Strength Characteristics and Rheological Behavior of a High Level of Fly Ash in the Production of Concrete

This study investigates the valorization of coal fly ash (FA-C) generated by the Jerada thermal power plant, aiming to address the pressing need for sustainable construction practices and reduced greenhouse gas emissions in the concrete industry. It is widely used as a pozzolanic material. The key objective is to harness the potential of FA-C as a supplementary material in concrete production, which not only reduces costs but also contributes to environmental sustainability. To achieve this objective, various concrete mixtures were formulated, with FA-C serving as a partial substitute for cement at percentages ranging from 15 to 50%. According to ASTM standards, compressive strength tests were conducted on standard-sized cylinders at 7 and 28 days. The results revealed that the blend containing 15% FA-C exhibited the highest compressive strength, indicating its effectiveness as a concrete additive. Furthermore, this study delves into the rheological properties of concrete mixes, an essential aspect of successful concrete processing. It was observed that a higher replacement level of FA-C significantly improved the rheology, leading to reduced water demand and a linear decrease in plastic viscosity over time. The rheological parameters stabilized after a certain period, demonstrating the controllability of concrete flow behavior with FA-C. The investigation also employed three analytical methods-Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), and scanning electron microscopy (SEM)-to comprehensively analyze both raw materials and processed samples. FTIR analysis highlighted the minimal impact of FA particles on hydration product formation, emphasizing the role of FA-C in enhancing the concrete's strength. XRD analysis confirmed the presence of an amorphous phase crucial for FA's reactivity. SEM observations revealed that concrete with 15% FA-C exhibited a more uniform microstructure with aluminosilicate gel, while 50% FA-C mixes showed increased porosity and nonhomogeneity due to unreacted FA particles.