Properties of concrete prepared with crushed fine stone, furnace bottom ash and fine recycled aggregate as fine aggregates

Construction and Building Materials 23 (2009) 2877–2886

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Construction and Building Materials

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Properties of concrete prepared with crushed fine stone, furnace bottom ashand fine recycled aggregate as fine aggregates

Kou Shi-Cong, Poon Chi-Sun *

Department of Civil and Structural Engineering, The Hong Kong Polytechnic University, Hung Hom, Hong Kong, China

a r t i c l e i n f o a b s t r a c t

Article history:Received 4 August 2008Received in revised form 29 December 2008Accepted 8 February 2009Available online 12 March 2009

Keywords:Fine aggregatesFurnace bottom ashFine recycled aggregateCrushed fine stoneConcrete

0950-0618/$ - see front matter � 2009 Elsevier Ltd. Adoi:10.1016/j.conbuildmat.2009.02.009

* Corresponding author. Tel.: +852 2766 6024; fax:E-mail address: [email protected] (C.-S. Poo

This paper presents the results of a study to compare the properties of concretes prepared with the useriver sand, crushed fine stone (CFS), furnace bottom ash (FBA), and fine recycled aggregate (FRA) as fineaggregates. Two methods were used to design the concrete mixes: (i) fixed water–cement ratio (W/C) and(ii) fixed slump ranges. The investigation included testing of compressive strength, drying shrinkage andresistance to chloride-ion penetration of the concretes. The test results showed that, at fixed water–cement ratios, the compressive strength and the drying shrinkage decreased with the increase in theFBA content. FRA decreased the compressive strength and increased the drying shrinkage of the concrete.However, when designing the concrete mixes with a fixed slump value, at all the test ages, when FBA wasused as the fine aggregates to replace natural aggregates, the concrete had higher compressive strength,lower drying shrinkage and higher resistance to the chloride-ion penetration. But the use of FRA led to areduction in compressive strength but increase in shrinkage values. The results suggest that both FBA andFRA can be used as fine aggregates for concrete production.

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1. Introduction

Natural materials such as river sand and crushed fine stone aregenerally used in concrete as fine aggregates. However, with thebooming in urban infrastructure development and the increasingdemand on protecting the natural environment, especially inbuild-up areas such as Hong Kong and some southern Chinese cit-ies in the Pearl River Delta, the availability of the natural resourcesis diminishing rapidly. Other sources of fine aggregates are ur-gently needed.

Furnace bottom ash (FBA) is a waste material generated fromcoal-fired thermal power plants. Unlike its companion – pulverisedfuel ash (PFA), it usually has much lower pozzolanic propertywhich makes it unsuitable to be used as a cement replacementmaterial in concrete. However, as its particle distribution is similarto that of sand which makes it attractive to be used as a sandreplacement material especially in concrete masonry block pro-duction. But few studies have been done on exploring the feasibil-ity of using FBA for making concrete.

Previous studies carried out by Bai et al. on using FBA as a nat-ural sand replacement material in concrete indicated that,although FBA has no adverse effect on the strength of concrete, be-yond 30% replacement level, the permeation properties of the con-crete would be detrimentally affected [1,2]. The porous structure ofthe FBA particles has been considered to have caused the increase

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in the permeation properties. However, the porous nature of theaggregate is believed to be a benefit for reducing the shrinkageof concrete [3,4], which is considered to be due to its ‘‘internal cur-ing effect’’ through slow release of moisture from the saturatedporous particles [5,6].

Recycled aggregates are produced from the re-processing ofmineral waste materials, with the largest source being construc-tion and demolition (C&D) waste. The coarse portion of the recy-cled aggregates has been used as a replacement of the naturalaggregates for concrete production. The potential benefits anddrawbacks of using recycled aggregates in concrete are well under-stood and extensively documented [7–13]. In general, the qualityof recycled aggregates is inferior to those of natural aggregates.The density of the recycled aggregates is lower than the naturalaggregates and the recycled aggregates have a greater waterabsorption value compared to the natural aggregates. As a result,a proper mix design is required for obtaining the desired qualitiesfor concrete made with recycled aggregates [14,15].

