Properties of self consolidating concrete containing type f fly ash

PCA R&D Serial No 2619 Properties of Self-Consolidating Concrete Containing Type F Fly Ash by Raissa P Douglas ©Raissa Patricia Douglas 2004 All rights reserved NORTHWESTERN UNIVERSITY PROPERTIES OF SELF-CONSOLIDATING CONCRETE CONTAINING TYPE F FLY ASH: WITH A VERIFICATION OF THE MINIMUM PASTE VOLUME METHOD A THESIS SUBMITTED TO THE GRADUATE SCHOOL IN PARTIAL FULFILLMENT OF THE REQUIREMENTS for the degree MASTER OF SCIENCE Field of Civil Engineering By RAISSA P DOUGLAS Evanston, Illinois May 13, 2004 © Copyright by Raissa Patricia Douglas 2004 All Rights Reserved Abstract Since the introduction of self-consolidating concrete (SCC) in Japan during the late 1980’s, acceptance and usage of this concrete in the construction industry has been steadily gaining momentum In the United States, the usage of SCC has been spearheaded by the precast concrete industry Good SCC must possess the following key fresh properties: filling ability, passing ability, and resistance to segregation In order to reduce segregation, SCC mixes are typically designed with high powder contents, and contain chemical admixtures such as superplasticizers and viscosity modifying admixtures (VMA) This tends to increase the material cost of SCC, however one way to reduce the material cost is through adequate mix proportioning and the addition of supplementary cementitious materials such as fly ash Millions of tons of fly ash are generated annually in Illinois; however Class F fly ash is more often landfilled than used Incorporation of Class F fly ash in self-consolidating concrete as a means to replace portions of cement can decrease the cost of SCC, as well as further the sustainable development of concrete An experimental program, aimed at investigating the behavior of SCC containing Class F fly ash has been carried out The fresh state properties of the concrete were assessed using methods of segregation and flow The rheology of the paste matrix was also characterized and compared with a previously developed paste rheology model Finally, some hardened state properties of the concrete were evaluated The objective of this research is to improve the understanding of the properties of SCC containing Class F fly ash and to provide information that could be used towards the commercialization of such a concrete The results indicate that it is possible to develop a SCC containing Class F fly ash that is high performing in its fresh state Furthermore, the addition of fly ash was shown to reduce superplasticizer dosage, increase workability, and increase overall chloride permeability resistance In addition, it was determined that the difference of densities between the aggregate and matrix influence the results of a previously developed paste rheology model i Acknowledgements Pursuit of this degree has been a journey, but at the end I am much better for staying on this path I thank the Lord for giving the strength to continue when I doubted myself and for all of his love and guidance Secondly, I would like to thank my advisor, Professor Surendra Shah, for his patience, guidance, and encouragement I would also like to thank the Dr Van Bui for training me to be a “slump flow” expert and for the invaluable experience that I was able to pick up from being in his presence I would also like to thank the Portland Cement Association (PCA) and Illinois Clean Coal Institute (ICCI) for funding this project I am also grateful to Dr David Bonen and Dr Yilmaz Akkaya for their advice and support I would also like to thank Dr Jeffrey Thomas, Dr Bonen, and Professor Shah for participating in my defense committee I would like to acknowledge the support of the Advanced Cement Based Materials Center staff, especially Steve Albertson and John Chiryal I also would like to thank the post-docs, and visiting scholars at ACBM for all of their help I also gratefully acknowledge the support of fellow graduate students at Northwestern University especially, Katie Kuder, Zhihui Sun, Jay Terry, Laura Dykes, Lexyne McNealy, Deidra Morrison, Michele Manual, Ashley Smart, Ade Gordon, and Maisha Gray I am extremely grateful to Dean Penny Warren and the Office of Minority Affairs for being there whenever I needed anything Thanks I would also like to thank the Illinois Minority Graduate Incentive Program for directly funding me through out this degree I would like to thank my family for encouraging