2009 World of Coal Ash (WOCA) Conference - May 4-7, 2009 in Lexington, KY, USA

http://www.flyash.info/

Strength development of concrete containing

coal fly ash under different curing temperature
conditions

Mohammed A. Elsageer1, Steve G. Millard1 and Stephanie J.

Barnett1
1
University of Liverpool, Department of Engineering, Brodie Tower, Brownlow Street,
Liverpool, UK, L69 3GQ

KEYWORDS: Temperature, Compressive strength, Fly ash

Abstract
Concrete containing fly ash (FA) has been investigated in order to determine the
effect of temperature curing conditions on the early age strength. Trial concrete
using Portland cement only and concrete containing FA with cement replacement
levels of 15%, 30% and 45% and varying water/binder ratios have been investigated
under standard 20 °C curing. For a given water/binder ratio, the 3, 7 and 28 day
strength was observed to be lower when using fly ash to replace cement. A concrete
with target mean strength of 70 N/mm2 was then designed using Portland cement
and FA concrete, with different water/binder ratios required to achieve 28day target
mean strength of 70 N/mm2. The strength development of Portland cement and FA
concrete with the target mean strength of 70 N/mm2 at 28 days has been
investigated under isothermal (10 °C, 30 °C, 40 °C, 50 °C) curing regimes and
compared to the strength development using standard curing conditions. At 10 °C
and 20 °C, the strength development of FA concrete with target 28-day strength of
70 N/mm2 was found to be equivalent to that of Portland cement concrete. At an
elevated curing temperature all concrete samples were observed to gain strength
more rapidly than at 20 °C and had higher 32-day strength with increasing levels of
FA. However, the longer term strength is detrimentally affected by the higher curing
temperatures, with Portland cement concrete being more detrimentally affected than
FA concrete.

1
 uction
Introdu

The usse of fly ash

h (FA) as a cement replacemen
r nt in concrrete resultss in signific
cant
enhanccement of the basic characteris
c stics of con
ncrete, both h in its fressh and harrdened
states 1. The advvantages of
o FA in con ncrete are:
• improved long term strength
s pe
erformance e and duraability,
• reduced heat of hydrration,
• reduced water
w requirred for equual workab bility,
• minimised risk of alkkali silica re
eaction.

In addition FA pro mental and economicc benefits 2.

ovides both environm

At earlyy ages (Figgure 1) and d with isothhermal curring at 20 °C,° the streength of a normal
grade concrete
c c
containing F has bee
FA en previouusly reporte ed as beingg lower tha
an an
3, 4
equivalent grade Portland concrete
c . Howeve
er at an ele evated curing temperrature
the earrly age streength of co oncrete con ntaining FAA has been n observedd to be
significcantly improoved. It haas also bee en observe ed that the use of FA will have less
detrime ental effectt to the late
er age streength comp pared to eq quivalent P
Portland ceement
5
concre ete . The raate of the reaction
r off FA concreete has been seen to o be increaased by
an elevvated ambient tempe erature and d also by th
he elevated d temperattures occurring
inside structural
s e
elements a early age
at es, which appear
a to provide
p the
e activation
n
6
energyy for the reaaction of th he fly ash to
t kick-in earlier
e .

This pa
aper is parrt of a wide
er study on the effect of tempera atures on tthe strengtth
development of FAF concrettes under different
d cu
uring regim
mes in ordeer to quantify the
strengtth that mayy be expeccted in structural elemments and to provide the basis for the
development of models
m to predict
p in-ssitu temperrature and strength d
development.

L cycle off concrete 7

Figure 1. Life

Research signifficance

If it can
n be demonstrated th hat the use
e of concrete containiing FA und
der an elev
vated
temperrature curinng regime has no detrimental effect
e on th
he early age strength, this
would allow
a the early
e removval of form
ms or the ap
pplication of
o post-ten
nsioning an
nd help
to redu uce the ove
erall cost of
o concrete structural elements.

2
Materials

Throughout this study, single batches of Portland cement (PC) and fly ash were
used. PC was provided by Castle Cement Ltd and FA was provided by Hargreaves
Coal Combustion Products Ltd. Chemical analyses of these materials are given in
Table 1. The fly ash used was low-calcium fly ash. The coarse aggregate was
crushed granite graded 20-5 mm. The fine aggregate used was 0-4 mm irregular to
round sand, which had 66% passing through a 600 µm sieve. All aggregates were
oven dried before use and allowance was made for water absorption when
calculating batch weights for mixing. The superplasticiser used was polycarboxylate
polymer (Fosroc Structuro 11180).

