influences of class f and c fly ash blending · headwaters resources influences of class f and c...

Head

wate

rs R

esou

rces

Influ

ence

s of C

lass F

and

C Fl

y Ash

Blen

ding

Ben

Fran

klin

Tech

nica

l Dire

ctor

Doug

Rho

des

Labo

rato

ry M

anag

er

2015

Wo

rld

of

Co

al A

sh (

WO

CA

) C

on

fere

nce

in N

asvh

ille,

TN

- M

ay 5

-7, 2

015

htt

p:/

/ww

w.f

lyas

h.in

fo/

2

•In

divi

dual

mat

eria

ls a

re te

sted

for c

hem

ical

oxi

des,

par

ticle

den

sity

an

d LO

I.

•O

bjec

tives

kee

p th

e su

m o

f con

stitu

ents

bet

wee

n 72

% a

nd 7

5%.

•M

ater

ial i

s bl

ende

d to

con

form

with

AST

M C

1697

uni

form

ity ±

5.0%

.

•LO

I is

kept

bel

ow 2

.0%

.

•Av

aila

ble

Alka

lis a

re h

eld

at 1

.3%

.

•Lo

wer

the

CaO

foun

d in

Cla

ss C

ash

that

can

exa

cerb

ate

sulfa

te

atta

ck a

nd A

SR

POZZ

OLA

N B

LEN

DIN

G O

BJE

CTI

VES

3

AST

M C

1697

BLE

ND

ED S

UPP

LEM

ENTA

RY C

EMEN

TITI

OU

S M

ATER

IALS

APP

ENDI

X X1

VER

IFYI

NG

BLE

ND

PRO

POR

TIO

NS

•X1

.1 T

his

Appe

ndix

pro

vide

s in

form

atio

n fo

r pur

chas

ers

of b

lend

ed s

uppl

emen

tary

ce

men

titio

us m

ater

ials

abo

ut ty

pica

l m

etho

ds th

at m

anuf

actu

rers

use

to c

ontro

l th

e bl

end

prod

uctio

n pr

oces

s an

d ve

rify

prod

uct c

onfo

rman

ce.

•X1

.2 M

echa

nica

l met

hods

, suc

h as

w

eigh

ing

indi

vidu

al c

onst

ituen

ts a

s ea

ch

goes

to th

e bl

endi

ng s

yste

m a

re a

dequ

ate

to p

rovi

de p

rodu

ctio

n co

ntro

l but

che

mic

al

anal

ysis

as

desc

ribed

bel

ow is

requ

ired

by

this

spe

cific

atio

n fo

r ver

ifyin

g ac

tual

ble

nd

prop

ortio

ns:

•X1

.2.1

Ens

ure

wei

gh fe

eder

s ar

e m

aint

aine

d an

d ca

libra

ted

befo

re

prod

uctio

n. W

eigh

feed

ers

are

to p

rovi

de

for g

ener

al c

ontro

l and

adj

ustm

ent d

urin

g pr

oduc

tion.

•X1

.2.2

Ens

ure

that

the

anal

ysis

met

hod,

X-

ray

fluor

esce

nce

(XR

F) o

r oth

er

qual

ified

met

hod

is c

alib

rate

d w

ithin

the

rang

es o

f mat

eria

ls b

eing

test

ed.

X1.2

.3 S

ampl

e an

d ch

emic

ally

ana

lyze

indi

vidu

al

cons

titue

nts

befo

re p

rodu

ctio

n be

gins

and

at

esta

blis

hed

frequ

enci

es d

urin

g pr

oduc

tion.

X1.2

.4 S

ampl

e an

d ch

emic

ally

ana

lyze

fini

shed

ble

nded

su

pple

men

tary

cem

entit

ious

mat

eria

ls a

t es

tabl

ishe

d fre

quen

cies

dur

ing

prod

uctio

n ru

ns fo

r qu

ality

con

trol p

urpo

ses

and

verif

icat

ion

of b

lend

pr

opor

tions

X1.2

.5 P

ropo

rtion

ana

lysi

s, a

s us

ed h

ere,

is a

cal

cula

tion

usin

g th

e ch

emic

al a

naly

sis

of th

e in

divi

dual

co

nstit

uent

s an

d th

e re

sulta

nt b

lend

.X1

.2.5

.1 T

he in

divi

dual

con

stitu

ents

are

ana

lyze

d an

d pr

edom

inan

t ele

men

ts a

re c

hose

n as

che

mic

al

iden

tifie

rs.

