SUITABILITY OF SINTERED FLY ASH LIGHTWEIGHT

AGGREGATE IN STRUCTURAL CONCRETE

V V Arora, P N Ojha & Mantu Gupta
National Council for Cement and Building Materials, India

ABSTRACT

The paper presents the experimental study of suitability of sintered fly ash lightweight aggregate
in structural concrete. Concrete using sintered fly ash aggregate has been made at two water-
cement ratios 0.55 & 0.45. The various Mechanical properties such as Compressive strength,
Flexural strength, Splitting tensile strength, Drying shrinkage, Modulus of Elasticity and
Poisson’s ratio has been determined. The Durability properties has also been investigated
conducting Rapid Chloride ion Penetration test (RCPT), Electrical Resistivity, Chloride
Migration test, Water Permeability and Sorptivity (Absorption) Index. The Mechanical &
Durability properties of Lightweight Aggregate Concrete (LWAC) have been compared with
corresponding test results of Normal weight Aggregate Concrete (NWAC) at same water-cement
ratio 0.55 & 0·45. The finding of the study is useful for formulation of a new Indian Standard for
production of Structural Lightweight Concrete (SLC) using sintered fly ash lightweight coarse
aggregate.

KEYWORDS:

Lightweight Aggregate (LWA), Lightweight Aggregate Concrete (LWAC), Normal Weight

Aggregate Concrete (NWAC) Structural Lightweight Concrete (SLC), Interfacial Transition Zone
(ITZ), Cellular Structure, Internal Curing and Bulk Density.

1.0 INTRODUCTION

On the one hand the availability of natural aggregates resources in India particularly in Metro
Cities has become a matter of concern; on the other hand solutions are being sought for the
utilization of increasing quantities of fly ash, released from coal based thermal power plants. The
use of fly ash for production of sintered fly ash lightweight aggregate is an appropriate step for
the solution of both problems. Use of such lightweight aggregate for production of Structural
Lightweight Concrete (SLC) is next appropriate step. The sintered fly ash lightweight aggregate
is being produced by Pelletization and Sintering done at temperature range of 1100 to 1300
degree centigrade. The burning of the carbon in the pellets and loss of moisture creates a cellular
structure bonded together by the fusion of fine ash particles. [1]

The following beneficial effects are advocated while using Structural Lightweight Concrete
(SLC) over conventional normal weight aggregate concrete. [2]

i) The reduction in foundation load, therefore less reinforcing steel.

ii) Reduced dead loads may results in smaller supporting members like beam, columns etc.
iii) Reduced seismic load because of reduced overall weight of structure.
iv) High thermal insulation
v) Enhanced Fire resistance

Abundance of literature & well developed national as well as international codes are available on
Mechanical and Durability properties of normal weight aggregate concrete. The lightweight
aggregate concrete has limited use in comparison to normal weight aggregate concrete and
perhaps this is the reason that literature on production and use of sintered fly ash aggregate in
structural lightweight concrete is scanty.
Internationally, ACI 213R-03 and ASTM C330 [4] are widely used two standards for the use of
lightweight aggregate (LWA) in SLC. The brief of the existing literatures on properties of
structural lightweight concrete is discussed below:

Concrete Mix proportioning of Structural Lightweight Concrete (SLC)

The principal factors necessitating modification of proportioning and control procedure for light
weight aggregate concrete compared to normal weight concrete are greater absorption higher rate
of absorption of most light weight aggregates.

As per ACI 211.2-91[3] , the weight method can be used for proportioning the concrete with
lightweight coarse aggregate and normal weight fine aggregate whereas volumetric method can
be used for concrete with all lightweight as well as combination of lightweight and normal weight
aggregates.

Damp aggregates are preferable to dry aggregates at the time of mixing, as they tend to absorb
less water during mixing and therefore reduce the possibility of loss of slump as the concrete is
being mixed, transported and placed. Absorbed water is accounted for in the mixture
proportioning.

Properties of Structural Lightweight Concrete (SLC)

i) Density, Compressive strength & Splitting Tensile strength of SLC: As per ASTM C330, the
conformity of concrete to SLC is evaluated on the basis of combined property of Density,
Compressive strength & Splitting Tensile strength. From the same batch of concrete one or
more of the compressive strength & splitting tensile strength requirements will be satisfied
without exceeding the corresponding maximum density values which is given below:

