DURABILITY PROPERTIES OF RECYCLED AGGREGATE

CONCRETE CONTAINING FLY ASH

Surya Mab, Lakshmy Parameswaranab and VVL.Kanta Raoab
a

Bridges and Structures Division, CSIR-Central Road Research Institute, New Delhi, India
b
Academy of Scientific and Innovative Research, New Delhi, India

ABSTRACT
The quantity of concrete waste has been increasing significantly over the years due to the
demolition and reconstruction of old structures. Efforts have been made to utilize the concrete
waste as aggregates in construction to address the environmental concerns such as use of
constructible land for dumping of concrete waste, diminishing availability of natural
aggregates and so on. A number of studies have been performed to examine the mix design,
mechanical properties and structural performance of concrete with recycled aggregates.
However, limited studies have been carried out to understand the durability aspects of
recycled aggregate concrete and based on which some methods to overcome the negative
effects on durability of concrete produced using recycled coarse aggregate have been
suggested. Some of these methods include improvement in mixing methods, enhanced curing
method and use of cementitious materials like silica fume and fly ash.
This paper describes the experimental studies performed to understand the durability
characteristics of recycled aggregate concrete of characteristic compressive strength of
40MPa produced with three different replacement ratio of coarse aggregate, i.e., 50%, 75%
and 100% and containing fly ash as filler. The characteristics of constituent materials,
improved mix design method and casting of various test specimens are discussed. The present
study includes understanding the aspects related to water absorption, concrete resistivity and
chloride permeability. Also, a comparison of durability properties of recycled aggregate
concrete with that of normal aggregate concrete produced with and without fly ash has been
accomplished.
Key-words: Recycled aggregate, recycled aggregate concrete, durability, RCPT, Concrete
resistivity

INTRODUCTION
The recent developments in Infrastructure have led to demolition and reconstruction of
various buildings and thus the quantity of construction and demolition waste is critically
increasing. On the other hand the sources of natural aggregates (NA) are dwindling rapidly.
Extraction of aggregates from C&D waste and using the same in fresh concrete is suggested
as a solution to counter these twin problems. The extracted aggregate is called recycled
aggregate (RA) and the concrete produced is known as recycled aggregate concrete (RAC).
The modern day infrastructural needs demand a concrete which is serviceable, sustainable
and durable. As sustainability and serviceability are also functions of durability it is more
important to study the durability of RAC along with other engineering properties of RA and
RAC.

BACKGROUND
The use of RA in concrete has been in practice from the time of Second World War [1].
However its use in new concrete construction is increasing due to the economic and
environmental considerations in the recent era [2]. Consequently the research on RAC has
gained momentum in the last four decades [3]. The key areas of research were fresh and
hardened concrete properties such as workability, compressive strength, split tensile strength,
elastic modulus etc,. Though these properties were found to be menial in RAC with increase
in percentage of RA [4], the same were improved by increased curing, use of supplementary
cementitous material, use of saturated surface dry aggregates, coating the aggregates with
chemicals such as polyvinyl alcohol [5] or cementitous material such as silica fume, fly ash
etc. But durability of RAC was a major concern due to increased water absorption of RA and
hence RAC, which was about 1.62 times that of NA concrete [6]. The chloride permeability
increased with increase in the replacement levels of RA and was found to be 53% higher than
that of NA concrete [7]. Similarly depth of chloride penetration was found to be 10 mm for
NA concrete and 11.8 mm for RAC after 28 days of ponding with 3% NaCl. RAC exhibited
1.3 3 times higher depth of carbonation than the NA, under similar exposure conditions [8,
9].
The researches were also carried out to explore the possibilities of improving the durability of
RAC. And it was reported that double mixing method improves the micro structure of
concrete and decreases the depth of ITZ, depth of chloride penetration and depth of
carbonation and thus enhances the durability of concrete [2, 10, 11]. Triple mixing method
reduces the chloride penetration and improves the ITZ of concrete [12]. The quality and
durability of RAC can be improved by increasing the duration of curing [13]. Use of
cementitous materials like silica fume [14] or fly ash [7] is an effective way to overcome the
negative effects of using RA in concrete production due to modification of pore structure.