In addition to the coarse recycled aggregates, fine recycledaggregates (FRA, <5 mm) can also be used to replace natural fineaggregates in the production of concrete. Khatib [16] reported thatwhen natural fine aggregates in concrete were replaced by 0%, 25%,50%, 75% and 100% fine recycled aggregates and the free water/ce-ment ratio was kept constant for all the mixes, the 28-day strengthof the concrete developed at a slower rate. Furthermore, the con-crete mixtures containing fine recycled aggregates had highershrinkage than the natural aggregates concrete. Evangelista et al.[11] indicated that the use of fine recycled concrete aggregates

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2878 S.-C. Kou, C.-S. Poon / Construction and Building Materials 23 (2009) 2877–2886

up to 30% replacement ratios would not jeopardize the mechanicalproperties of concrete.

This paper compares the properties of concretes that are pre-pared with the use river sand, crushed rock fine, furnace bottomash, and recycled fine aggregates as fine aggregates. The mechani-cal properties, deformational behaviour and durability of the con-crete were investigated by testing of compressive strength, dryingshrinkage and resistance to chloride-ion penetration of the con-cretes, respectively.

2. Experimental details

2.1. Materials

The cement used was the ASTM Type I Portland cement complying with BS EN197 – 1:2000 [17].

The coarse aggregate used was 10 and 20 mm crushed natural granite. The nat-ural fine aggregates used were river sand sourced from the Pearl River and crushedfine stone (CFS, granite) obtained from a local quarry. Both materials comply withBS EN 12620:2002 [18]. The FBA used was obtained from a local coal-fired powerplant. Before the FBA was used, it underwent a process of sieving so that all mate-rials used in the experiment were <5 mm. The fine recycled aggregate (FRA) was ob-tained from a local C&D waste recycling plant.

The physical and chemical properties of the materials used are shown in Tables1 and 2. Fig. 1 shows the particle size distributions of the FBA, the CFS, the FRA andthe river sand used in this study.

Table 1Chemical composition (% by mass) of cement and FBA.

SiO2 Al2O3 Fe2O3 MgO CaO

Cement 19.6 7.33 3.32 2.54 63.15FBA 60.7 18.3 6.56 1.28 3.25

LOI: loss on ignition.

Table 2Properties of aggregates.

Property Granite

10 mm 20 mm

Density (SSD) (kg/m3) 2620 2620Fineness modulus – –1-h Water absorption (%) 0.48 0.47

0

20

40

60

80

100

120

10 5 2.36 1.18

Size of tes

Cum

ulat

ive

perc

enta

ge p

assi

ng (

%)

FBA

River sand

CFS

FRA

Fig. 1. Comparison of particle size distribu

2.2. Mixture proportions

Two series of concrete mixes were prepared. In the concrete mixes, natural riversand was replaced by the FBA, CFS and FRA at replacement levels of 0%, 25%, 50%,75% and 100% by mass, respectively, and the cement content was fixed at 386 kg/m. In Series I, the concrete mixes were designed at fixed water–cement ratio of0.53. In Series II, the concrete mixes were designed to have a near constant slumpin the range of 60–80 mm; and as such, the free water content (and hence thewater–cement ratio) varied. Table 3 shows the detailed mix proportions. The con-crete mixes were designed based on the saturated surface dried condition as re-flected in Table 3. Water compensation was made during concrete batching.

2.3. Details of specimen

For each concrete mix, twelve 100 mm size cubes were cast to determine thecompressive strength. Three 75 � 75 � 285 mm prisms with an indentation at thecentre of the two ends were cast to determine the drying shrinkage. Two100 � 200 cylindrical specimens were cast to determine the resistance to chlo-ride-ion penetration.

