Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  ·...

45
Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates Project No. MLR-85-8 Highway Division July 1986 ----- Iowa Department ----- of Transportation

Transcript of Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  ·...

Page 1: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Evaluation of Fly Ash ConcreteDurability Containing

Class II Durability Aggregates

Project No. MLR-85-8

Highway DivisionJuly 1986

-----~~ Iowa Department-----~l of Transportation

Page 2: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Evaluation of Fly Ash Concrete DurabilityContaining

Class II Durability Aggregates

Project No. MLR-85-8

BySam G. Moussalli

Cement and Concrete Engineer

Office of MaterialsIowa Department of Transportation

April 1986

Page 3: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

DisclaimerThe contents of this report reflectthe views of the author who is respon­sible for the facts and the accuracyof the data presented herein. Thecontents do not necessarily reflectthe official views or policies of theIowa Department of Transportation.This report does not Constitute astandard, specification or regulation.

Page 4: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

TABLE OF CONTENTS

Page

Abstract •••.• ................................................................................................................ .ii

Introduction. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1

Scope •..•.... .. .. .. .. .. .. .. .. .. .............................. II .. 1

Laboratory Procedures. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2

Materials ••••••.•. .................................................................................................. 2

Portland Cement.Water ..Air Entraining Agent.Fly Ash •......••.Fine Aggregate •••Coarse Aggregate.

222223

Aggregate Classification Purpose 3

Aggregate Gradation ,. 4

Fly Ash Substitution Rates.................................................................................. 4

Concrete Controls.................................................................................................. 4

Concrete Tests . .. . . .... .... . . . ............ .. . . . ..... 4

Durability (Freeze/Thaw Test) •

................ " .Test Results and Interpretation.

.. . .. " .. .. .. . .. ..............6

6

Table No. 1 physicalTesting

Characteristics of Aggregate Quality. .. .. 7

Table No. 2 Durability of Fly Ash Containing Class II •.•..•••••.• 8Aggregates

Figure No. 1 Durability Factors Class II Aggregates •••• 9

Figure No. 2

Figure No. 3

Durability Factors With and without Fly Ash ....•..•• llMalcom Mine

Durability Factors With and Without Fly Ash .....•••• 12Douds Mine

Figure No. 4 Durability Factors With and Without Fly Ash. .. .. .13

Figure No. 5 Durability Factors With and Without Fly Ash ••....••• 14Nelson Quarry

Page 5: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

TABLE OF CONTENTS (continued)

Page

Figure No. 6 - Durability Factors With and Without Fly Ash .. .. .. .. .. .. .. .... 15Garrison Quarry

Figure No. 7 - Durability Factors With and Without Fly Ash ........ .. .. .. .. .. 16Carville/Bunn Quarry

Figure No. S - Durability Factors With and Without Fly Ash ..••.•..• 17Ames Mine

Figure No. 9 - Durability Factors With and Without Fly Ash .................. 18Durham Mine

Figure No. 10 - Expansion Factors with and Without Fly Ash ••••••••• 19Malcom Mine

Figure No. 11 - Expansion Factors With and without Fly Ash •••••.... 20Douds Mine

Figure No. 12 - Expansion Factors With and Without Fly Ash .••..•.•. 21Skyline "Au Quarry

Figure No. 13 - Expansion Factors With and Without Fly Ash .......... .. .. .... 22Nelson Quarry

Figure No. 14 - Expansion Factors With and Without Fly Ash .................. 23Garrison Quarry

Figure No. 15 - Expansion Factors With and Without Fly Ash .•....... 24Carville/Bunn Quarry

Figure No. 16 - Expansion Factors With and without Fly Ash .................. 25Ames Mine

Figure No. 17 - Expansion Factors With and without Fly Ash .•.••.••. 26Durham Mine

Air Content of Fly Ash Concrete .••............•......•.•...•....... 27

Discussion of Results It 28

Conclusion '" 29

Recommendation 29

References " 30

Appendices

Appendix A - Standard Specifications - Mix Proportions ••••••.•••• 32Appendix B - Durability Testing (Freeze/Thaw) •••••••••••••.•••... 34

Page 6: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Abstract

Fly ash was used in this evaluation study to replace 15% of the cement in

Class C-3 concrete paving mixes. One Class "c" ash from Iowa approved

sources was examined in each mix. Substitution rate was based on 1 to 1

basis, for each pound of cement removed 1.0 pound of ash was added.

The freeze/thaw durability of the concrete studied was not adversely af­

fected by the presence of fly ash. This study reveals that the durabil­

ity of the concrete test specimens made with Class II durability

aggregates was slightly increased in all cases by the substitution of ce­

ment with 15% Class "c" fly ash.

In all cases durability factors either remained the same or slightly im­

proved except for one case where the durability factor decreased from 36

to 34. The expansion decreased in all cases.

i i

Page 7: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 1

Introduction

Current Iowa DOT specifications allow the optional use of fly ash as a

partial cement replacement in Class A, Band C concrete paving mixes,

provided a highly frost resistant, coarse aggregate such as Class III du­

rability is used.