Table 1
Chemical analyses of materials
Component Portland cement Fly ash
% (by mass) % (by mass)
CaO 63.4 1-5
SiO2 20.6 45 - 51
Al2O3 5.5 27 - 32
Fe2O3 2.5 7 - 11
SO3 2.8 0.3 - 1.3
MgO 2.6 1-4
K2O 0.7 1-5
Na2O 0.2 0.8 - 1.7
Loss on ignition 1.8

Mix design methods

The normal BRE method 8 was used to design concrete with w/b ratio of 0.4 and
above to obtain normal strength concrete. The ratio free water/ (cement+k*fly ash) as
defined by the method was used to design FA concrete. The cementing efficiency
factor, k was proposed by Smith 9 to give the same strength as PC concrete of
similar workability (the workability required was 60-180 mm). In this study, k was
taken as 0.3.
For w/b ratio of 0.4 and below, where the BRE method produced concrete mix
proportions with very high cement content, the modified maximum density theory
method (MMDT) 10 was used. The fine:coarse aggregate ratio giving minimum void
volume was determined in the same manner as used in the usual maximum density
method. In the modified method, the fine:coarse aggregate ratio was set slightly
lower than that required to give the minimum void content and enough binder and
water was added to fill the void volume and give a slight excess of binder and water
(defined as a percentage overfill). A polycarboxylate polymer based high range
water reducing admixture (Fosroc Structuro 11180) was used to maintain workability
in these mixtures.
A total of 51 trial concrete mixes were produced to determine the strength
development under standard curing conditions of concrete with PC and also with
different levels of 15%, 30% and 45% FA (as a percentage of the total binder
content).

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A mix volume of 0.012 m3 was prepared for each concrete according to BS1881-
125:1986 11. After the concrete was mixed, the concrete was cast into steel 100 mm
cube moulds and then compacted on a vibrating table. The specimens were covered
with damp hessian and plastic sheeting. After 24 hours, the specimens were
demoulded and cured under water at 20 °C. The compressive strength of three
replicate specimens was tested at ages of 3, 7 and 28 days.

To investigate the strength development of concrete cured under 10 °C, 30 °C, 40

°C, 50 °C and standard (20 °C) isothermal curing conditions, mix proportions for
concrete with a target mean strength of 70 N/mm2 at 28 days were obtained from the
results from the above work. The mix proportions for PC concrete and concrete with
15%, 30% and 45% cement replaced by FA are shown in Table 2. These mix
proportions were obtained using the Modified Maximum Density Method. The mixing
was done according to BS1881-125:1986 11 in a 0.1 m3 capacity pan mixer.

Table 2
Mixture proportions for grade 70 concretes
% Cement Fly ash Granite Sand Free water SPA Free
Fly ash (kg/m3) (kg/m3) (kg/m3) (kg/m3) (kg/m3) (%) W/B
0 316 0 1426 612 145 0.20 0.46
15 284 50 1426 612 136 0.25 0.41
30 243 104 1426 612 123 0.31 0.36
45 202 165 1426 612 110 0.37 0.30

The concrete was cast into 100 mm cubes for compressive strength testing. These
cubes were cured under 10 °C, 30 °C, 40 °C, 50 °C and standard curing conditions
and were tested at ages of 0.25, 0.5, 1, 2, 4, 8, 16, 32, 64, 128 and 256 days.

Strength development of the trial concrete mixes under standard (20 °C) curing
conditions

The strength development under standard curing conditions of the trial mixes is
shown in Figure 2; the 3 and 28 day strengths are shown as function of water/ binder
ratio. In all mixes, the strength development depends on the water / binder ratio. The
3 and 28 days strength were highly dependent on the level of FA in the mix. The
strength using the same water/binder ratio was lower for the concretes containing
higher levels of FA.

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 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90

110 a) 28-day strength

PC
100
15% FA
90 30% FA
80 45% FA
BRE Mix Design
70
60
50
40
Compressive Strength (N/mm )

30
2

20
10
0
110 b) 3-day strength
100
90
80
70
60
50
40
30
20
10
0
0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90

water / binder
Figure 2. Trial mixes at 20°C – 3 and 28-day compressive strength vs. water / binder

Strength development under standard (20 °C), 10 °C, 30 °C, 40 °C and 50 °C

curing conditions

The strength development under standard (20 °C) curing condition for PC and FA
concrete is shown in Figure 3. At the standard 20 °C curing temperature, the early
strength of this particular FA concrete was not significantly affected by the standard
curing condition as indicated by earlier studies 3, 4, which reported a lower strength
gain of FA concrete at early ages. From an age of 32 days, the strength of FA
concretes continued to develop and was higher as the level of FA increased. This
finding is consistent with that of the earlier studies 3, 4.
The strength development of PC and FA concrete at 10 °C, 30 °C, 40 °C and 50 °C
isothermal curing temperatures is shown in Figure 4. At an early age, the strength
development of PC and FA concretes at higher curing temperatures is greater than
at lower curing temperatures. This is attributed to an increase in the hydration
reaction rate. However at a later age, the strength achieved at higher curing
temperatures was reduced. The later age strength of Portland cement concrete was
much more detrimentally affected by higher curing temperatures than that of fly ash