Sl. Average Air Dry 28-day Average 28-day Average 28-day

No. Density Splitting Tensile Compressive
Max, (kg/m3) Strength, Min (MPa) Strength, Min (MPa)
All Lightweight Aggregate
1 1760 2.2 28
2 1680 2.1 21
3 1600 2.0 17
Sand/Lightweight Aggregate
4 1840 2.3 28
5 1760 2.1 21
6 1680 2.1 17

ii) Flexural Strength: As per ACI 318 [5] code, Flexural strength, fcr = λ 0.55 √fck N/mm2 Where
λ is the modification factor for lightweight concrete and equals 1.0 for normal weight
concrete, 0.85 for sand-lightweight concrete, and 0.75 for all lightweight concrete. It indicates
that in case of concrete made with normal weight sand and lightweight coarse aggregate,
Flexural strength value is 15% less than the concrete made with normal weight aggregate. In
case concrete made with all lightweight aggregates, the flexural strength value is 25% less
than the concrete made with normal weight aggregate.
iii) Stress-Strain Behaviour: Thorsten Faust et al. [6] have worked on Stress-strain behavior for
concrete made with various combinations of light weight and normal weight aggregate. They
have observed that ascending branch of stress strain curve is comparatively linear in case of
light weight aggregate concrete in comparison to normal weight aggregate. They have also
observed lower E modulus and less ductility in the post cracking failure region.
iv) Modulus of Elasticity – The modulus of elasticity of concrete is a function of amount of paste
and aggregate and the moduli of its each constituent. Normal weight concrete has higher
modulus of elasticity than lightweight concrete because of higher moduli of sand, stone, and
gravel than the moduli of lightweight aggregates. As per ACI 213R-03, generally, the
modulus of elasticity for lightweight concrete varies between ½ to ¾ that of normal weight
concrete of the same strength.
v. Poisson’s ratio –As per ACI 213R-03, Poisson’s ratio determined by the static method for
lightweight and normal weight concrete varies between 0.15 and 0.25 and averaged 0.2.
vi. Drying Shrinkage – As per ASTM C330, the drying shrinkage of concrete specimens shall
not exceed 0.07%.
ACI 213R presents numerous instances of satisfactory durability results of Structural Lightweight
Concrete (SLC) in the existing structures of USA. However, the literature regarding investigation
on durability properties of SLC based on experimental study in the laboratory is scanty.

In India, IS: 9142[7] refers to Specification for Artificial Lightweight Aggregates for Concrete
Masonry Units and IS: 2185 (Part-II) [8] refers to production of Hollow & Solid Lightweight
concrete blocks. These codes are not specific to the use of sintered fly ash aggregates. Further,
there is no standard available for use of sintered fly ash lightweight coarse aggregate as concrete
marking material for production of SLC. Presently IS: 9142 is under revision. The new code will
be in two parts. The 1st part deal with Specification for Artificial Lightweight Aggregates for
Concrete Masonry Units and 2nd part deals with specification for Sintered fly ash Lightweight
Aggregate for Structural Concrete.

NCB has carried out performance study of Structural Lightweight Concrete made with sintered
fly ash aggregate. The investigation consist the various mechanical & durability properties of
Lightweight Aggregate Concrete (LWAC). The Mechanical & Durability properties of LWAC
have been compared with corresponding test results of Normal weight Aggregate Concrete
(NWAC) at same water-cement ratio 0.55 & 0·45.

2.0 EXPERIMENTAL INVESTIGATION

The experimental investigation consist the evaluation of concrete making materials, concrete mix
proportioning followed by casting & testing of concrete specimen samples. The detail of each
investigation is discussed below.

2.1 Material Properties

Lightweight aggregate of two fractions 8-16mm & 4-8mm with maximum nominal size of 16 mm
was used as coarse aggregate. NCB has evaluated the Micro-structural, Physical & Chemical
properties on these two fractions of sintered fly ash aggregates. The testing has been done as per
relevant Indian Standard. The dry Loose Bulk Density, Loss on Ignition, grading results of both
the fractions of LWA conforms the requirements of ASTM C330 and therefore can be used for
production of SLC. However, the Abrasion value, Impact value & Crushing values indicated that
these LWAs shall not be used for concrete to be used in wearing surfaces. Natural River sand
conforming to zone-II of IS: 383[9] [10], one brand of OPC-43 Grade conforming to IS: 8112[11] [12]
[13]
and Naphthalene based super plasticizer conforming to IS: 9103 [14] were used in this study.

2.2 Concrete Mix Proportioning of LWAC

The mix proportioning was done by Absolute volume method. In this method, the volume of
fresh concrete produced by any combination of materials was considered equal to the sum of the
absolute volumes of cementitious materials, aggregate, net water & entrained air. The principle
involved that the mortar volume consists of the total of the volumes of cement, fine aggregate, net
water, and entrained air. This mortar volume should be sufficient to fill the voids in a rodded
coarse aggregate plus sufficient additional volume to provide satisfactory workability.

