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February, 2017 Department of Civil Engineering Engineering School Of Final Report Title: Evaluation of Alternative Pozzolanic Materials for Partial Replacement of Portland Cement in Concrete FDOT Contract Number: BDV31-977-06 Submitted to: The Florida Department of Transportation Research Center FDOT Research Center [email protected] 605 Suwannee Street, MS 30 Tallahassee, FL 32399 c/o Dr. Harvey DeFord, Ph.D. Structures Materials Research Specialist State Materials Office Submitted by: Christopher C. Ferraro, Jerry M. Paris, Timothy G. Townsend, Mang Tia Engineering School of Sustainable Infrastructure and Environment University of Florida Gainesville, Florida 32611 February, 2017 Department of Civil Engineering Engineering School of Sustainable Infrastructure and Environment College of Engineering University of Florida Gainesville, Florida 32611 Disclaimer The opinions, findings, and conclusions expressed in this publication are those of the authors and not necessarily those of the State of Florida Department of Transportation or the U.S. Department of Transportation. Prepared in cooperation with the State of Florida Department of Transportation and the U.S. Department of Transportation. ii Approximate Conversions to SI Units (from FHWA) Symbol When You Know Multiply By To Find Symbol Length in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km Area in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yard 0.836 square meters m2 mi2 square miles 2.59 square kilometers km2 Volume fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 Mass oz ounces 28.35 grams g lb pounds 0.454 kilograms kg Temperature (exact degrees) °F Fahrenheit 5 (F-32)/9 Celsius °C or (F-32)/1.8 Illumination fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m2 cd/m2 Force and Pressure or Stress lbf pound-force 4.45 newtons N lbf/in2 pound-force per square inch 6.89 kilopascals kPa iii 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. 4. Title and Subtitle 5. Report Date Evaluation of Alternative Pozzolanic Materials for Partial Replacement of September 2016 Portland Cement in Concrete 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Christopher C. Ferraro, Timothy Townsend, Mang Tia, Jerry Paris 9. Performing Organization Name and Address 10. Work Unit No. Department of Civil and Coastal Engineering Engineering School of Sustainable Infrastructure & Environment University of Florida 11. Contract or Grant No. 365 Weil Hall – P.O. Box 116580 BDV31-977-06 Gainesville, FL 32611-6580 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Florida Department of Transportation 605 Suwannee Street, MS 30 Final Report 7/13-12/16 Tallahassee, FL 32399 14. Sponsoring Agency Code 15. Supplementary Notes None 16. Abstract The supply of class F coal fly ash throughout the United States has recently diminished due to supply of natural gas and alternative energy sources as well as environmental restrictions. As a result, the concrete industry in the state of Florida has experienced supply shortages of class F fly ash for construction of FDOT owned structures. To avoid future problems stemming from inevitable fly ash supply shortages in the future, the FDOT chose to explore alternative materials that can be used to replace some or all the fly ash that is currently required in FDOT concrete mixes. Physical and chemical material properties were characterized for nine different replacement candidates. A total of over 60 mortar mixes and 20 concrete mixes were prepared for evaluation of workability, structural adequacy, and durability. Thermal hydration data, plastic properties, mechanical properties, and durability properties were acquired from the mixes to determine ideal replacement proportions for the substitution of class F coal fly ash in portland cement concrete mixes. Since the goal was to find replacements for class F fly ash, performance was compared to that of mortars and concretes containing a 20% replacement of portland cement with class F fly ash. 17. Keywords. 