me, loving me, and being my rock at all times Finally, I would like to thank my fiancée, Marcus Ferron, for not only being an excellent typist (smile), but also for being my #1 advocate ONWARDS TOWARD THE PhD! ii Table of Contents Abstract i Acknowledgements ii List of Figures……………………………………………………………… v List of Tables…………………………………………………………………………….vii Chapter : Introduction 1.1 SCC: What is it? 1.2 Mix Proportioning 1.3 Fly Ash 1.4 Motivation 1.5 Objective and Scope 1.6 Organization Chapter :Fresh State Properties of Concrete 2.1 Introduction 2.2 Background 2.2.1 Fresh State Properties 2.2.1.a Filling Ability 2.2.1.b Passing Ability 10 2.2.1.c Stability 11 2.3 Testing Methods 12 2.3.1 Slump Flow Test 12 2.3.2 L-Box Test 14 2.3.3 Penetration Test 15 2.3.4 Experimental Program 16 2.3.4.a Materials 16 2.3.4.b Mix Proportions 18 2.3.4.c Mixing and Test Methods 18 2.4 Results and Discussion 19 2.5 Summary 21 Chapter 3: Fresh State Properties—Rheological Evaluation 22 3.1 Introduction 22 3.2 Background 22 3.2.1 Rheology 22 3.2.2 Rheological Models 26 3.2.2.a Self-Flow Zone Model 26 3.2.2.b Minimum Paste Volume Method 29 3.3 Experimental Program 34 3.3.1 Materials 34 3.3.2 Mixing Protocol 35 3.3.3 Flow test 36 3.3.4 Viscosity 36 3.4 Results and Discussion 36 3.4.1 Comparison with Rheological Model 36 iii 3.4.1.a Paste Flow Diameter 37 3.4.1.b Apparent Viscosity 37 3.4.1.c Optimum Flow-Viscosity Ratio 38 3.4.1.d Effect of difference between densities of aggregates and paste 41 3.5 Summary 45 Chapter 4: Hardened Properties 47 4.1 Introduction 47 4.2 Background 47 4.2.1 Compressive Strength 47 4.2.2 Permeability 50 4.3 Testing Methods 56 4.3.1 ASTM C39 (Compressive Strength) 56 4.3.2 RCPT 56 4.4 Results and Discussion 59 4.4.1 Compressive Strength 59 4.4.2 Permeability 61 4.5 Summary 66 Chapter Conclusions 67 5.1 Introduction 67 5.2 Conclusions 67 5.3 Research Extensions 69 Appendix A: Sample Analysis to Determine Viscosity 74 iv List of Figures pg 1.1 Timeline of SCC highlights 1.2 Schematic of SCC Fresh Properties 2.1 Excess Paste Theory 10 2.2 Stress generation due to relative displacement between aggregate 11 2.3 Schematic of upright and inverted slump test 13 2.4 Slump Flow of SCC 13 2.5 L Box with Penetration Apparatus 14 2.6 Flow through rebar in L-Box 15 2.7 Dimensions of L-Box 15 2.8 Penetration Apparatus 16 2.9 S45-F20 cross-section 20 2.10 Superplasticizer Dosage 21 3.1 Bingham model 23 3.2 Rheology testing methods 26 3.3 Spherical particle suspended in paste matrix 27 3.4 Self Flow Zone 29 3.5 Minimum paste volume theory 30 3.6 Minimum line for paste flow 32 3.7 Minimum line for viscosity 33 3.8 Model lines 33 3.9 Satisfactory zone obtained from combination of minimum 34 flow diameter, minimum viscosity, and optimum flow/viscosity ratio 3.10 Paste flow diameter 35 3.11 Self flow zone 39 3.12 Viscosity comparison using combined approach and 40 equilibrium approach 3.13 Paste flow and different products of ∆ρ and average radius (rav) 42 of aggregate v 3.14 Viscosity and different products of ∆ρ and average radius (rav) 43 of aggregate 3.15 Paste flow-viscosity ratio and different products of ∆ρ and average 43 radius (rav) of aggregate 3.16 Relationship between flow/viscosity ratio and P∆r 45 4.1 Compressive Strength Test Schematic 48 4.2 Range of typical strength to w/c ratio relationships of concrete based 49 on over 100 different concrete mixtures 4.3 Compressive Strength Development of SCC with time in 50 comparison with the regulations of Model Code 90 4.4 Relationship between total charge and initial current 54 4.5 RCPT Plot of hr charge vs 30 charge 55 4.6 Initial current vs total charge for various researchers 55 4.7 Compressive Test Set up 56 4.8 RCPT Test Setup 58 4.9 Top View of RCPT Test Set up 58 4.10 Compressive Strength Results 61 4.11 Temperature profile 62 4.12 Initial current vs total charge 63 4.13 Extrapolated total charge vs actual total charge 65 4.14 RCPT results 65 vi List of Tables pg 2.1 Fly ash composition 17 2.2 Coarse aggregate 17 2.3 Fine river sand 17 2.4 Concrete mix proportions 18 2.5 Overall fresh properties results 20 3.1 Rough estimate of typical SCC properties by countries 24 3.2 Paste mix proportions 35 3.3 Repeatability testing for viscosity 37 3.4 Paste flow diameter and viscosity 38 3.5 Product (P∆r) of ∆ρ and rav 42 4.1 Chloride ion penetrability test (RCPT) 52 4.2 Superplasticizer/binder 60 4.3 Chloride penetrability reduction percentages 66 vii the 28-day