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Chapter 4
For Concrete Durability- Supplementary Cementing Materials
Production of Every Ton of Portland Cement an Essential constituent of concrete, releases about
one Ton of Carbon dioxide (CO2) into atmosphere!!!
1 Partial replacement of cement with SCMs reduces greenhouse gas (GHG) emissions
proportionately, resulting in a more “green” concrete through reduced energy
consumption, which is required to produce cement with avoidance of process emissions,
Page | 1 related to limestone calcinations.
2 Additional benefits include minimization of waste disposal by using such materials for
land filling with these industrial byproducts, causing lesser pressure on natural resources,
such as reduction in limestone consumption, used for production of cement by
replacement of part of cement with SCMs, while SCMs are used judiciously, improved
concrete properties and durability can be achieved.
3 Also, required for sustainability of available energy for future generations to come.
4 Sustainable development demands that state of art technology should be developed in
such a way that current requirements are met, while preservation of energy should also,
be left available to be used by future generation, without difficulty or causing
unbalancing to natural equilibrium of energies.
5 It is also, true that yet, a thorough knowledge/technology requires development to
understand certainly, all aspects of producing durable concrete.
6 What is understood by article meaning of term durability being how far hardened
concrete can serve a structure keeping intact all its inherited properties at production
time, while accepting effects imparted by material hysteresis including its further adverse
impacts on reinforcement or other material constituents/ingredients
7 Supervision & Quality Requirement Assurance is also, necessary on concrete production
from plant or site mixer to site locations, which part has been missing or undervalued in
many areas of globe.
8 Thorough knowledge of concrete durability & other properties, require good
understanding by personnel working on concrete.
9 In particular, qualified site supervisors, semi qualified site supervisors, site consultants &
site foreman, must be trained to understand as well as, apply quality demands to achieve
durable status of concrete.
10 In fact, concrete technology has widened its scope to unlimited levels, yet it is distant
from clear understanding by common applicants, who should be responsible for concrete
application resulting in deliveries of substandard concrete, even in areas, where good
skilled supervisors are available.
11 It is also, suggested that all engineers should strive to have on front experience to
understand concrete technologies, in addition to having understanding of office &
laboratory activities.
Quality control
1 Fly ash from a given power plant may vary with time, depending on many factors, such
as changes in burning conditions or source and composition of coal.
2 Variations in fly ash properties may affect performance of concrete.
3 Fly ash properties that are most likely to affect its performance in concrete are fineness,
particle shape, glass content and composition, LOI, autoclave expansion, SO3, CaO, and
alkali contents.
4 Variability of fly ash colour should also, be monitored for architectural concrete
applications.
5 Changes in fly ash colour can also, indicate changes in carbon content or power plant
burning conditions, which may affect performance of fly ash in air entrained concrete.
Mineralogical composition
Aggregates
1 There are many reports indicating that alkali aggregate reactions can be mitigated by
proper use of fly ash or GGBFS.
2 Proper amount of these SCMs to control alkali aggregate reactions in concrete shall
depend on reactivity of aggregate and should be determined through a testing program.
Chemical admixtures
1 Chemical admixtures used in concrete incorporating SCMs, should conform to codal
requirements.
2 In determining quantities of admixtures to use, SCM is usually added to mass of cement.
Accelerators
1 Use of low calcium fly ash and to some extent, high calcium fly ash and GGBFS
generally, decrease early age strength of concrete particularly, in cold weather conditions
compared to a normal Portland cement concrete with similar workability and similar 28
day compressive strength.
2 Accelerators can be used to partially, compensate for this early age strength reduction.
3 However, calcium chloride is not recommended as an accelerator for concrete with high
volumes of fly ash or for any reinforced or pre stressed concrete.
Bleeding
1 Bleeding of fly ash concrete depends on manner, in which fly ash is used.
2 When fly ash is used as a direct replacement for cement with no reduction in water
content, bleed water of fly ash concrete generally, increases.
3 However, when a reduction of water due to use of fly ash, as a replacement of cement in
concrete is made to maintain similar workability, bleed water of resulting fly ash concrete
is generally, lower than that of concrete made without fly ash.
