Materials Today: Proceedings 26 (2020) 3250–3256

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Optimization of fly ash concrete mix – a solution for sustainable

development
A. Fuzail Hashmi ⇑, M. Shariq, A. Baqi, Moinul Haq
Civil Engineering Department, AMU, Aligarh, India

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

Article history: This paper presents a method for optimizing fly ash concrete mix using the data obtained through
Received 11 September 2019 planned experimental program.
Received in revised form 20 January 2020 The full factorial experimental technique involving three factors with their four levels (4x4x4) were
Accepted 13 February 2020
used. A total of 64 mixes with three replicates (192 specimens) were cast by taking three parameters
Available online 30 March 2020
for optimization. The three parameters were water to binder ratio (0.4, 0.45, 0.5, 0.55); coarse aggregate
to total aggregate ratio (0.5, 0.55, 0.6, 0.65) and four percentages of fly ash i.e. 0%, 25%, 40% & 60%. The
Keywords:
cement density used in the experimental program were 400 kg/m3. These parameters were taken in such
Fly ash
Optimization
a way that the various combinations of these factors would yield optimum concrete mix in the practical
Concrete mix proportion range of compressive strength. Two grades of concrete i.e. M20 and M30 were obtained from experimen-
Full factorial analysis tal investigation. The experimental data were utilized to develop the regression model for compressive
Compressive strength strength in terms of three design factors considered in this study. The test results showed that optimum
compressive strength was achieved at 0.45 water to binder ratio and 0.6 coarse aggregate to total aggre-
gate ratio at 25% replacement of cement with fly ash.
Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 10th International
Conference of Materials Processing and Characterization.

1. Introduction able development, it is important to replace some percentage of

cement with other cementing material, for example fly ash, which
Employing high-performance materials at a reasonable cost results in form of by-product from the power plants working ther-
that imparts a lesser impact on the environment is the basic con- mally, is the most available material worldwide and produced in
cept of sustainable construction and development for civil engi- very huge quantities. The disposal of fly ash is also the point of con-
neers. The environmental impact can be minimized by cern as it acquires a large amount of costly land and reduces the
decreasing the production of waste and emission of harmful green- agricultural area. Therefore, the utilization of fly ash in concrete
house gases, efficient use of minerals and increased use of recycled has a significant effect on the construction industry. The overall
materials like aggregates, gypsums etc. A well-known material is cost of the structure has considerably reduced after using fly ash
the Portland cement used as a binder material in most of the con- as a replacement for cement. The intervention of fly ash particles
struction practices conducting throughout the globe. But, manufac- produces some good results in the concrete [1]. In the construction
turing the same in factories results in discharging huge volumes of industry, the use of fly ash has already been started and its opti-
carbon dioxide gas into the atmosphere that results in greenhouse mum use as construction material may be enhanced, if useful data
effect and induces global warming. The environment is already is collected regarding the feasibility of construction with fly ash
much polluted and large scale manufacturing of the cement has along with other construction material. A number of researchers
considerably increased the number of harmful gases in the atmo- and scientists have investigated the concrete properties with fly
sphere. The cement production consumes a vast amount of natural ash and some of them have also proved the feasibility of construc-
material i.e. limestone and clay. So, in view of worldwide sustain- tion with fly ash.
Good compressive strength of concrete having a large volume of
class F fly ash can be achieved by maintaining a cement density of
⇑ Corresponding author. 400 kg per cubic meters with water cement ratio (W/C) in the
E-mail address: [email protected] (A.F. Hashmi). range of 0.35–0.45 [2]. The strength of fly ash mixed concrete in

https://doi.org/10.1016/j.matpr.2020.02.908
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 10th International Conference of Materials Processing and Characterization.
 A.F. Hashmi et al. / Materials Today: Proceedings 26 (2020) 3250–3256 3251