strength must be obtained prior to formwork removal Ninety percent of ready mixed concrete is designed with a 28-day strength ranging from 20 MPa (3000 psi) to 40 MPa (6000 psi), and with the majority of the strength are between 28 MPa (4000 psi) and 35 MPa (5000psi) (Kosmatka, Kerkhoff et al.) Therefore, if a structure is designed for a compressive strength of 35 MPa and 40% of the 28 day strength is required prior to form stripping, the strength should be at least 14 MPa (2030 psi) before the formwork is removed Even at the highest w/b ratio and highest fly ash replacement ratio, S45-F30 achieves a day strength of 15.4 MPa (2234 psi), thus exceeding the minimum strength requirement for formwork Hence, for typical structures, it is possible to achieve satisfactory early age strength using Class F fly ash made from Illinois coal However, extra measures such as the use of Type III cement, reducing the w/c ratio, and/or additional heating or insulation is often taken to when rapid strength gain is desirable Compressive strength is inversely proportional to w/c ratio, and it can be expected that the strength development of S35-F0 (the mix with the lowest w/c ratio) would proceed faster than the other mixes In general, the overall trend of strength development was similar for mixes with similar water/binder ratios Table 4.2 Superplasticizer/binder ratio Mix SP/binder S35-F0 0.422 S35-F20 0.315 S35-F30 0.255 S45-F0 0.209 S45-F20 0.206 S45-F30 0.215 60 Compressive Strength (MPa) 70 60 50 day 40 day 28 day 30 20 10 S35-F0 S35-F20 S35-F30 S45-F0 S45-F20 S45-F30 Mix Figure 4.10: Compressive Strength Test Results 4.4.2 Permeability Figure 4.10 shows the temperature versus time profile for the concrete specimens tested at 16 weeks of age Final temperatures were elevated for all specimens, but the temperature increase was more significant for specimens without fly ash After only one hour of testing S35-F0 and S45-F0 were experiencing temperatures of 80˚F, and at the end of theses specimens were experiencing temperatures of was 106˚F and 117˚F, respectively In general, the results show that differences between initial and final temperatures are considerably smaller for mixes incorporating fly ash Final temperatures were similar for all mixes containing fly ash, and increasing the fly ash replacement ratio did not significantly affect the rate of temperature development It is commonly accepted that prolonged exposure to high temperatures can damage the microstructure of concrete and one way to circumvent this effect is to reduce the duration of time in which the charge is applied 61 Termperature ( deg F) 120 110 100 90 80 70 60 Time (hr) S35-F0 S35-F20 S35-F30 S45-F0 S45-F20 S45-F30 Figure 4.11 Temperature profile As shown in Figures 4.5 and 4.6, many investigators have shown a good correlation between the total charge (Q) versus the initial current (Io) for NVC; however, results have indicated a deviation from the best fit line and a large amount of scatter at high charge values In order to investigate if this correlation also existed for SCC, the initial current at t=100 seconds versus the total charge was plotted for SCC specimens tested at 16 weeks of age (Figure 4.11) The results show that SCC mixes with fly ash also exhibit the same linear relationship between initial current and total charge 62 0.35 Initial Current (A) 0.3 0.25 SCC 0.2 Theoretical Line 0.15 0.1 0.05 0 1000 2000 3000 4000 5000 6000 7000 Total Charge (C) Figure 4.12 Initial current vs total charge Data points that fall below the theoretical line in Figure 4.6 and 4.12 indicate specimens that experienced higher electrical conductance than would have been predicted using the initial current method This represents an underestimation of electrical conductance (chloride resistance) from the initial current method Significant deviations from the theoretical line not occur until higher charge values and at a charge of 4619 Coulombs there is a deviation of about 22% between the theoretical line and the total charge Figure 4.13 is a plot of the experimental data in which the charge estimated from the initial current (Q100sec) versus the total charge is shown for the specimens tested at 16 weeks of age It can be seen that the two methods yield similar results at very low RCPT values, and even at the highest RCPT value the modified method is within 22% of the standard method As shown in the Table 4.1, the cut-off value for a “high” chloride