X1.2

.5.2

Tho

se c

hose

n id

entif

iers

are

then

use

d to

ca

lcul

ate

the

mas

s %

of c

onst

ituen

ts in

the

blen

ded

supp

lem

enta

ry c

emen

titio

us m

ater

ial.

An e

xam

ple

of th

is c

alcu

latio

n fo

llow

s. T

his

is a

bas

ic

exam

ple

for i

llust

rativ

e pu

rpos

es u

sing

one

ele

men

t. A

mor

e de

taile

d an

alys

is u

sing

mul

tiple

ele

men

ts

can

be p

erfo

rmed

usi

ng a

spr

eads

heet

pro

gram

su

ch a

s EX

CEL

Sol

ver

4

Blen

ded

fly a

shes

is a

hom

ogen

eous

ble

nd o

f su

b-bi

tum

inou

s an

d bi

tum

inou

s co

al a

sh.

Com

bini

ng s

ub-b

itum

inou

s an

d bi

tum

inou

s co

al

ashe

s pr

ovid

es c

onsu

mer

s th

e po

sitiv

e at

tribu

tes

of b

oth

mat

eria

ls a

nd re

duce

s va

riatio

ns th

at a

re

som

etim

es e

xper

ienc

ed fr

om p

ower

pla

nts

oper

atin

g un

der t

oday

’s m

ore

strin

gent

en

viro

nmen

tal c

limat

e. T

he b

lend

ed fl

y as

h of

fers

en

d us

ers

mor

e be

nefit

s ve

rsus

the

sum

of t

heir

parts

. Ble

nded

fly

ashe

s ca

n be

use

d in

any

ap

plic

atio

n w

here

a C

lass

F fl

y as

h is

spe

cifie

d.

BLE

ND

ED F

LY A

SH

5

–A

ppen

dix

X1. V

erify

ing

Ble

nd P

ropo

rtio

ns (s

umm

ary)

.–

X1.2

Mec

hani

cal m

etho

ds …

wei

ghin

g in

divi

dual

con

stitu

ents

as

each

goe

s to

the

blen

ding

sys

tem

. . .

but c

hem

ical

ana

lysi

s as

de

scrib

ed b

elow

is re

quire

d . .

. fo

r ver

ifyin

g ac

tual

ble

nd

prop

ortio

ns.

–X1

.2.3

Sam

ple

and

chem

ical

ly a

naly

ze in

divi

dual

con

stitu

ents

be

fore

pro

duct

ion

begi

ns.

–X1

.2.4

Sam

ple

and

chem

ical

ly a

naly

ze fi

nish

ed b

lend

ed

supp

lem

enta

ry c

emen

titio

us m

ater

ials

at e

stab

lishe

d fre

quen

cies

. .

. Fo

r qua

lity

cont

rol p

urpo

ses

and

verif

icat

ion

of b

lend

pr

opor

tions

. –

X1.2

.5.2

Tho

se c

hose

n id

entif

iers

are

then

use

d to

cal

cula

te th

e m

ass

% o

f con

stitu

ents

in th

e bl

ende

d su

pple

men

tary

ce

men

titio

us m

ater

ial.

