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The Effects of Silica Fume and Fly Ash On The Scaling Resistance and Flexural Strength of Pavement Concretes
The Effects of Silica Fume and Fly Ash On The Scaling Resistance and Flexural Strength of Pavement Concretes
The Effects of Silica Fume and Fly Ash On The Scaling Resistance and Flexural Strength of Pavement Concretes
To cite this article: Engin Yener & Sinan Hinislioğlu (2011) The Effects of Silica Fume and Fly
Ash on the Scaling Resistance and Flexural Strength of Pavement Concretes, Road Materials
and Pavement Design, 12:1, 177-194, DOI: 10.1080/14680629.2011.9690358
ABSTRACT. The purpose of this study is to investigate the effects of Silica Fume (SF) and Fly
Ash (FA) additives on the frost salt scaling resistance and flexural strength properties of
pavement concrete. An attempt is also made to attain a more durable and higher strength
concrete by a suitable combination of Ordinary Portland Cement (OPC), SF and FA. SF and
FA are used as cement replacement in proportions of 0, 5, 10% and 0, 5, 10, 15% by weight
respectively. Flexural strength is tested after 7, 28 and 91 days of the lime saturated water
curing period. The experimental results indicate that using FA only decreases while SF only
slightly increases 28-days flexural strength. On the other hand, using SF and FA together
shows relatively more strength gain. Among all those tested, maximum 28 days flexural
strength of 4.53 MPa is obtained for the mix proportions of 85% OPC + 10% FA and 5% SF.
SF significantly decreases the amount of liquid absorption by capillary suction and has a
significant effect on the scaling resistance. In addition, all the ternary mixtures showes better
scaling resistance than the control mixture with 100% OPC.
KEYWORDS: Concrete Pavement, Fly Ash, Silica Fume, Flexural Strength, Durability, Frost
and Deicing Salt Resistance.
Road Materials and Pavement Design. Volume 12 – No. 1/2011, pages 177 to 194
178 Road Materials and Pavement Design. Volume 12 – No. 1/2011
1. Introduction
Portland cement concrete pavements (PCCP) usually have design life from 20 to
60 years. A concrete pavement is to carry the traffic loads and resist the
environmental conditions in this long service life. To ensure this, the concrete used
in the pavement should have adequate strength and durability.
Concrete, used for the construction of road and footpath pavement, aside from
the ordinary resistance to freezing and thawing, must also be resistant to the effects
of de-icing agents. In many European countries the problem of concrete resistance to
freezing and thawing, in the conditions where de-icing agents are used, is of key
importance. Freezing a saline solution on the PCCP surface causes a superficial
damage named “scaling”. The scaling damage is progressive and consists of the
removal of small chips or flakes of material. It results in accelerated ingress of
aggressive species, such as chlorides, and the propensity for a high degree of
saturation. The former renders the body susceptible to corrosion of the reinforcing
steel, while the latter results in strength loss from internal frost action. Also scaling
increases surface roughness and decreases slab thickness. These worsen the riding
quality of the vehicles and reduce the bearing capacity of the pavement.
Consequently, salt scaling is one of the major durability issues facing PCCP in cold
climates.
A number of theories have been developed to explain the deterioration process of
frost – and de – icing salt. Rostam (1989) explains a special scaling feature as a
displacement of the freezing front due to salt in the pore water. He considers the
phenomenon to be caused by simultaneous salt and temperature gradients, leading to
initial freezing of the surface and a separate layer somewhat further down. This is
supposed to entrap water, seeking to escape, when the middle layer finally freezes.
An alternative explanation is that the salt concentration in the outer layer depresses
the freezing point in the outer layer, but not further down. Hence, temperature drop
from the outside under such conditions may cause the deeper level to freeze first. In
either case, the damage may occur as the spalling-off of a layer as described above.
Valenza and Scherer (2007) introduced a theoretical explanation of the
mechanism of frost salt attack called glue-spall. According to this theory, the
cracking of the ice/brine layer is the origin of scaling. The principal idea is that
following the ice formation on top of the concrete surface, ice starts to shrink due to
further cooling and the exerted tensile stress exceeds the tensile strength of ice and
breaks the ice, which triggers surface scaling. Acording to the authors, the strength
of the surface governs the ability of a cementitious body to resist salt scaling. Also
considering the other mechanisms, pore size, pore distribution, spacing factor,
degree of saturation of the pore system, permeability, salt concentration, salt
gradient and temperature gradient may be important parameters for salt scaling
resistance.