Damp aggregates are preferable to dry aggregates at the time of mixing, as they tend to absorb
less water during mixing and therefore reduce the possibility of loss of slump as the concrete is
being mixed, transported and placed. Absorbed water is accounted for in the mix proportioning.
The slump of the fresh concrete was kept in the range of 50-75 mm. The concrete mixtures were
prepared in pan type concrete mixer. The mix proportions details of LWAC are presented in
Table 1.
Table 1: Mix Proportions of LWAC

Mix Constituents At w/c-0.55, Mix At w/c-0.45, Mix

proportions (Kg/cum) proportions (Kg/cum)
Cement (OPC-43 Grade) 300 333
Water 165 150
Normal weight Fine Aggregate 657 662
Lightweight Coarse Aggregate
Fraction –I) 8-16 mm (65%) 502 505
Fraction –II) 4-8 mm (35%) 270 272
2.40 litre (@ 0.80% by 1.67 litre (@ 0.50% by
Chemical Admixture
weight of cement) weight of cement)

2.3 Tests Conducted on Concrete Samples

The experimental program consists the casting & testing of concrete specimen samples. Different
sizes and types of specimens as per relevant Indian codes/ International codes/test methods/
specifications were used in the investigation to determine the engineering properties of hardened
concrete. The details of test conducted on concrete samples are presented in Table 2.

Table 2: Detail Test Program with Standards & Specimens dimension

Testing
Sl. Standards/ Type of Specimen Size
Type of Test Age of
No. Codes/Procedure Specimen (in mm )
Sample
Compressive 1, 3, 7 & 28
1 IS:516 [15] Cube 150x150x150
Strength days
2 Flexural Strength 28 days IS:516 Beam 150x150x700
Splitting Tensile Dia=150,
3 28 days IS:5816 [16] Cylinder
Strength Ht=300
4 Drying Shrinkage 28 days IS:1199 [17] Prism Bar 75x75x300
Modulus of Dia=150,
5 28 days IS:516 Cylinder
Elasticity Ht=300
Dia=150,
6 Poisson’s Ratio 28 days IS:516 Cylinder
Ht=300
Rapid Chloride ion Dia=100,
7 28 days ASTM C1202 [18] Cylinder
Penetration Test Height=200
Four Point
Electrical
8 28 days Wenner Probe Slab 300x300x100
Resistivity
Resistivity Meter
 Table 2: (Contd…)

Testing
Sl. Standards/ Type of Specimen Size
Type of Test Age of
No. Codes/Procedure Specimen (in mm )
Sample
Chloride Migration Dia=100,
9 28 days NT Built 492 [19] Cylinder
Test Ht=200
DIN:1048 (Part 5) Dia=150,
10 Water Permeability 28 days [20] Cylinder
Ht=150
Sorptivity Dia=100,
11 28 days ASTM C1585 [21] Cylinder
(absorption) Index Ht=200

3.0 TESTS RESULTS AND DISCUSSION

3.1 Mechanical Properties of LWAC

The various Mechanical properties such as Compressive strength, Flexural strength, Splitting
tensile strength, Drying shrinkage, Modulus of Elasticity, Stress-Strain behaviour and Poisson’s
ratio has been determined. The testing has been done as per relevant Indian standards. The
mechanical properties results as obtained are presented in Table 3.

Table 3: Test Results of Mechanical Properties of LWAC

Age of Mix ID
Test Conducted
Testing LWAC (W/c 0.55) LWAC (W/c 0.45)
1day 8.96 13.16
3-day 21.37 29.99
Compressive Strength (MPa)
7-day 27.78 34.73
28-day 34.64 44.19
Flexural Strength (MPa) 28-day 3.79 4.25
Splitting Tensile Strength (MPa) 28-day 3.13 3.50
Drying Shrinkage (%) 28-day 0.022 0.018
Modulus of Elasticity (MPa) 28-day 20694.00 22352.33
Poisson’s Ratio 28-day 0.190 0.203

On analysis of test results and its comparison with relevant International standards/Existing
Literature following are the point wise discussion:

