which have
..:
Technical
FLY ASH FOR
Number 12
STRUCTURAL"-CONCREiE"
A major use for fly ash in the construc
tion induS!ly is in the production of high
quality structural concrete. Fly ash contrib- .
utes beneficia! properties to the concrete
while helping to mairJain economy. These
properties include compressive strength, lu
brication a.'ld increased durability.
CompressIve Strength. Specifica
tions lor normal strength concrete generally
require a given level of strength in 28 days.
Fly ash concrete is easily proportioned to
meet strength requirements at this age or
any other age desired.
Fly ash concrete designed 10 be
equivalent in strength to ordinary concrete
at28 dayswill normally exhibitslightly lower
strength at early ages. This slight early age
strength reduction does not adversely affect
job sequencing dueto cons!nlC1ion loading.
(See strength gain CIlIVeS in F;g. J).}
Fly ash concrete can be easily propor
tionedto meetstrength spedlicaliOll$ at early
ages (3 to 1 days). Economics, although stiU
attractive, will not be as great as when pro
portioninglor2lkla:Ys of age or later. Fly ash
has been utilized in many early strength
projects because of many beneficiallealures
other than economy.
Later agestrength gain after 28 days can
prove to be quite valuable. It may be used to
obtain required strengths at lower cost. It
may be relied upon ill deciding structural
acceptallilily where compressive strength
tests indicate tower than specified strengths.
It also plays a key role in producing high
strength concrete.
High compressive strengths from 6,000
p.s.i. to 14.000 p.sJ. are often required in
structural concrete. High quality fly ash
complying with ASTM C-6J8 is most advan
tageous in achieving these strength levels.
The strength gain derived from 10 to 25% fly
ash (by weight 01 cementitlous materials)
cannot beequaUed by adding cement.'lt has
also been fOund to produce the same high
strength levels in concrete as silicafume
without the high cost.
Fly Ash Lubricates the Mix. Fly ash
spheres imparl a ball bearing lubrication to
plastic concrete enhancing workability at the
same slump as ordinal)' concrete while re
ducingwater convenience. Enhanced work
ability contributes increased quality to
structural concrete in several ways:
1. Concrete pumping is made easier.
Flow rate may be increased without in
creasing line pressure. and line blockages
are reduced. Record pumping lime is
achieved as a result of the use of lIy ash. The
technique of il)jecting concrete into the
bottom of the fOrm from the pump hose is
made pOSSlble by the workability of the mix
from the lIyash.
2. Form Illling becomes easier. Fly ash
concrete is more responsive to vibration.
enabling forms 10 be fully filled more qUickly
and with less effOrt.
3. Segregation is reduced due to in
creased cohesiveness andworkabilityas well
as resulting reductions in voids, rock p0ck.
ets and other defects. Cost savings f.-o,",
reduced corrective action requIred on
defects alone can be significant.
Increased DurabUlly. The P02.Zo
lank actlvitywhich contributes cementitious
value to concrete also yields increased
density and reduced permeability. As a re
sult. penetration of aggressive media is
slowed or eliminated thereby increasing
concrete durability. .
Fly ash is especially effective in the ef
fort to restrict chloride ion penetration and
the accompanying disintegration it causes.
Concrete for parking struclures, highway
structures or anyother structures likely to be
subject to chlorides should require fly ash.
P02Zoianic activity also chemicallJ' binds
with cement alkalies, keeping them from
combiningwith reactive aggregates and also
acts to reduce internal expansion.
Reduced cement contents in Oy ash
concrete lowers the heat of hydration. which
is especially beneficial in mllSs concrete
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Technical f]3QllIllLlliJTI]1f\JJ
FLY ASH IMPROVES WORKABILITY
13
Though it is never specifIed, workability
ing Jly concrete in areas of difflcult
is one' of the most critical of
placement where rock pockets and other
concrete. Workability refers to the !,!ase of
placing defects oiten occur. Engineers un
handling, placing and finishing of fresh or
'plastic" concrete. Slump is the general in
dicatorof workability,yet different concretes
<:an have greatly different levels of workabil
ity with the same slump measurement.
Blemishes in concrete, typically called
rock pockets, are indicative of concrete
without suitableworkability, even though the
slwnp may be judged to be acceptlble. Rock
pockets indicate a separation of the pas:e
from the coarse aggregate in the concrete
mix. Concrete must be cohesiVe even at high
slumps to maintain its homogeneous char
derstand the effectiveness of using fly ash
concrete in tall thin walls, such as those
used in water tanks. They know they have a
belter chance of getting the dense, void free
concrete they have specified when fly aqh is
included in the mix.
TYPICAL
VEBE TIME
VS. SLUMP
acter and avoid segregation and costly rock
pockets. Fly ash offers this feature without
extra COS!.
Reduced Water of Convenience.
pounds (three gallons) of
water are normally required to hydrate 100
pounds of cement'. A normal concrete mix
will generdlly contain twice the required
amount of water to hydrate the cemen t
enough to facilitate handling and placing of
the concrete. This additional water, called
"water of convenience,' increases slump but
at the cost of decreased cohesiveness. Wa
ter of convenience is reduced when fly ash
is added to the mix because the plasticizing
ac:tion results in a two to ten percent water
reduc:tion in the plastic concrete to prodoce
the same level of slump as plain concrete. .
Reduced waler of convenience at the same
level of slump makes for more cohesive
concrete and decr .. .ases the occurrence of
costly segregation.
Greater Consolldatlon. Fly ash
concrete is adually more workable than plain
cement concrete at equivalent slump. The
VESI:: test measures the time and energy
necess31)' for consolidation of concrete un
der vibration. Figure 1 shows the remark
able difference in time and energy required
for consolidation of plain and fly ash con-
cretes.
Great benefits can be obtained when
llSing the easier, more complete consolidat
;
\x
.

ffi 10
:>
..
SLUMP-in..
Paste Volume Increases. The spe
Cific gravity of fly ash is lighter than cement.
When replacing cement wIth Jly ash on a
pound for pound basis, the result is a greater
solid volume 01 cementitious fines. Propor
tioning concrete mixtures with only water
reducing admixtures results in a greatly di
minished volume of cemenlitious fines. In
effect, this amounts 10 taking cement and
water out of the mix and replacing them with
sand and gravel. The strengths may be ac
ceptable. but the workability may not be.
Proportioning performance concretewilh fly
ash virtually guarantees a greater solid vol
ume of cementiliollS materials which in it.eli
helps promote cohesiveness and workability.
Cemenlitious fines are very important to
(continued on back)
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I Ponolanic tnlerna!IOtlal Cor
the contractor who finishes Ilatwork. These
fines are necessary to allow proper leveling,
sealing, and densification 01 the surface. Fly

by lubricating the surface, making il muc.h
easier and !aster to finish the job.
In lean mixes, or where aggregates are
defident in fines, an increase in the volume
of paste and an improvement in cor.slstency
will be advantageous forworkabililyand may
also increase strength by allowing more
::omplete compaction'.
Economical Mixture_ Pound lor
pound, no ether solid material improves tne
workability, strength, and otherproperties of
a concrete mix like fly ash can, resulting in
the mcst economical of mixtures.
..
".
Placing and finishing concrete becomes
easier due to Ihe improved workability from
th .. spherically shaped fly ash particles. Lower
slump'c.om:rete'cmrt5e'pllfc-edmutlieasTei' .
(and at lower water contents) due to the
plasticity provided by fly ash spheres. Segre
gation alld bleeding are r.,puced due to the
increased cohesiveness of fly ash concrete
so form finish and sharpness of detail are
enhanced. And coarse, clean sands can be
used in c.onc.relas utilizing Ily ash and still
have good workability.
For further information orspecific qua<;
lions about the workability of fly ash con
crete, contact your nearest Po220lanic tech
@
'Highw.y Re.,earc:h Board, Bullelin 284. -Fly Ash in Con",et.: January 1960. p, 21.
Gene:ra!ing Bot>rd, "Appiication of PFA in Concrete and Cemenr," R1BA Products Data.
Technical
FLY ASH DECREASES THE
Number 15
PERMEABILITYOFcCONCRETE-
Permeability of concrete and the result
ing level of durability are matters of the
greatest concem as the infrastructure of our
nation disintegrates before our very eyes.
Our task now is to replace that which has
fallen apart and to do so in such a manner
that it will last. Attention to permeability and
durability then become our prirna.ty goals.
Permeabillly is defined as the coefficient
representing "the rate at which water is
transmitted through a saturated specimen of
concrete !lnder an externally maintained
hydraulic gradient'. 'Permeability is in
versely linked to durabiJily in that the lower
the permeability. the higher the durability of
concrete.
Permeability is most frequently being
described now by the chloride-ion penne
abilily test which measures the passage of
electrical current through a concrete speci
men exposed to a batch of sodium chlo
ride". Limits of acceptability are as shown in
the table below'.
Table 1_ Chloride Permeablllty
Based on Charge Passed
CIwp f!'..u-cd Chfl)l'fd.
'.nnr.bruty 1'yplaJ 01
>4.000 mg- High wa.tw-eument ratio
!><l.6). PCC
2,000-4,000 fdodorubl MoOOrala walor-<:Mttm ralio
?(;(;
',000-2,000 low law watl!lK6.mGnt ralio
(,,)A),PeG
''''',1.000
Very lhw Lalox-modifiod o:ma'6to.
$lk:afums concr,e:le
<100 Negilgibio Polymer imprl!!lgnated
pc(yma.r c:orn:rabt
It has been cammon thought that only
Ialex modified and silicafume concretes had
the ability to obtain permeabilities low
enough to pose long term durability lor our
highway system. Recent testing. however.
has shown that properly proportioned con
cretes using a combination of /Iy ash, nor
ma! or highrange water red ucing admixtures,
and air entraining admixtures have the abil
ity to produce the same law levels of perme
ability.
Fly ash will increase the cemeotiuous
compounds, minimize waler demand, and
reduce bleed channels ail of which increase
concrele density. These factors yield con
crete of low permeabili!)! with low internal
voids. Durability is increased to freeze-thaw
damage (see Technical Bulletin "14) and
disintegration from attack by acids. salts or
sulfates (see Technical Bulletin "17).
fly Ash Helps Five Way". Using
Pozzolanic fly ash in the concrete mixgreally
aids permeability and durability in five ways:
1. Through pozzolanic activity fly ash
chemically combines with water and calcium
hydroxide forming addlllonal cementitious
compounds which result in denser. higher
strength concrete. The calcium hydroxide
chemically combined with fly ash is not
subject to leaching thereby helping to
maintain high density.
2. The conver.;ion of sahible calcium
hydroxide to cementitious compounds de
creases bleed channels, capillaty channels
and void spaces and thereby reduces per
meability.
3. At thesametime, theabovechemical
reaction reduces the amount of calcium hy
droxide suscepbble to attack by weak acids,
salts or other sulfates'.
4. Concrete density is also increased bY
the small, finely divided particles of fly ash
which acllike micro-aggregates to help fill in
the tiniest voids in the concrete.
5. Fly ash provides a dramatic lubricat
ing effect which greatly reduces water de
mand (two to ten percent). This water re
duction reduces internat voids and bleed
channels and keeps harmful ccmpounds out
of the concrete.
Forfurther information orspecific ques
tions regarding the use of fly ash to decrease
the permeability of concrete, contact your
nearest Pozzolanktechnical representative.
(continued on back)
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c H
Technical
CLASS F FLYASlLnECREASEc.. ' ..
'''c,''= .. -,.... -"
POTENTIAL ALKALI/AGGREGATE REACTION
[nternational Mh Utiliution Symposiom. 1973. p. 14.
4'S!ark. D. C. Reactivity: Som-e ReconsiderntiO'l1s... Fh!searc::h Bundin RDO?5.OJT
Portland Cemenl Association. 19S1.
'Dunstan, E.. R.. "Fly and Fly Ash Coocce!II;.!," of Redamatton. O<tllVet. Mil)' iS84.
"Graham. 0* E" "Fly Ash and lis use in Concrete."" NRMCA Public(flion No. 138, 1972, p. I(t
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"?oz;zgfunie kI:crrli::I:n;;! os::
The unique properties of class Ffly ash
make it not only beneficial, but absolutely
essential in some cases for decreasing re
action between cement and aggregates dur
ing the concrefingprocess' (see Fig. 1).
Under certain conditions imd in certain
areas, reactive silica in aggregates will react
with soluble alkalies Irom any available
source, causing excessive and deleterious
expansion. A volume Change will occur over
a period of time which causes the concrete
10 'spall" at the sur/ace. In addition to re
sulting ruptures, interiorstresses may
occur which cause cracking and seriously
impair structural integrity of the concrete_
The use of low alkali (L.A.) cement
0.6% alkalies) has become standard for
combatting reactive aggregates, although it
may by itself prove ineffective (Ner time.
ASTM C-227 limits expansion at six months
to 0.01%. While a mixture may prove ac
ceptable in the test, it may well undergo
destructive expansion later (see Fig. 2). Al
kalies from other sources, including the ag
gregate, ean fuel Ihe expansion reaction.
Some aggregates may also be so reactive
thai they expand tolailure before six months
with low alkali cement. Stark reported failure
of a mixture containing cement with as tittle
as .35% total alkalies',
Including Class F fly ash in the mix de
sign invariably reduces this reaction, pro
tecting the concrete (and the steel rein
forcement) from the deterioration which
lEiiert, R. J. "Bureau ol Reclamation Experient:e....
follows expansion. Class C fly ash may not
control expansion as well as class F. Dunstan
notes that Cao content may be a useful pa
rarneler to indicate the effectiveness of an
ash tocombal alkali/aggregate reaction' (see
Fig. 3)_
The decrease in alkali/aggregate reac
tion comes from the lact that class F fly ash
:-eacts chemically with and absorbs alkalies
in the cement, thus making Ihem unavail
aoie for reaction later with the reactive ag
gregate.
One e,xample 01 class F fly ash'S unique
propensity to reduce alkali/aggregate reac
tions was documented by the State of Ala
bama. In 1960, the Alabama Highway De
partment specified fiy ash in all concrete
pavement, bridges and culverts. TIme-l:ested
results in hundreds 01 lane-miles of fly ash
conc.""'te placed since then have been posi
tive accordinglodepartment represenllllives.
Bridges more than 20 years old have e"hii:>
ited improved resistance 10 alkali/aggregate
reaction.
In addition to tile use of p0220lanic ma
terial, it is recommended that low-alkali ce
ment (less than O.5'AI) and acceptable aggre
gates be used in order to prevent alkali/ag
gregate reaction'.
ror further information or specific
questions about the use 01 fly ash to de
crease alkali/aggregate reactions, contact
your nearest POZ4olanic technical represen
tative.
with fly A.')n and O:her in Concrete." Thin:
Technical
CLASS F FLY ASH INCREASES
Number 11
..
TO SULFATE ATTACK
Soluble sulfates in soils, ground waters,
and sewage waste destroy Portland cement
concrete unless it is designed with fly ash to
maximize sulfate resistance.
Sulfa!e attack is a two-ph""ed prpcess:
I)Sulfates combinewith calci urn ll:y!lroxi de,
fonning caldum sulfate (gypsum). The vol
ume of this gypsum is greater than the sum
ollis components, causingintemal pressures
which fracture the concrele. 2) Aluminate
compounds from Portland cement are at
tacked by sulfates forming a compound
called ettrlngite.. Ettnngite formation ruptures
the concrete in the same mannerasgypsum
formation.
Fly ash effedively reduces this suUate
deterioration in three important ways: I)
Class Ffly ash chemically binds free lime in
cementitious compounds rendering it un
available for sulfate reaction. 2) Fly ash ac
tivity reduces concrete permeability (see
Bulletin ;tt5) keeping sulfates from pen
etrating concrete. 3) Replacing a portion of
Portland cement with class F fly ash reduces
the amount of reactive a1uminates available
for sulfate reaction.
Studies by the Bureau of Reclamation
show that properly proportioned concrete
utilizing up to 35 percent class F lIy ash will
withstand sulfate alIack far better than con
ventional Portland cement. Plain and fly ash
concrete mixes using Type I, moderate sul
fate resisting Type II. and sulfate resisting'
Type V cements were compared under
standardized conditions of exposure to so
dium sulfate. In all instances, class F fiy ash
concrete dramatically outperlonned con
ventional Portland cement concrete. These
tests clearly demonstrated that Type n ce
ment with d?_ss 1" fly ash was mor" resistant
to sulfate atlacklhan Type V cement (seeFig.
1).
lDUnS13f1. E. R.o '"A spec
[nlerier. Water a.nd Pnwer
ResL..tant Concrete for the: 80"5," United States Depurlmen! of the
SerVice. 1980.
lDum'aan. R.o Ash and fly Ash COrlcte!e," U.S. Sl.Ireau oj US. Gov(!rnm.cr'lt Printing
May 1984.
'Helmuth. R. "Fly Ash In Ceme:ll and Concrete," Portland Cement As.'Y(}ci.<ttiofl, SkokIe. IL, 1987
ALASKA" BRITISH COlUMEt A CAL! FORNIA COLORADO IDAHO" MONTANA
NEVADA OR!;:GON' NEBRASKA' WASHINGTON' WYOMING UTAH
LCCALZl2-9320. (BOO) 42651"11
o Il"tctll,llloru;( Cl>pyn;hl 1$
Further Bureau of Reclamation work
correlates Ihe chemistry of a given fly ash
with its ability to resist sulfate attack through
a mathematical equation called the Rfactor,
fonnulated oeiow I