penetrability concrete is 4000 Coulombs, and therefore the initial current method can be employed instead of the total RCPT charge since significant deviations from the theoretical line not occur until around the threshold value Based on these results, only the initial currents were measured for the concrete specimens tested at two weeks of age 63 Figure 4.14 shows the total charge (based on the initial current method) for all the specimens As expected, the age of the concrete specimen is the most significant factor in determining the chloride permeability resistance However, it is interesting to note that the beneficial effect of fly ash does not occur until a later age and at an early age the permeability is most influenced by the w/b ratio This is because the pozzolanic reaction proceeds at a slower rate than the cement hydration reaction, but eventually the paste porosity is reduced since the overall solid volume will be increased by the continued pozzolanic reaction The decrease in porosity increases the durability (decreases the permeability) of the mixes containing fly ash when compared to the mixes without fly ash (S35-F0 and S45-F0) At 16 weeks of age, the chloride permeability of all the mixes with fly ash is significantly lower than those without fly ash; however for a given w/b, there is no significant difference between the chloride permeability for concretes containing 20% fly ash versus 30% fly ash Comparison of the chloride permeability at weeks versus the chloride permeability at 16 weeks shows that the concretes containing 30% fly ash exhibited a greater reduction in chloride permeability than those containing 20% (Table 4.3) 64 5000 Q 100sec (C) 4000 3000 SCC 2000 1000 0 1000 2000 3000 4000 5000 6000 Total charge (C) Figure 4.13 Extrapolated total charge vs actual total charge 6000 Q100sec (C) 5000 weeks 4000 16 weeks 3000 2000 1000 S35-F0 S35-F20 S35-F30 S45-F0 S45-F20 S45-F30 Mix Figure 4.14 RCPT results 65 Table 4.3 Chloride Penetrability Reduction Percentages Mix 4.5 Q100sec (C) Reduction ( weeks) (16 weeks) S35-F0 3758 2736 27 S35-F20 3097 983 68 S35-F30 3534 1102 69 S45-F0 4218 3823 S45-F20 5141 1624 68 S45-F30 5504 1253 77 (%) Summary In this chapter, the hardened state properties were evaluated Specifically, the compressive strength and chloride penetrability of the hardened concrete created in Chapter were assessed As expected, addition of fly ash resulted in a reduction of early age strength The addition of fly ash resulted in a greater strength reduction for the S35 mixes, and this is probably due to the dispersing effect of the superplasticizer The permeability of concrete is directly related to its durability The RCPT method is one test that is often used to assess the chloride penetrability of concrete, and was employed to test the concretes mixes It was shown that correlation exists between the initial current versus total charge for SCC specimens At an early age, chloride permeability is most influenced by the water/binder ratio, but the beneficial effect of fly ash in reducing the chloride penetrability occurs at later ages 66 Chapter Conclusions 5.1 Introduction This thesis examines the properties of SCC containing Class F fly ash produced from Illinois region The fresh state properties of the concrete were assessed using empirical methods such as the slump flow test, L-box test and penetration apparatus test In addition, the rheology of the paste matrix was evaluated in order to verify a previously developed paste rheology model Finally, the hardened state properties of compressive strength and permeability were also evaluated This chapter summarizes the conclusions made in this study and provides suggestions for future work 5.2 Conclusions Self-consolidating concrete is still considered by many to be a “special” concrete Within the last four years, production of SCC in North America has increased and the effort has been largely spearheaded by the precast industry Understanding the properties of SCC and the ways that local materials affect these properties is important in furthering the usage of SCC Since SCC is designed with higher paste volumes than normally vibrated concrete, this can lead to a significant increase in cost if the increase in paste volume is gained solely by using more cement In Illinois over million tons of fly ash is produced annually, and 2.4 millions tons of it is landfilled or ponded The addition of fly ash as a replacement for cement