The basis for this specification is that early durability research indi­

cated less frost resistance in fly ash concrete when an aggregate of me­

diocre quality was used. Research subsequently has shown that fly ash

concrete with other Class II aggregate may not have reduced freeze/thaw

durability.

Special study and testing where aggregates are salt treated indicates the

addition of fly ash may be beneficial; furthermore, the use of fly ash in

concrete is desirable for economical and environmental reasons.

Therefore, it was the purpose of this study to test durability of con­

crete containing several Class II aggregates to establish the effect of

fly ash and further to either substantiate or refute our present posi­

tion.

Scope

Eight Class II aggregates were evaluated in concrete in this evaluation

study, with and without fly ash. The aggregate represented a cross­

section of carbonate aggregates presently approved for use in Iowa.

Page 8: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 2

The fly ash studied conformed to ASTM C-618, "Fly Ash and Raw or Calcined

Natural Pozzolan for Use as a Mineral Admixture in Portland Cement Con-

crete". Only one Class "c" fly ash was used in this study from an ap-

proved Iowa source.

Currently Iowa does not have any Class "F" ash approved for use.

This study examines the freeze/thaw durability of Class II aggregates

when used in Class C-3 paving mixes with and without fly ash.

The C-3 paving mix has a cement factor of 604 pounds per cubic yard.

Laboratory Procedures

A. Materials

The following materials were used in this study:

1. Portland Cement: Type I, standard laboratory blend of the tenportland cements commonly available in Iowa, was used to prepare theconcrete specimens.

2. Water: Tap water, City of Ames

3. Air Entraining Agent: Neutralized vinsol resin, Carter-Waters, sin­gle strength, Lab No. ACA5-7

4. Fly Ash: Ottumwa Ash, mildly reactive, Class "c" (self cementing)Lab No. ACF5-64

5. Fine Aggregate: Cordova sand (Mississippi River sand), Lab No.AA55-0141

Page 9: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 3

6. Coarse Aggregates:

Source Name

Malcom MineDouds MineSki line QuarryNelson QuarryGarrison QuarryCarville/Bunn Quarry

Ames MineDurham Mine

B. Aggregate Classification Purpose

Reason for Class II Classification

Durability Factor & PerformanceDurability Factor & PerformanceDurability FactorDurability FactorPerformanceSimilar stone has poorerperformanceDurability FactorDurability Factor & Performance

In view of the fact that Iowa has some concrete aggregates that cause

premature concrete failure, a three-class system has been developed to

denote a portland cement concrete aggregate's expected service life. The

three service life classes are:

Class I - Deterioration in approximately 10 years and a durabilityfactor less than 80.

Class 2 - Deterioration in 10-20 years and a durability factor greaterthan 80.

Class 3 - Deterioration in over 20 years and a durability factor greaterthan 90.

Assignment to one of the service life classes is based on the aggregates

field performance in concrete, or in lieu of that, upon the performance

of concrete containing it in a modification of the ASTM C-666, "Resist-

ance of Concrete to Rapid Freezing and Thawing - Procedure B" test.

Although the latter test can be definitive in identifying low quality ag­

gregates, some aggregates that just pass the test give questionable field

performance. These could appropriately be termed as Class II aggregates.

Page 10: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 4

C. Aggregate Gradation

The coarse aggregate gradation was:

Sieve No.

1.06"3/4"0.525"3/8"No. 4No. 8

% Passing

10089408.00.80.4

D. Fly Ash Substitution Rates:

Fly ash was substituted for 15%, by weight of the portland cement. The

substitution of Class "c" fly ash was on a pound-for-pound basis. The

change in absolute volumes due to the fly ash substitution, was applied

to each aggregate in its proper ratio. For the C-3 mix, the volumes are

55% coarse aggregate and 45% fine aggregate.

E. Concrete Controls

Concrete mixes were controlled to a slump of 2.0" ± 1/2" and air content

of 6.0% ± 0.5%.

F. Concrete Tests

The investigation of the effects of aggregate and fly ash sources on con-

crete durability was accomplished by preparing test specimens in the lab-

oratory. These specimens were made from a Class C-3 concrete mix with a

cement content of 604 lb./yd 3 as defined in the standard specifications

series of 1984 (1). The variables in the mixes were the aggregate

sources. The specifications referenced above designate the proportions

Page 11: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 5

of Portland Cement-water-aggregate to be used in the mixes studied. The

specifications also itemize the slump and entrained air content (see Ap­

pendix A). The former is achieved by varying the water added and latter

by varying the amount of air entraining agent added.

The actual procedure, as to the preparation and mixing of the ingredi­

ents, was as outlined in ASTM C-192 (2) "Making and Curing Concrete Test

Specimens in the Laboratory".

