Influence of Quarry Dust and Fly Ash on the Concrete

Compressive Strength Development

S. N. Ramana, M. F. M. Zainb, H. B. Mahmuda, K. S. Tanb
a
Department of Civil Engineering, Faculty of Engineering, Universiti Malaya, 50603 Kuala Lumpur, Malaysia
Tel. No : 03 – 7967 4492; Fax No. : 03 – 7967 5318; Email : snraman@um.edu.my
b
Department of Civil and Structural Engineering, Faculty of Engineering, Universiti Kebangsaan Malaysia,
43600 UKM Bangi, Selangor, Malaysia

ABSTRACT reduction of environmental load, waste management

This paper reports the experimental study
undertaken to investigate the influence of partial
replacement of sand with quarry dust, and cement with
fly ash on the concrete compressive strength
development. Two types of replacement proportion of
sand with quarry dust, 20 % and 40 % were practiced in
the concrete mixes except in the control concrete mix.
Besides, replacement proportion of 10 % cement content
with fly ash was practiced in some of the concrete mixes.
Two types of curing methods, water curing and air
curing, under controlled laboratory conditions were
practiced during the entire study. The compressive
strength of the water cured specimens were measured on
the 7th, 28th, 56th and 91st day, whereas for the air cured
specimens, compressive strength were determined on the
28th, 56th and 91st day. Recorded results indicate that
concrete incorporating quarry dust without the inclusion
of fly ash exhibited lower compressive strength than the
control concrete at all ages. This weakness was
overcome by the inclusion of fly ash into the quarry dust
concrete in which it resulted in the enhanced
compressive strength at almost all conditions. It can be
concluded that quarry dust can be utilised as partial
replacement material to sand, in the presence of fly ash,
to produce concretes with fair ranges of compressive
strength.
Keywords: Quarry dust, fly ash, sand, concrete,
compressive strength.
(1) INTRODUCTION
In recent years, tremendous efforts have been taken
in the area of concrete engineering and technology to
research and study the utilisation of by-products and
waste materials in the production of concrete. The
successful utilisation of these materials will result in the
cost and concrete production cost, besides enhancing the
properties of concrete in both fresh and hardened state.
Efforts in this area have been focussed in identifying and
optimising the benefits of different types of cement
replacement materials as well as identifying alternative
materials as aggregates in concrete.
Fly ash, silica fume, ground granulated blastfurnace
slag and rice husk ash are the commonly researched
cement replacement materials with the aim to achieve
enhancement in the properties of concrete and to
produce concretes to meet special purposes. Of these,
silica fume can be said as the most successful material
due to numerous reasons. Silica fume is a highly
reactive pozzolana and the microfilling abilities of its
ultrafine particles results in concrete with a much denser
matrix. Besides that, silica fume also reduces the pore
volume in the concrete by the successful development of
highly refined pore structure [1], which results in
positive effects in the properties of the hardened
concrete.
Fly ash or pulverised-fuel ash, which is the ash
precipitated electrostatically or mechanically from the
exhaust gases of coal-fired power stations [2], is another
pozzolana which is beneficial in this aspect even though
it has been mentioned that it is not as effective as the
silica fume. It should also be observed that the cost of
fly ash is very much lower than silica fume, which
encourages its utilisation from the economical aspect.
Hassan et al. studied the influence of silica fume and fly
ash on the properties of superplastized high performance
concrete and concluded that even though fly ash
concrete exhibited relatively poor characteristics at early
ages, but it achieved similar strength and transport
characteristics to silica fume concrete in the long term
[3]. Meanwhile, Temiz and Karakeci investigated the
microstructure of cement paste containing fly ash and
silica fume concluded that the significant amount of
SiO2 in the chemical composition of high-calcium fly
ash and silica fume reacted with free Ca(OH)2 during the
chemical reaction period of Portland cement and formed
amorphous C-S-H gel, thus decreasing the amount of
Ca(OH)2 which is harmful to concrete [4]. The