AST

M C

-169

7B

LEN

DED

SU

PPLE

MEN

TARY

CEM

ENTI

TIO

US

MAT

ERIA

LS

AST

M-1

697

ASTM

 C1697

‐10 Ap

pend

ix X1.2.5.2 (W

orkshe

et)

±5%

 Max

P2Va

riance

Sample

Miller

Gaston

Blen

d %  C

 | F

Theo

retical

Actual

Actual vs

Date

Sample IDs

Type

Total Sum

Total Sum

Class C

Class F

Total Sum

Total Sum

Theo

retical

7/1/13

1480

MR;  161

2GT;  165

2P2A

Mon

thly

65.73

88.91

51%

49%

77.09

77.96

1.1%

8/1/13

1723

MR;  192

1GT;  193

7P2A

Mon

thly

62.89

88.67

51%

49%

75.52

76.2

0.9%

9/1/13

2071

MR;  205

6GT;  214

3P2A

Mon

thly

62.85

87.69

51%

49%

75.02

75.78

1.0%

10/1/13

2335

MR;  229

6GT;  235

2P2A

Mon

thly

65.39

87.82

51%

49%

76.38

76.51

0.2%

11/1/13

2422

MR;  261

4GT;  257

1P2A

Mon

thly

63.61

88.83

51%

49%

75.97

76.72

1.0%

12/1/13

2680

MR;  218

GT;  44P

2AMon

thly

65.54

88.54

51%

49%

76.81

76.88

0.1%

Calculations: A

STM C16

97‐10X

1.2.5.2 lim

its +/‐5%

7

•In

dust

ry S

peci

ficat

ions

–AS

TM –

Amer

ican

Soc

iety

for T

estin

g M

ater

ials

–

AASH

TO –

Amer

ican

Ass

ocia

tion

of S

tate

Hig

hway

the

Tran

spor

tatio

n O

ffici

als

•D

OT

Spec

ifica

tions

•H

eadw

ater

s R

esou

rces

’ Sta

ndar

d O

pera

ting

Proc

edur

es

(SO

P)

VER

IFIC

ATIO

N O

F C

OM

PLIA

NC

E

8

BLE

ND

ING

IMPA

CT

TO C

OLO

R

Clas

s F A

shRe

sultin

g Blen

dCl

ass C

Ash

9

Che

mic

al

Cla

ss F

75%

F /

25%

C

50%

F /

50%

C25

% F

/ 75%

C

Cla

ss C

Silic

on D

ioxi

de, S

iO2

47.7

3%45

.26%

42.7

4%40

.85%

39.3

2%

Alu

min

um O

xide

, Al2

O3

28.1

9%25

.65%

23.2

1%21

.17%

19.2

4%

Iron

Oxi

de, F

e2O

311

.92%

10.5

1%9.

28%

8.23

%6.

22%

Sulfu

r Tri

oxid

e, S

O3

0.32

%0.

78%

1.03

%1.

27%

1.52

%

Cal

cium

Oxi

de, C

aO4.

02%

8.75

%13

.56%

18.5

1%23

.25%

Sum

Of O

xide

s (C

lass

)87

.84%

81.4

2%75

.23%

70.2

5%64

.78%

Avai

labl

e Alk

..7

51.

261.

1.9

11.

33

Car

bon

% (L

eco)

1.94

1.47

1.06

0.58

0.15

7

Spec

ific

Gra

vity

gm

/cm

32.

382.

422.

422.

462.

49

LO

I %2.

131.

571.

090.

70.

31

Fine

ness

%24

.02

24.0

223

.76

22.6

425

.1

Moi

stur

e %

0.13

0.11

0.1

0.1

0.10

6

Sum

mar

y of

Che

mic

al a

ndPh

ysic

al P

rope

rties

10

CO

MPR

ESSI

VE S

TREN

GTH

A

STM

C-1

09

0

1000

2000

3000

4000

5000

6000

Cla

ss C

75/2

550

/50

25/7

5C

lass

F

7 da

y SA

I28

Day

SAI

11

AST

M C

-192

CO

NC

RET

E D

ATA

Con

trol

Cla

ss C

C

lass

F

50/5

0Sl

ump

.25

inch

66

66.

5U

nit W

t lb/

ft14

5.6

146.

314

6.3

147.