As Cao (calcium oxide increases and
1"e,o, (iron oxide) decreases, sulfate resis
tance decreases due to fly ash chemistry
(see Fig. 2).
The limits establish ed by the Bureau of
Reclamation requiring progressively lower R
values as sulfate attack severity increases
are as follows:
lIl1miu' SUlfate Resistance" CIJSi
<0.75
0.7510 1.5
1.5 to 3.0
>3.0
GreaUy Improved F
Moderately improved C
I/o sigllirocanl chango" C
Reduced C
'. A - ;;cae-SlIFe,C, p.rce.lage I,om fiy ash oxide
analysis; for very severe cydic condilions of welting
.M df)'ing or 101111980, ,educe I.. Rval"" by 0.50.
.. SUghdy irnptOyed 10 sliahdy reduced.
Compared 1.0 a Type II 00fn9nl control at 0.45
Tlje Portland Cement Association re
ports Ihe use of class F fly ashes improves
sulfate resistance while class C fly ashes are
less elfedive and may even accelerate de
ferioration' .
To ensure the most durable concrele
possible, class F fly ash is an essential In
gredient when the project will be vulnerable
to aUack by sulfates or other aggressive
compounds.
For further information or questions re
garding fly ash for sulfate resistance. contact
your nearest Pozzolanic technical represen
tative.
u;r1b ""l>l!

Technical
,
Number 18
FLY ASH HELPS MINIMIZE
CONCRETEvoiuMECHANGE
ALASKA. BKITISH COLUMBIA CALiFORNIA COLORADO" IDAHO" MONTANA
NeVADA OREGON NEBRASKA WASHINGTON WYOMING IJTAH
TELE.PHONE: LOCAL 232'9320. (BOO} 426-5171
'" i"oltCll)Il':; )n!etnmJOOal Cop/l!QI'l.! 1991;
It is natural that concrete changes volume
with changing environmental conditions. Three
primary factor.; are responsible far volume
changes in concrete: temperature, moisture. and
appfiedstress. Volume c,ange become$- a criti
cal element when concrete is placed in a re-.
strained area ultirnalety resulling in high stresses
and failure. Fly ash can he ir..sln.:.:nentaJ in
sis!ing to minimize the cbanges in voiume and
the resulting cracking assaciated wilh il.
Temperature. Concrete volume change..
in a manner diredly propo:l1iona! to changes in
temperature from lhetime it first looses ;>lasHcity
16when it gains ils permanent set. High heal of
hydration in lIS early life causes great expansion
Iollowed by gre.t conlraction as it cools back to
ambhmt conditions. Thermal cracking becomes
an issue as heal is re1ained inside the mass of
concrete mare than III the edges. This means the
outside shrinks faster than the inside with dif
ferential shrinkage accounting for ther:g1a[
craclcing. Concrete should be plated and kept as
dose to ambient lempetature as possibJe to
minimize thermal aackinS*
Moisture. Concretevolume change is also
directly proportional to changes in concrete
moisture. Concrete is produced wilh extrawater
(water01 convenience) beyond what is necessary
for the hydration of cementilious materials. The
grealer the amount of extra water. the greater the
dryingshrinlragepolenlial QI the concrete. At tbe
onset. the concrete has an initial volume. This
volume diminishes as water leaves: the matrix
during setting. Resaturatton wilh water wnt cau...e
the concrete to expand again. bUI it will never
reach its original The concrete volume
Will continue to change throughout its: life as its
moisture content changes. the amount of Change
depending upon the orJainalshrinkage potenlial
of the concrete.
An example of ditIereruia! shrinkage in
concrete is "curling." This phenomenon is
cbaracterized by Ihe edges of a slab curling up
and oIJ the sUbgtade below. The predominanl
reason fotlhi.'i are diHerenlial shrinkage itom top
to bottom caus.ed by improper Hni..<;hing and
curing. and moisture di!ferenliollrom lop to bot
tom. DHferentiai moisture moot appar
ent when the lop surface: is $ubjecll.o very drying
condilionswhiletnebortom remAins from
capillary aellon through the subgrade soils. The
surface shrinks while the bO!lom remains the
same causing the edges to curl upw.ards_
Applled S'res.. Applied stress (loading)
causes a change in concrcle shape and dirram
sIon called "dei'ormation." Deforml!1ion can 0(;..
currapidJycausing a qUick fallure. or it canbegin
immediately and continue fo: as long as the load
is maintained on the CO!'lcrete. Ti:ne depencer:t
<iclQrmation is called "creep. (See Technical
Bullelin #37)
Fly Ash Minimizes Change. POZ1:olanic's
high qualily fly ash vastly exceeds AS'IM
specifications yielding a product that contribules
to minimizing volume change by-providing:
2%-10% l1J<!ler reduc1ion thereby reducing
the potential lor shrinkage in the plastic and
hardened stales. This assists io reducing tbe se
verity01 plastic cracking as wen as craclcing from
drying shrinkage. (See Technical Bulletin #11).
Suplttiorworkab8i/ya\ lower slumps allows
for the easier placement of ""ncrete wilh low
"'!Ier content Drying shrinkage is primarily .E
!eded by the unit waler content qf
, (See Technical Bulletin #IS}.
Lower ermerel.lemperatures Ihrough gen
eration of lower heal o! hydration than cement
alon e generates. This reduced heat lessens
thermal cracking. (See Technical Bulletin #22).
For further informauO!! or specific questions
regarding the use of nyash to minimize conc:.rete
volwne.change. conlad your nearest Po:c:<:Olanic
.5
..t."",
.
u
i
l<I.l/<fit rt:'l,:"4""'lr!frP"H"''''f,,,b;1'''''''''''' !
) ; t1.:'l'I I"')
AGE. day.. ,WG SCALE.
- Drying shrinkage and autogenous. length
change of 4- by 4 by 30. inch bars 01 Po:'!
land cemenf concreie wilh 'lfario\.LG pOZZO
Ian replacemenls.
ot R,-"Clamation experiences
1 and Other Pouoians in Concrele,"
Third Internalional U1illzaUor. Symposium 1973,
p.14.

.o.",".;)n 111.ll! "'"1"1\l:bi
l:I,.fN'Q>rVbU"l'Irnf
"-lII':'WtSK1 ' .... ..r.
Technical
FLY ASH IMPROVES

