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Making Better Concrete
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TABLE of CONTENTS

Preface

Table of Contents

Introduction

Chapter 1   A Short History of Fly Ash and Pozzolans in Concrete

Chapter 2   What is Fly Ash? What are Pozzolans?

A. Pozzolans defined by source and standards organizations
   Class N, Class C, Class F
   Proposed simplified standard:
   Loss On Ignition (LOI), Particle Size, and Strength Activity Index (SAI)

B. Pozzolans defined by reactivity and availability
   1. Cementitious and highly active pozzolans
      Ground granulated blast-furnace slag, aka "slag"
      Class C fly ash
   2. Highly active pozzolans
      Silica fume
      Rice Hull Ash (RHA)
      Metakaolin
   3. Normal pozzolans
      Class F (low-calcium) fly ash
      Natural pozzolans
   4. Weak pozzolans
      Industrial by-products
      Natural materials


Chapter 3   How do Fly Ash and Pozzolans Affect Concrete?

The basic pozzolanic reaction

The transition zone

A. Effects of fly ash on fresh concrete
   1. Reduced water demand
   2. Reduced bleed water
   3. Increased workability and pumpability
   4. Continuing slump
B. Effects of fly ash on plastic concrete
   1. Extended set times
   2. Reduced heat of hydration
   3. Reduced plastic shrinkage cracking
C. Effects of fly ash on hardened concrete
   1. Slower rate of strength gain
   2. Reduced permeability
   3. Reduced drying shrinkage
   4. Resistance to scaling from deicing salts

Chapter 4   Design Considerations

A. Get the whole team on board
B. Call for the concrete performance you really need
C. Design, mix, place, and test trial batches ahead of time
D. Use HFAC to counteract common problems
E. Check for availability of fly ash-and expert help
F. Pay attention during construction
G. Check for exposure to deicing salts
H. Evaluate conditions: a rough guide to how easy or hard it may be to use
HFAC in different applications

Chapter 5   Construction Considerations

A. Controling the water content
B. Longer set time
C. Slabs - special considerations

   1. less or no bleed water
   2. vulnerability to premature drying
   3. vulnerability to shrinkage cracking
   4. staining and coloring
D. Hot- and cold-weather concrete placement
E. Formwork
F. Use of chemical admixtures
G. Aggregate gradation
H. Pumping HFA Concrete
I. Health considerations

Chapter 6 Why Use Fly Ash?

The big picture

Appendices

Appendix A: Sample Mix Designs

Appendix B: Resources

Appendix C: High Fly Ash Concrete and LEED®


Introduction

Ninety percent of this game is half mental.
Leo Durocher

The only thing new in the world is the history you don't know
Harry Truman

Coal fly ash is an abundant industrial waste product that happens to be high in reactive silica, and thus an excellent pozzolan (which we'll define in Chapter 2). For this simple reason it is rapidly becoming a common ingredient in concrete all over the world; it is already present to some degree in half the concrete poured in the US. The reasons for this are many, as will be described in the pages to follow. Of particular interest to the industry is the idea of not just adding fly ash to known concrete mixes, but using large quantities to replace 30%, 50%, or more of the portland cement-the glue-in a concrete mix. Most of the reasons for using fly ash in any proportion are practical, such as increasing strength and durability, decreasing heat of hydration, and decreasing permeability. Those reasons alone make the idea of high fly ash concrete (HFAC) worth considering, but there are many global economic, health, and environmental concerns that make HFAC even more attractive and compelling.

The use of fly ash as a performance-enhancing ingredient in concrete is one of the most outstanding examples of industrial ecology-i.e., making effective use of waste resources, and ultimately eliminating the concept of waste altogether. In fact, given the huge (and growing) volume of concrete production worldwide, the potential for effectively using fly ash (and other common industrial by-products) makes it one of the key components of a global industrial ecology.

There is, not surprisingly, disagreement among fly ash experts. Some will argue for higher or lower portions of fly ash than you will find presented in this book. The term HFAC is generally interpreted as referring to concrete in which fly ash replaces about 50% of the cement. However, in some cases 40% or 10% will be more appropriate, and in others 100% replacement is possible. Some experts will argue that 30% replacement is the most one should ever use, while others argue that you won't get the greatest benefits of HFAC until you get up to or over 40 or 50% replacement. The right figure for your project in your location will depend on many things, as will be reviewed in the pages to come.

This book is not an academic treatise. It will provide a cursory look at the history, economics, and performance effects of fly ash in concrete, but mainly is intended to provide practical guidelines for those who want to use it. Here you will find some basic do's and don'ts for ready-mix suppliers, concrete contractors, engineers, and others involved in concrete construction. Those who want more detailed material on any subject-and there's plenty available-can find references in the back of this book. Using HFAC is not rocket science, but neither is it obvious or intuitive. Now, however, you can now learn from the experience of others before using it yourself.


How much fly ash makes concrete "green"?

The short answer is: any fly ash in the mix as replacement for cement, up to the limits discussed in this text, will make for better concrete and reduce the atmospheric carbon load associated with cement production. In many areas, 15 to 20% addition or replacement is already standard practice, and is mandated by such governmental agencies as the California Department of Transportation (CALTRANS). The contention here is that, in most applications, about 50% replacement results in concrete that is better for the builder, for the building owner, and for the planet.