contribution of fly ash to the positive effects in the
strength in concrete has been attributed to direct water
reduction, the increase in the effective volume of paste
in the mix and its pozzolanic reaction [5]. Its pozzolanic
activity is due to the presence of finely divided glassy
silica and lime which produce calcium silicate hydrate
as is produced in Portland cement [5]. In the aspects of
durability, Neville mentioned that incorporation of Class
F fly ash into concrete improves its sulphate resistance,
probably mainly through the removal of calcium
hydroxide [2]. Similarly, Gambhir has mentioned that
fly ash concrete has high resistance to sulphate attack
[5]. Besides that, the reduced permeability of mature fly
ash concrete results in a reduced chloride ingress [2].
As for alternative materials as aggregates in
concrete, numerous types of by-product such as recycled
concrete aggregate, quarry dust, fly ash and slag, as well
as several types of manufactured aggregates have been
studied by many researchers. Quarry dust, a by-product
from the crushing process during quarrying activities is
one of those materials that have recently gained
attention to be used as concreting aggregates, especially
as fine aggregates. Quarry dust have been used for
different activities in the construction industry such as
for road construction and manufacture of building
materials such as lightweight aggregates, bricks, tiles
and autoclave blocks [6]. Researches and practical
applications have been conducted in different parts of
the world, including Malaysia, to study the effects of
incorporation of quarry dust into concrete. Tan et al.
studied the influence of varying replacement proportion
of sand with quarry dust (20%, 30% and 40%) on the
properties of concrete in both fresh and hardened state
[7]. Naidu et al. investigated the influence of partial
replacement of sand with quarry dust and cement with
mineral admixtures on the compressive strength and
pull-out force of concrete [8], whereas Celik and Marar
investigated the influence of partial replacement of fine
aggregate with crushed stone dust at varying percentages
in the properties of fresh and hardened concrete [9]. The
present study attempts to investigate the influence of
partial replacement of river sand with quarry dust, and
cement with fly ash on the concrete compressive
strength development.
(2) EXPERIMENTAL METHOD
(2.1) Materials
Type I ordinary Portland cement, crushed stone
granite coarse aggregate, river sand, locally available
quarry dust and Class F Malaysian fly ash were the
primary material used in this study. Sulfonated
naphthalene formaldehyde condensate based
superplaticizer (SP) and Darex air entraining admixture
(AEA) were used as liquid chemical admixtures. Normal
tap water (pH = 6.9) was used for both concrete mixing
and curing purposes. Table 1 shows the physical
properties of the materials.
Table 1 Physical Properties of the Materials
Material Properties
Specific gravity: 2.63; Absorption: 0.44 %;
Coarse
Maximum size: 10.00 mm;
aggregate
Fineness modulus: 6.82
Specific gravity: 2.57; Absorption: 2.12 %;
River
Maximum size: 4.75 mm;
sand
Fineness modulus: 4.20
Specific gravity: 2.63; Absorption: 0.60 %;
Quarry
Maximum size: 4.75 mm;
dust
Fineness modulus: 4.20
Cement Specific gravity: 3.15
Silica
Specific gravity: 2.20
fume
Fly ash Specific gravity: 2.26
SP Specific gravity: 1.21; Solid content: 40 %
AEA Specific gravity: 1.02; Solid content: 8 %
(2.2) Concrete Mix Proportions
Six types of concrete, OPC0QD, OPC20QD,
OPC40QD, FA0QD, FA20QD and FA40QD, each with
two water-binder ratios of 0.35 and 0.50 were produced
in this study. A total of 252 cubical concrete specimens
of 100 mm dimensions were prepared for this study. The
Sherbrooke mix design method [10] was used to obtain
the concrete mix proportions. OPC0QD was the control
concrete. 20% of the sand content in OPC20QD and
FA20QD concretes was replaced with quarry dust.
Similarly, 40% of the sand content in OPC40QD and
FA40QD concretes was replaced with quarry dust.
Besides that, 10 % of ordinary Portland cement was
replaced with fly ash as the binder in FA0QD, FA20QD
and FA40QD. The content of superplaticizers and air
entraining admixtures were fixed by monitoring the
desired workability and entrained air content in the fresh
concrete mixes. The details of mix proportions in
saturated surface dry condition are given in Table 2,
Table 3, Table 4 and Table 5 respectively.