1A

ir %

Pre

ssur

e6

5.5

5.2

5W

C R

atio

0.62

0.58

0.63

0.59

Tem

p. F

6565

6565

1 D

ay C

ompr

essi

ve *

* 15

0196

286

210

07

3 D

ay C

ompr

essi

ve *

*28

1922

4518

3720

887

Day

Com

pres

sive

3197

3552

2726

2813

14 D

ay C

ompr

essi

ve

3432

3513

3097

3440

28 D

ay C

ompr

essi

ve40

5842

2837

5541

3256

Day

Com

pres

sive

4580

5212

4693

5268

** 3

X6

Cyl

inde

rs a

ll ot

her a

ges 4

X8

12

CO

NC

RET

E ST

REN

GTH

AST

M C

-39

13

The b

lendin

g pro

cess

re

duce

s var

iabilit

y of

Clas

s F fly

ash f

rom

the po

wer p

lant. T

he

blend

in co

ncre

te at

a 25

perce

nt su

bstitu

tion

rate

perfo

rms b

etter

tha

n the

contr

ol mi

x an

d the

Clas

s F m

ix at

28 an

d 56 d

ays.

0

1000

2000

3000

4000

5000

6000

1 da

y3

days

7 da

ys14

day

s28

day

s56

Compressive PSI

Age

in D

ays

Com

pres

sive

Str

engt

h

Con

trol

Cla

ss C

Ash

50 /

50C

lass

F A

sh

CO

NC

RET

E ST

REN

GTH

14

SETT

ING

TIM

E O

F C

ON

CR

ETE

AST

M C

-403

15

ASTM

C-1

012 s

ulfate

expa

nsion

grap

h res

ults,

Clas

s C fly

ash i

s exc

eedin

g max

imum

ex

pans

ion lim

its at

six m

onths

. Blen

d doe

s not

perfo

rm as

well

as a

straig

ht Cl

ass F

ash;

howe

ver, p

erfor

ms be

tter t

han s

traigh

t Clas

s C

fly as

h.

“Tilk

asky

and C

arra

squil

lo(1

993)

; and

Dun

stan

(197

6); s

howe

d tha

t con

crete

conta

ining

some

hig

h-ca

lcium

fly as

hes a

re su

scep

tible

to su

lfate

attac

k, an

d gen

erall

y, hig

her v

olume

s of

high-

calci

um fly

ash m

ixtur

es ha

ve a

grea

ter

susc

eptib

ility t

o sulf

ate de

terior

ation

” (A

meric

an C

oncre

te Ins

titute

[ACI

], 200

8, p.

17).

Blen

ding C

with

F fly

ash m

itigate

s pro

blems

ca

used

by hi

gh C

aOC

ashe

s.

AST

M C

-101

2

0.00

0

0.02

0

0.04

0

0.06

0

0.08

0

0.10

0

0.12

0

0.14

0

1 w

k2

wk

3 w

k4w

k8

wk

13 w

k15

wk

4 m

th6

mth

Expansion %

Tim

e w

eeks

C A

shF

Ash

Blen

d

16

AST

M C

-156

7 D

ATA

•AS

TM C

156

7 co

mpa

rison

gra

ph

show

s th

e bl

end

outp

erfo

rms

stra

ight

Cla

ss

C’s

abi

lity

to in

hibi

t alk

ali s

ilica

reac

tivity

ex

pans

ion.

•

Com

bini

ng C

lass

C a

nd C

lass

F fl

y as

h cl

early

low

ers

the

perc

enta

ge o

f alk

ali

avai

labl

e in

Cla

ss C

fly

ash,

com

plim

entin

g th

e ad

vant

ages

of b

oth

prod

ucts

resu

lting

im

prov

ed c

oncr

ete

dura

bilit

y.•

Adde

d be

nefit

of a

llow

ing

conc

rete

pr

oduc

ers

to u

se h

ighe

r per

cent

ages

of f

ly

ash

in th

eir c

oncr

ete

prod

ucts

as

com

pare

d to

typi

cal C

lass

F fl

y as

hes.

•

Hig

her p

erce

ntag

es o

f fly

ash

repl

acem

ent,

impr

oves

con

cret

e du

rabi

lity

17

Comb

ining

Clas

s C

and C

lass F

fly as

h ha

s the

follo

wing

be

nefits

:

Lowe

r CaO

Lowe

r LOI

Lowe

r ava

ilable

Na2

O

18

•U

se o

f AST

M C

-169

7•

Perfo

rman

ce d

riven

sal

es w

ith a

sh th

at c

an b

e ta

ilore

d to

a

parti

cula

r reg

ion.