The determination of the durability factor of the concretes containing

the Ottumwa ash and various aggregates was done according to Iowa Test

Method 408A (3) "Method of Test for Determining the Resistance of Con­

crete to Rapid Freezing and Thawing" (see Appendix B). This test is a

modification of ASTM C-666, Procedure B (2) in that the 4" x 4" concrete

beams are 18" in length rather than 11" to 16" and 90-day moist room cure

is substituted for the 14-day lime water cure.

A total of three 4" x 4" X 18" beams were cast from each batch and each

combination for the durability testing. The beams were cured for 90 days

in the moisture room.

Upon completion of the appropriate curing period, the beams were sub­

jected to cyclic freezing and thawing with periodic sonic modulus and

change in length readings taken twice a week. This was continued until

they had undergone 300 cycles of freezing and thawing or until the speci­

men's relative dynamic modulus of elasticity reached 60% of the initial

modulus, whichever occurs first.

Page 12: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 6

The coarse aggregates used in the concrete currently are approved as

Class II durability aggregates which are associated with no deterioration

of pavements in less than 10 years and only minimal deterioration in

pavements of 10-20 years of age.

Test Results and Interpretation

Durability (Freeze/Thaw Test)

Table No. 1 shows the physical characteristics of the aggregate quality

testing, while Table No.2 shows the concrete mix characteristics and

itemizes the freeze/thaw durability test results for the various aggre­

gates. Each durability value indicated is the average of the three

beams. The data is depicted graphically in Figure 1 to point out the re­

lationship between the C-3 mixes with and without the substitution of fly

ash for a portion of the cement when Class II and Class III aggregates

are used.

Page 13: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

TABLENO.

1

DURABILITYOF

FLYASH

CONTAININGCLASS

IIAGGREGATES

MLR-85-8

AGGREGATESOURCE

COUNTYAGGREGATE

FREEZE-THAWPORE

INDEXABSORPTION

L.A.

SPECIFICCLASS

METHODA

%ABRASION

GRAVITY%

%

Ma1com;'

MinePow

eshiekII

1.016.0

2.8030.0

2.597(D

olomite)

Douds

Mine

VanB

urenII

2.018.0

5.0435.0

2.525(D

olo mite2Skyl

tne

Quarry

Winneshiek

II1.0

20.01.39

25.02.654

(Dolom

ite/Lim

estone)

Nelson

Quarry

Henry

II2.0

10.00.70

46.02.667

(Lim

estone2G

arrisonQ

uarryB

entonII

1.013.0

2.7026.0

2.653(D

olomite2

----------_......._

----_

.•------------_

...~----_

..-----------

------

--

--------

---_..•...-

Carville/B

unnQ

uarryFloyd

II1.0

18.02.99

30.02.630

(Dolom

iteL_

__

__~

__

__

__

__

__

__

__

__

__

__

_v:P-

Ames

Mine

StoryII

2.018.0

2.7541.0

2.584a:en

(Dolom

ite)-..J

Durham

Mine

Marion

II1.0

24.02.2

28.02.614

(Dolom

ite)

Page 14: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

TABL

ENO

.2

DURA

BILI

TYOF

FLY

ASH

CONT

AINI

NGCL

ASS

IIAG

GREG

ATES

MLR

-85-

8

AGGR

EGAT

ESO

URCE

FLY

ASH

FLY

ASH

W/C

RATI

OAI

RSL

UMP

DURA

BILI

TYEX

PANS

ION

SOUR

CECL

ASS

CEM

ENT

CEM

ENT

%(IN

CH)

FACT

OR%

ONLY

&%

FLY

ASH

Malc

omM

ine

Con

tro1

--0.

427

----

-6.

42.

2568

0.07

7M

alco

mM

ine

Ottu

mw

aC

0.46

60.

395

6.5

2.50

860.

039

Dou

dsM

ine

Con

trol

--0.

414

----

-6.

41.

7587

0.04

2D

ouds

Mine

Ottu

mw

aC

0.47

40.

401

6.5

2.25

930.

014

Skyl

ine

Qua

rry

Con

trol

--0.

420

----

-6.

01.

7597

0.01

4Sk

ylin

eQ

uarr

yO

ttum

wa

C0.

481

0.40

86.

32.

5097

0.01

3

Ne1s

onQ

uarr

yC

ontr

ol--

0.42

0--

---

6.1

2.00

770.

072

Nel

son

Qua

rry

Ottu

mw

aC

0.45

90.

388

6.5

2.25

840.

048

Gar

riso

nQ

uarr

yC

ontro

1--

0.43

9--

---

6.0

1.75

860.

026

Gar

riso

nQ

uarr

yO

ttum

wa

C0.

489

0.41

46.

12.

0095

0.01

8"J> G

> .,., 00

Car

vill

e/B

unn

Qua

rry

Con

trol

--0.

420

----

-6.

22.

0064

0.10

6C

arvi

lle/

Bun

nQ

uarr

yO

ttum

wa

C0.

496

0.42

06.

02.