(2.3) Scope of Test
A rotating pan type mixer (capacity 0.05 m3) was
used for the mixing of the constituent materials. Fresh
concrete was sampled immediately after completion of Table 4 Details of Mix Proportion for OPC0QD,
mixing for determination of slump and entrained air OPC20QD and OPC40QD Concretes with
content. A minimum slump of 190 mm and a minimum Water-Binder Ratio of 0.50 (kg/m3).
entrained air content of 1.5 % were maintained to ensure Type of Concrete
Materials
excellent workability of the freshly mixed concrete. The OPC0QD OPC20QD OPC40QD
fresh concrete was then cast into 100 mm cubical Coarse
moulds in two layers. Immediately after casting, the 1055 1055 1055
aggregate
specimens were stored in the curing room at 20±2oC and Sand 690 552 414
were covered with plastic sheets. The cubical specimens Quarry dust - 141 282
were demoulded after 1 day, and were allowed for water Cement 400 400 400
and air curing respectively. For water curing, specimens Fly ash - - -
were immersed in water in a curing tank and the water Water 200 200 200
temperature was maintained at 20±2oC, whereas for air SP 4.000 4.000 4.000
curing, the specimens were placed in the curing room AEA 0.220 0.220 0.220
and cured by air at 20±2oC. The compressive strength of
the cubical specimens was determined in accordance to Table 5 Details of Mix Proportion for FA0QD,
BS 1881: Part 116: 1983 [11]. The compressive strength FA20QD and FA40QD Concretes with
of the water cured specimens were measured on the 7th, Water-Binder Ratio of 0.50 (kg/m3)
28th, 56th and 91st day, whereas for the air cured Type of Concrete
specimens, compressive strength were determined on the Materials
FA0QD FA20QD FA40QD
28th, 56th and 91st day. Results presented are the average Coarse
of three specimens. 1047 1047 1047
aggregate
Sand 685 548 411
Table 2 Details of Mix Proportion for OPC0QD,
Quarry dust - 140 280
OPC20QD and OPC40QD Concretes with
Cement 360 360 360
Water-Binder Ratio of 0.35 (kg/m3).
Fly ash 40 40 40
Type of Concrete
Materials Water 200 200 200
OPC0QD OPC20QD OPC40QD
SP 4.000 4.000 4.000
Coarse
1013 1013 1013 AEA 0.356 0.356 0.356
aggregate
Sand 651 521 391
(3) RESULTS AND DISCUSSION
Quarry dust - 133 266
Cement 530 530 530
Strength of concrete is one of the most important
Fly ash - - -
characteristics of hardened concrete mix besides its
Water 185.5 185.5 185.5 durability, and the compressive strength represents the
SP 9.275 9.275 9.275 best indication to the state of strength of a particular
AEA 0.228 0.228 0.228 concrete. The experimental results of compressive
strength of the concretes with water-binder ratio of 0.35
Table 3 Details of Mix Proportion for FA0QD, produced in this study are shown in Figure 1 and Figure
FA20QD and FA40QD Concretes with 2, whereas Figure 3 and Figure 4 represent the
Water-Binder Ratio of 0.35 (kg/m3) compressive strength of the concretes with water-binder
Type of Concrete ratio of 0.50. The 91st day compressive strengths of
Materials
FA0QD FA20QD FA40QD concretes with water-binder ratio of 0.35 ranged
Coarse between 61.2 MPa and 70.9 MPa. For the case of
1003 1003 1003
aggregate concretes with water-binder ratio of 0.50, the 91st day
Sand 644 515 386 compressive strengths ranged between 37.6 MPa and
Quarry dust - 132 263 51.8 MPa. It can be observed that the incorporation of
Cement 477 477 477 quarry dust as partial replacement material to river sand,
Fly ash 53 53 53 and the inclusion of fly ash as cement replacement
Water 185.5 185.5 185.5 material resulted in significant effects to the
SP 9.275 9.275 9.275 compressive strength of concrete. The results indicate
AEA 0.493 0.493 0.493 that for both water-binder ratios, the incorporation
quarry dust into concrete without the inclusion of fly ash
resulted in a decrease in compressive strengths. Previous forming underneath [2], resulting in negative effects to
studies reported have also indicated similar findings [6- the compressive strength and durability of concrete. Tan
8]. Further reduction in the compressive strength was et al. reported that the increase in replacement
observed when the replacement proportion of sand with proportion of sand with quarry dust results in the
quarry dust is increased. reduction of compressive strength and this might be
caused by the coarser shape and surface texture of
75 quarry dust which is detrimental to the binding between
70 cement and aggregate paste [7].
Compressive Strength (MPa)

