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CHAPTER 6

TESTS FOR DURABILITY CHARACTERISTICS

6.1 GENERAL

High volume fly ash concrete is one of the green concrete

alternatives indirectly reducing the CO2 emission and energy consumption
related to the production of cement. This chapter describes the results of
durability tests on three concrete grades each with a different fly ash
replacement levels namely 0%, 50%, 55% and 60% at the age of 28 days, 56
days and 90 days.

Durability is the ability to last for a long time without significant

deterioration. A durable material helps the environment by conserving
resources and reducing wastes and the environmental impacts of repair and
replacement. Durable concrete will retain its original form, quality and
serviceability when exposed to environment. Durability of concrete may be
defined as its ability to resist weathering action, chemical attack, abrasion or
any other process of deterioration while maintaining its desired engineering
properties. Hence it becomes essential to test the durability. Also the concrete
code book which was last revised (IS: 456 -2000) was designed to be an
environment friendly code.

It is now recognized that the strength of concrete alone is not

sufficient, but also the degree of harshness of the environmental condition to
which concrete is exposed over its entire life is equally important. In order to
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obtain the durability of HVFA concrete the following tests have been
conducted and test results were discussed.

x Water absorption test

x Acid resistance study

x Sulphuric acid attack

x Hydrochloric acid attack

x Sulphate attack

x Chloride attack

x Water permeability test

The use of FA, a siliceous material derived from thermal plants, as a

partial replacement of ordinary Portland cement has found very suitable in
developing the durable concrete (Xinghua Fu et al 2002). Durability of
concrete is its resistance to deteriorating agencies to which the concrete may
be exposed during its service life (Mullick 2007). When one deals with the
durability aspects of concrete, it becomes an important to investigate the
nature of chemical attack. Thus chemical attack results in loss of weight,
cracking of concrete and the consequent deterioration of concrete (Prasad
et al 2006). Ordinary Portland cement concrete usually does not have good
resistance to acid attack. The addition of FA improves the micro structural
properties of concrete like porosity, permeability etc. (Gopalakrishnan et al
2001).

6.2 SATURATED WATER ABSORPTION TEST

Saturatedwater absorption (SWA) test was carried out as per ASTM

C 642-81 after 28 days of curing. The specimens were taken out from curing
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tank and dried in an oven at a temperature of 105°C for 24 hours, then cooled
to ambient temperature and weighed accurately (dry weight). Dried specimens
were then immersed in water. Weights of specimens at predetermined
intervals of 12 hours were taken after wiping the surface with a dry cloth.
This process was continued for at least 48 hours till a constant weight was
obtained in two consecutive observations. Percentage of water absorption was
determined.

SWA test on concrete has also been carried out on 150 mm size
cube specimens at the age of 28 days curing. The specimens were dried in
oven, weighed and kept in 50mm depth of water for 28 days. The test results
are presented in Table 6.1.

Table 6.1 Saturated water absorption test results of HVFA concrete

Sl. Cube Grade of % FA % of water absorption SWA at

No. ID concrete 28 days 56 days 90 days 28 days

1 A11 50% 6.05 3.17 2.79 1.26

2 A12 M20 55% 7.45 4.15 4.10 1.31
3 A13 60% 6.64 3.63 2.97 2.17
4 B11 50% 7.21 3.36 3.03 1.11
5 B12 M25 55% 6.96 3.95 3.76 1.29
6 B13 60% 6.78 3.52 3.47 1.73
7 C11 50% 7.36 3.75 3.39 1.20
8 C12 M30 55% 7.82 3.95 3.65 1.60
9 C13 60% 6.93 3.39 3.31 2.53

As the age of concrete increased, water absorption was found to be

decreasing. This may be due to reduced rate of pozzolanic reaction of fly ash
particles at the age of curing. As the fly ash content increases it gets increased
initially. But after 55%, the trend starts decreasing.
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In case of fly ash concrete there is an increase in water absorption

upto 28 days. This is observed in all the mixes studied. The increase in water
absorption may be due to the slow pozzolanic action in case of HVFA
concrete.