•Ab

ility

to m

aint

ain

cons

tant

sup

plie

s of

mat

eria

l.•

Poss

ibilit

y to

use

oth

er S

CM

suc

h as

Sla

g, S

ilica

Fum

e an

d na

tura

l Poz

zola

ns in

ble

nd.

•Ab

ility

to b

enef

icia

te o

ne s

ourc

e, w

ith a

noth

er o

f bet

ter

prop

ertie

s.•

Prov

ide

bina

ry p

erfo

rman

ce p

rodu

ct to

the

mar

ket f

or

sing

le s

ilo u

se.

BEN

EFIT

S C

/F B

LEN

DS

19

•Fl

orid

a•

Geo

rgia

•Al

abam

a•

Tenn

esse

e•

Kent

ucky

•Pe

nnsy

lvan

ia•

Loui

sian

a•

Mis

siss

ippi

•C

olor

ado

C-A

SH &

F-A

SH D

OT

PRE

BLE

ND

APP

RO

VALS

20

IOW

A D

OT

PER

MEA

BIL

ITY

DAT

A•

Iow

a D

OT

unde

rtook

a s

tudy

on

pavi

ng p

erfo

rman

ce to

m

easu

re p

erm

eabi

lity

of a

ll al

low

ed s

tate

pav

ing

mix

ture

s ut

ilizin

g SC

M a

vaila

ble

in th

e m

arke

t and

on

curre

nt

proj

ects

.•

Cla

ss F

is o

nly

avai

labl

e lo

cally

as

a co

mpo

nent

of a

lo

cally

pro

duce

d ce

men

t ble

nd. T

he b

lend

con

tain

s 20

%

clas

s F

fly a

sh.

•Io

wa

DO

T al

low

s fo

r the

pav

ing

mix

ture

to u

tiliz

e up

to a

40

% re

plac

emen

t of c

emen

t.•

Loca

l pav

ers

rout

inel

y us

e th

e 20

% F

cem

ent b

lend

with

20

% C

lass

C fl

y as

h, w

ith th

e re

sult

prov

idin

g fa

ster

set

tim

e in

coo

l wea

ther

and

low

er p

erm

eabi

lity.

21

0

500

1000

1500

2000

2500

3000

3500

4000

100%

Cem

ent

15%

C A

sh30

% C

Ash

Type

IS(2

5)20

% C

Ash

Type

IS(3

5)15

% C

Ash

Type

IPF(

25)

20%

C A

sh

Coulombs

Tern

ary

Mix

Des

ign

-Lab

Stu

dyPe

rmea

bilit

y A

ASH

TO T

277

-Virg

inia

Cur

e M

etho

d

>400

0

H

igh

2000

-400

0

Mod

erat

e10

00-2

000

Lo

w10

0-10

00

Ver

y Lo

w<1

00

N

eglig

ible

w/c

= 0

.41

w/c

= 0

.41

w/c

= 0

.41

w/c

= 0

.41

w/c

= 0

.426

w/c

= 0

.40

22

•Ph

ysic

al P

erfo

rman

ce im

prov

ed o

n te

sted

ash

es.

•U

tiliz

atio

n of

Mar

gina

l Ash

es E

nhan

ced.

•AS

R M

itiga

tion

of B

lend

ed C

/F fl

y as

hes

impr

oved

ove

r C

lass

C fl

y as

h al

one.

•Pe

rmea

bilit

y's

wer

e re

duce

d si

mila

r to

the

use

of s

ilica

fum

e.•

Res

ultin

g bl

ends

of c

lass

C a

nd c

lass

F fl

y as

hes,

mee

t AS

TM C

-618

.

SUM

MA

RY O

F FI

ND

ING

S

23

•Am

eric

an C

oncr

ete

Inst

itute

. (20

08).

Man

ual o

f con

cret

e pr

actic

e: U

se o

f fly

ash

in c

oncr

ete

com

mitt

ee-2

32.

Farm

ingt

on H

ills, M

I: Au

thor

.

•AS

TM C

39.