Flexural strength of concrete is of
importance in highway and street
pavements, warehouses, parking
facilities - any area where concrete
must support vehicles. While the
flexural capacity of concrete may be
low in comparison with other
materiais, such as steel, it can be
proportioned and its application
engineered to provide durable, long
lasting service.
Concrete Capacity. The capacily
of a rigid concrete to support a given
dynamic, repetitious loading is basi
cally a function of concrete section
thickness. flexural strength and sub
grade stability. Many current specifi
cations cail far the flexural perform
ance of conventional concrete with
out realizing the benefits fly ash can
effect to achieve more durable. longer
lasting pavements at lower cosL
Fly Asb Advantages. The advan
tagesaffered byflyash are both physi
cal and chemical in nature and posi
tively affect flexural strengths.
Physical Advantages. Fly ash
consists 01 microscopic spheres
which interact in the concrete mix to
give the following benefits cement
. and other additives cannot
I. Fly ash spheres impart a bal!
bearing action that greatly increases
workability. This increased workabil
ity can be utilized to reduce sand
content which reduces aggregate sur
face area to be coated and increases
flexural strength.
2. Increased density is achieved as
fiyash concrete is mare easily consoli
dated and voids filled with the small
spherical particles.
Number 19
3. This ball bearing effect reduces
the resistance to flow that ordinarily
occurs between angular cement and
sand particles. redUCing water of con
venience demand by two to ten per
cent and increasing both flexural
capacity and density.
4. More workable fly ash concrete
can be easily placed and consoli
dated at lower slump than can ordinary
portland cement concrete. further
reducing water content
Chemical Advantages. Fly ash is
a pozzolan and reacts with calcil,lm
hydroxide generated by portland
cement hydration to form stable.
durable cementitious compounds.
This pozzolanic activity is benefici.al
because:
L Weak. leachable calcium
hydroxide is chemically captured by
the fly ash and fixed in strortg cementi
lious compounds. increasing flexural
strength and density, while decreasing
permeability.
2. Pozzolanic activi ty continues at a
high rate long after cement hydration
slows to provide higher flexural
strength.
Increased flexural strength derived
by the use of fly ash may be utilized to
decrease section thickness and save
money. If thickness is maintained.
longer useful life will result
For additional information re
garding designing concrete mixes for
flexural strength, Contact your nearest
Pozzolanic technical representative.
lR
ALASKA BRlrlSK COLUMBIA GAUFORNiA COlORADO" lDAHO" MONTANA
NEVADA - OREGON' NEBRASKA' WASKINGTOII' WYOMING UTi\H
TELEPHONE; LOCAL 2329320, (aoo) 426..,5171
Q POl:,l:Ql,anic Imomaliona! COP'l6ghf ,
Technical
Number 20
FLY ASH FOR IDGH STRENGTII
r-.I"\"'-T,.,....... Y, ..............
As recently as i960. concrete com
pressive strengths over 6.000 p.s.i.
were rarely achieved and seldom
used in the design and construction
of concrete structures. By 1972,
Material Service Corp. in Chicago was
regularly producing 9,000 p.s.i. con
crete for the construction of high-rise
concrete structures. High strength
concrete 01 12,000 p.s.i- and above is
becoming fundamental to the archi
tecture and engineering of the 1980'5.
Achieving high strength concrete
is a great deal more complex than
merely adding more cement to every
day concrete mixes. Decades of testing
and research have been required by
the finest technical people in the
world to achieve the kind of reliable.
consistent results required to make
high strength concrete a sale building
material.
Attention To Mix. Research has
shown that careful 'attention 'must be
paid to all ingredients of the concrete
mix. choosing irom among the many
to select those which produce the
best results. Careful appraisal of all
available materials has shown that
"the use of a good quality fly ash is a
must in the production of high
strength concrete and a fly ash with an
ignition loss under three percent or
less is preferable"" In terms of the
capacity for generating high strength.
"the strength gain achieved from the
use of l() percent to 15 percent fly ash
(by weight of cement) cannot be
attained through additional cement."
Strength Requirement. In line
with the innovative thinking required
to develop high-strength concrete
comes a change in the age at
strength is commonly specified. It is
well known that the level oi achieved
strength is time dependent. The older
the concrete, the stronger it will be
come. Deiaying design strength re
quirements to later ages makes it
infinitely more practical to produce
hIgh strengths. Whiie ny ash concreie
is beneficial in many ways up tQ the
"ormaiiy required 28 days. il has a
higher rale of strength gain at later
ages than portland cemenL This laler
age strength gain allows higher
strengtns to be ach ieved than can be
achieved with portland cement alone.
High strength concrete requires
very carefu I appraisal of available
materials. care in production and. of
course, the use Of.3 high quality fly.
ash.
Please contact your nearest
Pozzolanic technical representative
. for more information or specific
tions about fly ash in high-strength
concrete.
I Blick. R L. '"Some raCWts lnflucn<:ing HiSh-Swwglh Concrete:' Modem COII(I'"lW. Vol. .36. N(1. 12, April i!Ji:l
'" ALASKA BRITISH COLUMBIA' CALlFOANIA - COLORADO' IDAHO' MONTANA
NEVADA' OREGON - NEBRASKA' WASHINGTON - WYOMING - UTAH
TELEPHONE: LOCAL 2329320, (800)426-5171
II POl.lol;:n',\C ,,,,etni)I'Ofl.,.1 Copy!!g", I
H'.............. ....=..
so that it
sired area.'
costs controlled_
g...
various
Maximum
Materials
faclors in mind:
1.
2.
must be
:t T1H::.
(11
1965. pp. ,,>l--\R
Technical ]]3lUJIULm1Vfl
---,
Number 21
... ASH.EOR.....
PUMPED CONCRETE
Pu mped concrete must be designed
can be easily conveyed by
pressure through" rigid pipe or flexible
hose for discharge directly into the de
Changes in design mixes to improve
pllmpability can enhar.ce the quality 01
the ccncrete. These changes may result in
imprcved concrete strength and
concrete performance but they can bc
more costly. However. by using Pozzo
I"oie fly ash. pumpabilityclln be en,ured.
quality of the concrete improved lind th"
Mix Homogeneity. The designer
must be aware of the need 10 improve
"dation and maintain uniformity of til<'
materials used in the pum]}!.'d
mix in oroer IO.achieve greater homo
geneity of the lOla) mix.' Three mix pro
portioning methods frequently tu
produLc pumpable concretp are:
Density or Combined
Maximum Density - Leas! Voids
Minimum Voids - Minimum Art'"
Mixes must be designed with sen'ral
.
Pumped concrete must h(' Illmt'
fluid with enough fille material and wat"r
to [ill internal Yoids.
Since the surlace area and
con lent 01 fine material below 3()O micron,
contwl the liquid under pressure. the,,'
more of these sizes than ill ;[
norma) mix. Generallyspeakillg. tlw [ill"r
the materia!. the the cOllfn:)!.
C{HlfSe grading
$hOlild he continuous amel ortc:n the sam!
C()l1lf:nl must bt' increased by lip 10 fi\\.,
tile of tht' O_l1,rs('r
agg'ega!e so as to balance t:'e 500 micron
- 5mm fraction against the finer solids.
Fly Ash Effective_ Unfortunately.
adding extra water and fine aggregate
feuds 10 a weaker concrete. The usual
forthis are eitherto increase the
content. wh\Fh is costiy. crto use
chemical admixtures. which a)so can be
and may lead 10 segregation in
mixes. There is another and far
more effective alternative: POZ2oianic fly