All concrete specimens were prepared in accordance with BS 1881: Part125:1986 [19]. All specimens were cast in two layers and compacted on a vibratingtable until no more air bubbles appeared. They were covered with a plastic sheetand left in the mould in the laboratory at 22(±1) �C for 24 h. After that, different cur-ing regimes were used as described below: (1) The 100 mm cubes were cured inwater 27(±1) �C until they were tested at 3, 7, 28 and 90 days to determine the com-pressive strength; (2) the concrete prisms were covered with a damp Hessian clothand a plastic sheet. After 1 day, the covers were removed and the specimens werewiped clean, and then the initial length was measured. The prisms were then stored

Na2O K2O TiO2 SO3 Others LOI

– – – 2.13 – 2.970.89 2.12 0.95 0.82 1.00 4.13

CFS River sand FBA FRA

2610 2620 2190 23103.56 2.18 1.83 3.180.89 0.38 28.9 2.38

0.6 0.3 0.15 0.075

t sieve (mm)

tions of FBA, river sand, CFS and FRA.

Table 3Mix proportion of concrete mixes in Series I and II (based on saturated surface dried condition).

Series no. Mix notation SRLa (%) Cement Free water W/C Sand FBA FRA CFS Coarse agg.

Control 0 386 205 0.53 652 – – – 1110I FBA25 25 386 205 0.53 457 163 – – 1110

FBA50 50 386 205 0.53 262 326 – – 1110FBA75 75 386 205 0.53 67 489 – – 1110FBA100 100 386 205 0.53 – 545 – – 1110FRA25 25 386 205 0.53 473 – 163 – 1110FRA50 50 386 205 0.53 293 – 326 – 1110FRA75 75 386 205 0.53 114 – 489 – 1110FRA100 100 386 205 0.53 – – 592 – 1110CFS25 25 386 205 0.53 489 – – 163 1110CFS50 50 386 205 0.53 325 – – 326 1110CFS75 75 386 205 0.53 162 – – 489 1110CFS100 100 386 205 0.53 – – – 650 1110

II FBA25 25 386 190 0.49 494 167 – – 1127FBA50 50 386 170 0.44 318 343 – – 1126FBA75 75 386 150 0.39 138 529 – – 1135FBA100 100 386 130 0.34 – 725 – – 1184FRA25 25 386 200 0.52 490 – 164 – 1114FRA50 50 386 195 0.51 307 – 331 – 1086FRA75 75 386 190 0.49 130 – 500 – 1073FRA100 100 386 185 0.48 – – 671 – 1086CFS25 25 386 208 0.54 487 – – 162 1105CFS50 50 386 211 0.55 322 – – 323 1099CFS75 75 386 214 0.56 161 – – 482 1093CFS100 100 386 217 0.57 – – – 640 1087

a SRL: sand replacement level.

S.-C. Kou, C.-S. Poon / Construction and Building Materials 23 (2009) 2877–2886 2879

in an environmental chamber at 23(±1) �C and 50(±1)% RH until the drying shrink-age was tested at the ages of 1, 4, 7, 14, 28, 90 and 112 days; (3) The concrete cyl-inders were cured in water at 27(±1) �C until the curing ages of 28 days and 90 days.The cylinders were then cut by a diamond saw to obtain 100 mm diame-ter � 50 mm thick concrete discs for the chloride-ion penetration test.

2.4. Test procedures

2.4.1. WorkabilityThe workability of fresh concrete was measured by the slump test, in accor-

dance with BS 1881: Part 102: 1983 [20].

2.4.2. Compressive strengthThe compressive strength was measured by crushing 300 mm cubes in accor-

dance with BS 1881: Part 116: 1983 [21] using a Denison compression machinewith a capacity of 3000 kN. The loading rates were 200 kN/min for the compressivetests. The compressive strengths of the hardened concrete were determined at theages of 3, 7, 28 and 90 days.

2.4.3. Drying shrinkageThe drying shrinkage values were determined following ASTM C490-07 [22].

The prism specimen size was 75 � 75 � 285 mm. The specimens were demoldedafter curing for 24 h and the initial lengths of the specimens were measured. Afterthe initial reading, the specimens were conveyed to a drying-chamber with a tem-perature of 23 �C and a relative humidity of 55% until the time when the next mea-surement at 1, 4, 7, 28, 56, 90 and 112 days was reached. The accuracy in the lengthchange measurement was ±0.0025 mm.