PRESENT STUDY
The present study aimed at determining the durability properties of RAC with fly ash and
produced using triple mixing method. The study was carried out in three stages. Initially the
properties of RA were studied. Based on the aggregate properties a concrete mix for 40 MPa
characteristic compressive strength and slump 25 50 mm was designed and its mechanical
properties were determined and finally the durability properties of the RAC were studied. The
durability properties of RAC studied include water absorption, concrete resistivity and rapid
chloride penetration. The properties of RAC were also compared with that of NA concrete
with and without fly ash

EXPERIMENTAL PROGRAM
Materials
Coarse aggregate
Crushed granite natural aggregate (NA) of 20 mm size and down available in Delhi region
have been used in this study. The recycled aggregates have been generated by crushing of
concrete cubes of strength greater than 35 MPa and the age 2 to 3 years, which were cast and
tested in CSIR-CRRI and also those cast at various bridge construction sites. Thus, it is
primarily recycled concrete aggregate (RCA). All the cubes were first manually broken into

pieces 100 150 mm size and then are crushed using a mini jaw crusher. The crushed
material passing through 20 mm sieve and retained on 4.75 mm sieve were used. The RCA
generated is considered to comprise of two phases namely the original virgin aggregate and
the adhered mortar. The quantity of residual adhered mortar depends on the process of
manufacture of RCA and this quantity influences the engineering, mechanical and durability
properties of the aggregate to a great extent. Thus, determination of residual mortar content
becomes very important in characterization of the RCA.
Determination of residual mortar content
Of the various methods [15-18] available for the determination of residual mortar content of
RCA the method suggested by Abbas et al [17] was used in the present study and the
determined values of residual mortar content of RCA of various fractions are given in Table
1. The average percentage of residual mortar of the coarse RCA used in this study is 20%,
influence of which may be observed in the material properties.
Table 1 - Residual Mortar Content in RCA
Sl. No

Size
of aggregate (mm)

Weight taken (g)

Weight of
aggregates after 5
cycles (g)

Loss in weight
(g)

Percentage
loss
(%)

20.0 - 12.5

670

584.0

86

12.84

12.5 10.0

330

252.0

78

23.48

10.0 4.75

300

229.0

71

23.67

Average = 20 %

Engineering Properties of Coarse aggregate

The physical and mechanical properties of coarse aggregates were studied and are reported in
Table 2, from which it is found that the RCA had a lower specific gravity and higher water
absorption when compared to NA. The other mechanical properties though found inferior to
NA were well within the satisfactory limits. It can be inferred that except for the water
absorption of RCA other properties were readily suitable for use in concrete.
Table 2- Properties of coarse aggregates used in the present study
Property

RCA

NA

Fineness Modulus

6.65

6.52

Specific Gravity

2.501

2.675

Water Absorption (%)

2.76

0.42

Abrasion Loss (%)

Crushing value (%)
Impact value (%)
Bulk Density kg/m3

29.24
28.87
16.04
1340

26
27.12
21.77
1630

Soundness test
As the water absorption of RCA used in the study is greater than 2 %, MORTH [19] suggests
the soundness test of aggregates as per IS 2386 (Part V) [20] is mandatory. Accordingly, the

test has been performed and the loss in weight is determined as 25.4% whereas the
permissible limits for loss is less than or equal to 12% as per IS 383 [21].
As the RCA used in this study does not satisfy the soundness criteria it is likely that it may
affect durability when used in structures. To overcome this problem, in the present study fly
ash is used as an admixture or filler.
Fine aggregate, water and super plasticiser
Crushed stone sand, of specific gravity 2.63 and water absorption 0.72% conforming to zone
I of IS 383 [21], available in Delhi region was used as fine aggregate in the study. Tap water
of pH 7.2 was used for mixing the concrete. The plasticizer used in the present study was
Glenium SKY 777.
Mix Design, Casting and Curing
From the studied properties of NA a mix design for a characteristic compressive strength of
40 MPa and slump 25 50 mm was prepared. A modified mix design method was developed
and adopted for RAC mixes [22]. The method involves modification of coarse aggregate
content obtained using IS 10262 [23], by multiplying the same by the ratio of specific gravity
of RCA to the specific gravity of NA. A standard mix with 0% fly ash and 0% RCA (NAC)
and concrete mixes with 0%, 50%, 75% and 100% RCA with 25% fly ash, viz. NAF, R50,
R75 and R100 respectively, were prepared using this mix design and their proportions are
given in Table 3.
The concrete mixes were prepared in a drum mixer of capacity 300 kg. Triple mixing
method, developed by Kong et al [12] was adopted for the production of RAC. The steps
adopted in present study during triple mixing are as follows: coarse (RCA and NA) and fine
aggregates were initially mixed for 15 s. A part of water equal to the water absorption of
aggregate was then added to the aggregate mixture and mixed for 15 s, and to this wet
saturated aggregate the fly ash was added and further mixed for 15 s to facilitate coating of
the surface of aggregate with fly ash. Cement was then added to the surface coated aggregate
and the remaining water was added and the mixing was continued for further 60s.
Immediately after mixing the oiled moulds were filled with concrete in layers and vibrated on
a table vibrator. The specimens were demoulded after 24 hours and water cured till the date
of testing. The water absorption test samples and concrete resistivity test samples were
exposed to moderate environmental conditions for 14 months (427 days) after 28 days of
curing and 13 months (399) days after 56 days of curing respectively.

