Cement and Concrete Research 33 (2003) 539 – 547

Effect of fine aggregate replacement with Class F fly ash on the

mechanical properties of concrete
Rafat Siddique*
Department of Civil Engineering, Thapar Institute of Engineering and Technology, Deemed University, Patiala 147004, India
Received 28 February 2002; accepted 16 September 2002

Abstract

This paper presents the results of an experimental investigation carried out to evaluate the mechanical properties of concrete mixtures in
which fine aggregate (sand) was partially replaced with Class F fly ash. Fine aggregate (sand) was replaced with five percentages (10%, 20%,
30%, 40%, and 50%) of Class F fly ash by weight. Tests were performed for properties of fresh concrete. Compressive strength, splitting
tensile strength, flexural strength, and modulus of elasticity were determined at 7, 14, 28, 56, 91, and 365 days. Test results indicate
significant improvement in the strength properties of plain concrete by the inclusion of fly ash as partial replacement of fine aggregate (sand),
and can be effectively used in structural concrete.
D 2002 Elsevier Science Ltd. All rights reserved.

Keywords: Concrete; Fly ash; Compressive strength; Tensile properties; Elastic moduli

1. Introduction aggregate with fly ash as a means of incorporating significant

amounts of fly ash.
The quantity of fly ash produced from thermal power
plants in India is approximately 80 million tons each year,
and its percentage utilization is less than 10%. Majority of fly 2. Literature review
ash produced is of Class F type. During the last few years,
some cement companies have started using fly ash in Though number of significant results have been reported
manufacturing cement, known as ‘pozzolana Portland on the use of Class F fly ash in concrete [1– 14], but there is
cement,’ but the overall percentage utilization remains very not much literature available on the use of Class F fly ash as
low, and most of the fly ash are dumped at landfills. Fly ash partial replacement of fine aggregates [10 –14]. Maslehuddin
is generally used as replacement of cement, as an admixture et al. [10] carried out investigations to evaluate the com-
in concrete, and in manufacturing of cement. Whereas pressive strength development and corrosion-resisting char-
concrete containing fly ash as partial replacement of cement acteristics of concrete mixes in which fly ash was used as an
poses problems of delayed early strength development, admixture (equal quantity of sand replacement). Concrete
concrete containing fly ash as partial replacement of fine mixtures were made with fly ash additions of 0%, 20%, and
aggregate will have no delayed early strength development, 30%, and water – cement ratios of 0.35, 0.40, 0.45, and 0.50.
but rather will enhance its strength on long-term basis. This Based on the test results, they concluded that addition of fly
study explores the possibility of replacing part of fine ash as an admixture increases the early age compressive
strength and long-term corrosion-resisting characteristics of
concrete. The superior performance of these mixes compared
to plain concrete mixes was attributed to the densification of
the paste structure due to pozzolanic action between the fly
* Present address: Center for By-Products Utilization, Department of ash and the calcium hydroxide liberated as a result of hyd-
Civil Engineering and Mechanics, College of Engineering and Applied
Science, University of Wisconsin-Milwaukee, P.O. Box 784, Milwaukee,
ration of cement.
WI 53201, USA. Tel.: +1-414-229-4105; fax: +1-414-229-6958. Berg and Neal [11] used municipal solid waste bottom ash
E-mail address: siddique_66@yahoo.com (R. Siddique). (MSWBA) as a potential aggregate for concrete masonry

0008-8846/02/$ – see front matter D 2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 0 8 - 8 8 4 6 ( 0 2 ) 0 1 0 0 0 - 1
540 R. Siddique / Cement and Concrete Research 33 (2003) 539–547