2.4.4. Chloride-ion penetrationThe resistance to chloride penetrability of concrete was determined in accor-

dance with ASTM C1202-94 [23]. The resistance of concrete against chloride-ionpenetration is represented by the total charge passed in coulombs during a test per-iod of 6 h.

3. Results and discussion

3.1. Property of fresh concrete

The slump values of the fresh concretes in Series I and II areshown in Figs. 2 and 3, respectively. From Fig. 2, it can be seen that,at the fixed W/C ratio, the slump of the FBA and FRA concretemixes was increased with an increase in FBA or FRA content. This

was due to FBA and FRA had higher water absorption values thanthat of river sand making more free water was made available toincrease the fluidity of the fresh concrete. However, the slump ofCFS concrete mixes was decreased with an increase in CFS contentprobably due to the angular shape of the CFS when compared toriver sand. This result is similar to that of Cabrera and Donza[27] who reported that when crushed sand was incorporated inconcrete, the increase of water demand due to the shape and tex-ture of the crushed sand can be mitigated by using a water reduc-ing admixture. Fig. 3 shows the slump values of the Series II mixeswere maintained at approximately the same value by reducing theadded free water (Fig. 4) when FBA and FRA were used to replaceriver sand. However, for the case of the CFS mixes, more free waterwas needed to produce the same workability due to the angularshape of CFS.

3.2. Compressive strength

Figs. 5–10 show the compressive strength results of the con-crete mixes in Series I and II, respectively. It can be seen from Figs.5 and 6 that when using the same W/C ratio, generally the com-pressive strength of the FBA and FRA concrete decreased at allthe ages with an increase in the FBA and FRA contents. This maybe due to the high initial free water content used in the mixes ren-dered bleeding and poorer interfacial bonding between the aggre-gates and the cement pastes.

Moreover, it can be seen from Fig. 7 that at replacement levelsof 75% and 100%, the compressive strength of the CFS concrete de-creased when compared with the control. This was due to the de-crease in slump when the angular CFS was used to replace sand.This is consistent with other researchers’ findings that the use ofcrushed sand in concrete would increase both the water and ce-ment content in order to maintain an adequate workability [24–27]. The amount of additional water and cement required wasdependent on the shape, texture, grading and dust content of thecrushed sand.

0

30

60

90

120

150

180

210

Control FBA25 FBA50 FBA75 FBA100 FRA25 FRA50 FRA75 FRA100 CFS25 CFS50 CFS75 CFS100

Mix notation

Slum

p (m

m)

Fig. 2. Slump values of fresh concrete in Series I.

0

10

20

30

40

50

60

70

80

90

Mix notation

Slum

p (m

m)

Fig. 3. Slump values of fresh concrete in Series II.

0

50

100

150

200

250


Mix notation

Fre

e w

ater

con

tent

(kg

/m3 )

Fig. 4. Free water content of concrete in Series II.


0

10

20

30

40

50

60

70

Control FBA25 FBA50 FBA75 FBA100

Mix notation

Com

pres

sive

str

engt

h (M

Pa)

3-day 7-day 28-day 90-day

Fig. 5. Compressive strength of concrete mixes in Series I (FBA).

0

10

20

30

40

50

60

70

Control FRA25 FRA50 FRA75 FRA100

Mix notation

Com

pres

sive

str

engt

h (M

Pa)


Fig. 6. Compressive strength of concrete mixes in Series I (FRA).

0

10

20

30

40

50

60

70

Control CFS25 CFS50 CFS75 CFS100

Mix notation

Com

pres

sive

str

engt

h (M

Pa)


Fig. 7. Compressive strength of concrete mixes in Series I (CFS).


0

10

20

30

40

50

60

70

80

Control FBA25 FBA50 FBA75 FBA100

Mix notation

Com

pres

sive

str

engt

h (M

Pa)


Fig. 8. Compressive strength of concrete mixes in Series II (FBA).