0073

0.09

7

Ames

Min

eC

ontr

o1--

0.40

8--

---

6.1

2.50

360.

167

Ames

Min

eO

ttum

wa

C0.

474

0.41

46.

42.

5034

0.12

2

Dur

ham

Min

eC

ontr

o1--

0.47

7--

---

6.0

2.00

770.

098

Dur

ham

Min

eO

ttum

wa

C0.

519

0.43

96.

02.

5078

0.12

6

-- ~

.

Page 15: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Fig

ure

#1

DU

RABILITY

FACTORSW

ITH&

WITHOUT

FLYASHC

LA

SS2

QU

AR

RIE

SIO

WA

DO

T2

39

-12

04

APR

IL1

98

6SA

VEC

OO

EC

L2FL

Y

NO

FLYA

SH

[@&

15

"FLY

ASH

~([

oI­u«LL>­I­H..JHCD«([

::Jo

100'1l'"r>

t1<?O

lI

80

60

40

200.LJ.:::Ll1X

Xl

V/j1

XX

lV

/j1X

Xl

V/jIX

XI

V/jIX

X!

V'1

IXX

lv'1

12

og

v/IIX

X!

v/IIX

X!

vtl'i'Sl<

!vtl""'l<

!I

CL

ASS

2Q

UA

RR

IES

-0

»G)

enco

Page 16: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 10

While the durability of concrete test specimens was slightly increased in

most cases by the substitution of 15% of the cement with fly ash, the ex­

pansion was decreased in all cases. The results of the durability fac­

tors in combination with the fly ash used in this evaluation study are

shown in Figures 2-9. The expansion factors of the same combinations are

graphically presented in Figures 10-17.

Page 17: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#2

PERCENTO

RIGIN

AL

MODULUS

EAGLECITY

LEDGEFROM

THEMALCOM

MINE

LABNUM

BERA

AC

5-428

STANDARDOTTUM

WA

FLYASH

~~

I100

-l4

--

-X...-.

-X--

901\...

~-""'-..

--l90

en<

,:::>

I-----x..-

-.J'-

-)(

:::>0080

I.-<

,--l

80::E-.J<

{

ZH70

I--...............

--l70

(!)Ha:0~

60

1-

-l60

-o»G)

CT1

~~

501I

II

,,

,I

500

50100

150200

250300

350

FREEZE-THAWCYCLES

IONADDT

JULY1,

19861-515-239-1339

CODE:M

ALCMIN1

Page 18: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#3

PERCENTO

RIGIN

AL

MODULUS

SPERGENLEDGE

FROMTHE

DOUDSM

INELA

BNUM

BERA

AC

5-543

STA

ND

AR

DO

TTUM

WA

FLY

AS

H

-.

10

0K

I100

~~-~

"---~

-l4--

-.l'-

-"--~

(J)9

0L~

--J90

::l...J::l00

BO

L.

-----J

80L...J«ZH

70

1-

-l

70(!)Ha:0~

60~

~60

-o'>GO

rn~N

50II

II

II

II

50

050

100150

200250

300350

FREEZE-THAWCYCLES

IOIIA

DOT

JULY

1.19B

61

-51

5-2

39

-13

39

CODE:

DO

UD

MIN

1

Page 19: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Fig

ure

#4

PERCENTO

RIGIN

AL

MODULUS

STEWARTVILLE

LEDGEFROM

THESK

YLIN

E'A

'QUARRY

LABNUM

BERA

AC

5-465

STANDARDOTTUM

WA

FLYA

SH-

-.

10

0j

I100

iIE.......~iIti

~"i'-

IIIIII

illill

-r-'-

oj(

(J)90~

J90

:::>-.J:::>00

80~

---l80

:E-.J«ZH

70

1-

---l70

(!)H([

0~6

01

--J

60" »G

O[T

l

~wI

50II

II

II

II

500

50100

150200

250300

350

FREEZE-THAWCYCLES

IOWA

DOTJU

Ly1,

19861-515-239-1339

CODE:SK

YLlN

E1

Page 20: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

STANDARD

Figure

#5

PERCENTO

RIGIN

AL

MODULUS

CEDARFORK

LEDGEFROM

THENELSON

QUARRYLAB

NUMBER

AA

C5-523

OTTUMW

AFLYASH

~4

i~

u:

TC

-X........--l

90

::l~~

-X

--

X--~

+...J

----.....-l'-

-~

::l+

x.-

I~

x.-

0........

-l(

aeo

I...----

--leo

::E...J«ZH

70I...-

~70

(!)H([

a~6

01

--l6

0"»G

")rn~.".

50II

II

II

II

50

050

100150

200250

300350

FREEZE-THAWCYCLES

IOWA

DOTJU

Ly1,

19B6

1-5

15

-23

9-1

33

9CO

DE:N

ELSON

1

Page 21: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#6

PERCENTO

RIGIN

AL

MODULUS

CORALVILLELEDGE

FROMTHE

GARRISONQUARRY

LABNUM

BERA

AC

S-007

STAN

DA

RDOTTUM

WA

FLYASH-

--

.