The effect of fly ash induces the pozzolanic reaction only at the later
stages forming CSH gel and increases durability and strength properties.
However when comparing the results at 56 and 90 days, the 90 days results
are corresponding to reduce the pozzolanic reaction. Hence the improvements
in the results are slightly less.
Percentage of water absorption due to capillary rise is very less in
all types of test. From the test results, it has been absorbed that the capillary
rise of water is stopped after the third day of immersion. Good concrete
according to BS 1881-Part 5 has absorption values of less than 3%.The
percentage of water absorbed the HVFA concrete containing 50% of fly ash
of concrete grade M20 was lower when compared with 55% and 60%
replacement of fly ash. This is due to pozzolanic reaction and improved micro
structural properties of the concrete resulting in durable concrete.

6.3 ACID RESISTANCE STUDY

The HVFA concrete cubes of size 150mm were cast and cured for a
period of 28 days. After 28 days curing of specimens, cube surfaces were
cleaned using standard preliminary surface cleaning process and weighed.
The identified specimens were immersed in prescribed acid solution. The
solution was checked periodically. After the prescribed duration, the
specimens were removed from the solution. Using weight loss method,
percentage weight loss was determined. For the durability studies, the test
specimens are subjected to Acid attack, Sulphate attack, and Chloride attack.
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6.3.1 Study on Sulphuric Acid Attack

To study the effect of sulphuric acid attack, all the three grades of
concretes namely M20, M25 and M30 were considered. The test specimens
were cast with and without fly ash. For the first 28 days, the specimens were
cured in potable water. After 28 days curing, cube surfaces were cleaned and
weighed. The identified specimens were then immersed in 3% H2SO4
(sulphuric acid) solution for 90 days. The solution was checked periodically
for ensuring constant concentration throughout the study. The percentage
weight loss of the sample was determined. The test results are presented in
Table 6.2.The PCC mix suffered the most deterioration in terms of weight
loss when immersed in 3% H2SO4 solutions.

Table 6.2 Test results on weight loss of concrete cubes in sulphuric acid

Grade of % of fly Weight of concrete cube(kg) Weight

Sl No
concrete ash Dry weight Wet weight loss (% )
1 0 7.96 7.45 6.40
2 50 7.55 7.12 5.69
M20
3 55 7.40 7.02 5.13
4 60 7.10 6.85 3.52
5 0 7.98 7.61 4.63
6 50 7.16 6.84 4.46
M25
7 55 6.95 6.68 3.88
8 60 6.78 6.55 3.39
9 0 8.54 8.13 4.80
10 M30 50 8.93 8.69 3.80
11 55 8.76 8.50 2.96
12 60 8.58 8.37 2.44

To know the trend between% of fly ash and % of weight loss of concrete
cubes in sulphuric acid, a graphical representation is given in Figure 6.1.
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18
16

% of Weight Loss
14
12
10
8
M30
6
M25
4
M20
2
0
0% 50% 55% 60%

% of Fly Ash

Figure 6.1 % of fly ash Vs % of weight loss of concrete cubes

(Sulphuric acid)

In the case of HVFA concrete specimens, there was reduction in

weight loss as the percentage of fly ash replacement increased. OPC concrete
specimens of M20, M25 and M30 grade concrete showed maximum weight
loss than that of the HVFA counterparts.

6.3.2 Study on Hydrochloric Acid Attack

To conduct this test, 5% by volume of hydrochloric acid was mixed

with ordinary potable water. The specimens were cured for 28 days in
ordinary potable water and then immersed in the solution for a period of 28
days. The percentage of weight loss is found out after 28 days.