will not only decrease the price of SCC, but also there are also environmental benefits that occur from the utilization of a waste material and the reduction in landfill space In chapter one, the development of SCC was presented and a discussion on mixture proportioning and fly ash was also given Chapter began with reviewing the key fresh state properties of SCC and discussing common testing methods The results from this chapter show that it is possible 67 to produce a good performing SCC using type F fly ash For similar workability, the addition of fly ash resulted in a decrease in superplasticizer dosage Chemical admixtures such as superplasticizers are generally an expensive component, and reducing the amount of superplasticizer used in SCC aids in keeping the price of SCC down In chapter 3, a review of rheology was given and the paste rheology model was introduced As expected, for a given w/b, the addition of fly ash decreases the viscosity This supports previous findings that there are rheological benefits to using fly ash without increasing the superplasticizer dosage or increasing the water demand The results indicate that paste rheology model does a good job of predicting the fresh state performance of the concrete for mixes, but the mixes used in the model should have density differences between the aggregate and the matrix that are similar to the ones that were used to develop the model Otherwise, large deviations can occur, and it was apparent that small differences in the density difference could have major effects This is believed to be due to the effect of the density difference and the confounding that occurs in the flow/viscosity ratio from low viscosities measurements It was determined that both aggregate spacing (Dss) and the product (P∆r) between average aggregate radius and difference between densities of aggregates and paste influence the correlation of paste rheology with fresh SCC’s properties In chapter 4, the compressive strength and chloride permeability of the concrete were evaluated using ASTM C-39 and ASTM C-1202, respectively The addition of fly ash resulted in reduced compressive strength, however all mixes were able to obtain strengths exceeding 15 MPa after one day A relationship between superplasticizer/binder dosage and compressive strength was also discussed For the RCPT test, it was shown that there is a correlation between initial current and total charge for SCC The results show that at an early age, chloride permeability is most influenced by the water/binder ratio However, at later ages the beneficial effects of fly ash is apparent and is the governing parameter in reducing permeability 68 5.3 Research Extensions There are a number of areas that could be explored in the evaluation of SCC Foremost, further investigation should be done on the effect of density difference on the rheological properties of SCC A better understanding on how the density difference affects the yield stress and viscosity of paste would enable it to be incorporated into the rheological model This would make the model more generalized and robust In addition, a study on the rheology of paste and its relationship to the rheology of concrete could provide insight on the mechanism controlling the filling ability, passing ability, and segregation resistance 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Cement and Concrete Research 27(3): 381-394 Westerholm, M., P Skoglund, et al (2002) Chloride Transport and Related Microstructure of Self-Consolidating Concrete First North American Conference on the Design and Use of Self-ConsolidatingConcrete, North America Evanston, IL 73 Appendix A: Sample Analysis to Determine Viscosity S35-F0: shear_stress shear_stress_upslope ⎯⎯⎯⎯⎯⎯⎯⎯⎯ → fit( shear_rate_upslope ) shear_rate fit( 100) = 35.923 fit( 100) = 35.923 η := fit( 100) 100 η = 0.359 Pa⋅ s 74 ... as fly ash Millions of tons of fly ash are generated annually in Illinois; however Class F fly ash is more often landfilled than used Incorporation of Class F fly ash in self- consolidating concrete. .. PROPERTIES OF SELF- CONSOLIDATING CONCRETE CONTAINING TYPE F FLY ASH: WITH A VERIFICATION OF THE MINIMUM PASTE VOLUME METHOD A THESIS SUBMITTED TO THE GRADUATE SCHOOL IN PARTIAL FULFILLMENT OF. .. different water to binder ratios (w/b), approximately 73% of those mixes had water to binder ratios of 0.38 – 0.40 In addition, only 12 of the concretes contained Type F fly ash 1.3 Fly Ash Fly