111ere are nlallY advantages to in
cluding Pozzolank fly ash in concrete
mix"s to be pumped Among them are:
1. Partide Size. Fly ash meeting
ASTM Specification 618 must ha\"e G6
pa<sing the 325 (,15 micron)si,,""
and these fine particles are idea) for void
1iI1ing. Just a smail deficienc)' in the mix
iines can olten preventsuccesslul pumping.
2_ Particle Shape. Microscopic
exam ination shows most Ily ash particles
<lre spherical and act like miniature ball
bearings aiding the movement oj Ihe
nmcrete by reducing frictional 10$"" in
lilt' pump and piping. Studies haw sh"wn
that fly ash can be {''''in; as effective- iIS
l'l'mcilt in improving workability and.
Itlcl'l:forc. pUnlpabilily.'
3. POZ2:oiankActivity_ Th;, chem
ical reaction combines the fly ash
with lhe calcIum hydroxide libprated
Ihrough the hydraticm Ilf cement 10 form
ilddilional COlllPOlll1d$
\"hkh increase ('(mcr(;'te stnngtll.
4. Wate.. Requirement. Excess
\\-111('( in pumped mi."\{'s ill
Inch s!ump:-: will uit<'u 111.ttt'l"iaJ
f('tJtHirtLH'd fJII /'(lC'/,'I
)-il'h! fkhrl'IWt' :"l,!lll);lj-,)'pr"frll! h" _,"tm./ruIII 1Ift'W/f"JII, .... j'lIb :{! ' .. ": 1!1;:";': ; ...
CtlUt'fl'lt" - _.)("! I'uilln fIIl"U .'U',l',. p.1;
;IMissner, H.S_ -,Eu(!ct 01 Mineral Addili....!!;.,. \ ....Vrkilbiiily.- $1:Jm7icam-,..
COnCf(!ll! and Conuete /lfokin/S Malr:tiaf.,>, STP
ALASKA COLUMBIA
'"
COLORADO IDAHO MONTANA
NEVADA OREGON NEBRASKA WASHINGTON' WYOMING, UTAH
TELEPHONE: LOCAL 2329J2<I. (800) <26-S 171
t> PenolilnlC COPl!"'SI1"I1
l
TechnicalIB3UJJILlLIE1TI1Iffl
FLYASH REDUCES HEAT OFHYDRATION
Number 22
well documented by many sources, incrud
ing the U,S. Army COl])S of Engineers and
Bureau of Reclamation. Typical examples of
projects utilizing fly ash in mass concrete
indllde the Hung!}' Horse Dam, additions tc
the Bonneville Dam, Hocver Dam repair, the
Canyon Ferry Dam, the 1-205 Bridge piers
and the Hood Canal Floating Bridge anchors.
Mass concrete is defined as {any vol
ume of co:n:':;rete with dhnensions lar
enough to require that measures he taken
cope with generation 01 heat f10m hydration
of the cement and attendant volume change
to minimize cracking.. "J
Guidance is available in ACl 207.:.<R-?3.
"Effect of Restraint, Volume Change and
Rein forcement on Cracking of Mo.,s Con
rI to determine when existing condi
tions warrant mass concrete practices.
Smaller Rlse_ Replacement 01 cement
by pozzolanic fly ash results in a decreased
temperature rise in fresh concrete,2 This is
especially important in massive structures
such as dams and large bridge piers where a
large temperature rise can lead \0 cracking,
Hydralion of portland cement generates
heal very quickly causing the concrete tern
perature to rise. This increase comes at an
early age where plastic strain capacity is high
and the concrete readily accepts expansion.
With age, the temperature falls to ambient.
This occurs where plastic strain capacity is
very low and may cause concrete to crack.
Criteria. Established criteria exists for
selecting proportions for mass concrete in
ACt 207-1R-70 'Mass Concrete for Dams and
Other Massive Structures" and are:
1. Utilize the largest maximum sized
aggregate possible while maintaining mini
mum sand contents, thereby requiring the
minimum amount of cementitious materials
for a given strength level.
2. Maintain slump at a minium to
mize water demand and cememilious mate
rials'content.
3. Utilize low heat cement.
4. Make judidous use of admixtures.
5. Proportion for th highest fly ash con
tent within the constraints of time and
strength.
t Central Elecnlcil)' Geoeratir.g
Fly ASh Beneflts. Fly ash is a tremen
dous aid as it generates oniy 15 to 35 percent
as much heat as cement at early ages. This
coupled with long term strength gain and
physicalily ash characteristics henefit mass
concrete by:
I. Significantly reduclng heat gain to re
duce thermal cracking.
2, Functioning <IS a workabiiity aid in
typically lean. coarse mass concrete ;nixes.
3. Acting as a water reducing agent by
a!iowing approximately twe te ten perce,,!
reduction in Waler content.
The rate and amount of heat generation
is dependent upcn the fineness and quality
of the fly ash and its proportion in lhe tolal
mix. When Type II cement is used with fly
ash, the heat generated by the pozzolanic
reaction up to the age of approximately 28
days will be, on the average, about 50 per
cent less than the cement it replaced.
For large structures such a< concrete
dams, not only is the possihilily 01 thermal
shrinking and cracking reduced, hut the low
ered heat of hydration aiso decreases the
amount of artificial cooling required. Thus
larger placements can be made and con
struction expedited at lower cost.'
For designem woo want to minimize heat
problems in mass concrete, the following
caloric test results reflect the decreased heat
thai can be obtain ed through the use 01 a
specification fiy ash in concrete mixes,
SAMPLES CURED AT 73F.
MIX DAY CALORIES
Type I Cement 3 67
Type I Cement
1 Part Type If
2 PartS Fly Ash
1
3
81
35
I Pan Type 1/
2 Parts Type 1/
I Pan Fly Ash
2 FMs Type If
1 Part Fly Ash
3
7
48
61
For rurther or specific questions
regarding the use of fly ash La reduce heat oj
hydration. contact your nearest Pozzolanic
technical representative,
191!'l,
Abdum.Nur, EdwolIrd A.; Ash In C\lncrete"; Highway Reseatc!! 8001; SviJerin No. 281,' Januaty 1961; p.28.
ALASKA - BRITISH COlUMBIA' CAUFORNIA COLORADO' IDAHO, MONTANA
NEVADA' OREGON - NE BRASKA WASHINGTON' WYOMING' UTAH
l'ELEPHONE; LOCAL 2329320. {aaO} 4:26-$171
<;I Pouol..mc Iflleml'l"OI\I;Il Copyn9hl lS9(
Technical1Q3[u]lllLIEUTIIi\l]
........ Number 23
CONCRETE PRODUCTS
Production of precast concrete products
involves intricate, difficult' patterns. Precast
concrete products can be produced with or
without reinforcement, but units typically
consist of narrow, deep sections which are
heavily reinforced making concrete place
ment very difficult Reinforcement typically
includes the use of fibers, conventional re
inforcing steel. and prestressing stee: ten
dons. eitherpretensioned crpost-tensioned
or combinations thereof. Mixtures must have
enough workability to flow well under
brallon and totally fill the
regation. Hand finishing is often
necessitaling a mixture workable enough to
allow for this kind of manipulation.
By definition. precast concreleproducts
are cast and cured in other than their fina!
position', This enables the use of reusable
forms which, due to economic concerns,
are cycled as rapidly as possible. For this
reason, these concrete products generally
.achieve their competitive position in the
marketplace by using a limited number of
fonns with a rather short production <:ycle.
Normal production schedules allow for one
usage of forms per day; however, I{} to 12
hour schedules are common. Accelerated
curing, typically employed to enhance early
age concrete strength for handling, shipping,
and product utilization, accelerates the poz
zotanic reaction of fly ash to help develop
the necessary arly strengths'.
Concrete mixtures for these products
are proportioned for high levels of perfor
mance at early ages. Compressive s,tfengths
of 3500 to 5000 psi (24 to 28 MPa) are typi
cally required at the time of form removal or
stripping. These early concrete strengths are
generally achieved with cementilious mate
ria! contents of 600 to 750 Ib/Cf (355 to 445
kg/cm). Conventional and high-range water
reducing agents are often employed to attain
workability at very low water content Non
chloride accelerating admixtures are also
sometimes used. While the early strength
gain characteristics of lIy ash has generally
been considered too slow for use in these
mixtures, conditions are changing toward
the use of fly ash in these applications..A.s is
true Clf all mixtures used in precast concrete
work, mixture proportioning and curing
procedures used must produce adequate
early strength or the turnaround time on
forms or molds will be increased'.
While early age strength levels are r.,.
qui red for stripping and handling, higher
strength levels are required for the ultimate
use oithe products. Theuseofquality lIy ash
meeting ASTM C61B (class F) specifications
is a must in L'le production of high strength
concrete of 6000 p.s';. and higher'. The
strength gain achieved from the use of 10 to
15 percent fly ash cannot be readily attained
through the addition of a proportionate
amount of cement.
Pretensioned hollow.-core structural
slabs are producedwith no-slump concrete.
It is consolidated and shaped as it passes
through an extrusion machine. The particle
shape of the coarse aggregate and the
amount of fine aggregate are very important
to workability. Fly ash is widely cOI'.sidered
as a beneficial ingredient to increa'le the
workability 01 these dry, harsh mixes'. Early
strength performance of these mixtures us
ing class F ny ash closely parallel mixtures
without fly ash in terms of early compressive
strength. No early strength reduction is ap
parent.
Although most concem is directed at
obtaining desired early compressive
strengths, these concrete products must
possess durability to resist destructive attack
from numerous environmentai factors". Class
F fly ash is seen as a major ingredient utilized
in the production of durable concrete and as
such should be included in any concrete
subject to severe environments. For further
information on the role of class F fly ash as
an ald to durability, see technical bulletins
#14 (freeze/thaw resistance), "15 (perme
ability), and 1117 (sulfate attack).
(continued on back)
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Technical
24
-ELY-ASHFQ&
CONCRETE PAVEMENT
Fly ash has been used in rcad paving
for more than 2,000 years.
The Romans used naturally occurring
volcanic ash from Mount Vesuvius to cement
the paving stones in their roadways. Many
mites of this ancient roadway - although
by our standards still exist as a
highway,
Today in Eu rape, paving stones have
been replaced by modem day pavement-but
a product almost identical v:')icanic ash is
stil! used. In fact. most European highways
have been constructed with fly ash in all
levels, including the wearing COurse.
On this side 01 the Atlantic, ,I has been
only in relatively recent years that we have
begun to recognize the value of fly ash in
concrete pavements.
Many Slates Use Ash. Roadways and
interstate highways in Alabama. California,
Georgia. Florida, Nebraska. Utah and appm.
imately20 otherstatesand Canadian provinces
have been successfully constructed with fly
ash, many dating back te> the early SO's and
60's. These roads are found in every Iype of
climatological condition that exists from
virtually subtropical to sub-zero.
In January of 1974, tbe Federal Highway
Administration encouraged the use of fly ash
in concrete pavement with its Notice NS080A
which urged the states to allow partial'substi
tution offlyash for cement whenever feasible).
The FHWA indicated that the replacement of
cement with fly ash 01 the order of )0 to 25
per<:ent can be made giving equal or better
concrete strength and durability. tn addition.
inJalluary, 1983, the Environmental Protection
Agency published federal pmcurement guide
lines for cement and concrete containing
ash which encourage the utilization
and establish compliance deadlines.
Compres.ive Strengths.
departments frequently specify a
14-day flexural strength, These requirements
can readily be mel through the ulilization of
proper mix designs incorporating spedfic:a
Uon fly ash. Equal compressive strengths 13.( aH
ages can be readily attained providing specifi
cation fly ash. properly proportioned, is substj
tuted for up to 25 percent of the cement
Some of the reasons fly ash is used in
concrete paving have more 10 do with the
physical characteristics of fly ash than the
chemical and strength gain characteristics.
With modem construction techniques - such
as paving trains using SHpjOlTI'I equipment
Lio;e fly ash facilitates placement of the con
crete at lower slumps while marntaining
excellen! workabilily. This means less hand
work for paving contractor, . _ and bette:
surfac.e texture and edge characterist1cs for
design engineers.
Denser Concrete. Using ny ash aIso
results in a denser concrete .. and one that
will have much greater ultimate strength and
contractors are increasingly
asking that fly ash be used in their concrete
because they are able to place the pavement
or curb with less tearing and thus. a smalter
finishing Cfew is required.
These are other advantages to using fly
ash which result in a stronger and more
durable pavement:
Fly ash concrete pavement will im
prove the resIstance of the concrete to sulphate
attack
The concrete will be more resistant to
road salts and freeze/thaw action as well as
redu<:ed alkali/aggregate reaction,
In many areas or our country. fly ash
also can help keep the initial cost of concrete
pavement competitive with asphalt pavements,
Many Advantages. These are all valid
reasons - and time tested advantages for
producers and speciliers to request the use 01
fly ash in their paving concrete. The fact that
the ancient Roman roadways still exist today
is profound testimony to the Wisdom of using
both Iiy ash and concrete in road construction.
for further information or spec.ific ques*
lions regarding the use of fly ash in concrete
pavement. please contact your nearest Paz.lO
lanie technical representari\'e.
!"Use of Fly Ash in Portland Cement Cooc!ele and Stabilized Base Construclion, Federal Highway
Administration (FHWA), NOlice N 5080.4, p. 6. Janu'1JI11. 1974.
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utilize fly ash:
soils.
utilization.
gate is
minimum
compaction:.
five percent.
construction
developments.
Once the
Technical IDillJLU
---c tt','cVASHFORSOIl.SW6Rf{---,-Number2S
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Five basic: types of 50US work commonly
!. Cement Treated Base (eT8) - pro
duced a mixing plant
2. Soil Cemenl- produced by dis.'<ing the
cemen: and fly ash into insitu soils.
3. Lime Treated 3ase/Type A- produced
I. pug mill.
Lime Treated 3ase/Type B- produced
by disking the lime and fly ash bto in-situ
5. Flow Fill Placement - produced by
mixing large quantit:es of fly ash. sand and
water with minimal orzero quantityorcemenL
Cement Treated Base (CTII). This
melhed most closely resembles normal con
crete work because of the: o! the
material with which It is The r
designed to achieve a given strength
factor at a given age.. placed using a i
lypevehicle ... brought 10 grade with a scraper
... and compacted with either rubber tired or
steel drum compactors. Moisture is added
alter the malerial has been placed and graded
and sometimes after roillng.
This process makes replacement 01 ceo
ment with fly ash feasible with 15102S percent
replacement common and up to 60 percent
representing dose to the maximum.
Design strengths Can be antidpated al
about the same ages as with straight cemenl
Soli CemenL The gradation of materialS
used in the son cement method resembles
block and pipe mixes- Basically. small aggre
used with cementing materials at
water contents and subjected 10
Large amounts of this type of work have
beeodonein the U.s. andCan.da USing fly ash
replacements of upto 33 percentandas lowas
With flya.o;;h the soil cement surface will
exhibit strengths over a longer period
of time. For thaI reasor.. it is cHen used in the
of road bases in housing
Lime Treated Bases. The practice of
lJsi ng Hy ash and lime to produce cemel1titious
bases is several centuries old The process
Ulilizes lime and. for the mo:;t parL naturally
occurring water (eilher ground water or rain
water,) to produce cement-like compounds,
Eme and fly ash have been
mixed together by means of Ca) a pug mill or
d isking into the soil, the normal peino"
c action between the lime and the fly ash
begins.
This prc.:ess initially uses either water
ir:!roduced at the pug mill or applied to the
of the designated area bya water trJcl<.
Over the long term. moisture from ground
water and rain wiII continue to supply adequate
moistu:e to sustain the pouolanic activity of
these two materials and thus generate con
tineal strength gain.
Subgrade Application- This characler
istic of slow strength gain usuaUy is not
because. in most cases, the
material is being applied as a subgrade for
asphaltic concrete or to stabilize 50115_
In these instances. high early strengths are not
necessary. and may. in fact. be undesirable.
It must be remembered, however, tha!
this is a soils product thai becomes "concrete
like:' rather than concrete, and cannot. there
lore. be expected to perform like concrete at
early ages. It wiU perform in early ages in a
manner very similar to normal. compacted
soils. At medium ages (90 to 120 days). it will
begin to acquire properties of low slrength
concrete. At later ages. it will begin demon
strati ng the properties of nonnal concretes.
Several projects where lime and fly ash
naye been used have shown extraordinary
strengths (3.525 p.s.L to 5.000 p.s.')' at live to
ten Years .
. . Flow Fill Placement. One of the more
recemusesof tJyash is as the bindirlgmedium
and auxiliary carrying medium in a liquidly
placed soH rill. TIlis method uses somewhat
high fly ash contents. 300 to 1,000 pounds per
cubic yard and low. 10 to 100 pounds per
cubk yard. 01' zero cement contents.
Zero Voids. This method is designed to
produce. soils product thaI has zeroair"oids
and high, inter-particle surface contact. Fly
ash has just the properties for achie\-jng both
criteria
As a
cerlain crystaline structures thaI as (;
source or i Ilternal s1abiHzation in the s,()iI
system.
nmm'!!' than i. tt) 1.1;:)/1 p.:;j, 1",
rt!qulred of the soil rna:->5. it [s recomnlendf::d
InurlJfl1wd H(/ hfJrkl
Technical
FL __ Number
The use of fly ash in asphaltic
concrete is common practice in
manyparts of the United States and
Canada
Fly ash is most commonly used
in this application where adequate
fines in the local sand are not
available. However, even where
adequate sands do exist, including
ily ash in the mix design can
improve h'1e quality of the asphaltic
concrete.
Fly Ash Ideal Choice. When
ever a mineral filler is required, fly
ash is the ideal choice for two
reasons:
1. The particle size of fly ash is
virtually 100 per-cent minus 200
sieve. This means less asphaltic
oil is required to fill the voids and,
therefore, the result is a less
expensive mix.
2. Fly ash promotes a denser
mix and surface which assures a
longer pavement life with less re
pair work required to maintain
satisfactory surface conditions for
traffic. '
The tremendous increases in
the cost of asphaltic oil make the
use of fly ash extremely attractive
even in areas where sands normally
contain adequate fines for asphalt
work.
The round, hard, spherical
particle shape of the fly ash con
tributes a great deal to its ability to
minimize the amount of oil required
for the mix , ' . and its ability to
produce greater density in the
asphaltic concrete. These round
particles act like little baU bearings,
much the same in asphaltic con
crete mixes as in portland cement
conCFete - promoting flowability
and compactability oi the mix.
Reduces Oil. Just as this lubri
cating characteristic reduces the
need for more water in portland
cement concrete, it reduces the'
need for oil in asphaltic concrete
with obvious cost savings resulting.
The surface of the fly ash par
tides are generally very hard and,
therefore, will not absorb the oiL
They have few crevices or rough
points to retain or demand oil.
Others Porous. Neither of
these attributes is true of other
mineral fillers. In fact, other min
eral fillers have a porous surface
which causes them to soak up
more oil. are also angular
with many crevices and peaks,
increasing the need for oil to assure
proper fluidity and compaction,
Another very important factor
to consider in selecting a mineral
filler is the cost, in energy, to
produce it. A ton of fly ash- since it
is the by-product of a power gener
ation facili ty - costs zero BTUs of
energy. Manufacturing a 'ton of
cement by comparison, consumes
7.3 million BTUs of energy. Similar
comparisons are relevant for lime.
other manufactured fillers or
alphaltic oil.
Because of the fact that it is a
by-product and not the product of
an energy-intensive manufacturing
process, the cost oi fly ash versus
the cost of other fillers is generaily
lower.
ior asphaltic concrete, contact
representative.
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NlJmMi2S
ASHe
AND HOT WEATHER CONCRETE
Hot Mud' The statement is heard
often in the concrete industry,
Rapidly setting concrete is gen
erally considered a good
However, when the mercury goes
above 80 degrees and as-placed
concrete temperatures rise above
85 degrees, a complex set of prob
lems must be solved,
Problems: Dehydration of
concrete due to high temperatures,
low humidity. wind and subsur
face wkking aggravates plastic
cracking and crazing. Increased
concrete water demand due to
temperature and rapid ce
ment hydration increases drying
shrinkage and reduces strength.
Since cement generates J20
BTU's,per pound of weight, it is
important to reduce the amount of
cement-generated heat This can
be done with fly ash which de
creases the heat of hydration in the
mix. During the first critical 24
hours, replacement of 100 pounds
of cement with the same amount of
fly ash reduces the heat of hydra
tion by 19 percent. but does not
sacrifice any strength or durability
features. Since fly ash minimizes
water requirements by two to ten
percent. it is not necessary to dilute
the mix with water during placing
and thus strengths can be main
tained.. Pumpabiiity, placeabitity
, and finishability also are improved
by adding By ash to hot weather
mixes because they will move more
fluidly throughout placing and
finishing processes,
Other methods that the ready
mix producer and the contractor
use to keep concrete cool during
hot weather are:
Ready-mix Producer:
L Design mixes for strength
using higher percentage of quality
fly ash and reducing cement.
2. Use a chemical retarder 1n
prescribed dosage to slow initial
heat build up_
3. Spray aggregate piles to cool
by evaporation.
4. Chill water or add shaved ice
to mix water.
5, Keep spray on cement silo.
6. Reschedule to night pours.
Contractor:
L Soak subsurlace for mini
mum of two hours before placing,
2. Keep spray on rebarahead of
pour.
3, Erect wind screen.
4. Erect shade covering.
S. Don't allow ready mix trucks
to stand in the sun.
6, Screed immediately and
don't overwork the concrete. Spray
on surface evaporation retardant if
applicable.
7, immediately after finishing,
white pig
mented) or pond the concrele,
cific questi'ons about using fly ash
for hot weather concrete, contact
your nearest POZ2olanic technical
rep resen tative_
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.Technical.'rnliliIlrLmmJ
.
Fly ash has been used success
fully iil concrete pavement jacking for
airports and highways and subseaHng
aIld stabilizing concrete' pavements
with grout slurries ..
Grou!s are used in concrete main
tenance in two ways:
1. Jacking Sags. As slurries for
concrete pavement jacking where the
pavement is sagging or dipping due to
a settlement or vertical displacement.
Proper slurry applications can restore
the pavement to original grade, thus
avoiding costly replacement
2. FillingVoids.ln the subsealing
and stabilization of concrete pave
ments to fill voids caused by pumping
action resulting from repeated flexing
under the stress of heavy wheel loads.
This flexing causes free water to
"pump" at very high pressures and
velocities, eroding the sub grade ma
teri.al beneath the pavements and
creating voids.
For many years, it was common
practice to use a silty loam or simi
larly fine soil as a grout slurry under
pavements. These Tllud slurries were
not very satisfactory because de
watering required many days and the
dried material was. constantly subject
to erosion from water. The addition of
cement provided some stability to the
mud grouts but probiems persisted.
Problem Materials. Attempts
were made to perform grouting with
better controlled materials such as
,References:
.' ,
sand/cement combinations. These