(200

0). S

tand

ard

test

met

hod

for c

ompr

essi

ve s

treng

th o

f cyl

indr

ical

con

cret

e sp

ecim

ens.

In R

. Alle

n, N

. Ba

ldin

i, E.

Gut

man

, E. K

eefe

, J. K

ram

er,

& C

. Lei

nweb

er e

t al.

Ann

ual B

ook

of A

STM

sta

ndar

ds: V

ol. 0

4.02

. C

oncr

ete

and

aggr

egat

es. W

est C

onsh

ohoc

ken,

PA:

Am

eric

an s

ocie

ty fo

r tes

ting

and

mat

eria

ls.

•AS

TM C

109

. (20

00).

Stan

dard

test

met

hod

for c

ompr

essi

ve s

treng

th o

f hyd

raul

ic c

emen

t mor

tars

(Usi

ng 2

-in. o

r [5

0-m

m] c

ube

spec

imen

s. In

R. A

llen,

N. B

aldi

ni, E

. Gut

man

, E. K

eefe

, J. K

ram

er,

& C

. Lei

nweb

er e

t al.

Ann

ual

Boo

k of

AS

TM s

tand

ards

: Vol

. 04.

01. C

emen

t;lim

e;gy

psum

. Wes

t Con

shoh

ocke

n, P

A: A

mer

ican

soc

iety

for t

estin

g an

d m

ater

ials

•AS

TM C

618

. (20

00).

Stan

dard

spe

cific

atio

n fo

r coa

l fly

ash

and

raw

or c

alci

ned

natu

ral p

ozzo

lan

for u

se a

s a

min

eral

adm

ixtu

re in

con

cret

e. In

R. A

llen,

N. B

aldi

ni, E

. Gut

man

, E. K

eefe

, J. K

ram

er,

& C

. Lei

nweb

er e

t al.

Ann

ual

Boo

k of

AS

TM s

tand

ards

: Vol

. 04.

02. C

oncr

ete

and

aggr

egat

es. W

est C

onsh

ohoc

ken,

PA:

Am

eric

an s

ocie

ty fo

r te

stin

g an

d m

ater

ials

.

•AS

TM C

101

2. (2

000)

. Sta

ndar

d te

st m

etho

d fo

r len

gth

chan

ge o

f hyd

raul

ic-c

emen

t mor

tars

exp

osed

to a

sul

fate

so

lutio

n In

R. A

llen,

N. B

aldi

ni, E

. Gut

man

, E. K

eefe

, J. K

ram

er,

& C

. Lei

nweb

er e

t al.

Ann

ual B

ook

of A

STM

S

tand

ards

: Vol

. 04.

01. C

emen

t; lim

e; g

ypsu

m. W

est C

onsh

ohoc

ken,

PA:

Am

eric

an s

ocie

ty fo

r tes

ting

and

mat

eria

ls.

•AS

TM C

156

7. (2

004)

. Sta

ndar

d te

st m

etho

d fo

r det

erm

inin

g th

e po

tent

ial a

lkal

i-silic

a re

activ

ity o

f com

bina

tions

of

cem

entit

ious

mat

eria

ls a

nd a

ggre

gate

. Ann

ual B

ook

of A

STM

sta

ndar

ds: V

ol. 0

4.02

. Con

cret

e an

d ag

greg

ates

. Wes

t C

onsh

ohoc

ken,

PA:

Am

eric

an s

ocie

ty fo

r tes

ting

and

mat

eria

ls

•AS

TM C

169

7. (2

010)

. Ble

nded

sup

plem

enta

ry c

emen

titio

us m

ater

ials

. Ann

ual B

ook

of A

STM

sta

ndar

ds: V

ol. 0

4.02

. C

emen

t,lim

e, g

ypsu

m .

Wes

t Con

shoh

ocke

n, P

A: A

mer

ican

soc

iety

for t

estin

g an

d m

ater

ials

•G

ratta

n-Be

llew,

P. E

. (19

87).

Con

cret

e al

kali-

aggr

egat

e re

actio

ns. P

ark

Rid

ge, N

J: N

oyes

Pub

licat

ions

.

REF

EREN

CES