The Effects of Silica Fume on the Scaling Resistance 179
The use of mineral admixtures such as Ground Granulated Blast Furnace Slag
(GGBFS), Silica Fume (SF) or Condensed Silica Fume (CSF) and Fly Ash (FA) and
these are by-products of other industries, has recently increased to enhance the
strength and durability properties of concrete.
The durability of the concrete with or without puzzolanic materials in the marine
environment is very important. Alexander and Mackechnie (2004) have studied the
concrete mixes for durable marine structures. Du Prezz and Alexander (2004) have
also studied durability indexes for concrete in marine conditions. They reported that
three blended binders (GGBS, FA and CSF) were used to cast a series of wall and
slab elements. The elements were cured using practical site methods currently
employed in the industry. Cores were extracted at early (28-day) and delayed (120-
day) ages and used to determine the durability index properties. The results
indicated that it is possible to manufacture, place and cure site concrete to achieve
acceptable durability properties using GGBS, FA and CSF.
This type of pozzolanic materials convert Calcium Hydroxide (CH) (a product of
cement hydration) to Calcium Silicate Hydrate (C-S-H). This improves strength, yet
removes the potential for the soluble CH to leach (increasing porosity) or Carbonate
(decreasing pH and increasing delayed ettringite formation potential). There is also a
physical effect of SF: Extremely fine SF particles fill the pores in aggregate-cement
paste interface, which cause a denser interface. Thus, SF increases the adherence
between the aggregates and cement paste. Sabir (1997) points out that for low levels
of SF (5-10%) and at low concrete strength levels (up to 40MPa compressive
strength), the SF is more efficient in acting as a filler than as a pozzolan.
In general, SF incorporation results in the improvement of tensile strength.
Bhanja and Sengupta (2005) showed that, while other mix design parameters
remaining constant, SF incorporation in concrete results in significant improvement
in the tensile and compressive strengths of concrete. The optimum SF replacement
by percentage for tensile strength has been found to be a function of water-
cementitious material (w/cm) ratio of the mix. The optimum 28-day split tensile
strength has been obtained in the range of 5-10% SF replacement level, whereas the
same for flexural strength ranged from 15% to 25%. Both the split and flexural
tensile strengths at 28 days follow almost the same trend as the 28-day compressive
strength. Increase in split tensile strength beyond 15% SF replacement is almost
insignificant, whereas sizeable gains in flexural tensile strength have occurred even
up to 25% replacements.
For the purpose of pavement thickness design, pavement concrete is
characterized by its flexural strength (AASHTO, 1993; FAA, 1995). Also flexural
strength at early days is important as it is an indication of the pavement’s ability to
withstand traffic loads before opening the road. Therefore, the flexural strengths at
early, moderate and late days of with FA and SF modified concrete are investigated
in this study.
180 Road Materials and Pavement Design. Volume 12 – No. 1/2011
The details of the materials and methods were given below. This study is based
on the master thesis by Yener (2004).
2.1. Materials
2.1.2. Aggregate
A growing number of transportation-related agencies are experimenting with
increased control of aggregate gradation in their specifications for the production of
Portland cement concrete. The justification is that modest controls in gradation that
do not require an inordinate amount of increased effort or cost can yield significant
benefits in workability, strength, durability, and reliable mix design. MDOT (1996)
provides an optional incentive if the mix aggregate gradation meets the following
requirements: “The combined aggregates shall be well graded from the coarsest to
the finest with no more than 18 percent nor less than 8 percent of the combined
aggregate retained on any individual sieve with the exceptions that the No. 50 sieve
may have less than 8 percent retained, and the coarsest sieve may have less than 8
percent retained” (MDOT, 1996; Cramer and Carpenter, 1999). Therefore, three
coarse and one fine crushed basalt aggregate batches with different size ranges are
combined at the designated ratios to satisfy the 8-18 band requirement for aggregate
gradation and used in this study. Maximum aggregate size is 25mm. The combined
aggregate gradation is shown in Figure 1.