65 55
60 50

Compressive Strength (MPa)

55 45
40
50
35
45
30
40
25
35
20
OPC20QD

OPC40QD
OPC0QD

FA20QD

FA40QD
FA0QD

15
10

OPC20QD

OPC40QD
OPC0QD

FA20QD

FA40QD
FA0QD
7th day 28th day 56th day 91st day

“Fig. 1” Compressive Strength Development of Water

Cured Concretes with Water-Binder Ratio of 0.35 7th day 28th day 56th day 91st day

66 “Fig. 3” Compressive Strength Development of Water

64 Cured Concretes with Water-Binder Ratio of 0.50
Compressive Strength (MPa)

62 50

60 45
Compressive Strength (MPa)

58 40

56 35

54 30
52 25

50 20
OPC20QD

OPC40QD
OPC0QD

FA20QD

FA40QD
FA0QD

15

10
OPC20QD

OPC40QD
OPC0QD

FA20QD

FA40QD
FA0QD

28th day 56th day 91st day

“Fig. 2” Compressive Strength Development of Air

Cured Concretes with Water-Binder Ratio of 0.35 28th day 56th day 91st day

Properties of aggregates used in concrete mixes “Fig. 4” Compressive Strength Development of Air
such as size, particle shape, surface texture, grading and Cured Concretes with Water-Binder Ratio of 0.50
aggregate-cement ratio influences the strength of the
concrete [2,12]. The quarry dust used in this study It can be observed from Figure 1 to Figure 4 that
recorded a flakiness index of 54.58 % which implies the negative effects of reduced compressive strength in
substantial amount of flaky particles in the quarry dust the quarry dust concrete was compensated by the
sample. Aggregates with flaky particle shape tends to be inclusion of fly ash into the concrete. Concrete
oriented in one plane, with air voids and bleeding water containing fly ash has recorded higher compressive
strength than the quarry dust concrete under all
conditions. The beneficial effects of fly ash in the
strength development and durability properties of
concrete are widely accepted. The contribution of fly ash
to the positive effects in the strength in concrete has
been attributed to direct water reduction, the increase in
the effective volume of paste in the mix and its
pozzolanic reaction [5]. Besides the effect of chemical
reaction, fly ash has a physical effect of improving the
microstructure of the hydrated cement paste [2].
Therefore, it can be mentioned that quarry dust can be
utilised as partial replacement material to sand, in the
presence of fly ash, to produce concretes with fair range
of compressive strength.
In the aspects of contribution of water-binder ratio,
it can be observed that concretes produced with water-
binder ratio of 0.35 have always recorded higher
compressive strength than the concrete produced with
water-binder ratio of 0.50. This is in agreement with the
theoretical understanding that concretes produced with
lower water-binder ratio would exhibit higher
compressive strength compared to concretes produced
with higher water-binder ratio. Similarly, water cured
specimens recorded higher compressive strengths than
air cured specimens in all conditions. Curing of
concrete, especially in the early period of hydration is
one of the governing factors in ensuring the
development of good concrete properties. Zain et al. has
mentioned that compressive strength, modulus of
elasticity and durability of concrete are improved with
efficient uninterrupted curing [1]. The lower
compressive strength of air cured concretes might be
caused by the fact that hydration is greatly reduced when
the relative humidity within the capillary pores drops
below 80% [2].
(4) CONCLUSIONS
The following conclusions can be derived based on the
results and discussions above:
1. The partial replacement of river sand with quarry
dust without the inclusion of fly ash resulted in a
reduction in the compressive strength of concrete
specimens.
2. The reduction in the compressive strength of quarry
dust concrete was compensated by the inclusion of
fly ash into the concrete mix.
3. Under all conditions, concretes with water-binder
ratio of 0.35 and water cured specimens recorded
higher compressive strength than the concretes with
water-binder ratio of 0.50 and air cured specimen
respectively.
4. Quarry dust can be utilised as partial replacement
material to sand, in the presence of fly ash, to
produce concretes with fair ranges of compressive
strength.
(5) REFERENCES
[1] M.F.M. Zain, Md. Safiuddin and H. Mahmud,
“Development of high performance concrete using silica
fume at relatively high water-binder ratios”, Cement and
Concrete Research 30 (9), pp. 1501-1505, 2000.
[2] A.M. Neville, Properties of Concrete – Fourth and
Final Edition, Pearson Education Limited, Essex, 2002.
[3] K.E. Hassan, J.G. Cabrera and R.S. Maliehe, “The
effect of mineral admixtures on the properties of high-
performance concrete”, Cement & Concrete Composites
22 (4), pp. 267-271, 2000.
[4] H. Temiz and A.Y. Karakeci, “An investigation on
microstructure of cement paste containing fly ash and
silica fume”, Cement and Concrete Research 32 (7), pp.
1131-1132, 2002.
[5] M.L. Gambhir, Concrete Technology – Second
Edition, Tata McGraw-Hill Publishing Company
Limited, New Delhi, 1995.
[6] M. Safiuddin, M.F.M. Zain, M.F. Mahmud and R.S.
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cubes”, Testing Concrete, British Standards Institution,
London, 1983.
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New York, 1996.