Strategies for Developing High-Volume Fly Ash Concrete with High Early-Age Strength for Precast Applications

Sao, Zacharia; Kaladharan, Gopakumar; Yoon, Jinyoung; Kamasani, Chiranjeevi Reddy; Rajabipour, Farshad; Gombeda, Matthew J.

doi:10.1061/jmcee7.mteng-18004

Strategies for Developing High-Volume Fly Ash Concrete with High Early-Age Strength for Precast Applications

Journal Article · Wed Jul 31 00:00:00 EDT 2024 · Journal of Materials in Civil Engineering

DOI:https://doi.org/10.1061/jmcee7.mteng-18004· OSTI ID:2562926

Sao, Zacharia ^[1]; ^[2]; ^[3]; ^[4]; ^[4]; ^[5]

Sargent & Lundy, Chattanooga, TN (United States); Illinois Institute of Technology
USG Corporation, Libertyville, IL (United States)
Konkuk University, Seoul (Korea, Republic of)
Pennsylvania State University, University Park, PA (United States)
Illinois Institute of Technology, Chicago, IL (United States)

Partial replacement of portland cement with supplementary cementitious materials (SCMs), such as fly ash, is an effective strategy for improving durability and reducing the CO₂ footprint of concrete. However, using high-volume fly ash (HVFA) binders in precast and prestressed concrete is currently limited; largely due to reduced early-age strength development that impedes rapid production and prestressing of precast concrete. To investigate and address this challenge, HVFA mortars with a minimum of 40% fly ash by mass of cementitious materials were developed and tested in this study. Two fresh fly ashes (an ASTM C618 Class F and a Class C) and a landfilled fly ash (Class F) were included. Various strategies for improving the early strength were evaluated, including gypsum optimization, chemical accelerators, steam curing, use of CSA cements, and adding other reactive SCMs like silica fume, calcined clay, and slag cement. Steam curing and the use of CSA cement at high dosages (40% of total binder) were found to be the most successful strategies across all three fly ashes. Additionally, significant improvements were observed with gypsum optimization (for Class C fly ash) and the use of accelerators (for Class F fly ashes), and these strategies are likely to be more feasible considering later-age strength and economic viability. Interestingly, HVFA mixtures made with the landfilled fly ash used in this study were able to achieve high early strengths with water-to-cementitious materials ratio adjustment alone. As a result, these HVFA mixtures were also found to be less responsive to accelerators when compared to the fresh Class F fly ash, highlighting an important distinction between the materials despite the similarity in chemical composition.

View Accepted Manuscript (DOE)

Research Organization:: Illinois Institute of Technology, Chicago, IL (United States)

Sponsoring Organization:: USDOE Office of Fossil Energy and Carbon Management (FECM)

Grant/Contract Number:: FE0031931

OSTI ID:: 2562926

Journal Information:: Journal of Materials in Civil Engineering, Journal Name: Journal of Materials in Civil Engineering Journal Issue: 10 Vol. 36; ISSN 0899-1561

Publisher:: American Society of Civil EngineersCopyright Statement

Country of Publication:: United States

Language:: English

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