• The compressive strength of LWAC at 28-days for w/c-0.55 & 0.45 are 34.64 N/mm2 &
44.19 N/mm2 respectively which is in the same range to that of NWAC.
• The flexural strength of LWAC at 28-days for w/c-0.55 & 0.45 are 3.79N/mm2 & 4.25N/mm2
respectively. As per IS: 456-2000 [22], the estimated value of flexural strength are 4.12 N/mm2
and 4.65 N/mm2 corresponding to the actual compressive strength 34.64 N/mm2 & 44.19
N/mm2 of normal weight aggregate concrete respectively. The actual flexural strength of
LWAC is lower by 8% & 8.6% respectively which is in agreement with the existing literature
for LWAC. It may be noted that ACI 318 estimates 15% lower value of flexural strength of
SLC than that of normal weight aggregate concrete for the same compressive strength.
• The Modulus of Elasticity (MOE) of LWAC at 28-days for w/c-0.55 & 0.45 are 20694N/mm2
& 22352.33N/mm2 respectively. As per IS: 456-2000 [21], the estimated value of MOE are
 29427.88N/mm2 and 33237.78N/mm2 corresponding to the actual compressive strength 34.64
N/mm2 & 44.19 N/mm2 of normal weight aggregate concrete respectively. The actual MOE
of LWAC is lower by 29% & 32.75% respectively which is in agreement with the existing
literature for SLC. It may be noted that ACI 213R-03, the MOE value of SLC can be lower
by in between 25% to 50% than that of normal weight aggregate concrete for the same
compressive strength.
• The Poisson’s ratio of LWAC at 28-days for w/c-0.55 & 0.45 are 0.19 & 0.203 respectively
which is in agreement with the existing literature for SLC.
• The Drying Shrinkage of LWAC at 28-days for w/c-0.55 & 0.45 are 0.022% & 0.018%
respectively which is less than the maximum limit 0.07% specified in ASTM C330.

3.2 Durability Properties of Concrete

The Durability properties such as Rapid Chloride ion Penetration test (RCPT), Electrical
Resistivity, Chloride Migration test, Water Permeability and Sorptivity (Absorption) Index has
also been investigated. The testing has been done as per relevant International standards. The
Durability properties results are given in Table 4.

Table 4: Test Results of Durability Properties of LWAC

Mix ID
Age of
Test Conducted LWAC at *NWAC at LWAC at *NWAC at
Testing
w/c 0.55 w/c 0.55 w/c 0.45 w/c 0.45
RCPT at 28 Days, 5832.7 2447 3829 2298
28 day
(Coulombs) (High) (Moderate) (Moderate) (Moderate)
Electrical Resistivity
28 days 28 day 4.61 9.60 5.39 11.00
(KΏ-cm)
Chloride Migration
Test, at 28 Days, 28 day 26.42x10-12 22.37x10-12 21.14x10-12 12.85x10-12
(m2/s)
Water Permeability
Test, at 28 Days 28 day 14.67 23.00 12.33 33.00
(mm)
Sorptivity Initial- Initial- Initial- Initial-
(absorption) 28 day 0.0141, Sec. 0.0057, Sec.- 0.0179, Sec.- 0.0039, Sec.-
mm/sec1/2 -0.0047 0.0047 0.0031 0.0024
* Mix using Normal weight aggregate concrete (NWAC) is taken from NCB data Bank.

On analysis of test results and its comparison with NWAC following are the point wise
discussion:

• The Rapid Chloride Penetrability Test (RCPT) of LWAC at 28-days for w/c-0.55 & 0.45 are
5832.70 Coulombs (High) & 3829 Coulombs (Moderate) respectively. Corresponding RCPT
values in case of normal weight concrete aggregate at same water cement ratio are 2447
Coulombs (Moderate) and 2298 Coulombs (Moderate) respectively. This test have been
conducted on saturated sample of LWA concrete which may have higher pore water inside
aggregate due higher porosity in comparison to normal weight aggregate. This could have
been the reason of higher RCPT values.
• The Electrical Resistivity values of LWAC at 28-days for w/c-0.55 & 0.45 are 4.61 KΏ-cm &
5.38 KΏ-cm respectively. Corresponding electrical resistivity values in case of normal weight
 concrete aggregate at same water cement ratio are 9.6 KΏ-cm and 11.00 KΏ-cm respectively.
This test have been conducted on saturated sample of LWA concrete which may have higher
pore water inside aggregate due higher porosity in comparison to normal weight aggregate.
This could have been the reason of lower resistivity values of LWAC.
• The Chloride Migration test results of LWAC at 28-days for w/c-0.55 & 0.45 are 26.42x10-12
m2/s & 21.14x10-12 m2/s respectively. Corresponding test results vales in case of normal
weight concrete aggregate at same water cement ratio are 22.37x10-12 m2/s and 12.85x10-12
m2/s respectively. This indicates higher migration of chlorides in LWAC than normal-weight
concrete.
• The Water Permeability values of LWAC at 28-days for w/c-0.55 & 0.45 are 14.67 mm &
12.33mm respectively. Corresponding Water Permeability values in case of normal weight
concrete aggregate at same water cement ratio are 23.00 mm and 33.00 mm respectively. This
result indicates that LWAC has better resistance against water penetration in comparison to
normal-weight aggregate concrete. It seems that the lower penetration value is because of
better aggregate-paste bond in interfacial zone in case of LWAC.
• The Initial & Secondary Sorptivity (absorption) values of LWAC at 28-days for w/c-0.55 are
0.0141mm/sec1/2 and 0.0047 mm/sec1/2. Corresponding Initial & secondary absorption values
in case of normal weight concrete aggregate at same water cement ratio are 0.0057 mm/sec1/2
and 0.0047 mm/sec1/2 respectively. Similarly, Initial & secondary Sorptivity (absorption)
values of LWAC at 28-days for w/c-0.45 are 0.0179 mm/sec1/2 and 0.0031 mm/sec1/2.
Corresponding Initial & secondary absorption values in case of normal weight concrete
aggregate at same water cement ratio are 0.0039mm/sec1/2 and 0.0024mm/sec1/2 respectively.
It seems that higher absorption values are due to the cellular structure of LWA in upper layer
of concrete specimen. However, lower water permeability indicates that porosity in the LWA
is discontinuous and aggregate-paste bond is stronger in LWAC.