materials created.probiems in
angularity of the particles usually
present in mostsands made it diffiCult
to achieve a flow of material into
narrow spaces. When sufficient water
was added lor Ilowability, the sand
tilen settled out of suspension, par
ticularly when pressure was appiied.
Bentonite and other .materials were
added in an attempt to keep the sand
in suspension but grout strengths
were lowered. There were also mixing
problems with dust grouts.
Fly Ash Flowability. Although
the use of pozzolanic materials dates
back many centuries, the use of fly
ash in grout slurries is a fairly recent
development Properties of fly ash
beneficial to pavement maintenance
grouts are the particle size and shape,
the gradation, and the pozzolanic ac
tivity of the material. Grouts for sub
sealing or pavement jacking flow bet
ter into tiny voids when fly ash is the
solid constituent'because the sphen
cal shape of the particles and its
fineness assures flows into even the
tiniest voids. The predominantly
spherical shape of the particles also
creates lubricating action and facili
tates pumpability. Fly ash benefited
grouts are far more pumpabJe than
those containing only cement or other
mineral fillers. These fly ash flow
(continued on back)
Del Val,JOhn: January IS8L "Pressure: Groulingo! Concrete Pavements": paperprepare:d for presentation 011 the"
of the Transportation Rescarch:S,?ard and pU,blisbed"in the Transportafion Research Record
Be and ?avement Mainlenance". : .
. ' '. " .
HOllow.. J. S. and Covey:J, july. I9S:?: "The' Use of Fly Asb .Grouts tOt Concrele Pavement Maintenance": Sixth'
" Inrernarional Ash Ull!iza;ion Proceedings:. sponsored by Morgantov,'l1
US. Department of e.oergy. Morg,anto\Vrt, W.es! Virginia and The N!'ltional Ash
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Technical
FOR CONCRETE
Number 30
PIPE MANUFACTURING
Class F fly ash has been used success
fully in the m<lnufach.:re of concrete pipe for
more than 30years.l! has becomean almost
indispensable ingredle."ll to the dry, harsh
mixes used in mode:n pipe manu
facture.
The manufacture of concrete pipe is
accomplished by :We different processes,
one using extremely dty concrete mixtures
and the other using plastic concrete mix
tures. Dty cast concrete pipe are produced
utilizing mechanical compaction and/or vi
bration to consolidate the dry concrete
mixture into a form which is remCY\led as
soon as the casting is finished. With removal
of the form, the green pipe is carefully
transported to its place of curing. Acceler
ated, atmospheric curing is typically used to
obtain early age performance.
Wet cast concrete uses plastic concrete
placed and compacted in a fom, which re
mains around the pipe until certain levels of
performance are achieved. Wet cast pipe
may be manufactured by the spinning pre>
cess to remove excess water and air to
produce great density and low permeability.
Flyash has found widespread use in the
manufacture of concrete pipe as a cementi
tious material and as an aggreg;>.te mineral
filler to enhance quality and economy.
The major reasonS for the use 01 fly ash
in concrete pipe are:
Hostlle CondItIons. Pipe is inevita
bly subject to hostile conditions. It is most
often used to convey sewage to arid through
sewage treatment plants. where hydrogen
sulfide attack may erode Portland cement
concrete as if it were butter. Properly pro
portioned mixtures containing fly ash make
the ccncrete less permeable, and pipe con
taining fly ash may be more resislaru to weak
acids il11d sulfates (Davis 1954; K. Mather
1982). Factors 10 the life of con
. crete pipe exposed to.su Ifate attack include .
the type of cement, class 0/ fly ash, quaiity of _
concrete, bedding andbacklilJ used. ground
and sulfate concentration."
Reduced Cement. Dry cast concre:e
pipe mixes without fly ash typically use
greater.cement contents than necessary for .
s'.rength to obtain the required workabilllY.
In a "packerhead" pipe casting operation,
concrete with a very ruy consistency and
low water cor-tent is compacted into a verti
cal pipe form using a revolving cbmpad:on
tool. Vibratoty pipe use mechanical vibra
tio.. to compact dry mix concreteinto a form.
Fly ash allows the producer to remove as
much as 30 percent of Ihe cement from a
mix without sacrificing strength while, a! ihe
same time, reducing the amount of water in
the mix. Fly ash is then used as a cementi
liolJs material and aggregate mineral Eller to
promote added workability and plasticity.
Workabllity. Pipe manufacturers
throughout the world recognize that the
spherical shape of Dy ash makes very dry
mixes, as used in packerhead machines,
extremely workable. This added worKability
reduces <;ycle type, wear on moving parts
and forms, and makes a denser, less per
meable and more airtight pipe. Equipment
used in pipe production may last longer due
to the lubricating effed of the fly ash. Use 01
fly ash can increase the cohesiveness of the
no-slump. freshly placed concrete facilita!
ing early form stripping and movement 01
the produd to curing.
fewer Rejects. The wet cast and
centrifuge process of Ripe manufacture also
benefit from the workability and densmca
tion that fly ash contributes to each mix.
Most manufacturers using Ily ash in their
mix have found less reject pipe due to voids,
crazing or collapse after dry mOlding.
Other benefits attributed to the use 01 fly
ash include a reduction in Ihe heal 01 hy
dration of concrete mixtures containing fly
ash which can reduce Ihe amount of hair
line crad<s on the inside surface of stored
pipe sections (Cain 1979). Concrete mixtures
containing fly ash also tend to bleed less
(cont inued on oack}
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nical IDUlJILllIEl]1]Bj
FLY ASH FOR BLOCK MANUFACTURING NumberS)
The manufactcre of c.oncrete masonry
units uses a dry, harsh concrete mixture
compacted into molds with great mechani
cal energy. When demolded, these units
maintain their shape during handling and
IranspoJtalion ioto a curing environment.
Curing methods consist of the high pressure
high temperature autodave and the atmo
spheric pressure high temperature kiln. The
use of high q:.lality class F 111' ash has be
come accepted practice in the industry.
Class F 111' ash improves block manu
facture in two bas,c ways. It gives producers
the strength required and, at the same time,
the added plasticity that fly ash contributes
(reported by Belel 1(75) to the relatively
harsh block mixes assures improved finish
and texture, better maid life and better,
sharper corners. Additional benefits for fly
ash in block include reduced permeability
and shrinkage, increased durability and vir
tual elimination of efflorescence.
Fly Asb Chemical Activity. Fly ash
is produced by burning powdered coal to
generate electricity. Fly asb is a chemically
active, finely divided mineral product high in
Silica, alumina and iron. Type F f!y ash that
has a low lime content and has been burned
in the process of manufacturing (in the same
sense that Portland cement clinker is
"bumed")seeks lime. One hundred pounds
01 Portland cement during hydration usually
liberates from 12 to 20 pounds or more of
free lime (calcium hydroxide). Fly ash then
chemically reacts with this free lime to Iorm
additional stable cemeotitious compounds.
The formation of insoluble cementing com
pounds is accelerated and can be secured in
a mattero! hours in the steam curing cycle 01
the concrete products plant (autoclave or
nonautoclave).
Steam.. Curing. Autoclave curing,
though not as common as in the past. is still
used to manufacture high quality masonry
units. Concrete masoriryuni!SclJred in
pressure autodaveS sno"" early
. equivalent to that. o! 2S:day moistcured
strength and reduction in volume change in
drying (Hope 198\). The process 'uses tern
peratures 0(275' to 375" 1" (ISS" to 190" C)
and pressures of 75 to 17D p.s.i. (0.52 to 1.17
MPa). These conditions allow for the use of
fly asn as a 'cement replacement up to 35
percent for :lass C and 30 percent for class
F lly ashes. Percentages greater than this
can resul: in efflorescence class C fly
ash. care shcujd be taken to insure
that the Ily ash meets the soundness re
quirement of ASTM C-S18, indicated in note
C, Table 2 especIally where the fly ash will
more than 20 percent of to e total
cementitiol!S material.
Low-pressure stear;! curing is usually
performed in insulated kilns at elevated
temperatures, The exact temperalcure used
b-eing a function of the materials and op
eration of the specific plant. This process
allows for the use 01 lly ash as a cement
replacement up to 35percent for cl ass C and
25 percent for class F fly ash. T"",Is witb 25
percent class F fly ash were successful with
a curing lmlperalure above 160' F (7J' C)
and indicate that drying shrinkage of low
pressure steam-cured concrete units can be
reduced by the addition of fly ash.
Accelerated curing techniques allow for
a period of preset before the concrete
products are subjected to elevated tempera
tures. The preset period may lengthen slightly
where cement is replaced with fly ash and if
so, it must be allowed for.
Tests for resistance to freezing and
thawing of concrete masonry units contain
ing /11' ash indicate that such units, in gen
erai, could be expected to perform well in
vertical wall construction. 1"or the more se
vere conditicn 01 horizontal exposure, a
minimum compressiv<; strength oi 3000 p.sj.
(21 MPa) based upon lh e net area ollhe unit
is recommended when normal weight ag.
gregates are used. This is true if fly 'ash is
used or not. .
Air-entraihment is not practical at the
extremely low or zero slumps used lor con
crete block. it could be applicable to slump
block or quarry tile. To provide adequate
(continued on back)
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tl Pouolanic Ifitetrn:Jtional C(lpyr-.,rn 19'5l6
... .
freezing and thawingdurabiiity for units made for the. manufac:ture concrete masonry
with slump concrete. air is is not an exact science. Conditions may vary
'!1eeded (R:edmond'i969c):'"' wIdelY from' prai'll'
The acceptance by the engineering pro tioneng mixtures. concrete product produc
. Cession and code bedies of the use ers should ched< the grading and types of
concre:e masonry units lor highstrength, ""Jll'egates. cements, equipment, and kiln
. highrise, load-bearing construction is in telnperatures, and then adjust trial batches
creasing. To. meet this demand, block pro with various amounts of fly ash to achieve
ducers find it necessa.y to produce both light specific technical or economic objectives.
and normal weight unils testing 35DO p.s.:. (Val ore 1070). For in this regard,
net area (11860 gross area assuming 53 the reader is referred to Siliceo\is Fines
cent solid units) and 5000 p.s.i. net area the Cementing Medium of Steam CUred Cor-
(2650 gross area), respectively. The 1860 crete Masonry Units", a 1967 publication by
p.s. i. gross area strength ;;nits are know;) as the National Concrete MasoolY Association.
high strength block and those of 2650 p.sJ. For further information or specific gues
gross area strength are known as extra high tio;:ts about using fly ash for concrete block
strength blocl<. manufacturing.-contactyour nearest PQzzer
Trial Mixes. Proportioning of mixtures lanie Technical Representative.
)
References:
1 Blc>ek, Ready-Mix Concrel.a and Conc.rete Pipe,"" Concrete; Industries Yearbook, w
2 & "How Fly Ash Improves Concrete Block. Ready-mix concrete, Concrete Pipe.- Concrete industries
book
3 - Grant. William. "Manufacture or Concrete Masonry Units," Concrete Publishing Corporation, 1959.
4 .. American Concrele Institute Committee 517. "Low Pressure Steam Curing of Concrete," Journal ot the
American Concrete Instit"te, Aug. 1969.
5 "Recommended Practice for Atmospheric Pressure Steam Curing of Concrete,W Journal of the Amerieao
Concre.e In.sti,u'e, Aug. 1965.
American Concrete instilute Committee 515, "High Pressute Stearn Curing! Modem Practice and Properties
of Products," Journal of the American Concre1e Instirule. Aug. 1965.
7 Betet. LR., Jr., Ash in Concrete and Concrete Block Manufacturing," Proceedings, 1st Fly Ash
Utilization Symposrum Mar.) lnIormation Circular No. 8348. Buteau of Mine,:;, D.C,
1967.
8 Hope. Brian B Concrele Containing Fly ANh." Cement and COncrele Research, Vot 11. No.
2, pp. 227-233, Mar. 19BI.
9: Redmond, "'Freezing and Thawing Tests of Cohcrele Mason:y !Jnils wi,h Cement and Cement,Flr
.. N?tional Concrele Masonry AssDciaiion, Herndon. Oct i 969,. "
Techni'cal
1+-- Number 33
Advances in technology are usually
associated with sophisticated and compli
cated pro<;:esses that <;:orrespond
ing!y impressive price tag, the Willow
Creek Dam constructed at Heppner,
Oregon is apt to go on the books as a
major step toward reversing the quality!
cost ratio in the matter of mass concrete
construction. The aggressive effor"lS of the
Army Corps of Engineers are resulti;1fl in
what is the United States' first roller
compacted concrete (RCC) dam.
Rollcrele Is Born_ "Ro!lcrete'" is
likely to become the more common tern.
for this simple process that compresses a
damp aggregate into an embankment
like fill with a resulting density greater
than conventional concrete poured wet
into forms. The additional densily is attrib
uted to the use of fly ash and the new RCC
process. This rollcrete mass cures more
quickly, and is stronger, yet contains a
smaller percentage of cemen t and fly ash
than a conventional dam. The 9,000 tons
of fly ash needed for!hlsjob wassupptled
byPozzolanic International which met the
rigid supply schedule from one of their
dass Fsources meeting federal specifica
tion SS-C-1960!S.
UseOfOn-site Material. At Heppner,
material standards allowed for use of all
but the lop soil of the overburden at the pit
site located just above the dam. Some
extra sand was mined out of the bottom of
what will become the pool area. This
added blend sand allows use of all pit
material without washing. There is very
little material that is not useable in con
crete if properly blended. The Heppner
project has no reject pile.
The Willow Creek Dam has been
designed and contracted by the Corps as
a 160 f901 high flood control structure. !tis
to act as a capacitor in absorqing the
surging run-off sparked by thunderstorms
and clOUdbursts that are historically in
tense in the Blue Mountain foothills
drained by Wiliow Creek.
The cost of Hood contrel in such a
remote use area had placed any pending
project at a low priority level. Now the
rolk:rete dam will be completed for approx
imately one-third the cost of the more
massive earthfill structure iliat had been
on the Corps' drawing board. The benefit
of the lower cost may result in stimulating
other activily as well. In April 1982, ilie
COE made a public announcement of a
$285,000 eval uat;on study that will encom
pass some 80 new hydroelectric sites in
the Northwest Corps spokesmen say that
design lime for rollcrete structuring is
relatively short. "from concept to con
crete in less than two years," is how one
engineer described the designing of
Willow Creek Dam.
The Eucon Corporation of Pasco,
Washington, won a $14,000,000 contract
to build the 1,700 foot long structure thaI
topped out 218 feet above the excavated
bedrock and contains over 400,000 cubic
yards of concrete. Eucon's diVisions were
well suited for such a project. The
Steelman-Duff Division based at
Clarkston, Washington, was experienced
and equipped for the rock and earth
excavation. The DeAtley Company of
Lewiston, Idaho, another division of
Eucon, produced the aggregate. Before
the roll began, half the material was
crushed and segregated into huge stock
piles for feeding into a two drum noble
600 batch plant. A dozen or so subcon
tractors al)d suppliers drilled, fenced, and
provided steel, pipe. concrete. cement. fly
ash and many other services.
t l"Ul!'lutl('d 1)J1 back)
Kloplenslej l1. Inez: "Ro!lcrete Dam - More Strength, Less Price':; Pacific Builder and
ALASKA - BRITISH COLUMBlA - CALIFORNIA - COLORADO' IOAHO ' MONTANA
NEVADA' OREGON - NEBRASKA' WASHINGTON - WYOMING - UTAH
TELEPHONE: LOCAL232-!1320, (800) <26-5171
o POO:JO::Qlsnle copyt.gt'lt 1S96
Technical
FLY-ASH lNocONTROhLEcJ)"
DENSITY FILL
Sincethe beginning oHime, the materi
als and methodology used for void filling has
remained virtually UIlchanged. The filling
process has involved compacting granular
materials into voids to provide stabilized fill.
Modem technology has only provided for
mechanized compaction versus the use of
manual labor in past centuries. This meth
odology bas become so ingrained in our
method of operation that we have accepted
its deficiencies without questioning if there
might be a better way. We have merely ace
cepted the failures of the old system with its
costly repair; we have gone along with what
has always been done without asking why.
Now available is an engineered product of
the 20th centulj' designed to ellminate
failures. This product is called CON
TROLLED DENSITY FllL (CDF).
CDI' is an engineered, controlled, fill
material which is sell placing, self leveling,
self compacting and non-settling. It is easily
proportioned to suit almost any application
while USing conventional materials found in
almost every conCIcte production facility,
Reasons to use CDF. The first reason
to use COl'was likelyoneofbeing able to do
a difficult job well. Since that time, the list 01
reasons lor its use has grown greatly and
continues to grow. Afew of those reasons to
useCDFare:
1. COF perfectly encapsulates whatever
has been installedin the trench andprol:ects
it against damage.
2. There is no damage to InstaUed utili
ties as no mechanical force is needed to
place or compact CDF.
3. COF does not settle alter consolidation
sothere is complete long term protection lor
encapsulated umiHo....
4. The job can be done onCe and lor
gotten since COF eliminates costly repairs
due to settlement.
5. CDF consolidates rapidly to allow
and then paved.
5. Placing of CDF fills can be accom
plished with reduced personal and expen
sive equipment.
1, Future access !o the Iii! is assured by
designing in excavatabilily of the CDF.
8. CDF protects utilities in nils against
loss of support during adjacent excavation
operations. Loose peagro.veJ WI can !lowout
If exposed by excavation causing a loss of
support. Should this occur, however, relill
log is made easy with CDF.
9. Tralficaccidenls (and accompanying
litigation) resulting from setlled fills are
eliminated. The public safely is maintained
with nonsettling CDF.
10. CDI' improves worker safely as no
one need enter Ihe excavation for placing or
consolidation.
11. Field inspection is eliminated as CDF
can be depended upon to pe1fonn, whereas
conventional fill materials must be tested lor
density in each Iifr.
12. Excavation costs are reduced as
excavations can be made -narrower which
reduces the volume of spoils and fills needed.
13. CDFcan be pJaced in any weather at
any time-It will even displace standing water,
which reduces dewatering costs,
14. The speed of construction with CDF
minimizes pavement downtime and helps
keep traffic moving.
15. COl" requires nostorage or dumping
area as it is delivered fresh from the ready
mix concrete truck directly into the void.
16. CDP is the perfect filJ material for
remote locations where access is difficult.
Simply pump CDI' in place with a concrete
pump. Proportioning for pumpability is
simple.
17. CDl" is the most versatile 01 materi
also I! can be easily adjusted to meet re
quirements lorgreater flowability, lower unit
weight and higher strength.
Materials for CDI' Pro ductlon. The.
ALASKA' BRITISH-COLUMBIA' CALIFORNIA' COLORADO' IDAHO' MONTANA
NEVADA' OREGON NE8RASKA WASHINGTON WYOMtNG UTAH
TELEPHONE: LOCAL 232.9320.18(0) 421>-5171
Il> It\t(;matlr;11'1ai Ccpyrighl 1!$6
Technical
--FtYASHIN MASONRY GROUT
Number 35
HoUow core masonry units form asig.
nificant portion of the building materials
used in housing and commercial projects.
Strength and stab;;;ty of masonry construc
tion is often increased by encasing rein
forcing steel bars in some, or all of the
cores with a concrete mixture. Dil!icuities
b piacing and consolidating concrete in
side these long, small diameter cores re
quire the use of grout, ail extremely fluid.
self consolidating mixture.
Ordinary Grollts. Ordinary grouts
use large quantities of sand and water to
achieve desired workability although tney
create the following undesirable side.ef
fecls:
1. Large voids will result from a high
sand content requiring large quantities of
portland cement to produce normally re
quired 2.000 p.s.i. to 3.000 p.s,L compres
sive strengths at 28 days of age. High ce
ment contents result in very expensive
grouts. .
2. Segregation frequently occurs as
these mixes Dilen lack cohesiveness. As
the mix lIews down the hollow core. seg
regation occurs yielding; a variable. non
homogeneous core of poor qUality.
3. Cracking is common due to the high
shrinkage characteristics of nch, sandy.
wet mixtures and segregation.
Fly As.b Improvements. Fly ash
utilized as an ingredient in grout mixtures
improves these undesirable aspects yIeld
ing a greatly improved product Fly asn
affects grout mixtures in the foIiowing ways:
l. Fly ash particles are spherical in
shape which greatly increases workabiHty
and cohesiveness. allowing complete care
filling with grouts of lower slump. The re
duced segregation results in a more homo
geneous core of uniform strength with a
reduced tendency to crack.
2. Spherical particles also reduce wa
ler demand .for a given degree of workabil
ity which in turn reduces drying shrinkage
and propensity for cracking.
S. Fly ash is a pOllolan which chemi.
caUy combines with lime liberated by port
land cement hydration to form durable,
strong cementing compoc::ds similar to
those of portland cement This reacticn
provides higher \Iltimate strength than can
be achieved with portland cement alone.
4. Efflorescence from grout is greatly
reduced as soluble compounds wbich form
efflorescence are chemically fixed inside
the mass by pozzolanic activity. Tills chemi
cal fixation renders these compounds non
soluble, preventing them from migrating to
the surface where they would form objec.
tionable depOSits.
5. Just as fly ash particles increase
workabi!i\y. they increase pumpability. al
lowing grouts to be pumped farther, faster
and with less effort
Grout Mixtures. Conventional
grollt mixtures typically contain SOO to 950
pounds of portland cement. sand contents
of 60 percent of total aggregate and 40 to
50 gallons of water per cuhic yard. Fly ash
contents of 200 pounds per cubic yard have
been used, replacing a like amount of port
land cement while reducing sand content
and water demand by 4 ro 5 gallons.
With the benefits imparted by fly ash.
it is easy to see why fly ash is a desirable
component in concrete grout.
questions regarding fly ash in masonry
grout. contact your nearest Pozzolanic tech
. ALASKA BRITISH COLUMBlA CAUFOANIA COLORADO" 100HO MONTANA
NEVADA' OREGON' NeaRASKA WASHINGTON' WYOMING' UTAH .
TELEPHONE: LOCAL 232-9320, (800) 71
.. Ponolanlr; Inwnath.)fial im
Technical
Numb_erJ.6.
STRENGTH OF FL
fly ash concrete can be d!!Signed to
achieve any Jevel of strength obtainable
by concrete containing only portland
cement
Compressive Strength. Strength
gain contributed by portland cement
occurs very rapidly at early ages up to
about seven days, after which it slows
markedly. Strength development contrib
uted by fly ash occurs through chemical
combination of reactive fly ash glass with
calcium hydroxide generated by hydra
tion of portland cement This process is
called pozzolanic activity.
A fly ash concrete mix, designed for
equivalent performance to conventional
. concrete at nonnal ages, will generally
gain strength more slowly at early ag!!S.
After about seven days. the rate 01
strength gain of fly ash concrete exceeds
that of conventional concrete, enabling
equivalence at the desired age. This
higher rate of strength gain continues
over time enabling fly ash concrete to
produce significantly higher ultimate
strength than can be achieved with con
ventional concrete.
7-Day Perl<mnance
1