Table 1 Table 3
Physical properties of Portland cement Physical properties of aggregates
Physical test Results IS: 8112-1989 Property Fine aggregate Coarse aggregate
obtained [15] specifications
Specific gravity 2.63 2.61
Fineness (retained on 90-mm sieve) 8.5 10 max Fineness modulus 2.25 6.61
Fineness: specific surface 285 225 min SSD absorption (%) 0.86 1.12
(air permeability test) (m2/kg) Void (%) 36.2 39.6
Normal consistency 30% – Unit weight (kg/m3) 1690 1615
Vicat time of setting (min)
Initial 120 30 min
Final 215 600 max
Compressive strength (MPa)
mortars of water to Portland cement ratio of 0.3, 0.4, and
3 days 23.5 22.0 min
7 days 36.0 33.0 min 0.5, in which the fine aggregate was replaced with fly ash at
28 days 46.0 43.0 min 25% and 50% levels. Test results showed that rheological
Specific gravity 3.15 – constants increased with higher replacement level of fly ash
and that, when water to Portland cement ratio was main-
tained, the strength development and carbonation properties
were improved.
units (CMU). The test results indicate that MSWBA could be Bakoshi et al. [14] used bottom ash in amounts of 10–
used as an aggregate in concrete to produce CMU that meets 40% as replacement for fine aggregate. Test results indicate
ASTM C 90 standards when it is processed for maximum size that the compressive strength and tensile strength of bottom
and gradation and ferrous removal by magnetic separation. ash concrete generally increases with the increase in
Ghafoori et al. [12] carried out investigations on a series replacement ratio of fine aggregate and curing age. The
of laboratory-made roller compacted concretes (RCC) con- freezing– thawing resistance of concrete using bottom ash is
taining high-calcium dry bottom ash as a fine aggregate. lower than that of ordinary concrete and abrasion resistance
Concrete specimens of six different proportions (cement of bottom ash concrete is higher than that of ordinary
content of 188 –337 kg/m3 and coarse aggregate content of concrete.
1042 –1349 kg/m3) were prepared at their optimum mois-
ture content and fabricated in accordance with ASTM C
1170 Procedure A. Specimens were tested for compression, 3. Experimental program
splitting tension, drying shrinkage, and resistance to abra-
sion and rapid freezing and thawing. Based on the test 3.1. Materials
results, they concluded that good strength, stiffness, drying
shrinkage and resistance to wear, and repeated freezing and 3.1.1. Cement
thawing cycles can be obtained with compacted concretes Ordinary Portland (43 grade) cement was used. It was
containing bottom ash. tested as per Indian Standard Specifications IS: 8112-1989
Hwang et al. [13] examined the effects of fine aggregate [15]. Its properties are shown in Table 1.
replacement on the rheology, compressive strength, and
carbonation properties of fly ash and mortar. Rheological 3.1.2. Fly ash
properties, compressive strength, and rate of carbonation of Class F fly ash obtained from thermal power plant at
Bathinda in India was used in this investigation. Chemical
composition of the fly ash was determined according to
ASTM C 311. The results are shown in Table 2.
Table 2
Chemical composition of fly ash
Chemical analysis Class F fly ASTM requirement
ash (%) C 618 (%) Table 4
Silicon dioxide, SiO2 55.3 – Sieve analysis of aggregates
Aluminum oxide, Al2O3 25.70 – Fine aggregates Coarse aggregates
Ferric oxide, Fe2O3 5.3 –
SiO2 + Al2O3 + Fe2O3 85.9 70.0 min Sieve no. Percent Requirement Sieve Percent Requirement
Calcium oxide, CaO 5.6 – passing IS: 383-1970 size passing IS: 383-1970
Magnesium oxide, MgO 2.1 5.0 max [16] [16]
Titanium oxide, TiO2 1.3 – 4.75 mm 98.4 90 – 100 40 mm 100 100
Potassium oxide, K2O 0.6 – 2.36 mm 93.8 85 – 100 20 mm 98 95 – 100
Sodium oxide, Na2O 0.4 1.5 max 1.18 mm 73.8 75 – 100 10 mm 31 25 – 55
Sulfur trioxide, SO3 1.4 5.0 max 600 mm 61.4 60 – 79 4.75 mm 4 0 – 10
LOI (1000 C) 1.9 6.0 max 300 mm 35.8 12 – 40
Moisture 0.3 3.0 max 150 mm 6.5 0 – 10
 R. Siddique / Cement and Concrete Research 33 (2003) 539–547 541