Table 3 - Details of mix proportions

Mix
Designation
NAC
NAF
R50
R75
R100

Cement
(kg/m3)
410
410
410
410
410

Water
(kg/m3)
164
164
164
164
164

Fly Ash
(kg/m3)
82
82
82
82

Fine Aggregate
(kg/m3)
(SSD
Condition)
706
706
706
706
706

Coarse
Aggregate
(kg/m3)
(SSD Condition)
NA

RCA

1172
1172
568
280
-

568
839
1119

Super
plasticizer
(Percentage by
weight
of
cement )
0.6
0.6
0.6
0.6
0.6

Slump
(mm)
65
61
63
62
68

Mechanical Properties
Mechanical properties such as compressive strength, split tensile strength and elastic modulus
were evaluated 28 days and 56 days. The results of the tests are as given in Table 4 from
which it can be seen that the compressive strength, split tensile of RAC were comparable to
that of NA concrete. Also, visual observation of split tension specimen after failure shows
that in case of NAC and NAF (i.e.) natural aggregate concrete mixes the surface of failure is
rough and uneven and the specimen failed through the ITZ. In case of RAC mixes surface of
the failure through both new ITZ and the recycled aggregate, i.e., the ITZ between the old
mortar and the aggregate were found. Thus, it can be inferred that the new ITZ in RAC is
improved by triple mixing method adopted for concrete mixing during which, the RA gets
coated with a thin layer of fly ash. This fly ash layer during hardening of concrete improves
the interfacial transition zones through the filler effect and pozzolanic effect [12].
However, the modulus of elasticity of RAC mix reduced with increase in percentage of RCA;
the reduction for R100 mix was about 34%. This may be due to the lower elastic modulus in
RCA due to presence of mortar and innate cracks developed at the time of aggregate
manufacture.

Table 4 - Strength properties of various mixes of concrete used in present

Mix
Designation
NAC
NAF
R50
R75
R100

Compressive strength
MPa
3
7
28
56
days
days
days
days
33.85 43.85 45.63
53.19
33.33 41.03 47.25
57.77
28.89 37.49 47.40
54.02
30.67 34.96 46.61
54.22
30.15 43.11 48.89
57.33

Split tensile strength

MPa
28 days
56 days
3.49
3.74
3.49
3.11
3.68

3.96
4.15
3.53
3.63
4.15

Elastic Modulus
GPa
28
56
days
days
28.55
30.15
29.15
35.20
24.07
27.17
21.54
26.28
19.38
25.03

Durability Properties
Water Absorption
The variation in water absorption for the concrete mixes was studied at 28 and 455 days and
is given in Fig.1, from which it can be inferred that water absorption increases with increase
in proportion of RCA.
The water absorption at 28 days has increased by 57%, 62.3% and 78.5% for R50, R75 and
R100 mixes, respectively when compared with NAC, and the same increased by 70.3%, 76%,
93.6% when compared with NAF. Similarly, the water absorption at 455 days has increased
by 35.7%, 67.9% and 72.4% when compared to NAC and the same increased by 37.3%,
69.9% and 74.3% when compared to NAF. This may be attributed to higher water absorption
of RCA when compared to NA. In the present study the water absorption of RCA is about 6.5
times higher than that of NA. It is also observed from Fig.1 that the water absorption of the
concrete has increased with aging. The exposure of concrete to the atmosphere for about 14
more (427 days) could have led to the development of more open microstructure, which in
turn could have resulted in increased water absorption.

9,00
8,00

Water Absorption

7,00

6,15

6,00
5,00
4,00

7,81

7,61

4,53
3,21

3,00

5,04

5,21

5,73

4,48

28 days
455 days

2,96

2,00
1,00
0,00

NAC

NAF

R 50

R 75

R 100

Fig.1 - Variation of water absorption of different concrete mixes

Concrete Resistivity
The resistivity of saturated concrete specimens has been determined at the age of 56 days
using Wenners probes. Concrete prism specimens of size 500100100 mm have been used
for the purpose and Fig. 2 shows the testing while in progress.