4 High volume fly ash concrete at low unit water content does not bleed.
5 This generally creates a problem for finishers of flatwork surfaces, who are used to work
with more bleed water at surface during finishing.
6 As with some concrete particularly, with a low water to cementitious material ratio, care
is required to prevent plastic shrinkage cracking at surface immediately, after placing
concrete by following required measures on hot weather concreting.
7 Plastic cracking occurs when rate of evaporation at concrete surface exceeds rate at
which, bleed water replenishes water at surface.
Setting time
1 For similar 28 day compressive strength and workability, setting time of fly ash concrete
may be longer than normal Portland cement concrete for a given combination of cement
and chemical admixtures.
Page | 6 2 This may influence schedule for finishing horizontal surfaces, particularly, at high levels
of replacement (>~30%) and/or in cool weather.
3 In this case, using a dosage of water reducer in lower limit of range proposed by
manufacturer, can contribute at decreasing to some extent, initial setting time of fly ash
concrete.
4 However, this should not be conducted at expense of strength development and durability
of concrete.
5 Still, in hot weather conditions, extended setting time can be beneficial.
6 Concrete accelerators may be used to offset increase in setting time, when using fly ash.
Mechanical properties
Strength development
1 Strength development of fly ash concrete is strongly affected by type of fly ash and
curing temperature.
2 Use of low calcium fly ashes generally, decreases compressive strength of concrete at
early ages (up to 28 days) and increases it at later ages due to pozzolonic reaction of fly
ash, when compared to Portland cement concrete with similar 28 day compressive
strength.
3 On other hand, use of high calcium content has a marginal effect on strength
development.
4 In cool weather, low temperature generally, slows down chemical reaction between
cement and water and therefore, strength development of concrete.
5 For fly ash concrete, this effect is more pronounced due to reduced Portland cement in
mixture and greater dependence of pozzolonic reaction on temperature.
6 However, concrete with fly ash can be proportioned to achieve similar 1day strength as
Portland cement concrete mixture by judicious proportioning of mixture.
7 This usually requires a reduction in water to cementitious materials ratio (W/CM),
reduction being greater with higher levels of SCMs.
8 It should be noted that reduction in strength might not be as pronounced in precast
concrete, where heat curing is used.
9 Reduction in early age strength can also be partially compensated for, by incorporating
silica fume with fly ash to produce a ternary blended cement or by using suitable
accelerators.
Drying shrinkage
Page | 7 1 Effect of fly ash on drying shrinkage is highly dependent on how concrete is
proportioned.
2 If full advantage is taken of reduced water demand and unit water content is reduced and,
if W/CM is also, reduced to achieve strength parity at 28 days, fly ash concrete shall have
significantly, reduced shrinkage compared to Portland cement concrete.
3 Impact of fly ash on drying shrinkage also, depends on maturity of concrete, when drying
commences.
4 If drying starts at one day, fly ash concrete may shrink more.
5 Hence importance of proper curing of fly ash concretes is envisaged.
Creep
1 Effect of fly ash on creep is mainly related to impact that fly ash has on ultimate strength
of concrete.
2 Since, fly ash increases ultimate strength of concrete due to pozzolonic reaction, creep of
fly ash concrete is generally, lower than that of a Portland cement concrete with similar
28 day compressive strength.
3 However, if fly ash concrete is loaded at an early age, creep may be higher.
Durability characteristics
Corrosion resistance
1 Incorporation of fly ash within concrete results in finer pores in hydrated cement paste
leading to a decrease in permeability and chloride ingress rates.
2 Properly proportioned fly ash concrete subjected to adequate curing should in general, be
less permeable at later ages than a corresponding Portland cement concrete (having
similar 28d strength) resulting in better corrosion protection for reinforcing steel.
3 Fly ashes shall generally, increase chloride binding leading to further improving
resistance to rapid chloride penetration.
Sulphate resistance
1 In general, low calcium fly ashes have been found to increase sulphate resistance of
concrete.
2 However, this may or may not be applicable for high calcium fly ashes.
Page | 8
Alkali Silica reactions (ASR)
1 In general, inclusion of fly ash can mitigate expansion caused by alkali silica reactions in
concrete.