10

0K

I1

00

x..-X

-X--

XX

--~

-X

.--X

--

-X--~

90

l

__

3

++

i+

--I90

UJ

.....::::J-l

::::J00

80I.-

--I8

0~-l

«ZH70

I.---I

70(!)Ha:0~

50~

-l5

0-0»G)

en~U1

50I

II

II

II

I5

0

050

100150

200250

300350

FREEZE-THAWCYCLES

IOIlA

DOTJU

Ly1.

19861-515-239-1339

COD

E:SA

AR

i

Page 22: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

STANDARD

Figure

#7

PERCENTO

RIGIN

AL

MODULUS

CORALVILLELEDGE

FROMTHE

CARVILLE/BUNNQUARRY

LABNUM

BERA

AC

S-419

OTTUMW

AFLY

ASH

~t

I~

90~

-I

90(J)

~~

:::::>~x.--..

..J:::::>

~'"

0080

<,

-I

802

:

..J<

<,

z-,

H70

-I

70(.!J

X

Ha:0~6

0f-

""'+-j

60-o»G

>fT

1

~en

50II

II

II

II

500

50100

150200

250300

350

FREEZE-THAWCYCLES

IOWA

DOTJULY

1.1986

1-515-239-1339CODE:

CARBUNN1

Page 23: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

STAN

DA

RD

Fig

ure

#8

PERCENTO

RIGINAL

MODULUS

GILMORE

CITYLEDGE

FROMTHE

AMES

MINE

LABNUM

BERA

AC

5-446

OTTUMW

AFLYASH

~t

i~

Page 24: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#9

PERCENTO

RIGIN

AL

MODULUS

EAGLECITY

LEDGEFROM

THEDURHAM

MINE

LABNUM

BERA

AC

4-14

STANDARDOTTUM

WA

FLYASH

aD70 90~

"-~

.l(

<,

~~

-X--.~~

aD70 90

~(

I~

en:::J..J:::Joo2..J«ZH(!)H0

:o~

6060

"J>G)

rn~co

300100

150200

250

FREEZE-THAWCYCLES

50

50I

II

II

II

I50

o

IOIlA

DOTJU

Lyi.

19861-515-239-1339

CODE:DURHAM1

Page 25: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#10

PERCENTEX

PAN

SION

ASTMC

666-BEAGLE

CITYLEDGE

FROMTHE

MALCOM

MINE

LABNUM

BERA

AC5-428

STANDARDOTTUM

WA

FLYA

SH

.2I

i

.1

zaH(f)

Z«0...xWl­ZWU0

:W0...

?-

...J4-

_X

--

.-X--

.-X--

.-X--

-X

---

..x---

X--

-X-0

'>""' rn~<.0

350300

250200

150100

50ov-:

I!

II

II

!

oFREEZE-THAW

CYCLESIOW

ADOT

FEB04.

19861-515-239-1339

CODE:M

ALCMIN2

Page 26: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Fig

ure

#11

PERCENTEX

PAN

SION

SPERGENLEDGE

FROMTHE

LABNUM

BERA

AC5-543

ASTMC

666-BDOUDS

MINE

STANDARDOTTUM

WA

FLYA

SH

.2'Iii

-0

»G)

r-t

No

350300

250

.x--_~

-X~

200150

_X

--

X--

10050

--0

,*....,..........

II

II

II

I

o

.1

zoH(j)

Z«n,

XWI­ZWU0:

Wo,

FREEZE-THAWCYCLES

IOWA

DOTFEB

04.1966

1-515-239-1339CODE:

DOUDMIN2

Page 27: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#12

PERCENTEX

PAN

SION

ASTMC

666-BSTEW

ARTVILLELEDGE

FROMTHE

SKY

LINE

'A'

QUARRYLAB

NUMBER

AA

C5-465

STA

ND

AR

DO

TTUM

WA

FLY

AS

H

.2i

I

.1/-

50

FREEZE-THAWCYCLES

zaH(f)

Z<t:

0..XW~ZWua:ur0..

'"II"

---r100

---r~

150

r200

I250

~--*

I300350

-0

ij';mN~

IOWA

DOTFEB

04,1986

1-515-239-1339CO

DE:S

KY

LlNE

2

Page 28: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Fig

ure

#13

PERCENTEX

PAN

SION

ASTMC

666-BCEDAR

FORKLEDGE

FROMTHE

NELSONQUARRY

LAB

NUMBER

AA

C5-465

STANDARDOTTUM

WA

FLYASH

.2i

i

-0»'" ,."NN

350300

~X

---X

250

:.-x--

200150

x--~~

10050

Or:

II

II

II

I

o

.1

zoH(f)Z<

t:0...XWI­ZWUa:W0...