,//
Fly Ash concrete>/
Plain Con<:rete
!!
OJ

a
E
8
Age (Oays) __ 28
Rates of strength gain of conven
tionat concrete and fly ash concrete
based on eq u iva!ent peri armance at
7 days,
Fly ash concrete designed lor equiva
lent performance at seven days or earlier.
will yield practically the same strength
gain. prior to the design age. At all ages
thereafter, fly ash concrete will exhibit
much higher strength gain than conven
tional COncrete.
Concrete made with Type C fly ash
(as opposed to Type F) has higher early
strengths' because it contains its own
lime. This allows pozzolan ic activity to
begin earlier. At later ages Type C behaves
very much like Type F- yielding hig!':er
strengths than conventional concrete at
56 and 90 days.
Uniformity. Statistical analyses of
compression tests have shown thaI the
use of fly ash often lowers the variabliity
of strengths (lower coefficient of va,ia
,tion). This can result in a reduction in
"overde5ign" yielding a direct cost savings
to the concrete producer.
flexural Strength. In general. a
relationship exists between the compres
sive and flexural strengths of concrete.
Concrete, which has a higher compres
sive strength, will have a correspondingly
higher flexural stTength. This holds true
for fly ash concrete. However. in many
cases. fly ash concrete has demonstrated
flexural strength exceeding that of con
ventional concrete when compressive
strengths were roughly equal. .
HighStrength Concrete. In instances
where high strength concrete has been
specified (above 7.000 p.s.L), fly ash has
consistently proven its usefulness. After a
certain amount of cement has been added
to a mix (usua!ly about 700 pounds). the
addition of fly ash usually results in
higher strengthS than an equal amount of
added cemenl This is especially true for
56 and 90 day stTengths. Production of
high strength concrete requires the use of
high quality fly ash at a minimum of 15
percent by weight of total cementilious
materials,
For further information regarding the
strength of fly ash concrete. contact your
(comirlUeu on ba;'k)
ALASKA' BRITISH COLUMBIA CAlJFOANIA' COLORADO' IOAHO MONTANA
TELEPHONE: LOCAL 23Z93:/0. (SOO) '265171
It) Po%Wlll<'l!e InromiiUi.onal Copy<9f'\l 1-996
Technical a3illJILILll;
Creep of concrete is defined as
"time dependent deformation due
to a sustained 10ad"I, can be
a serious problem when long term
building loads cause concrete
members to dimension
and impact the qualitv 01 their
function. Excessive
can cause beams to sag with re
sulting difficulties in the function
of a structure.
The late of creep is dependent
upon elastic modulus and
mately upon compressive strength.
High quality fly ash used in con
crete mixes affects compressive
strength in a positive manner.
During the early construction
where settlement and con
struction practices cause unusual
loadings, fly ash concrete has a
lower elastic modulus which
accommodates slightly greater
creep. This early age extensibility
allows fly ash concrete to accept
unusual loading without cracking.
When a structure is completed and
creep is undesirable, the later age
strength gain of fly ash concrete
gives significantly Iligher elastic
modulus than in concrete without
fly ash and resu Its in less creep.'
. The use of fly ash in structural
concrete is a great benefit in con-
deformation to work ior
rather than against the inteS1ritv of
the structure.
representative.
:AO "115R7B; "Cem.::-nt and Cpncrete ACl Manuaf Of Concrete
-Gosh. R S. and Timu$k, J.: "Creep of Fly Ash Concrete'": .-!leI Journal; September
ALASKA' BRITISH COLUMBiA' CALIFORNIA' COLORADO' IDAHO' MONTANA
NEVAOA' OREGON' NEBRASKA' WASHINGTON' WYOMING' UTAH
TELEPHONE: LOCAL 232-9320, (800) 426-5171