18. Distribution Statement Concrete; Supplementary Cementitious Materials; No restrictions. Pozzolans; Portland Cement; Fly Ash 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. Pages 22. Price 342 Unclassified Unclassified iv ACKNOWLEDGEMENTS The Florida Department of Transportation (FDOT) is acknowledged for their funding and other contributions to this study. Special acknowledgement is given to Dr. H.D. DeFord for his guidance and assistance throughout this project. The authors would like to thank Michael Bergin, Shelby Brothers, Richard DeLorenzo and Patrick Carlton for their contributions to this work which included laboratory planning and assistance. The authors would like to thank the donors of material used throughout this research: Florida Rock/Argos, Boral Materials, WR Grace, Burgess Pigments, Separation Technologies, Metaloy, Sioneer, Titan America, Gainesville Renewable Energy Center, and the donor of sugarcane bagasse ash. The following students are acknowledged for their tremendous contributions for conducting laboratory research: Phillipe Holas, Taylor Humbarger, Eric Johnson, Danielle Kennedy, Heather Mariscal, Katherine Maslak, Tyler Mokris, Josias Oeudraogo, Marissa Romero, Tyler Swanson, Caitlin Tibbetts, Paul Thomas, Kiersten Wang, and Benjamin Watts. v EXECUTIVE SUMMARY Background The supply of class F coal fly ash throughout the United States has recently diminished due to supply of natural gas and alternative energy sources as well as environmental restrictions. As a result, the concrete industry in the state of Florida has experienced supply shortages of class F fly ash for construction of FDOT owned structures. Reduced availability and increased demand for class F fly ash will continue to pose potential fly ash supply problems, especially in regions that are not close to a source. To avoid future problems stemming from inevitable fly ash supply shortages in the future, the FDOT chose to explore alternative materials that can be used to replace some or all the fly ash that is currently required in FDOT concrete mixes. Thus the primary objective of this research was to evaluate pozzolanic materials that are not currently in use by the FDOT. This research incorporated material characterization with regards to physical and chemical properties, workability characteristics, mechanical properties, and durability characteristics of binary - and ternary-blended mortars and concretes. Since the goal was to find replacements for class F fly ash, performance was compared to that of mortars and concretes containing a 20% replacement of portland cement with class F fly ash. Research Objectives The primary objective of this research project was to identify potential alternative pozzolanic materials not currently in use by the FDOT that can be employed to partially or completely replace class F fly ash in FDOT concrete with no significant decrease in performance with respect to plastic, mechanical, and durability properties. Recommendations borne from analysis of the results of this investigation were expected to include revisions of some sections of the FDOT Standard Specifications for Road & Bridge Construction. Main Findings The main findings from this study are summarized as follows: • Portland cement concrete mixtures, which incorporated sugarcane bagasse ash having loss on ignition values exceeding 25%, showed no deleterious effects on the air content of normal concrete. • Binary mixes incorporating ground glass or class C fly ash in the appropriate proportions performed comparably to concrete containing class F fly ash. • Ternary mixes incorporating class C fly ash and either Micron3 ultrafine fly ash, sugarcane bagasse ash, class F fly ash, slag, ground glass, silica fume, or metakaolin in the appropriate proportions performed comparably to concrete containing class F fly ash concrete. • Class C fly ash can be blended with a highly siliceous material to re-qualify it as a class F fly ash that performs comparably or superior to control concretes in a variety of qualifying metrics. • The use of ground glass, with an average particle size of less than 20 microns can be used to replace portland cement in concrete at replacement levels of 20% or lower. vi • Rice husk ash was found to have a propensity for deleterious reactions based on results from the accelerated alkali silica reactivity test (ASTM C 1260). • The maturity method and equivalent age-concepts are not appropriate for applying to mortars and cementitious systems containing alternative supplementary materials; the curve-fitting functions do not adequately describe strength-time relationships. • There are a number of sources of alternative pozzolans in Florida that may be used as a replacement for class F fly ash. Recommendations Based upon the findings from this study, the following recommendations are suggested: • Revise the FDOT Standard Specification for Road and Bridge Construction Section 929 to make allowances for the use of class N fly ash that does not meet ASTM C618 with respect to loss on ignition only. • Revise the FDOT Standard Specification for Road and Bridge Construction Section 929 to make allowances for the use of class C fly ash that meets ASTM C618, to be used for structures placed in non-aggressive environments.
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