6.3.3 Study on Sulphate Attack

A solution of magnesium sulphate (MgSO4) was prepared in which

5% by weight of magnesium sulphate was mixed with water. The cubes
which were cured for 28 days were then immersed in this solution. The cubes
were taken from the solution after 28 days of exposure to the solution and
were surface dried. The surfaces of cubes were cleaned, scrubbed and final
surface dry weights were found.
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6.3.4 Study on Chloride Attack

A solution of sodium chloride (NaCl) was prepared in which 5% by

weight of sodium chloride was mixed with ordinary potable water. The cubes
which were cured for 28 days were then immersed in this solution. The cubes
were then taken out from this solution after 28 days and were surface dried.
The surface of cubes was cleaned scrubbed and then final surface dry weights
of the specimen were found.

The resistance of cement based materials to chemical attack is

mainly due to permeability and alkalinity of concrete mass. The HVFA
concrete used in the test shows very high resistance to the penetration of
chloride ions in the tests performed according to ASTM C 1202 and higher
resistance than conventional concrete.

Plain cement concrete is known to be susceptible to acid attack. The

high content of CaO in PCC makes it vulnerable as it is readily soluble in acid
environment as it was claimed by other authors (Pavlik 1996, Dan et al 2003
and Beddoe et al 2005). Since the fly ash contains very less CaO, it becomes
a promising alternative for aggressive environments also. The specimens
immersed in the respective chemical solutions are shown in the Figures 6.2(a)
and 6.2(b).

Figure 6.2 (a) Cubes in acid solution Figure 6.2 (b) Cubes in sulphate
solution
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The results of the acid resistance tests of various % of fly ash concrete

mixes at the age of 28 days are given in Table 6.3.

Table 6.3 Percentage difference in weights of cubes in acid test

Percentage difference in weight (kg)

% of fly
Sl No.
ash
In HCL In MgSO4 In NaCl
1 0 1.325 0.413 -0.245
2 50 0.979 0.235 -0.154
3 55 0.678 0.179 -0.146
4 60 0.53 0.155 -0.126
‘ – ’ indicates in increment in weight

The results of % of fly ash and% of weight loss of concrete in acid resistance
tests of various % of fly ash concrete mixes at the age of 28 days are given in
Table 6.3.

2
1.8
1.6
% of Weight Loss

1.4
1.2
1
NaCl
0.8
MgSO4
0.6 HCL
0.4
0.2
0
0% FA 50%FA 55%FA 60%FA
% of fly Ash

Figure 6.3 % of fly ash Vs % of weight loss of concrete

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6.3.5 Water Permeability Test

Permeability is defined as the coefficient representing the rate at

which water is transmitted through a saturated specimen of concrete under
externally maintained hydraulic gradient. Permeability is inversely linked to
durability, the lower permeability, the higher the durability of concrete.
Testing has shown that properly proportioned concretes using a combination
of fly ash, normal or high-range water reducing admixtures, and air entraining
admixtures have the ability to produce the same low levels of permeability as
latex modified and silica-fume concretes.

Permeability of concrete is governed by many factors such as

amount of cementitious material, water content, aggregate grading,
consolidation and curing efficiency. CH liberated by hydrating cement is
water soluble and may leach out of hardened concrete, leaving voids for
ingress of water. Through its pozzolanic properties, fly ash chemically
combines CH with water to produce CSH, thus reducing the risk of leaching
CH. When fly ash concrete is properly cured, fly ash reaction products
partially fill in the spaces originally occupied by mixing water that were not
filled by the hydration products of the cement, thus lowering the concrete
permeability to water and aggressive chemicals.

Fly ash increases the cementitious compounds, minimizes water

demand and reduced bleed channels, all of which increase concrete density.
By the reaction of fly ash and CH to CSH, a reduction of bleed channels,
capillary channels and void spaces occurs. The small particles of fly ash will
fill in the tiniest voids and increase the density of the concrete. When the
amount of CH decreases, the resistance to weak acids, salts and sulphates
increase.
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The water permeability test was conducted as per IS: 3085-1965.