. For further information or spe
cific questions regarding fly ash
for the control of creep, contact
?rae/ice. Par! lSf':'
October 1981.
o Po:lJ:ol(tJ'lic Ca::>;f'igrc 199
Technicallli3

FLY ASH/CEMENT SLURRIES
Cement slurries have been
used to support and protect well
casings and prevent vertical migra
tion between strata since the early
1920's. In the oil well environment,
the slurry may be subjected to
temperatures ranging from below
freezing to as much as 700 degrees
Fahrenheit, while having to remain
flowable for several hours under
pressures ,as high as 10,000 p.sj.
use of fly ash in these mix
tures has significantly improved
the ability of the well drilling indus
try to cope with such harsh condi
tions while cutting material costs
well below those of the previous
100 percent cement technology,
SlunyWeight. Thelowerspe
cHic gravity of fiy ash makes it
possible to cut the weight of the
slurry by approximately ten per
cenl This can lower the total
column weight of the slurry in the
well- easing the stress on weaker
subsurface formations.
Thickening Time. Fly ash per
mits greater control of thickening
time (set) which ensureS that
placement can take place with
ample time for minor breakdowns
in equipmenl
Increased Flow Rates. The
improved workability imparted by
the fly 1\sh lowers the'energy costs
during placement and decreases
the total time necessary to com-'
pJete the job.'
Compressive Strength. High
c,?mpressive strengths are not
necessary in oil well cementing,
but the waiting period during
strength development must be
kept to a minimum, In most cases
the compressive strength of fly
ash/cement mixtures is com
parable to neat cement mixtures.
Accelerating adm ixtures are some
times used in low temperature
situations to control strengths in
the desired range.
Corrosion. Low permeability,
which is typical of fly ash concrete.
is also a beneficial characteristlc
of hardened fly ash grout Cor
rosive water zones may cause
deterioration in neat cement grout
- leaving the well casing exposed
to corrosive attack. Fly ash mix
tures are an industry wide solution
to this problem.
cific questions concerning oil well
cementing, contact your nearest
Pozzolanic technical representative,
WeHs," Sixth jnternatronal Ash lllHiz<Jlicn
ALASM BRITISH COLUMBIA' CALIFORNIA - COLORADO - IDAHO MONTANA
NE.VAOA OREGON NEBRASKA - WASHINGTON WYOMING - UTAH
TElEPHONE; LOCAL 2329320. (800) 425-5171
10 P<axot.n.ic rnleftt:alional copyriliht
Technical rnUJJIlJLIEUIJli\!I
Number 39
----------+------
Technological advancements in the con
crete indusny haVe made available a wide new
range of products at heightened performance
levels. Increased perlormance, while bringing
benefits to:he engineer and contractor in terms
of capabilities and economy, can be confusing
for the specifier dealing with recipe specifica
tions. This complexity makes it advantageous
for the specifier to draft pedonnance specifica
tions whlch assure desired results without re
sponsibility for error.
Performance concrete can best be de
fined by referring toASTM C-94 Standard Speci
fication for ReadyMixed Concrete, Section 5.3,
"Where the purchaser requires the manufac
turer to assume lull responsibility for the selec
tion of proportions for the concrete mixture."
The specifier must then specify requirements
for strength, workability, placeability, dmabil
ily, stuface texture er other pertinent perfor
mance parameters. The combination of ingre
clients used and their relative proportions are
then left to the producer (or a testing agency
representing the producer) as is the
bility for their perfOIIDallCe. Testingprocedures
and methods of interpreting data are fully COl
ered in existing documents for resolution of
cfisagreement
P02Z0lanic provides this specification
guideline utilizing the perfonnance specifica
tion approach.1l may be inserted in specifica
tions as is or may be adjusted to meet indi
vidual needs and situations:
A Materlals
L Portland cement conforming to ASTM
C-150 or ASTM C-595 for blended cement
2. Fly ash pozzolan conforming to ASTM
C.{jIB, loss on ignition (LOJ.) maximum I
percent .
3. Aggregate conforming to ASTM C-33.
4. Water reduong admixtures conforming
to ASTM C-494
5. Air entraining admixtures conforming
to ASTM C-260
8. C;'mposltlon of Concrete
. L Concrete mixtures shall consist of the
appropriate proportions of portland cement, fly
ash, water, coarse and fine aggregate, air en
training agent and water reducing agent for the
intended appEcation.
Z. Concrete furnished under this speqfi
cation shall be provided under allemate 2 of
ASTM C-94. Concrete mixes shall be propor
tioned for each type and stnength of concrete
specified. Mixes shall be selected by either the
!abcratOly trials batch method or the field ex
perier:ce methods specified in ACI 301 current
revision.
a. All concrete classes including, but not
limited to, structural, architectural, paving and
!remie shall be covered by these specifications
b. Minimum fly ash content is 10 percent
by weight of tola! cementitious material in all
classes oi concrete where fly ash is used.
Cementitious material is defined as portland
cement and fly ash.
e. Special Aggressive Environments:
1. Refer to ACl318-83, Section 4.5, Table
4.5.2 for maximum allowable water
cementitious material ratio, Table4.5.1 ferrec
ommended air content and Table 4.5.3 for
cement type, for the special aggressive envi
ronment encountered
2_ For sulfate envirorunents refer to AD
318-83, Section 4.5, Table 4.5.3 and Commen
tary Section 4.5.3 for cement type and maxi
mum water-<:emenfitious material ratio. Water
cementitlous materials ratio shall be equal to
water-<:ement ratio W/C=W/C+P. Class F fly
ash with acceptable R value may be used to
obtain sulfate resistant concrete. R vaiue is
determined as:
R= Cao-5%
Fe,03
The recommended "R" value for respective
degrees of sulfate resistance are listed
LIMITS FORA RESISTANCE FACTOR (R) FOR
CONCRETE'S CONTAINING FLY ASW
RUmits-' Sulfate Resistance'*'**
0.75 Greatly improved
0.75 to 1.5 Moderately improved
1.5 to 3.0 No significant change"
3.0 Reduced
AlJISKA' BRITISH COLUMBIA' CALIFORNIA' COLORADO' IDAHO - MONTANA
TELEPHONE: LOCAL 232-9320. (800) 426-5171
o PozzolBnic Copyright 1996
*R' (CaO-S)/Fe
2
0, percentage iram fly ash
oxide al1alysis; For vel)' severe cyclic condi
lions of wetting and or for
proved to slightly reduced "Compared to
a Type II cement control at OASw/c
Fly ash having higher than recommended R
value maybe used provided it can be shown
that sulfate resistance will not be adversely
affected.
Special aggressive environments in
dude, but are not HmUed to. seawater:, fresh
water. mild acids. soluble sulfates. sewage
sludge and deic.ir.g sal!S.
d. Alkali Reactive Aggregates;
1. Portland cement shall mee: A5TM C
150 including optional Table I A lor alkali
limitation.
2. Class P fly ash meeting ASTM C-618
induding optional Table IA for alkali limita
tion.
3. Where reactivity is cantralle d by low
alkali portland cement, any fly ash meeting
ASTM CGIS may be used provided it does
not increase expansion of concrete.
e. Mass Concrete:
I. RefertoACl21l.l-8I, Appendix 5-Mass
Concrete Mix PropOltioning.

..
C. Curing
Flalwork: All concrete shall be continuo
ously in accordance with AQ 30172
c[
design compressive or flexural strength is
achie...ed, whkhever is less. Curing lime and
procedures shall be adjusted to suit hot and
cold weather condillons. Curing shall be
started as sOOn as the concrete is finished.
All concrete placed in hot weathershall have
an Initial moist cure.
Formed Su:faces: Prior to removal of
all forms shall be kept covered with
material to prevem mOIsture evapo
from concrete. forms are
moved. curing compound shall be applied
or log spray shall be initiated until seven-day
or 70 percent minimum requirement is met.
Caulion: Curing compound shall not be
used on anysurface against which additional
concrete or orner material is to be bonded
unless it is proven that the curing compound
will not prevent bond or unles positive mea
sures are taken to remove it completely from
areas to receive bonded applications.
For further infonnation or assistance on
specifications, contact your nearest Poz
20Ianic representative.
-1
POZZOLANIC INTERNATIONAL
CEMENT TESTING CENTEI{
CeMAP B!dg No 1 Cpi. Cruz St. cor. E. Rodriguez Jr. Ave.
Bagong Ilog, . Pasig City 1600 Philippines .
Tei (632) 671-7583 Fax (632) 671-8402
PAO ACCREDITED
TESTING LABORATOR'I
PNS ISOIIEC 17025:200:
LA-1997016D2
[ TEST CERTIFICATE
~ ~ - - -
Test Certificate No.: 'Datc of IS,5UO:
P-092012-48821 12-0ct-12
Sample Reference No.: and Type of Sumple:
C54248-0912
Name of Company/Individual:
Pozzolanic Phils
Address:
Unit 810 Pioneer Highlands, Pioneer Mandaluyong
$a,mpfed
Not Specified Abelardo B, Gomez
Test Specirication. Test Methods Used:
- 07 as specified below
Sampling Method Used,
not specified
Sample identification:
of Pages
1 of 2
Portland Cement, T - I
Dale Sampled:
9/5/2012
,Dale Received:
9/5/2012
Date oUest.
9-Sep-12
PHYSICAL TESTS
SPECIFICA TlON
LIMITS
A
A
TEST RESULTS
UNCERTAINTY
*)
REMARf<;;S:This not be' reproduced exceptin full, without the written approval of the Cement Testing Center
. This report gives the result 9f tests that relate only to the above sample sUbmitted to the CTC,
A B flat required by the test' methOd o not req,lested bythe customer
t) The expanded uncertainty values are calculated at 95% confidence leirel.
z
CTC Adm r-"rm No.4ic Date of Issue: April 2010 Revision No. O.
CEMENT TESTING CENTER
CeMAP Bldg. No.1 CpL Cruz St. cor. E. ROdriguez Jr. Ave.
8agong lIog, Pasig City 1600 Philippines
Tel. (632) 671-7583 Fax: 671-8402 Email: ctcenter@cemap.org.ph
PAO ACCREDITED
TESTING LABORATORY
PNS ISO/IEC 170252005
LA-1997-016D1
TEST CERTIFICATE
Test Certificate No.:
P-0920 12-48821
Dote of Issue""
3-0ct-12
No. of Pages.
2 of2
Sample Reference No ..
C54248-0912
-Kind and Type of Sample.
Portland Cement, T-I
Pozzolanic Phils
Address:
Unit 810 Pioneer Highlands, Pioneer St, Mandaluyong City
Sampled by:
Not Specified
Submitled by:
Test Specification:
ASTM C150
Test Methods Used:
Date Sampled:
Date l'?ecelVed
Abelardo B. Gomez
Date of Test
ASTM C114and as specified
9/5/2012
9/5/2012
19-5ep-12
Sampling Method Used:
not
EPL-01
C HEM IC A L A N A L Y SI S
COMPONENTS, (%)
SPECIFICATION
TEST RESULTS.
UNCERTAINTY
( * )
REMARKS
certlfl.cate shall rlOtbe reproduced exceptin full, without the written approval of the Manager, Cement Testing Center (CTC).
Thisreport gives theresults of iests that relate only to the above sample submitted to CTC.
A- not applicable D - not requested b'lcustomer
expanaea uncertainlv values ar&: calculated at 95% confidence leveL

..