Table 5 IS: 383-1970 [16]. Its physical properties and sieve analysis
Mixture proportions
results are shown in Tables 3 and 4, respectively.
Mixture no. M-1 M-2 M-3 M-4 M-5 M-6
3
Cement (kg/m ) 390 390 390 390 390 390 3.1.5. Superplasticizer
Fly ash (%) 0 10 20 30 40 50 A commercially available melamine-based superplasti-
Fly ash (kg/m3) 0 50 110 170 220 280
cizer was used in all mixes.
Water (kg/m3) 185 187 190 190 192 195
W/C 0.47 0.48 0.49 0.49 0.49 0.50
Sand SSD (kg/m3 ) 560 510 450 390 340 280 3.2. Mix proportions
Coarse Aggregate 1170 1170 1170 1170 1170 1170
(kg/m3) Six mixture proportions were made. First was control
Superplasticizer 2.6 3.5 3.6 3.7 3.7 3.9
mix (with out fly ash), and the other five mixes contained
(l/m3)
Slump (mm) 100 90 65 40 30 20 Class F fly ash. Fine aggregate (sand) was replaced with fly
Air content (%) 5.2 4.8 4.4 4.0 3.8 3.2 ash by weight. The proportions of fine aggregate replaced
Air temperature (C) 27 26 27 26 25 26 ranged from 10% to 50%. Mix proportions are given in
Concrete 28 26 28 27 26 27 Table 5. The control mix with out fly ash was proportioned
temperature (C)
as per Indian Standard Specifications IS: 10262-1982 [17],
Fresh concrete 2308 2310 2314 2314 2316 2319
density (kg/m3) to obtain a 28-day cube compressive strength of 26.4 MPa.
Concrete mixes were made in power-driven revolving type
drum mixers of capacity 0.76 m3.

3.1.3. Fine aggregate 3.3. Preparation and casting of test specimens

Natural sand with a 4.75-mm maximum size was used as
a fine aggregate. It was tested as per Indian Standard The 150-mm concrete cubes were cast for compressive
Specifications IS: 383-1970 [16], and its physical properties strength, 150  300 mm cylinders for splitting tensile
and sieve analysis results are shown in Tables 3 and 4, strength, 101.4  101.4  508 mm beams for flexural
respectively. strength, and 150  300 mm cylinders for modulus of
elasticity. After casting, all the test specimens were finished
3.1.4. Coarse aggregate with a steel towel. Immediately after finishing, the specimens
Coarse aggregate used in this study were 20-mm nominal were covered with plastic sheets to minimize the moisture
size, and were tested as per Indian Standard Specifications loss from them. All the test specimens were stored at

Fig. 1. Compressive strength versus age.

542 R. Siddique / Cement and Concrete Research 33 (2003) 539–547

Fig. 2. Compressive strength versus fly ash percentage.

temperature of about 23 C in the casting room. They were Indian Standard Specifications IS: 1199-1959 [18]. The
demolded after 24 h, and were put into a water-curing tank. results are presented in Table 5.

3.4. Fresh concrete properties 3.5. Hardened concrete properties

Fresh concrete properties such as slump, unit weight, tem- The 150-mm concrete cubes were tested for compressive
perature, and air-content were determined according to strength, 150  300 mm cylinders for splitting tensile

Fig. 3. Splitting tensile strength versus age.