Concrete cubes after 28 days of curing were kept in the cube compartment of
the test set up. Sides of cubes were sealed using a mixture of wax and rosin to
achieve water tightness. Water at a constant pressure of 0.5MPa was
maintained throughout the study period of 3 days. Quantity of water
percolating over the entire period of test after the steady state was noted. The
permeability coefficients for OPC concrete and HVFA concrete were
determined (Equation 6.1) and the results are given in Table 6.4. The results
were compared for OPC concrete and HVFA concrete in Figure 6.4. It is
evident that there is considerable reduction in the permeability with the
decrease of water binder ratio from 0.55 to 0.45. Lowest value of permeability
was observed in case of HVFA concrete and 50 % replacement of fly ash
concrete of Mix M20.

The co-efficient of permeability was calculated using the following

Equation 6.1.

K = Q / AT (H/L) (6.1)

Where, K = Co-efficient of permeability in cm/sec

Q = Quantity of water in milliliters percolating over the entire

period of test after the steady state was reached

A = Effective area of specimen in cm2

T = Time in seconds over which ‘Q’ is measured

H /L= Ratio of Pressure head to thickness of specimen in cm

The following Table 6.4 shows the permeability coefficient for mix M20,
M25 and M30 grade concrete with various % of replacement of fly ash in
cement.
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Table 6.4 Permeability coefficient for mix M20, M25 & M30grade
concrete

Grade of % of Replacement of Co efficient of permeability

Sl. No
concrete fly ash (10 -7 in cm/sec)
1 0 9.28
2 M20 50 6.94
3 55 7.14
4 60 7.62
5 0 9.43
6 M25 50 7.91
7 55 8.32
8 60 8.56
9 0 9.53
10 M30 50 8.15
11 55 8.38
12 60 8.72

The following Figure 6.4 shows the permeability comparison for OPCC and
various % replacement of flyash in HVFA concrete.

12
Co efft. of Permeability 10 -7 cm/s

10

8
M20

6 M25

M30
4

0
0% 50% 55% 60%
% of Fly ash

Figure 6.4 Permeability comparison for OPCC and HVFA concrete

The test results on water absorption as well as acid test were

confirmed by the permeability test results. Permeability test results give the
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nature of micro pores inside the concrete. Least value of coefficient of

permeability was obtained in the case of 50 % replacement of HVFA concrete
(6.94 x 10-7 cm/sec) as against (9.28 X 10 -7
cm/sec)in OPC concrete
specimens. It clearly indicates the increased corrosion resistance capacity of
HVFA concrete over OPC concrete.

6.4 KEY FINDINGS

The following conclusions were drawn within the limitations of

experimental investigations. From the limited study carried out, it was
concluded that the concrete with fly ash has shown improvements in the
strength and the durability characteristics of concrete. The concrete is
workable one for higher percentage of water to binder ratio due to the use of
high volume fly ash and super plasticizers. Due to the better micro structural
properties the concrete was found to be more durable than conventional one.

x In case of fly ash concrete there is an increase in water

absorption at 28 days. At a later stage as the aging increased
from 28 days to 90 days water absorption was found to be
decreasing with increase in percentage replacement of ash.

x In the case of HVFA concrete specimens it was found that ,as

the percentage replacement of fly ash increased from 0% to 60
% there was decrease in water absorption at all stages of
curing. The reduced water absorption at the age of 28 days
curing makes HVFA concrete more compact, which is an
advantage over OPC concrete.

x Weight loss of HVFA concrete was found to decrease as

percentage of ash is increased.
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x The performance of chemical attack on HVFA concrete is

significantly better than that of ordinary Portland cement
concrete. The better performance of HVFA concrete than that
of Portland cement concrete in acidic environment might be
attributed to the lower calcium content of the source material.

x The results confirmed that HVFA concrete of all the

replacements show good resistance against acidic, chloride
and sulphate environment.

x The weight loss results obtained in the study showed better

performance than OPC counterparts which were reported to
more weight loss as claimed by few authors in earlier studies.
The better performance of HVFA concrete than that of
Portland cement concrete in acidic environment might be
attributed to the lower calcium content of the source material
as a main possible factor, since HVFA concrete does not rely
on lime like PCC.