--_.. _._... _ ...... _..... _......
Adm Form No.. 4-.18 'Date of Issue: April -201 0 . Revision NO.8
CeMAP Bldg. NO.1 Cpl. Cruz SI. cor. E. Rodriguez Jr. Ave.
Bagongllog,Pasig City 1600
TeL (632) 671-7583 Fa::c(632) 671-8402 Email: ctcenter@cemap.org.ph
PAD ACCREDITED
TESTI NGLABORATORY
PNS ISOIIEC
LA-1997cO 1602
.[TESTCERTIFI CATE
P-092012-48822
Sample Reference No.:
CS4249-0912
Name of
Address:
Unit 810 Pioneer Pioneer St,
Sampled by.
Not Specified
Test Specification'
ASTM'C150 - 07
Sampling Method Used.
Sampleldenlificalion:
Dale of Issue.
12-0ct-12
No. of Pages:
Kind and Type of Sample:
Portland Cement, T - 1
Pozzolanic Phils
Date Sampled:
City
Dale Received.
Submilted by:
Abelardo B. Gomez
Date of test.
Test Metnods Used.
as specified below
not specified
EPL-02 w/Admix
1 of 2
9/5/2012
9/5/2012
9-Sep-12
PHYSICAL T'ESTS
SPECIFICA nON
the result of tests tothe above sample
of the Manager, Cement Testing Center (CTC).
t6 the CTC
A not applicable, B nol required by Ihe lesl method o-not requested by the customer
are calculateC! at 95% confidence lever
rJ
uz
TC Adm Form No.4-1c bato.or 1.sue::April Revision No. 0
CeMAP Bldg. No.1 Cpl Cruz Sl. cor. E. Rodriguez Jr. AVe.
Bagon9 1109. Pasig City 1600 Philippines
Tel (632) 671-7583 Fax: (632) Email: ctcenter@cemaporg.ph
PAO ACCREDITED
TESTING LABORATOr:;
PNS ISOIIEC 17025:20(
LA-1997-016D2
[ TEST CERTIFICATE
Test Corlificate No..
P-092012-48823
Date of Issue:
1-0et-12
No. of Pages.
1 of 2
Sample Reference No..
C54250 -0912
Kind and Typo of Sample:
Blended Cement, T - IP
Pozzolanie Phils
. Date Sampled:
9/5/2012
AddreSS:
Unit 810 Pioneer Highlands, Pioneer St., Mandaluyong City
Date Received:
9/5/2012
Sampled by:
Not Specified Abelardo B. Gomez
Date of test.
9-Sep-12
, Test Specification:
ASTM C595 - 08a
Test Methods Usod:
as specified below
Sampling Method Used: not specified
PH Y S I CAL T EST S
L-------,.------fTESTlViEm0i5s1'-SPEC,RCATfON TEST RESULTS (*)
REMARKS
- - - - - r - - ~ - - - - - - - ~ - - ~ - - - - - 4 - f .------
REMARKS: This ceriificate
This report gives
A- no/applicable;
. ( ~ ) - The e)(panded uncertainly
A
290
330
. ucedexceptinfull,without the written approval oftlie Manager,Cement Testing Ce\lter(CTC).
above sample submitted to the' CTC.
the lest method D not requested by ihecustomer
calculated at level.
eTC Adm Form Dale bf Issue: Apnl2010 RevisionN6.0
CEMEN1' TESTING
2)
CeMAP Bldg No.1 Cpl. Cruz SL cor E. Rodriguez Jr. Ave.
Bagong lIog, Pasig City 1600 Phillppines AB
Tel. (632) 671-7583 Fax: (632) 671-8402 Email: ctcenter@cemap.org.ph
PAD ACCREDITED
TESTING LASORA TOR
PNS ISOIIEC 17025200
LA-1997-01602
,[ - -TEST CERTIFICATE
Test Certificate No.: Date of Issue:
No. of Pages:
P-092012-48826 12-0ct-12
1 of 2
Sample Reference No.: Kind and Type of Sample:
C54253-0912 Blended Cement, T - IP
.Name of Company/Individual'
Pozzo!anic Phils
9/5/2012
Date Received: Address:
Unit 810 Pioneer Highlands, Pioneer St., Mandaluyong City
9/6/2012
Submitted by: Date of lest:
Abelardo S. Gomez Not Specified 9-Sep-12
Test Methods Used: Test Specification:
as specified below AST"M C595 08a
not specified
EC2-02 w/Admix
LIMITS
( * )
PHYSICAL TESTS
TEST METHODS I SPEC/FICA nON UNCERTAINTY
I
PROPERTIES TEST RESULTS REMARKS
Manager, Cemen{Testing Center (CTC).
repbrtgives result of tests that relate only to the above sample submitted to the CTC.
A - not applicabfe; B - not required by the test method o - not requested by the customer
( .) - The expanded uncertainty values are calculated at .95% confidence level,

-. 17
T Manager
CTC Adm Form NO.. 4-1c Da(" of Issue: April 2010 Revision No. 0
CeMAP Bldg. No.1 Cpl. Cruz Sf. cor. E. Rodriguez Jr. Ave
Bagong Ilog, Pasig City 1600 Philippines
TeL (632) 671-7583 Fax (632) 671-8402 Email: rtt"pntprfi>lr<'"""
PAO ACCREDITED
TESTING lABORATOR'l
PNS [SOIlEC 17025200:
lA-1997-01602
[ TEST CERTIFICATE
Test Certificate No..
P-092012-48821
Dale of Issue:
Sample Reference No..
C54248-0912
Portland Cement,
Name of Company/Individual.
Address.
810 Pioneer Mandaluyong
Sampled by:
Not Specified
Submilled by:
Abelardo B. Gomez
I Dale of lest:
Test Specification.'
ASTM'C150 - 07
Test Methods Used:
as specified below
not specified
EPl-01
No. of Pages:
1 of 2
T - I
9/5/2012
Dale Received:
9/5/2012
9-Sep-12
PROPERTIES
SPECIFICA TlON
TEST RESULTS
UNCERTAINTY
REMARKS
::<.EMARKS: This certificate .shall ntitbe reproduced except in full, without the written approval of the Manager, Cement Testing Center (CTC).
This .report gives the result of tests that relate only to the above sample submitted to the CTC.
A - not applicable; B - not required by the test method D not requesled by Ihe customer
rJ - The expanded uncertainty values are calculated at 95% co.nfidence level.
~ ~ ~
7 Manager
PHYSICAL TESTS
'TC Adm Form No. 4 ~ 1 c O ~ t G of Issue: AprH 201Q Revision No. 0
CeMAP Bldg, No.1 Cpr. Cruz St cor. E Rodriguez Jr. Ave.
8agong Ilog, Pasig City 1600
Tel. (632) 671-7583 (632) 671-8402 Email ctcenter@cemap.org.ph
PAO ACCREDITED
TESTING LABORATORY
PNS ISOIIEC 17025:200:::
r----- - --- -
LA-1997-01602
I TEST CERTIFICATE
L-____________________
(Partial Results) INo of Pages
1 of 2
Portland Cement, T - I
as specified below
not speCified
EPL"02
Sample ReferenceNo.:
Name of Company!lndividua(-
Address:
Unit810 Pioneer
P-092012-48822
Date of Issue:
18-Sep-12
C54249-0912
Kind and Type of Sample
Pozzolanic Phils
9/5/2012
Pioneer St, Mandaluyong City
Dale Received.'
9/5/2012
Sampled by.
Not Specified
Submitted by.
Abelardo B, Gomez
Date attest
9-Sep-12
Test Specification:
Used:
C100-0?
Test Methods Used:
PH Y 5 I CAL TESTS
TEST METHODS SPEC/FICA TfON
PROPERTIES TEST RESUL TS REMARKS
LIMITS
A
This certificate shall not be reproduced infuli, without the written approval of the Manager, Cement Testing Center (CTC).
This repQrt gives the result of tests that relate only to the above sample submitted to the CTC.
A - not applicable; B c not required by the test method D - not requested by the customer
(*) The expanded uncertainty values are calculated at 95% confidence level.

(
:TC Adm Form No. 41c Date of [ssu'" Apri[ 2010 Revision No. 0
Eagle T ~ l and Eagle Blended with Flyash Quality Test
Properties! Components
ASTM
Specifications
Specification Limits
Test Results.
EPL-01 EPL-02 EC1"()2 EC2"()2
Plain Eagle
Cement T-1
Plain Eagle
Cement T*1
(with 1%
Admix)
Eagle
Cement with
15% Fly ash
and 1%
ArlmiY
Eagle
Cement with
20% Flyash
and 1%
Arlmjy
Physical
Tests
Fineness (%)Blaine C2M 260 min 346 346 297 285
Fineness(% Passing 75 urn
sieve and 45 urn sieve)
C 786/C430 N-A 9B.9 98.9 86.4 87.8
Time of Setting (Initial) mins. C 191
45 minutes (min)
375 minutes (max)
175 485 615 270
Time of Setting (Final) mins. C191 N-A 260 675 715 745
AutoClave Expansion (%) C 1611 C 151M 0.8 max 0.02 0.03 0.02 0.02
Density. (glee) C188 N-A
Compressive Strength (Mpa)
C 109/C 109M
3 Days 12min 24 31 33.2 28.7
7 Days 19min 31.9 38.9 42.7 36.3
28 Days 28 min 38.9 46.6 53.5
._
47.B
I
Chemical
Analysis
.. _
Silicon Dioxide Si02 19.8
Aluminum Trioxide
Ferric Oxide
Calcium Oxide
Magnesium Oxide
Loss on Ignition
AI203
Fe20S
CaO
MgO
LOI
.
6.0 max
3.0 max
,
,
5.6
3.32
63.4
2.1
2.1
Insoluble Residue IR 0.75 max 0.32
Sulfur Trioxide
Undetermined
S03
UD
3.5 max 2.5
1.18
TOTAL
FREELIME F-CaO
COMPLEXES
Tri-calcium Silicate C3S
Di-calcium Silicate C2S
Tri-calcium Aluminate CSA
Tetra-calcium Alumino..f"errite C4AF
RATIOS
Silioca Modulus S.M.
Hydraulic Modulus H.M.
100
0.8
58
13
9
10
2.2
2.2
Alumina-Iron
Lime saturation Factor
. ~ - ~ - - - ......-.
A!F
_ ~ L-,S.F._ .
1.7
95.9
Eagle T-1 and Eagle Blended with Flyash Quality Test
Test Results
EPL"()1 EPL"()2 EC1"()2 EC2"()2
Eagle Eagle
ASTM
Plain Eagle
Specification Limits Properties! Components
Cement with Cement with
Specifications
Plain Eagle CementT-1
15% Fly ash 20% Flyash
CementT-1 (with 1%
and 1% and 1%
Admix)
Admix Admix -
Physical
Tests
Fineness (%)Blaine C204 260 min 346 346 297 285
Fineness(% Passing 75 um
sieve and 45 um sievel
C 78S/C 430 N-A 98.9 98.9 86.4 87.8
Time of Setting (Initial) mins. C 191
45 minutes (min)
375 minutes (max)
175 485 615 270
Time of Setting (Final) mins. C 191 N-A 2S0 675 715 745
AutoClave Expansion (%) C 161/C 161M 0.8 max 0.02 0.03 0.02 0.02
Density. (glee) C 188 N-A
Compressive Strength (Mpa)
. ~
-
C 109/C 109M
3 Days 12 min 24 31 33.2 28.7
7 Days 19 min 31.9 38.9 42.7 36.3
28 Days 28 min 38.9 46.6 63.6 _ ~ 47.8
Chemical
Analysis
Silicon Dioxide Si02 19.8
Aluminum Trioxide AI203 6.6
Ferric Oxide Fe203 3.32
Calcium Oxide CaO 63.4
Magnesium Oxide MgO 6.0 max 2.1
Loss on Ignition LOI 3.0 max 2.1
Insoluble Residue IR 0.75 max 0.32
Sulfur Trioxide S03 3.5 max 2.5
Undetermined UD 1.18
TOTAL 100
FREELIME
I
F-CaO 0.8
COMPLEXES
Tri<alcium Silicate C3S 68
Di<alcium Silicate C2S 13
Tri<alcium Aluminate C3A 9
Tetra<alcium Alumino-Ferrite C4AF 10
RATIOS
Silioca Modulus S.M. 2.2
Hydraulic Modulus H.M. 2.2
Alumina.Jron A1F 1.7
Lime Saturation Factor L.S.F. 95.9
~
CEMENT TES'fING CEN'fER
CeMAP Bldg. No.1 Cpl. Cruz SI cor. E. Rodriguez Jr. Ave.
8agong Ilog, Pasig City 1600 Philippines
Tel. (632) 671-7583 Fax (632) 671-8402 Email ctcenter@cemap.org.ph
[
TEST CERTIFICATE
._-------'
PAO ACCREDITED
TESTING LA80RATOR'
PNS ISOIIEC 17025200:
LA-1997-016D2
of 2
T - IP
9/5/2012
. 9/6/2012
9-Sep-12
P-0920 12-48826
Dale of Issue:
1
No. of Pages:
Sample Reference No :
C54253-0912
Blended Cement,
Name ofCompanylindivi dual:
Pozzolanic Phils ,Dale Sampled
Unit 8.10 Highlands, Pioneer St., Mandaluyong City
Sampled by: Submitted by'
Abelardo B. Gomez
Spedfication:
ASTM C595 - 08a
res/Methods Used:
as specified below
Sampling Method Used: not specified
Sample identification: EC2-02
Date of/est:
PROPERflES
SPECIFICA nON
TEST RESUL TS
LIMITS
A
UNCERTAfNTY
(*)
This certificate shall not be reproduced 'except in full, without the written approval of the Manager, Cement Testing Center (CTC).
report gives the result oftests thafreiate only to.the above sample submitted to the CTC.
A - not applicable; B - not required by the test methOd 0 not requested by the customer
(*) - The expanded uncertainty values are calculated at 95% confidence level.
RUZ
CTCAdm No: 4-1c Date of Issue: April 2010 Revision No. 0
REMARKS
PHYSICAL TESTS
CeMAP Bldg No.1 Cp!. Cruz St. cor. E. Rodriguez Jr. Ave.
Bagong 1I0g, Pasig City 1600 Philippines
Tel. (632) 671-7583 Fax: (632) 671-8402
PAO ACCREDITED
TESTING LABORATOR
PNS ISOIIEC 17025200
LA-1997-016D2
[ TEST CERTIFICATE
Dale of Issue. 18-Sep-12
P-092012-48823 1 of 2
Sample Reference No.. Kind and Type of Sample.
CS42S0-0912
9/5/2012
Date Received: Address: Unit 810 Pioneer Highlands, Pioneer
9/5/2012
Dale ortesi.' Sampled by:
Not Specified Abelardo 8, Gomez
9-Sep-12
Test Specification: Test Methods Used:
ASTMC595 - 08a as specified below
Sampling Method Used:
not specified
EC1-02
PROPERTIES
PHYSICAL TESTS
TEST METHODS SPECIFICA nON
LIMITS
TEST RESUL TS
A
A
A
UNCERTAINTY
(')
REMARKS
Thiscertificate shall not be reproduced except in full, without the written approval of the Manager, Cement TestingCen!er (CTC),
'. This report gives the result of tests that relate. only ,to the'above sample submitted to the CTC.
A not applicable; B not required by the lest method
o - not requested by the c;ustomer
( ) The expanded uncertainly values are calculated at 95% confidence level.

7
Manager
CTC Adm Form No, 4-1c Date of Issue: April 2010 P,evision No, 0

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