FREEZE-THAWCYCLES

IOW

ADO

TFEB

04.19B

61-515-239-1339

CODE:

NELSO

N2

Page 29: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

STANDARD

Figure

#14

PERCENTEX

PAN

SION

CORALVILLELEDGE

FROMTHE

LAB

NUMBER

AA

C5-o07

OTTUMW

AFLYASH

ASTMC

666-BGARRISON

QUARRY

.2i

i

zoHenz«0-

X.1

llJ~ZllJU~llJI

~0

-I

~

-'"

-=r~

_X

--

--X--

-X

01¥

riii

J"

---:t:t=I

L0

50100

150200

250300

350

FREEZE-THAWCYCLES

IOIlA

DOT

FEB

04.19B

61

-51

5-2

39

-13

39

CODE:

BARR

2

NW

Page 30: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#15

PERCENTEX

PAN

SION

CORA

LVILLE

LEDGEFROM

THEASTM

C666-B

CARV

ILLE/BUN

NQUARRY

LABNUM

BERA

AC

5-419

STANDARDOTTUM

WA

FLYA

SH

.2i

I

zaH(f)

Z«0..xW~ZWua:w0..

.1

:x--

-:?

"/

-0

~rnN..".

350300

250200

150100

50

Ov

II

II

II

I

oFREEZE-THAW

CYCLESIOW

ADOT

FEB04.

19B6

1-515-239-1339CODE:

CARBUNN2

Page 31: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Figure

#16

PERCENTEX

PAN

SION

ASTMC

666-BGILM

ORECITY

LEDGEFROM

THEAM

ESM

INELAB

NUMBER

AA

C5-446

STAND

ARD

OTTU

MW

AFLY

AS

H

.2i

i

zaH(f)Z«0..xWt­ZWUa:tu0..

.1

e-:-s>

j/

!/~

~V

/-o;poG

)

rnNo-r

350300

250200

150100

50

Or:

II

II

II

I

oFREEZE-THAW

CYCLESIO

WA

DOT

FEB04.

19861

-51

5-2

39

-13

39

CODE:

AMESM

IN5

Page 32: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Fig

ure

#17

PERCENT

EAGLEEX

PAN

SION

CITYLEDGE

FROMTHE

LABNUM

BERA

AC

4-149

ASTMC

666-8DURHAM

MINE

STANDARDOTTUM

WA

FLYA

SH

.21

I

./

zoH(J)

Z«Q.

XWI­ZWUITWQ.

.1

/;;/

~,/

»:

/

-0»G)

fT1

N0">

350300

100150

200250

FREEZE-THA

WCYCLES

50

0'lV

""

II

II

II

I

o

IOWA

DOTMAY

27,1986

1-515-239-1339CODE:

OURHAM2

Page 33: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 27

Air Content of Fly Ash Concrete

It should be noted that one of the common problems which has been en­

countered with the use of fly ash in concrete is the effect on entrained

air content. Failure to increase the amount of air entraining agent to

compensate for the negative effect of the presence of fly ash can produce

concrete with a lower than desired air content. This can then result in

the premature failure of concrete due to the action of freezing and

thawing processes.

Page 34: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 28

Discussion of Results

1. This study reveals that the durability of concrete test specimens

made with Class II durability aggregates were either slightly in­

creased or remained the same when 15% of the cement was substituted

with fly ash. However, fly ash is not expected to materially affect,

either favorably or unfavorably the freeze/thaw behavior of concrete

in which it is used, and the general use of Class II aggregate in fly

ash concrete may not insure satisfactory laboratory durability.

2. The slightly improved durability test results shown with the fly ash

mixes are not regarded as significant, and can be attributed to the

lower water cement ratios. The cause for the lower durability fac­

tors of Class II aggregate - fly ash concrete in past studies cannot

be related directly to Class II aggregates as a whole nor is it

likely to be an aggregate - fly ash reaction. It is more likely due

to combination of a particular Class II aggregate with a freeze/thaw

susceptible pore system. Research studies in the past have shown

that some of Iowa's Class II aggregate possess a pore system that has

a need to expel water during freezing if they are to retain their

structural integrity.

Some Iowa pavements, however, have undergone deterioration associated

with coarse aggregates that is primarily caused by adverse chemical

reactivity rather than freeze/thaw susceptibility. Other coarse ag­

gregate do not become affected and the addition of fly ash to the

concrete may restore the durability properties.

Page 35: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 29

Conclusion

Based on the laboratory test data gathered in this study, the addition of

fly ash as a partical cement replacement in the concrete mix can be ac­

complished without detrimental effects to the freeze/thaw durability of

concrete. Therefore, portland cement concrete containing Class II dura­

bility aggregates should either remain largely unaffected with respect to

durability or, in a few isolated cases, exhibit improved long term per­

formance with 15% replacement of the cement with quality fly ash.

Recommendation

It is recommended that the substitution of fly ash from approved sources

for up to 15% of the portland cement in concrete paving mixes containing

Class II aggregates be allowed in the specifications.