2 However, amount of fly ash to be used for controlling alkali silica reactions depends on
type of reactive aggregate, exposure conditions, alkali content of concrete, type of fly ash
and water to cementing materials ratio of mixture.
3 Published data indicate that percent replacement of cement by low calcium fly ash
required to mitigate ASR, may range from 25 to 35%.
4 For high calcium fly ashes, there is some indication that effective replacement levels may
be much higher than those for low calcium ashes.
Carbonation
1 Use of fly ash decreases permeability of concrete inhibiting easy penetration of carbon
dioxide into concrete.
2 However, it also, reduces calcium hydroxide content in concrete due to pozzolonic
reaction consequently, showing an increased propensity for carbonation.
3 Also, fly ash concrete usually takes longer to reach same level of strength as concrete
made without fly ash.
4 Therefore, not properly cured fly ash concrete may carbonate more than Portland cement
concrete particularly, at higher replacement levels.
5 When carbonation is likely to be an issue, concrete with high levels of SCM requires
extended curing and/or reductions in W/CM.
GGBFS (Slag)
1 Properties of fresh concrete as well as, its mechanical properties and durability shall be
influenced by inclusion of slag as replacement for Portland cement.
2 An extent to which, these properties can be affected, depends on percentage of slag used
and its fineness.
3 Description outlines manner in which, replacement of Portland cement by slag affects
properties of concrete.
Properties of fresh concrete
1 Slump and workability
2 GGBFS improves workability and cohesion of concrete, but greater improvement is
obtained with higher GGBFS contents.
Bleeding
1 Use of slag does not have a significant influence on bleeding of concrete.
Setting time
1 Setting time of slag concrete may be longer compared to Portland cement concrete
particularly, in cold weather.
2 Slower set shall depend on reactivity of slag and its percentage used.
3 This may influence schedule for finishing flatwork surfaces particularly, for higher
volume replacements, such as more than 40%.
4 Due to its slightly slower strength development, slag concrete is more sensitive than
conventional concrete to cold weather conditions for concrete placing.
5 This may further slow setting time of slag concrete.
6 In warm weather, setting times are similar to those of Portland cement concrete.
Mechanical properties
Strength development
1 In general, concrete containing GGBFS gains strength more slowly, tending to have
lower strength at early ages and equal or higher strength at later ages compared to that of
Portland cement concrete of similar 28day compressive strength.
2 However, at an equivalent replacement level effect is comparatively, less than that for
most fly ashes.
3 In hot weather, strength gain can be as high as /higher than Portland cement concrete.
4 Slightly slower strength development and resulting lower early age strengths of slag
concrete might be a problem for form removal in some cases, when high percentages of
slag are used particularly, in cold weather conditions.
5 As for fly ash is concerned, this can be overcome by a judicious proportioning of
concrete mixture, such as reducing W/CM or adding silica fume to produce a ternary
blend.
Drying shrinkage
1 There is no significant difference in shrinkage characteristics of concrete with and
without GGBFS as part of cementitious materials, if paste content is same.
2 Also, advantage may be taken of improved workability and associated water reduction
achievable with GGBFS.
Corrosion resistance
1 Inclusion of GGBFS in concrete increases its resistance to chloride ion penetration
particularly, at later ages.
2 It also, improves chloride binding, which is very advantageous for protecting reinforcing
steel from corrosion for which requirement, slag concrete should be well cured as
applicable for fly ash concrete.
Sulphate resistance
1 Concrete containing GGBFS dosages greater than 35% by mass of cementitious material,
has demonstrated an improvement in resistance to sulphate attack.
2 For equivalent performance to Type HS cement, slag levels of 35 to 65% may be required
depending on Al2O3 content of slag.
3 Increasing slag levels would be required with increasing Al2O3 content in slag.
Carbonation
1 As for fly ash concrete, concrete with GGBFS, if not properly cured, may carbonate more
than Portland cement concrete.