4.0 CONCLUSIONS

Based on various test results of LWA, it may be concluded that both the fraction of coarse
aggregate can be used as a lightweight coarse aggregate for production of Structural Lightweight
concrete.

The various test results of mechanical properties of LWAC indicate that concrete made with
lightweight coarse aggregate can be used as Structural concrete. However, various structural
design codal provisions needs to be established for structural lightweight concrete since
parameters such as Flexural strength & Modulus of elasticity values are lower than that of normal
weight concrete for the same compressive strength.

The durability test results indicates that these values are in the acceptable range for construction
of durable concrete structure however they are lower than that of normal aggregate concrete.
Codal provision such as minimum cement content, maximum water-cement ratio, concrete cover
to the reinforcement etc shall be further strict than that of normal weight aggregate concrete to
ensure similar level of durability in the same exposure conditions.

5.0 ACKNOWLEDGMENT

This paper pertains to a R&D work carried out by Construction, Development and Research
Centre at National Council for Cement and Building Materials. The Authors acknowledge the
sponsor M/s IMFA (Indian Metals Ferro Alloys) for carrying out this research work at National
Council for Cement and Building Materials, Ballabgarh.
References:

1. Chandra Satish, Berntsson Leif, for Lightweight Aggregate concrete (Science, Technology
and Applications) copyright © 2003 by Noyes Publications.
2. ACI213R-03: Guide for Structural Lightweight-Aggregate concrete.
3. ACI 211.2-91: Standard practice for selecting proportions for structural lightweight
concrete
4. ASTM C330-00: Standard Specification for Lightweight-Aggregates for Structural concrete.
5. ACI 318: Building Code Requirements for. Structural Concrete
6. High Strength Lightweight-aggregate Concrete: Thorsten Faust et al, University of Leipzig,
Institute of Structural Engineering & Building Material, 2nd Int. PhD. Sysmposium in Civil
Engineering 1998 Budapest.
7. IS: 9142-1997 Specification for Artificial Lightweight Aggregate for concrete Masonry
units.
8. IS: 2185 (Part-II)-1989: Specification for concrete Masonry units Part II: Hollow and Solid
Lightweight concrete Blocks.
9. IS: 383-1970 Specification for Coarse and Fine aggregate from natural sources of
aggregates
10. IS: 2386-1997: (Different parts) Methods of test for aggregates for concrete
11. IS: 8112-2013: 43 Grade Ordinary Portland Cement- Specification.
12. IS: 4031: (All parts) Method of physical tests for hydraulic cement
13. IS: 4032: Method of chemical analysis of hydraulic cement
14. IS: 9103-1999: Concrete Admixtures-Specification.
15. IS: 516 : Methods of tests for strength of concrete
16. IS: 5816 : Method of test for splitting tensile strength of concrete
17. IS: 1199: Method of sampling & analysis of concrete
18. ASTM C1202: Standard test method for electrical indication of concrete’s ability to resist
chloride ion penetration
19. NT Build 492 : Nordtest method for determination of the chloride migration co-efficient in
concrete, mortar or cement-based repair material from Non-steady-state migration
experiments
20. DIN 1048 Part 5: Testing of Hardened Concrete.
21. ASTM C 1585: Standard test method for measurement of rate of absorption of water by
hydraulic - cement properties
22. IS: 456-2000: Plain & reinforced concrete – code of practice (fourth revision)