Page 36: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 30

References

1. Iowa Department of Transportation, Standard Specifications for High­

way and Bridge Construction, Series of 1984, Iowa Department of

Transportation, Section 2301 "Portland Cement Concrete Pavement".

2. ASTM (American Society for Testing and Materials), Annual Book of

Standards, Section 4, Volume 04.02, Concrete and Mineral Aggregates

ASTM 1984.

3. Iowa Department of Transportation, Office of Materials, Laboratory

Manual.

Page 37: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

APPENCICES

PAGE 31

Page 38: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 32

APPENDIX ASTANDARD SPECIFICATIONS

MIX PROPORTIONS

Page 39: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 33

Proportions for Pavement ConcreteSection 2301.04

Class C ConcreteBasic Absolute Volumes of Materials Per

Unit Volume of Concrete

Mix Cement Water Entr. Fine CoarseNo. Minimum Air Aggregate Aggregate

C-2 0.110202 0.148144 0.06 0.272662 0.408992C-3 .114172 .153840 .06 .301895 .370093C-4 .118330 .159808 .06 .330931 .330931C-5 .122867 .166318 .06 .358448 .292367C-6 .127782 .173371 .06 .384308 .254539

Approximate Quantity of Dry Materials PerCubic Yard of Concrete *

Fine CoarseMix Cement Aggregate AggregateNo. Pounds Tons Tons

C-2 583 0.6087 0.9130C-3 604 .6739 .8262C-4 626 .7388 .7388C-5 650 .8002 .6527C-6 676 .8579 .5682

*These quantities are based on the following assumptions: Specific grav­ity of cement 3.14; specific gravity of aggregate 2.65, water cement ra­tio 0.430 pound of water per pound of cement, air voids 6.0 percent.

Page 40: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

APPENDIX BDURABILITY TESTING

(Freeze/Thaw Testing)

PAGE 34

Page 41: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Page 1 of 5

PAGE 35

Test gethod No. Iowa 40B-AApril 1980

IOWA DEPARTMENT OF TRANSPORTATIONHIGHWAY DIVISION

0ffice of Materials

METHOD OF TEST FOR DETERMINING.THE RESISTANCEOF CONCRETE TO RAPID FREEZING AND THAWING

(CONCRETE DURABILITY)

This method covers the determination ofthe resistance of concrete beam specimens(4 11x4"x18") to rapidly repeated cyclesof freezing in air and thawing in water.The Procedure is a slight modificationto ASTM C-666 Procedure B.

Procedure

2. A polished brass button shall becast into each end of each prismfor the purpose of providing asmooth reference surface forlength measurements.

3. Three specimens shall be cast foreach variable under study.

E. Test Procedure

2. Twenty-four hours prior to place­ment in the freeze-thaw apparatus tthe specimens shall be placed inthe tempering tank.

D. Curing

1. Upon removal from their molds thetest specimens shall be placed inthe moist room for a period of notless than 89 days or not more than128 days.

A. Apparatus

1. Freezing and thawing Appara­tus, Temperature MeasuringEquipment, Dynamic TestingApparatus, Scales.

The freezing and thawingapparatus t temperaturemeasuring equipment t dy­namic testing apparatus,and scales shall conformto ASTM C-666 Procedure B.

2. Length Comparator

The length comparator fordetermining the lengthchange of the specimensshall be accurate to 0.0001".An invar steel reference baris provided' for calibratingthe comparator.

3. Tempering Tank

The tempering tank is temper­ature controlled at 40 + 2 QF.

It is to be used for coolingspecimens prior to placementinto the freezing chamber.

B. Freeze-Thaw Cycle

1. The freezing and thawingcycle shall be identical toASTM C-666 Procedure B.

C. Test Specimens

1. Unless otherwise specifiedthe test specimens shall be4 1x4"x18" prisms.

1. Beam Rotation

Prepare the order for random rota­tion of the specimens as follows:

a. Prepare paper slips with thespecimen identification num­bers for each specimen in thefreezing chamber.

b. Place all the paper slips ina pan.

c. Draw out the ·slips one at atime and record the resultingrandom sequence.

Rotate the beams in the followingmanner:

a. Withdraw the first specimenin the sequence and place itto one side.

b. Move each successive specimenin the sequence into the posi­tion of the specimen precedingit.

Page 42: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Test Method No. Iowa 408-AApril 1980

c. When the last specimen inthe sequence has been moved,replace it with the firstspecimen.

2. Length Measurements

a. Before any length measure­ment is taken, calibratethe beam comparator to0.0200 using the Invarsteel reference bar. Thisbar should be cooled forapproximately 30 minutesin water to 40°F. Adjustthe comparator dial ifneeded.

b. Remove the specimen fromthe tempering tank or thefreezer depending uponwhether the beam is a newone or one with severalcycles on it.

c. Place the specimen in thecomparator with the identi­fication numbers facing upat the left end of the com­parator. Care should beexercised to insure thatthe specimen is firmlyagainst the back stopsand the right end of thecomparator.

d. Allow the dial indicatorto come to rest on thebrass button on the endof the specimen. Readthis value on the indica­tor to the nearest 0.0001 11

Record this value. Repeatthe measurement by com­pletely removing the speci­men from the comparator,replacing it, and remeasur­ing it until two successivereadings are equal.

e. If measuring three speci­mens at once, -cove r thosespecimens immediately afterremoving from the sub-zerounit with a towel soaked inthe thawing water.