0

10

20

30

40

50

60

70

Control CFS25 CFS50 CFS75 CFS100

Mix notation

Com

pres

sive

str

engt

h (M

Pa)


Fig. 10. Compressive strength of concrete mixes in Series II (CFS).

0

10

20

30

40

50

60

70

Control FRA25 FRA50 FRA75 FRA100

Mix notation

Com

pres

sive

str

engt

h (M

Pa)


Fig. 9. Compressive strength of concrete mixes in Series II (FRA).



Fig. 8 indicates that for concrete designed with a fixed slumprange, the compressive strength of the FBA concrete was higherthan that of the control. The improved in compressive strengthshould be attributed to the decrease in free W/C due to the fact thatfor a given slump of concrete, the high water absorption propertiesof FBA would lead to a reduction of free water required (Fig. 4) toproduce the target slump value.

Fig. 9 shows the compressive strength of the concrete decreasedwith an increase in the FRA content at all the test ages. This is prob-ably because similar to the case of FBA, the free water required forthe fixed slump in the case of the FRA mixes was also decreased. Butdue to the water absorption value of FRA was a lot lower than thatof FBA (see Table 2), the water reduction effect on FRA concrete wasnot as significant as that on the FBA concrete. Under such condi-tions, the effect of the relative weaker FRA on concrete strengthwould lead to an overall reduction of compressive strength.

Moreover, it can also be seen from Fig. 10 that at replacementlevels of 75% and 100%, the compressive strength of the CFS con-crete decreased when compared with the control. This was dueto the increase in free W/C ratio used (Table 3) to compensate

0

10

20

30

40

50

60

70

80

3-day 7-dayMix n

Com

pres

sive

str

engt

h (M

Pa)

Control

FBA100

FRA100

CFS100

Fig. 12. Comparison of compressive strength of concrete mixes in S

0

10

20

30

40

50

60

70

3-day 7-dayTim

Com

pres

sive

str

engt

h (M

Pa)

Control

FBA100

FRA100

CFS100

Fig. 11. Comparison of compressive strength of concrete mixes in S

for the decrease in slump when the angular CFS was used to re-place river sand.

Figs. 11 and 12 show the comparison of the compressivestrength of the concrete made with 100% FBA, 100% FRA and100% CFS in Series I and II, respectively. Fig. 11 shows at all the testages, when the W/C was kept constant, the compressive strength ofFBA, FRA and CFS concrete was lower than that of the control. Theconcrete mixes with 100% FBA had the lowest compressivestrength. However, Fig. 12 shows that when designing the concretemixes at a fixed slump range, the concrete made with FBA had thehighest compressive strength while the FRA concrete had the low-est compressive strength. The above results further illustrate howthe water absorption properties of the different fine aggregates af-fected the free water required in the concrete mixes (hence W/C)which had direct bearings on the compressive strength.

3.3. Drying shrinkage

The drying shrinkage results of the concrete mixes in Series Iand II are presented in Figs. 13 and 14, respectively. Fig. 13 indi-

28-day 90-dayotation

eries II prepared with 100% FBA, FRA and CFS as fine aggregate.

28-day 90-daye (day)

eries I prepared with 100% FBA, FRA and CFS as fine aggregate.

0

100

200

300

400

500

600

700

800

900


Mix notation

Dry

ing

shri

nkag

e (M

icro

stra

in)

Fig. 13. Drying shrinkage of concrete mixes in Series I at 112 days.

0

100

200

300

400

500

600

700

800

900


Mix notation

Dry

ing

shri

nkag

e (m

icro

stra

in)

Fig. 14. Drying shrinkage of concrete mixes in Series II at 112 days.


cates that at the fixed W/C of 0.53, the drying shrinkage values ofall FBA and CFS concretes are lower than that of the control con-crete with the exception of the 100% FBA replacement level. The re-sults agreed with the findings of Bai et al. [28] who suggested thatwith a fixed W/C of 0.45 and 0.50, the drying shrinkage of concretecould be reduced by using FBA to replace sand. This was due towith the use of FBA in the concrete mixes, moisture would beslowly released from the porous FBA particles during the dryingof the concrete resulting in lower drying shrinkage values than thatof the control concrete. But the drying shrinkage values of FRA con-cretes increased with an increase in FRA content due to the ad-hered old mortar in FRA.