Table gives a summary of general effects of fly ash and GGBFS on concrete properties
Summary of General Effects of Fly Ash and
GGBFS on Concrete Properties (Comparison
Page | 11 GGBFS Comments
with Portland cement concrete with similar 28day
compressive strength) Fly Ash
Fresh properties
1 Fly ash-water reduction decreases with increasing fineness and
Water demand ↘ ↘~ carbon content of fly ash.
2 GGBFS-does not have a strong effect on water demand.
1 Fly ash-spherical particle shape of fly ash assists in improving
workability.
Workability ↗ ↗~ 2 GGBFS-does not have a strong effect on slump, but increases
pumpability.
1 Fly ash-bleeding and segregation are in general reduced and
pumpability is improved.
Bleeding ↘ ~ 2 However, low bleed water may increase risk of plastic shrinkage
cracking.
3 GGBFS-does not have a strong effect on bleeding.
1 Fly ash-longer setting times compared to normal concrete, which
may affect finishing schedule.
Setting times ↗ ↗ 2 Cold weather conditions may further slow setting times.
3 GGBFS-its effect on setting times is less than that of fly ash.
1 Fly ash-generally reduces risk of thermal stress and cracking
(especially type F and CI).
Autogenous temperature rise ↘ ↘ 2 GGBFS-may reduce risk of thermal cracking if at least 50% is
2
used and Blaine fineness is lower than 6000 cm /g and if at least
65% is used in warm weather.
Mechanical properties
1 Fly ash-Decreases mechanical properties at early ages (especially
↘ ↘ at 1d and in cold weather).
Compressive strength
↗ ↗ 2 Long-term mechanical properties, such as compressive and
flexural strengths and modulus of elasticity of fly ash concrete
↘ ↘ are typically superior to those of Portland cement concrete of
Flexural strength similar 28day compressive strength.
↗ ↗ 3 GGBFS-similar behavior to fly ash concrete, except that slag
↘ ↘ concrete has higher early age mechanical properties and lower
Modulus of elasticity long term mechanical properties compared to fly ash concrete
↗ ↗ with similar contents.
1 Fly ash-long term drying shrinkage and creep of fly ash concrete
Drying shrinkage ~↘ ~ shall be similar to or lower than that of Portland cement concrete
of similar 28day compressive strength.
Creep ~↘ ~↘ 2 GGBFS-appears to reduce creep and has no significant effect on
drying shrinkage.
Durability
1 Fly ash-reduces water and chloride ion permeability, especially at
Permeability ↘ ↘ later ages if well cured.
2 GGBFS-similar to fly ash
1 Fly ash-increases protection of reinforcing steel from corrosion if
Corrosion resistance ↗ ↗ well cured.
2 GGBFS-similar to fly ash
1 Fly ash-use of low calcium fly ash (CSA Class F and Cl with
CaO content < 20%) increases resistance to sulphate attack.
2 Fly ashes-with more than 20% CaO should be investigated for
Sulphate resistance ↗ ↗ sulphate resistance (rarely used).
3 GGBFS: content required should be investigated (usually more
than 35% is required)
Above steps may be dictated depending on method used for incorporation of fly ash/GGBFS in
concrete.
Selection of W/CM
1 Selection of W/CM is related to durability requirements and to specified compressive
strength, usually at 28 days.
2 Use of fly ash and GGBFS affects strength development of concrete and consequently,
relationship between compressive strength and W/CM.
3 Trial batches can be made in order to develop this relationship.
Maximum W/CM
requirements for different † ‡
CSA Classes of exposure, and Not HVSCM (High Volume HVSCM2 exposed to freeze HVSCM1 exposed to freeze
different SCMs contents SCM) concrete thaw cycles thaw cycles
*
Class of exposure
C-XL 0.37 0.37 0.32
C-1 0.40 0.40 0.35
C-2 0.45 0.45 0.40
F-1 0.50 0.50 0.45
F-2 0.55 0.55 0.50
A-1 0.40 0.40 0.35
A-2 0.45 0.45 0.40
A-3 0.50 0.50 0.45
S-1 0.40 0.40 0.35
S-2 0.45 0.45 0.40
S-3 0.50 0.50 0.45
*
Exposure lasses as defined by CSA A23.1 Class of exposure Definition
1 Structurally reinforced concrete exposed to chlorides or
other severe environments with or without freezing and
C-XL
thawing conditions, with higher durability performance
expectations than C-1, A-1 or S-1 classes.