 R. Siddique / Cement and Concrete Research 33 (2003) 539–547 543

Fig. 4. Splitting tensile strength versus fly ash percentage.

strength, 101.4  101.4  508 mm beams for flexural 4. Results and discussion
strength, and 150  300 mm cylinders for modulus of
elasticity. Tests were performed at 7, 14, 28, 56, 91, and 4.1. Compressive strength
365 days in accordance with the provisions of the Indian
Standard Specifications IS: 516-1959 [19]. Compressive Compressive strength of concrete mixes made with and
strength results are shown in Figs. 1 and 2, splitting tensile with out fly ash were determined at 7, 14, 28, 56, 91, and 365
strength in Figs. 3 and 4, flexural strength results in Figs. 5 days of curing. The test results are given in Table 6 and
and 6, and modulus of elasticity results in Figs. 7 and 8. shown in Figs. 1 and 2. Fig. 1 shows the variation of

Fig. 5. Flexural strength versus age.

544 R. Siddique / Cement and Concrete Research 33 (2003) 539–547

Fig. 6. Flexural strength versus fly ash percentage.

compressive strength with age for various fly ash percen- Fig. 1 that compressive strength of all mixes continued to
tages, and Fig. 2 shows the variation of compressive strength increase with the increase in age.
with fly ash percentages at different ages. From the test From Fig. 2, it can be seen that there is increase in
results, it can be seen that the compressive strength of fly ash strength with the increase in fly ash percentages; however,
concrete mixes with 10%, 20%, 30%, 40%, and 50% fine the rate of increase of strength decreases with the increase in
aggregate replacement with fly ash, were higher than the fly ash content. This trend is more obvious between 40% and
control mix (M-1) at all ages. It is evident from Table 6 and 50% replacement level. However, maximum strength at all

Fig. 7. Modulus of elasticity versus age.

 R. Siddique / Cement and Concrete Research 33 (2003) 539–547 545

Fig. 8. Modulus of elasticity versus fly ash percentage.

ages occurs with 50% fine aggregate replacement. This fly ash percentages, and Fig. 4 shows the variation of
increase in strength due to the replacement of fine aggregate splitting tensile strength with fly ash percentages. From
with fly ash is attributed to the pozzolanic action of fly ash. Table 7 and Fig. 3, it is evident that splitting tensile strength
In the beginning (early age), fly ash reacts slowly with of all mixes continued to increase with the age.
calcium hydroxide liberated during hydration of cement From Fig. 4, it can be seen that there is increase in
and does not contribute significantly to the densification of strength with the increase in fly ash percentages; however,
the concrete matrix at early ages. Concrete with fly ash the rate of increase of strength is becoming lesser with the
shows higher strength at early ages because inclusion of fly
ash as partial replacement of sand starts pozzolanic action
and densification of the concrete matrix, and due to this Table 7
strength of fly ash concrete is higher than the strength of Splitting tensile strength test results
control mix even at early ages. Mix M-1 M-2 M-3 M-4 M-5 M-6
Fly ash (%) 0 10 20 30 40 50
4.2. Splitting tensile strength
Test age (days) Splitting tensile strength (MPa)

The splitting tensile strength of concrete mixes made with 7 2.5 2.6 2.6 2.7 2.8 2.7
14 2.7 2.8 2.8 3.0 3.1 3.1
and with out fly ash were measured at the ages of 7, 14, 28, 28 3.0 3.1 3.2 3.4 3.5 3.5
56, 91, and 365 days. The results are given in Table 7 and 56 3.2 3.3 3.4 3.7 3.9 4.0
shown in Figs. 3 and 4, respectively. Fig. 3 shows the 91 3.3 3.5 3.6 4.0 4.2 4.3
variation of splitting tensile strength with age for different 365 3.4 3.6 3.8 4.2 4.4 4.4