Fig. 2 - Concrete resistivity test

The variation of concrete resistivity in the concrete mixes is presented in Fig. 3. It is found
that the resistivity of R50, R75 and R100 mixes is less than that of the NAF mix and greater
than that of NAC mix.
It is noted that the resistivity of the RAC mixes studied at the age of 56 days fulfills the
criteria to be categorized as low chloride ion permeability concrete, according to the
criteria of Florida Method of Test FM 5-578 [24] as presented in Table 5 and pose low risk of
corrosion as suggested by Broomsfield [25] as given in Table 6. Similarly the mixes at age of
455 days can be categorized as very low chloride ion permeability concrete and pose a low
risk of corrosion. It is also observed that the mixes with fly ash exhibited about 72 93 %
increase in resistivity of the concrete while in NAC mix without fly ash the increase in

resistivity of concrete was 53%. Thus, it can be inferred that though the RAC mixes exhibit
higher water absorption with the use of fly ash a higher concrete resistivity has been
achieved.
70

65,95

Resistivity k cm

60
49,1

50
40
30
20

45,43

42,43

36,675
28,46

56 days
25,33

24,613

24,575

455 days

18,55

10
0

NAC

NAF

R 50

R 75

R 100

Fig. 3 - Variation of concrete resistivity of different concrete mixes

Table 5 - Chloride ion permeability based on surface resistivity of concrete

Resistivity k cm
< 12
12 21
21 37
37 254
> 254

Chloride ion permeability

High
Moderate
Low
Very low
Negligible

Table 6 - Resistivity of concrete and possible risk of corrosion

Resistivity k cm
> 20
10-20
5-10
<5

Corrosion Risk
Low
Moderate
High
Very High

Rapid Chloride Permeability Test

The rapid chloride permeability test has been performed on concrete disc specimens of 95
mm diameter and 50 mm thick as per ASTM C1202 [26] specification after 56 days of
curing. The specimens were prepared by cutting cores from concrete slabs, and then slicing
them to the required thickness. Fig. 4 shows the process of core cutting. The disc specimens
were saturated in a vacuum desiccator for 18 hours. The saturated samples were then
mounted in specimen cells and the test was performed as shown in Fig .5

Fig. 4 - Cutting of cores from slabs

Fig. 5 - RCPT test setup

The test results of the various concrete specimens are shown in Fig. 6, which indicate that the
chloride ion penetration of NAF and RAC mixes is lower than that of the NAC mix. The
chloride ion penetration of NAF is lower than that of the RAC mixes. The chloride ion
penetration has increased with increase in percentage of RCA. The chloride ion permeability
is higher by 20.60%, 53.56% and 75.21% when the percentage of RCA was 50%, 75% and
100%, respectively, when compared to NAF mix. However, its value is lower by 37.90%,
20.93% and 9.78%, respectively, when compared to NAC mix. The enhanced resistance to
chloride penetration in concrete mixes with fly ash may be attributed to the pore size
refinement of concrete mixes by which the pore structure of the concrete mixes is altered
through formation of more C-S-H products which fills the voids in the concrete. The
increased quantity of C-S-H product, would block the ingress path and the alumina present in
the fly ash forms C3A and absorbs more chloride ions to form Friedels salt
(C3A.CaCl2.10H2O) [27].
The observed chloride permeability data suggests that all the mixes used in the present study
except NAC (without fly ash), can be classified under the low permeability class i.e.
chloride permeability between 1000 coulombs to 2000 Coulombs, as per ASTM C 1202 [26]
and the NAC is classified under the medium permeability class.

Chloride Permeability,
Coulombs

2500

2045

2000

1617

1500

1053

1845

1270

1000
500
0

NAC

NAF

R 50

R 75

R 100

Fig. 6 - Measured chloride permeability of various concrete mixes

CONCLUSIONS
Based on the results from the study, the following conclusions were drawn.
1. The recycled aggregate used in the present study exhibited satisfactory physical and
mechanical properties; however the same were lower than those for natural
aggregates.
2. The natural aggregate concrete mixes i.e. NAC, NAF and the RAC mixes R50, R75
and R100 exhibited similar behavior in compression, split tension.
3. The elastic modulus of RAC decreased with increase in percentage of RCA. This
phenomenon is a major concern when RCA is proposed to be used in structural
concrete as the expected deformation may be more in case of RAC than in case of
NAC.
4. The water absorption of RAC increased with increase in percentage of recycled
aggregates.
5. However, the RAC had a relatively higher resistivity as compared to that of NAC.
The higher resistivity of RAC indicates lower permeability to chloride and lower
possibility of reinforcement corrosion.
6. The RCPT tests on RAC exhibit low chloride permeability and the same is lower than
NAC which had moderate chloride permeability.
7. From the study it can be reported that the use of fly ash and triple mixing method has
improved certain mechanical and durability properties of RAC. Based on which it
may be suggested that the properties of RAC with fly ash are satisfactory for use in
concrete; however a detailed investigation on long term performance of RAC is
needed before their actual use in structure.

ACKNOWLEDGEMENTS
The authors wish to thank Mr. Sushil Kumar Senior Technical Officer, Mr. Narendra Kumar,
Technical officer and Mr. Rajveer Singh, Technician of Bridges and Structures Division for
their invaluable help in carrying out the experimental work. The authors also thank the
Director, Central Road Research Institute for kindly according permission to publish this
paper.

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