1 Structurally reinforced concrete exposed to chlorides
C-1
with or without freezing and thawing conditions.
1 Non structurally reinforced (i.e. plain) concrete
C-2
exposed to chlorides and freezing and thawing.
1 Continuously submerged concrete exposed to
C-3
chlorides, but not to freezing and thawing.
1 Non structurally reinforced concrete exposed to
C-4
chlorides, but not to freezing and thawing
1 Concrete exposed to freezing and thawing in a
F-1
saturated condition, but not to chlorides.
1 Concrete in an unsaturated condition exposed to
F-2
freezing and thawing, but not to chlorides.
1 Concrete exposed neither to chlorides nor to freezing
N
and thawing.
1 Structurally reinforced concrete exposed to severe
manure and/or silage gases with or without freeze thaw
exposure.
A-1
2 Concrete exposed to vapour above municipal sewage
or industrial effluent, where hydrogen sulphide gas
may be generated.
1 Structurally reinforced concrete exposed to moderate
A-2 severe manure and/or silage gases and liquids with or
without freeze thaw exposure.
Properties of fly ash and slag i.e. reactivity, influence on water demand in concrete, influence on
dosage of admixtures and variability of material shall relate to following considerations.
1 Required service life of structure and type of exposure to which, concrete is subjected.
2 Curing temperature, whether hot or cold weather.
3 Type of structural element (vertical/horizontal).
4 Usually, suspended horizontal elements require higher early age strength for formwork
removal as well as, all horizontal elements require more care in finishing.
5 Other factors to be considered before determining specific percentages of supplementary
cementing materials to be used in concrete in a specific region include
a Availability of SCMs.
b Current percentage of fly ash or slag commonly used in local concrete
operations/applications.
c Experience of concrete producers and contractors with use of SCMs in concrete.
d Introduction of concrete incorporating percentages of fly ash or slag higher than those
used in common concrete practice in a specific region, may require training of personnel
in local construction industry including cement suppliers, concrete producers, contractors
and testing laboratories.
In cold weather
1 Minimum 40% of fly ash - Minimum 50% of fly ash
In hot weather:
1 Minimum 50% of fly ash - Minimum 65% of fly ash
2 However, it should be noted that for some fly ashes and slag, even use of 65% would not
be enough to reduce risk of thermal cracking.
3 In this case, concrete mixtures should be evaluated for this particular property.
Structurally reinforced concrete exposed to chlorides with or without freezing and thawing
cycling
1 Most effective way to produce concrete resistant to chloride ion penetration is by using
SCMs and a low W/CM.
2 In order to produce a concrete with a coulombs value for chloride ion penetrability less
than 1500 (being an unit used for measurement of Rapid Chloride Penetration) into
hardened concrete within 56 days, it is recommended to use regardless of weather
conditions
Page 15 of 20 2012 Int. P Eng Suraj Singh
Buildings Practice Facilities Plants/Petrochemicals
Chapter 4
For Concrete Durability- Supplementary Cementing Materials
a Minimum 30% of SCMs (fly ash or slag or a mixture of both).
b Use of ternary blends with silica fume can also, produce concrete with coulombs values
less than above maximum.
1 To achieve above coulombs value, concrete must be properly proportioned,
correctly/properly laid, vibrated & well cured.
Page | 16
Hand finishing concrete flatwork exposed to a combination of deicing salts and freezing and
thawing cycles
1 Resistance to deicing salt scaling of concrete mixtures including either fly ash or slag,
still remains highly controversial.
2 Indeed, numerous laboratory test data based on test procedures have indicated that
concrete mixtures including more than about either 20% fly ash or 25% slag, often
perform unsatisfactorily, when exposed to freezing and thawing cycles in presence of
deicing salts.
3 On other hand, several reported cases of concrete structures including significant amounts
of fly ash indicate that such concrete performed well, when exposed to deicing salts in
field.