182 Road Materials and Pavement Design. Volume 12 – No. 1/2011
2.1.3. Superplasticiser
A naphthalene sulfonat basis superplasticizer is used. The workability of
pavement concretes is limited to 15-50mm slump range according to Turkey
Highway Administration Agency (KGM, 2006). Thus, superplasticizer is
incorporated in all mixes and the content is adjusted slightly for some mixes to
maintain the same degree of workability (20-30mm slump). The workability and
consistency of the fresh concrete mixes are measured using the slump cone test
(ASTM C 143M-97). The superplasticizer contents and the slump results are shown
in Table 2. After the slump test, the fresh concrete samples are filled into the molds
in three layers, each approximately one-third volume of the mold. Each layer is also
rodded with 25 strokes for consolidation, and sample surface is then levelled with a
trowel.
2.2. Methods
were then removed from the water tank and stored in the air at 20ºC for surface
drying for 21 days. 2 days before presaturation the specimens were sealed on their
lateral surfaces with a solvent free epoxy resin, whereas the bottom of the specimens
and the test surface were kept free. Following the dry storage, the specimens were
placed in test containers on the 5mm high spacers with the test surface underneath.
Subsequently, deicing agent solution composed of 97% distilled water and 3% NaCl
was filled into the container to a height of 10±1mm without wetting the specimen’s
top. The test containers were closed with a cover during the capillary suction. The
capillary suction period was 7 days at a temperature of 20±2 ºC. 7 days later, the
weight gains of the specimens were measured. The calculated liquid absorption
values by capillary suction are shown in Table 3. A 12 hours freeze-thaw cycle
changing from +20ºC to -20ºC were applied. The reference temperature was
measured in the cooling bath liquid below the bottom of the test container. After 14
and 28 cycles, the surface scaling measurements were made. To make the scaling
measurements the solution comprising the scaled material was filtered.
Subsequently, the paper filter was dried at an oven and cooled in air. Then, the mass
of the dried scaled material was weighted and the scaling results were recorded as
mass per unit area (Table 3). The CDF acceptance criterion is a maximum mean
scaling of 1500g/m² after 28 freeze-thaw cycles (RILEM TC 117 FDC, 1996; Setzer
et al., 1997).
Figure 2. A view of the flexural test of concrete using the third-point loading method
The Effects of Silica Fume on the Scaling Resistance 185
All test results are shown in Table 3. Most of them are also presented in
graphical form, evaluated and discussed.
Table 3. Test results of flexural strength, capillary suction, scaling and density
3.1. Density
The densities of the hardened concretes ranging from 2.241 to 2.391gr/cm3 are
shown in Table 3. According to the test results, increasing amount of FA and SF
replacement of cement decreased the densities. The densities of the concretes with
SF are lower than the control mixture since both FA and SF have smaller specific
gravities.
The data obtained from the CDF test were used to calculate the amount of the
liquid absorption by capillary suction. The results of the liquid absorption were
shown in Table 3 and Figure 3 to 5. It is clearly seen from the Figure 3 that as the SF
is increased capillary suction decreased. SF contributes to decreasing the capillary
suction in two ways. First, very thin SF grains resulting in microfiller effect
increased the compasity of the binder paste. Second, the interface region between
the aggregate particles and the binder paste is affected by SF. This contribution is
provided by both preventing the water pockets forming under the aggregate grains
by decreasing sweating, and converting the CH at the interface to the C-S-H. In the
binary mixtures with FA, capillary suction increased with increasing FA up to 10%
FA, after that it decreased at the 15% FA (Figure 4). Among all the mixtures,
186 Road Materials and Pavement Design. Volume 12 – No. 1/2011
minimum capillary suction of 1118gr/m2 was obtained for the mix proportions of
85% OPC + 5% FA +10% SF (M6). Maximum liquid absorption of 1688 g/m2 was
reached at mix proportions of 90% OPC + 10% FA and 0% SF (M7).
3.3.1. The effect of SF on flexural strength of binary mixtures with OPC and SF
concrete could be attributed to the improvement in the bond between the hydrated
cement matrix and the aggregate. SF mixtures also exhibited higher long term
strength development than the control mix due to the pozzolanic effect of SF with
high content of SiO2+Al2O3+Fe2O3.