As shown in Fig. 14, at the fixed slump range, the drying shrink-age values of all the FBA concretes are lower than that of the con-trol. This was due to the fact that with the increase in FBA content,the required free water content decreased (Table 3). However,Fig. 14 also shows the drying shrinkage of the FRA concrete in-creased with an increase in the FRA content probably due to theinstability of the old adhered cement mortar in the FRA.

Moreover, the drying shrinkage values of all the CFS concretesin both the fixed W/C and the fixed slump range mixtures were

lower than that of the control. This is probably due to the CFS usedhad larger particle sizes distribution and hence lower specific sur-face areas (SSA) than that of the river sand. It has been suggestedthat SSA of aggregates is one of the properties that affects concreteshrinkage [29], and in general a sample of aggregate with a lowerSSA (i.e. larger particle size) would result in lower shrinkage of theconcrete produced.

3.4. Chloride-ion penetration

The test results of chloride-ion penetration of the concretemixes in Series I and II are shown in Figs. 15 and 16, respectively.Fig. 15 shows at the same W/C, the resistance to chloride-ion pen-etration of the concrete mixes decreased with increasing percent-ages FBA, FRA and CFS replacement of river sand. This may bedue to the FBA and FRA concretes had more free water than thecontrol concrete which led to a looser microstructure. In the caseof FRA concrete, the adhered mortar should lead to a worse micro-structure too. For CFS, the decrease in slump of the CFS concretemight have rendered a poorer microstructure due to difficulty incompaction.

0

1000

2000

3000

4000

5000

6000

7000

Mix notation

Tota

l cha

rge

pass

ed in

cou

lom

bs

28-day 90-day

Fig. 15. Total charge passed in coulombs of concrete mixes in Series I at 28 days and 90 days.

0

1000

2000

3000

4000

5000

6000

7000


Mix notation

Tota

l cha

rge

pass

ed in

cou

lom

bs

28-day 90-day

Fig. 16. Total charge passed in coulombs of concrete mixes in Series II at 28 days and 90 days.


Moreover, at a fixed slump range (Series II, Fig. 16), due to theinitial free water required was decreased (see Fig. 4), the resistanceto chloride-ion penetration of all FBA, FRA and CFS concrete mixeswas better than that of the control. Again, the effect was most sig-nificant for the FBA mixes due probably to the pozzolanic effect be-tween the hydrated cement paste (i.e. calcium hydroxide) and thesmall FBA particles.

4. Conclusion

Based on the present investigation, the following conclusionscan be drawn:

(1) At a fixed W/C, the compressive strength and the dryingshrinkage decreased with the increase in the FBA content.FRA decreased the compressive strength and increased thedrying shrinkage of the concrete.

(2) At a fixed slump value, the use of FBA and FRA was able toreduce to free water requirement of the concrete mixes.

(3) For the mixes prepared with the same slump range and withthe use of a lower free W/C ratio, the FBA concrete had thehighest compressive strength values.

(4) But the use of FRA led to a reduction in compressive strengthdespite the use of a lower free W/C. This might be due to theinherent weaker mechanical properties of FRA.

(5) The drying shrinkage decreased with the increase of the FBAcontent. FRA increased the drying shrinkage of the concrete.

(6) At a fixed slump value, the resistance to chloride-ion pene-tration of all FBA, FRA and CFS concretes was higher thanthat of the control concrete.

(7) It is feasible to use FBA and FRA as fine aggregate in prepar-ing concrete mixes.

Acknowledgements

The authors would like to thank the Research Grants Council(PolyU 5259/06E) and the Hong Kong Polytechnic University for


funding support. The FBA for this research was provided by theChina Light and Power Co. Ltd. and the FRA was provided by the Ci-vil Engineering Development Department of the Hong Kong SARGovernment.

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Documents

Properties of concrete prepared with crushed fine stone, furnace bottom ash and fine recycled aggregate as fine aggregates