Table 6 Table 8
Compressive strength test results Flexural strength test results
Mix M-1 M-2 M-3 M-4 M-5 M-6 Mix M-1 M-2 M-3 M-4 M-5 M-6
Fly ash (%) 0 10 20 30 40 50 Fly ash (%) 0 10 20 30 40 50
Test age (days) Compressive strength (MPa) Test age (days) Flexural strength (MPa)
7 19.4 21.4 22.6 25.0 26.5 27.2 7 3.2 3.3 3.4 3.6 3.6 3.6
14 22.0 23.0 24.6 27.6 29.3 30.2 14 3.4 3.6 3.7 3.8 3.9 3.8
28 26.4 28.2 30.8 34.9 38.9 40.0 28 3.7 4.0 4.2 4.4 4.4 4.3
56 29.0 31.2 34.0 40.2 44.6 46.3 56 3.9 4.2 4.4 4.7 4.8 4.7
91 31.0 34.2 38.0 44.0 49.8 51.4 91 4.2 4.5 4.7 4.9 5.2 5.2
365 32.8 36.3 40.5 46.4 52.3 54.8 365 4.3 4.7 4.9 5.2 5.5 5.4
546 R. Siddique / Cement and Concrete Research 33 (2003) 539–547

Table 9 As fly ash is available free of cost in India and it may only
Modulus of elasticity test results
involve transportation cost of bringing it to either laboratory
Mix M-1 M-2 M-3 M-4 M-5 M-6 or site, it does not incur any additional cost in making
Fly ash (%) 0 10 20 30 40 50 concrete as money will be saved on use of lesser sand.
Test age (days) Modulus of elasticity (GPa)
7 17.5 18.5 18.5 20.0 20.5 20.5
14 18.9 19.5 20.0 22.0 23.0 23.0 5. Conclusions
28 20.0 21.0 21.5 23.5 24.0 24.5
56 20.5 22.0 22.5 25.0 27.0 27.0 The following conclusions can be drawn from the present
91 21.5 23.5 24.5 27.0 27.5 28.0
investigation.
365 22.0 24.0 25.5 27.5 28.5 29.0

1. Compressive strength, splitting tensile strength, flexural

strength, and modulus of elasticity of fine aggregate
increase in fly ash content. This trend is more obvious (sand) replaced fly ash concrete specimens were higher
between 40% and 50% replacement level. However, max- than the plain concrete (control mix) specimens at all the
imum strength at all ages occurs at 50% fine aggregate ages. The strength differential between the fly ash con-
replacement. The rate of increase in strength is more crete specimens and plain concrete specimens became
prominent after 28-days. This may be attributed to the more distinct after 28 days.
late pozzolanic reaction for forming pozzolanic C – S– H 2. Compressive strength, splitting tensile strength, flexural
gel. strength, and modulus of elasticity of fine aggregate
(sand) replaced fly ash concrete continued to increase
4.3. Flexural strength with age for all fly ash percentages.
3. The maximum compressive strength occurs with 50% fly
The flexural strength test results of fly ash concrete are ash content at all ages. It is 40.0 MPa at 28 days, 51.4
given in Table 8 and shown in Figs. 5 and 6, respectively. MPa at 91 days, and 54.8 MPa at 365 days.
Fig. 5 shows the flexural strength development with age, and 4. At all the ages, the maximum splitting tensile strength
Fig. 6 shows the variation of flexural strength with various was observed with 50% fly ash content. It is 3.5 MPa at
percentages of fly ash. It is evident from Table 8 and Fig. 5 28 days, 4.3 MPa at 91 days, and 4.4 MPa at 365 days.
that the flexural strength of fly ash concretes continued to 5. The maximum flexural strength has been found to occur
increase with the age. with 50% fly ash content at all ages. It is 4.3 MPa at 28
From Fig. 6, it can be seen that flexural strength continued days, 5.2 MPa at 91 days, and 5.4 MPa at 365 days.
to increase with the increase in fly ash percentages at all ages, 6. At all ages, the maximum value of modulus of elasticity
and there is significant increase in strength with that of occurs with 50% fly ash content. It is 24.5 GPa at 28
strength of control mix. This is believed to be due to the large days, 28.0 GPa at 91 days, and 29.0 GPa at 365 days.
pozzolanic reaction and improved interfacial bond between 7. Results of this investigation suggest that Class F fly ash
paste and aggregates. could be very conveniently used in structural concrete.

4.4. Modulus of elasticity

References
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