3.3.2. The effect of FA on flexural strength of binary mixtures with OPC and FA
As it is clearly seen from Figure 7, seven days flexural strength increased with
increasing FA replacement in the binary mixtures. As minimum 7 days flexural
strength was obtained at control mix, maximum 7 days flexural strength which is
3.26 MPa is reached at the type M10 mix containing 15% FA. As it can be seen
from Table 1, CaO content of FA is %11.82. It means that FA used in the study has
higher than 10% CaO. C.D. Atis et al. (2004) have stated that FA increased the early
flexural strength 3 days and beyond. In addition, Yasar et al. (2003) have also
reported that mixture containing fly ash developed higher or comparable flexural
tensile strength at 7 days and beyond. High CaO content of a FA improves the
strength of a FA concrete at early days (Papayianni, 1987). Due to not to be used
high volume of FA in the mixes, the strength development at 7 days may be
attributed to the high CaO content, which means high chemical reaction. 5% FA
replacement decreased the 28 days flexural strength in binary mixtures, because FA
replacement resulted in some decrease in OPC content. There is an increase in
strength development at the replacement levels beyond 5% FA. This can be
attributed the considerable increase of the binder volume due to FA replacement
with OPC by weight because the specific gravity of the FA is lower than the OPC.
The results showed that the incerases in flexural strength after 28 days for the binary
mixes containing FA are higher than that of the control mix. High long-term strength
development of the FA mixtures can be attributed to pozzolanic reactions
(Papayianni, 1987).
The scaling test results are found to be between 1004 and 5827 g/m² after 28
freeze-thaw cycles, depending on the quality of the concretes. The highest scaling
was observed 5827 g/m² in the control mixture. SF samples without FA exhibited
very low scaling satisfying CDF criterion. The lowest scaling was observed 1004
g/m² in M3 (90%OPC+10%SF+0%FA). Increasing SF content dramatically
increased deicer-scaling resistance. The effect of SF on scaling can be seen clearly
in Figure 9. 5% SF replacement level were found enough for binary mixtures to
resist the scaling effect of freeze-thaw-and-deicing agent. Scaling values of the
binary FA samples without SF were less than the control sample’s scaling, but they
did not satisfy CDF criterion. The effect of FA on scaling can be seen in Figure 10.
Deicer scaling resistance of the ternary mixes containing FA and SF is higher than
the control mix. However, the unique ternary mix providing the CDF criterion is the
type M6 mix containing 85% OPC + 5% FA+ 10% SF (1414 g/m²) (see Figure 11).
It can be seen in Figures 9-11 that the CDF scaling results after 14 f-t cycles
have a same trend as the results after 28 f-t cycles. Therefore, the CDF scaling
results after 14 f-t cycles may be used to evaluate the scaling resistance of concretes
like used in this study.
Acording to the glue-spall theory (Valenza and Scherer, 2007a and 2007b), the
strength of the surface governs the ability of a cementitious body to resist salt
scaling. The results of this study showed that there is not a direct relationship
between the flexural strength and the salt scaling (see Table 3). Because high
flexural strength do not guarantee high surface strength, the difference between
surface and internal strength may result from bleeding and segregation. Especially,
the concretes with low slump consist of seperation of the mortar from the body of
concrete during consolidation. The contribution of SF to scaling resistance can be
attributed to improvement of the concrete’s surface strength. Increasing the
replacement ratio of the ultrafine SF particles with OPC grains decreases
segregation and bleeding resulting in stronger surface. 5% FA replacement ratio
decreased scaling, while beyond this ratio scaling increased. Therefore, this can be
attributed to the segregation and bleeding. In such a way that, increasing FA
replacement increases binder volume resultingly decreases bleeding. However,
The Effects of Silica Fume on the Scaling Resistance 191
Figure 11. CDF scaling test results of the ternary cementitious mixtures
4. Conclusions
This study has demonstrated that more durable and stronger pavement concrete
can be obtained with a suitable combination of OPC, FA and SF. The experimental
results in the current test conditions have indicated that using FA only decreases
while SF only slightly increases 28 days flexural strength. On the other hand, using
SF and FA together shows relatively more strength gain. Among all those tested,
maximum 28 days flexural strength of 4.53 MPa is obtained for the mix proportions
of 85% OPC + 10% FA and 5% SF. SF significantly decreases the amount of liquid
absorption by capillary suction and has a significant effect on the scaling resistance.
In addition, all the ternary mixtures shows better scaling resistance than the control
mixture with 100% OPC
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