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concrete. This is the so-called "crossover effect", where concrete cured at higher
temperatures initially has higher strength but later has lower strength than concrete
cured at lower temperatures. It is believed to be due to the reaction products not
having time to become uniformly distributed within the pores of the hardening paste.
In addition, shells made up of low permeability hydration products build up around
the cement grains. The non-uniform distribution of hydration products leads to larger
pores that reduce strength 12. As shown in Figure 5, at curing temperatures of 10 °C
and 30 °C, the strength development of FA concretes is more or less equivalent to
that of PC concrete up to the age of 32 days. From this age onwards the strength of
the FA concretes continues to develop due to the pozzolanic reaction. The FA reacts
slowly with the lime produced by reaction of the cement to produce cementitious
hydrates, providing additional strength gain for up to three to ten years 13, 14. At
curing temperatures of 40 °C and 50 °C, the FA concretes have strength equivalent
to PC concrete at early ages. After 4 days at 50 °C, the 30% FA and 45% FA
concretes achieved 86% and 97% respectively of their 32-day strength at 20 °C,
whereas the equivalent figure for PC concrete was 73%. At later ages, the strength
is greater as the level of FA increases, since the Portland cement concrete is more
detrimentally affected by the high curing temperatures.

110
PC
100 15% FA
30% FA
90 45% FA
Compressive Strength (N/mm2)

80

70

60

50

40

30

20

10

0
0.5 1 2 4 8 16 32 64 128

Age (Days)

Figure 3. Strength development of PC and FA concrete, under standard (20 °C) curing
condition

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 110 a) Portland cement b) 15% FA c) 30% FA d) 45% FA 110

20oC
100 100
10oC
90 30oC 90

80 40oC 80
50oC
70 70

60 60

50 50

40 40

30 30

Compressive Strength (N/mm2)

20 20

10 10

0 0
0.5 1 2 4 8 16 32 64 128 0.5 1 2 4 8 16 32 64 128 0.5 1 2 4 8 16 32 64 128 0.5 1 2 4 8 16 32 64 128

Age (Days)
Figure 4. Strength development of PC and FA concrete, under 10 oC, 20 oC, 30 oC, 40 oC and 50 oC curing conditions

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 1.4 1.4
a) 2-day b) 4-day c) 8-day d) 16-day e) 32-day
1.3 1.3
PC
1.2 15FA 1.2
30FA
1.1 45FA 1.1

1.0 1.0

0.9 0.9

0.8 0.8

0.7 0.7
Strength (MPa)

0.6 0.6

0.5 0.5

Ratio strength / 32-day 20 °C strength

Ratio strength / 32-day 20 °C strength

0.4 0.4

0.3 0.3

0.2 0.2
10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50
o
Curing temperatures ( C)

Figure 5. Strength development of PC and FA concrete, under 10 oC, 20 oC, 30 oC, 40 oC and 50 oC curing condition relative to achieved
standard 32 day strength.

8
Conclusions

• The strength development of this particular FA concrete was observed to be

similar to that of an equivalent Portland cement concrete at standard curing
temperature (20 °C) up to 32 days. From this age onwards the strength
continues to develop and is higher as the level of FA increases.
• At 40 °C and 50 °C, the strength development of FA concretes is similar to
that of an equivalent Portland cement concrete at early ages. At later ages the
strength development is dependent on the level of FA and is higher as the
level of FA increases.
• At 10 °C, FA and Portland cement concretes gain strength more slowly than
at 20 °C and the strength of FA concrete is approximately equivalent to that of
Portland cement concrete.
• The crossover effect is observed earlier as the level of FA decreases and the
curing temperature increases. 
• This work indicates that FA concrete could be used in projects when early age
strength is required without having a detrimental effect on the early or later
age strength development. Its early age strength was found to be equivalent
to that of Portland cement concrete. The later age strength in a structural
element, where temperatures are likely to exceed standard 20 °C curing
temperatures, may be significantly higher than the target mean strength of the
concrete when FA is used. In contrast to slag cement15, which is detrimentally
affected by cold temperatures, FA concrete showed the same strength
development at 10 °C as Portland cement concrete and could potentially be
used at significant levels even in colder conditions without causing delays to
construction schedules. This applies for this particular FA and that it may be
different for FA from another source. The effect of temperature on this
particular FA seems to be the same as that for PC at early ages– irrespective
of whether the temperature is higher than or lower than normal curing
temperature.

Acknowledgements
The principal author would like to express gratefulness for the PhD scholarship
sponsored by Libyan government and Dr Marios Soutsos for his advice throughout
the research. The authors would also like to thank Mr Paul Farrell for his assistance
with the laboratory work.

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