3. Weight Measurement

Weigh the beam on the scale tothe nearest ~ 'g~ams. Recordthe value obta~ne .

4. Dynamic Modulus

a. Place the specimen on thesupport such that the

PAGE 36

Page 2 of 5

driving oscillator is midwaybetween the end of the speci­men. Make sure the specimenis firmly against the back­stops of the support.

b. Place the tone arm pickup onthe end of the specimen aboutmidway between the sides.

c. On the oscilloscope, rotatethe large knob slowly back­and forth until an elipseshape is formed on the cathoderay tube of the oscilloscope.

d. Set the nOse. Frequencyll knobto II 1011 and read the frequencyfrornXthe indicator on the oscil-"loscope. Add 1000 to this valueand record the number obtained.

5. Replace the specimen in the freezechamber inverted from its originalposition.

6. Repeat steps 2 through 5 for allof the speoimens.

7. Continue each specimen in the testuntil it has been SUbjected to 300cycles or until its relative dy­namic modulus reaches 60% of theinitial modulus! whichever occursfirst.

F. Calculations

1. Record all the required data onthe "P.C. Concrete nurab Ll.Lt.y" labworksheet.

2. From the recording charts, obtainthe number of cycles completedsince the specimens were lastmeasured. (Mark the date read andthe number of cycles to that pointon the recording chart.) Add tothis number the number of cyclesat which the specimens were lastmeasured. Record this cumulativevalue in the column labeled "Cycles".

3. Subtract the" dial reading at zerocycles from the latest dial reading.Record this value in the columnlabeled tlGro. In".

4. Calculate the relative dynamic mod­ulus of elasticity using the for­mula:

where:

Page 43: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

PAGE 37

Page 3 of 5 Test Method No. Iowa 40B-AApril 1980

n

relative dynamic modulusof elasticity after ccycles of freezing andthawing, percent

fundamental transversefrequency at 0 cycles offreezing and thawing

N number of cycles at whichP reaches the specifiedminimum value for discon­tinuing the test or thespecified number of cyclesat which the exposure is tobe terminated, whichever isless

8. Report. The final report (work­sheet) should be submitted to theGeology Section, and it shouldinclude all data pertinent to thevariables or combination of vari­ables studied in the evaluation.Also, any defects in each speci­men which develop during testingand the number of cycles at whichsuch defects were noted should bedocumented on the worksheet.

fundamental transverseafter c cycles of freez­ing and thawing

Record this value in the'columnlabeled '1% of Orig."

5. When all of the above calcula­tions have been made for asimilar set of specimens, com­pute the average for the setfor the items "% of Orig.",'IGro. %", and "Gro. In".Compute "Gro. %" using theformula:

M specified number of cyclesat which exposure is to beterminated. (Three-hundredcycles in most cases.)

G s x 100iflT8T

where:

G = average growth for the setof specimens in %.

S the sum of the growths foreach specimen.

T the total number of speci­mens in the set.

DF = the durability factor ofthe specimen

6. Repeat the preceding steps foreach specimen.

Record these values in theappropriate columns on theworksheet.

PN11

DF

where:

"T" should include only numberof specimens which showeda normal reading

7. Should it be desired to handcalcul~te the'durability factor,use the following formula:

P the relative dynamic mod­ulus of elasticity at Ncycles, percent

Specimens in theFreezing & Thawing Apparatus

Page 44: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Page 4 of 5

Freezing & Thawing Apparatus"Cincinnati"

PAGE 38

Test Method No. Iowa 408-AApril 1980

Freezing & Thawing Apparatus"Con r ad"

Beam Comparator Dynamic Testing Apparatus

Page 45: Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates ·  · 2013-07-10Evaluation of Fly Ash Concrete Durability Containing Class II Durability Aggregates

Page 5 of 5orm 8212'88·75

PAGE 39Test Method No. Iowa 408-A

P.C. CONCRETE DURABILITY

w/c: Mix:

Lab. No.:

Date Made:

Cejl1. Content:

Beam No. ----------

3sklyd

Fine Agg. :

Coarse Agg.:

Lab. No.:

Lab. No.:

Sp. Gr.:

sp , Gr.:

Date Weight

Slujl1p: Air: Grams--------

AEA @ fl. oz./sComments:

Admixture @ flo oz·/s...._..._. ---_.._--

I._-- Set Average

I--

Date Dlal Gro. % of % ·of Gro. Gro.

CYcles Rdq. In. F~ Oriq. Remarks Orig. % In.,

Read

I

I,I

k.

k .