4 Based on actual data, it is recommended to use
In cold weather:
1 Maximum 25% of fly ash - 35% of fly ash
In hot weather:
1 Maximum 35% of fly ash -Maximum 50% of fly ash
Production
Effect of SCMs use on technical requirements, such as equipment and operation (sequence of
mixing) of ready mix concrete plants
1 Production of concrete including SCMs should meet requirements for production and
delivery of concrete.
2 However, following indications should be taken into account particularly, when using
high volumes of SCMs (more than 30% fly ash or 35% slag).
3 In general, fly ash has a relative bulk density much lower than that of cement (2.00 to
>2.60 v/s 3.15 for Portland cement and ~2.9 for GGBFS).
4 Therefore, silo and weighing scale volumes may require redesign to accommodate larger
volumes of powder (particularly, with high volumes of SCMs) or be prepared to deal
with possibility of double or even, triple batching to make a load of concrete.
5 As all cementing materials are pneumatically, loaded into silos by either dropping or
auguring to weighing mechanism, there appears a lot of potential dust and again, due to
lightness of some products, air pressures should be adjusted accordingly, in silos as well
as, in weigh hoppers to prevent false weights.
6 It is preferred, but not always possible to auger fly ash as it has a propensity to flow past
gates.
7 A slight incline to augers is also, preferable.
Finishing
Concrete with high volumes of SCMs >30 to 35% and low W/CM
1 Concrete with low W/CM with including high volumes of SCMs can present problems
with finishing.
2 Problems would reveal in most cases due to impact resulting from reduced water content
in mix releasing less bleed water available to condition surface of fresh concrete.
3 Effects of low bleed water can be mitigated if diligent attention is made to control
amount of surface drying on fresh concrete.
Stripping
1 Form removal/stripping/de shuttering being an operation contingent upon attaining a
predefined in situ compressive strength for respective element.
2 In cases of vertical elements, a value of 6 to 10 MPa is usually required prior to stripping
forms.
3 Concrete easily achieves this stripping strength at 1day or even, earlier with high volumes
of SCMs.
4 For suspended slabs, a higher strength is required typically 70 – 75% of design 28day
strength.
5 Concrete with moderate levels of SCMs up to 25% easily achieves required stripping
strength at early age.
6 For concrete with high volumes of SCMs > 30 to 35%, a judicious proportioning of
concrete mixture is required to achieve a required stripping strength in a timely manner.
7 This usually requires a reduction in W/CM, incorporation of silica fume or use of some
non chloride accelerators particularly, in cool weather.
8 Structural designers may permit stripping time earlier for suspended slabs, if properly re
shored during stripping.
9 To be kept in consideration that generally, specification do require allowance of removal
of plywood or plates prior to stripping time, provided props or vertical supporting system
members are kept intact, until full stripping time is over & even, in some case, upper
slabs are laid.
1 For formed components, leaving forms in place, until above criteria are met, complies
with intent of basic and additional curing regimes.
2 If forms are removed earlier, concrete components should be wrapped in plastic or coated
uniformly, in line to manufacturer's recommended, either rate of application with a high
quality membrane curing compound or be kept wet by application of water through
hessian/soaker hoses or fog sprays.
3 For flatwork maintenance, a moist condition is needed, not only to promote hydration,
but also, to reduce drying shrinkage that could lead to excessive cracking.
4 Moisture can be applied either by fog sprays or by covering with presoaked burlap or
proprietary mats that hold moisture.
5 Covering soaked hessians with polyethylene sheets can reduce water loss from concrete.
Conclusion:
1 Concrete should be placed using SCMs to achieve better production, better placement,
better curing, better protection from plastic cracking, better site controls as well as, to
achieve durability, which is mainly affected by reduction of Rapid Chloride penetration
impacts.
2 Advance arrangements required for suitable forms & receiving concrete deliveries.
3 Do not permit any lapse on any activity during concrete from trial design to finishing on
site.
4 Cure in line with agreed method statements.
References:
Use of Fly Ash and Slag in Concrete: A Best Practice Guide / January 2005
Personal field experience instances