2c -Pozzolana

1. Pulverized Fuel Ash (PFA)

 Pulverized fuel ash is a by-product originated in the furnaces of power stations

where pulverized coal is used as fuel to generate electricity.
 The ash produced suspended in the exhaust gases is extracted by electrostatic
precipitation.
 Physically, it consists of glassy, spherical, solid or hollow particles from 1 to 200
μm.
 PFA can be used to replace some of the cement in the mix. (Typical PFA
proportion is about 25-35% of total cementitious content.)
 PFA initially assists in reducing the water demand of the concrete, but later,
acting as a pozzolana, it increases the strength of the concrete.
 In the process of hydration of cement, calcium hydroxide is formed. Calcium
hydroxide has no cementitious value and is water-soluble. It may come out or
the concrete with moisture, leaving voids in concrete.
 PFA reacts in the presence of moisture with the calcium hydroxide to form
calcium-silicate-hydrate (C-S-H) which improves the concrete strength and
impermeability. (This pozzolanic reaction is generally observed after 1-7
days.)

1.1 Main Effects of PFA on Properties of Concrete

(Comparison of PFA concrete with OPC concrete)

1.1.1 Water demand / workability

 PFA demands less water than OPC.

 The workability of PFA concrete is increased with a fixed water content, or
 The water content and the W/C ratio can be reduced with a fixed workability.

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1.1.2 Strength development

 PFA concrete has a lower early strength.

 Provided it is properly cured, the long-term
strength of PFA concrete is higher OPC
concrete.

1.1.3 Temperature and thermal stress

Typical relative rate of strength
 Since the chemical reaction of PFA is slow, the development of OPC concrete and
PFA concrete.
rate of heat evolved is reduced which helps to (Source: Neville & Brooks)

reduce thermal stress in mass concrete.

1.1.4 Drying shrinkage of PFA concrete is reduced.

1.1.5 Creep of PFA concrete is reduced.

1.1.6 Permeability of PFA concrete is reduced.

1.2 Portland Pulverized Fuel Ash Cement (PPFAC)

 Portland pulverized fuel ash cement is OPC cement blended with PFA in the
manufacturing process.
 Typical proportion of PFA is 25% of total cementitious content.

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2. Silica Fume (SF)

 Silica fume is a by-product resulting from the production of silicon or

ferrosilicon alloys or other silicon alloys.
(Partial replacement of the cement by silica fume was originally done for
economical reason, but now it is more expensive then cement.)
 Silica fume consists of very fine vitreous spherical particles with average
diameter about 0.1 m. Untreated silica fume has a very low bulk density
(200-300 kg/m3) and is referred to as undensified silica fume or microsilica.
(Caution: continuously exposed to silica fume may suffer from silicosis.)
 For the convenience of handling, silica fume is condensed (bulk density about
600 kg/m3) and referred as condensed silica fume, or mixed with water to form
slurrified silica fume.
 Like PFA, SF can be used to replace some cement (typical 5-15% of total
cementitious content) and reacts with calcium hydroxide to form C-S-H. (This
pozzolanic reaction is generally observed after 3-7 days.)
 In normal concrete, a high concentration of calcium hydroxide nucleates at the
aggregate interface which forms a zone of weakness. CF acts as a nucleating
agent for the calcium hydroxide so that is dispersed throughout the paste. This
improves aggregate/paste bond hence further increases the strength of the
concrete.
 On the other hand, SF acts as micro filler reduces the porosity of the concrete and
makes the early strength of the SF concrete comparable with the concrete without
SF replacement.

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Cement paste Superplasticized cement paste OPC + SF paste
(Source: M.S.J. Gani)
2. Main effects of silica fume on properties of concrete

2.1 Water demand / workability

 Being extremely fine, SF demands more water. However, the use of SF usually
associated with a water reducer or a superplasticizer that compensates this bad
effect.

2.2 Strength development

 The early strength of SF concrete is comparable with concrete without SF

(depending to the percentage of SF replacement).
 The long term strength of SF concrete is much higher.
(Compressive strength of 100 MPa can be easily achieved by incorporating SF
with suitable water reducing agent and aggregates.)

2.3 Permeability of SF concrete is reduced.

Reference:

A.M. Neville & J.J. Brooks (1990), Concrete Technology, Longman Group Ltd.

M.S.J. Gani (1997) Cement and Concrete, Chapman & Hall

J. Bensted and P. Barnes (2002), Structure and Performance of Cements, Spon Press.
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