compression improved gradually with respect to time whereas the as workability, drying shrinkage, corrosion reinforcement, and
normal concrete strength stopped after 56 days of curing [3]. The alkali-silica expansion. He found that the utilization of fly ash in
environmental pollution and cement consumption can be mini- concrete is sustainable development. Shamshad [20] had given a
mized by developing green concrete incorporating fly ash [4]. statistical approach that is helpful in obtaining the optimum pro-
Cheewaket et al. [5] reported that the fly ash concrete showed bet- portion of concrete mix. The full factorial experimental technique
ter durability and strength under marine environment exposure. A was used taking three parameters i.e. water/cement ratio, cement
concrete containing ultra-pulverized fly ash and super-plasticizer content and fine aggregate/total aggregate ratio for optimization.
have lower values of permeability, shows good resistant against Optimization of concrete is a process of obtaining such a con-
freeze–thaw, and possess lower drying shrinkage [6]. Fly ash crete mix which is economical and satisfying the necessary charac-
increases the setting time and improved strengths at later ages of teristics of concrete such as strength, durability and workability.
about 91 & 365 days [7]. The applications of F Class fly ash as a par- Water binder ratio, coarse aggregate to total aggregate ratio and
tial substitution against the cement particles in concrete decreased different percentages of fly ash are the important factor which
its 28-day strengths in compression, tension as well as in flexural, influences the strength of concrete. Higher W/C ratio resulted in
its elastic modulus and concrete resistance against abrasion [8]. A the low strength of concrete whereas low W/C ratio generally gives
significant value of compressive strength and elastic modulus can good strength. Various approaches have been used in the past for
be achieved in high volume fly ash (HVFA) concrete if super- concrete optimization using the experimental, analytical or statis-
plasticizer are added in the concrete mix [9]. For the purpose of tical methods. In full factorial experimental technique, one factor is
proportioning fly ash concrete, Ram S. Ghosh proposed a method allowed to vary at a time against other factors, keeping all other
for gaining similar strengths in compression as that for normal factors constant. This process is repeated by varying other factors
Portland cement mix concrete [10]. The method is based on the one by one until all the factors have been treated. This methodol-
Abrams’ law which correlates compressive strength and water- ogy leads to a large number of trials. So, in this way, the response is
cement ratio. Takashi et al. [11] have prepared a concrete by mix- observed at all factor level combinations of independent variables
ing a combination of clinker ash and fly ash while testing its flow- and the effects of factor level combinations are investigated simul-
ability and bleeding characteristic along with analyzing short and taneously. Shariq et. al., Abbasi et. al., Soudki et. al., Nath and Barua
long term strengths under compression (progress analyzed for [21–24] were studied the full factorial analysis to optimize the
age till 91-day). The strength magnitude boosted upon raising concrete mix proportion. The present study investigates the com-
the clinker ash’s replacement rate up to 50 percent. Maiti et. al prehensive effect of fly ash its proportion on concrete mix design
[12] developed the relationship of 28 days compressive strength to achieve optimum strength of concrete.
using mix proportioning of Portland cement, fly ash & ground gran-
ulated blast furnace slag (GGBFS) with different W/C ratios. The
2. Research significance
mineral admixtures such as GGBFS and fly ash contribute to the
strength development process at the age and beyond 28 days. P.
The research presented in this paper gives a meaningful result
J. Tikalsky et al. [13] had conducted an experiment on fly ash mix
obtained via full factorial analysis. The optimization of concrete
proportioning concrete for finding resistance against freeze–thaw,
with fly ash carried out using the three parameters i.e. water to
creep, shrinkage and abrasion while producing strengths limits
binder (W-B) ratio, coarse aggregate to total aggregate (CA-TA)
against applied flexural & compression loads. Fly ash contents of
ratio and different percentages of fly ash. These parameters were
type Class-C, as well as Class-F, was considered in the range of
optimized in the best possible way to obtain desired compressive
0–35 percent by weight of Portland cement. Adequate freeze–thaw
strength which is useful in the mix design.
resistance, reduced creep deformation, similar or reduced shrink-
age under similar curing conditions, equal or greater resistance
to abrasion, slightly reduced early age compressive and flexural 3. Experimental program
strengths and improved long term compressive and flexural
strength were obtained. Pilar Alaejos Gutierrez [14] established a 3.1. Materials properties
mix proportioning method to proportion cement, aggregates,
admixtures, W/C ratio for HPC to gain strength up to 110 MPa. The various properties of the materials used in the preparation
Francis A. Oluokun [15] proposed the law for designing concrete of 64 mixes such as cement, fly ash, fine aggregate and coarse
possessing fly ash content. The strength prediction ability of the aggregate has been conformed to the specification as per the in
proposed augmented water-cementitious material ratio law corre- the Indian Standard codes [25–28]. Ordinary Portland Cement 43
lates nicely with test data and can be used for mix design purposes grade (OPC 43) was used right through the experimental work.
when fly ash is used as a part of the cementitious materials. Berry The recommendation stated in IS 4031 [25] for cement has been
and Malhotra [16] did a critical review on fly ash concrete and completely followed during the entire investigation. The cement
found that the mix has shown improvised work-ability, pump- bags were covered with airtight polythene to prevent from mois-
ability, cohesiveness, finish, ultimate strength limits, as well as ture. The physical and chemical properties of cement and fly ash
durability under certain circumstances. Fly ash particles also used are given in Tables 1 and 2. The fine aggregate i.e. locally
improved the performance of concretes when exposed against available coarse sand was tested according to the procedures men-
deterioration due to sulfate or by alkali-aggregate interactions. tioned in IS-383 [26] to determine its properties. Locally available
Lane and Best [17] have discussed various properties of fly ash coarse aggregates of maximum nominal size of 16 mm having
and its physical and chemical effects on freshly mixed and hard- quartzite composition have been used for preparing the concrete
ened concrete. A method was proposed for the proportioning of mix. The sieve analysis and physical properties of the coarse aggre-
fly ash concrete mix. Robert W. Cannon [18] prepared a method gate (CA) were obtained according to IS-383 recommendations and
for optimizing cement and fly ash. By using this method, the the results are given in Table 3. No additives or super-plasticizer
strength of resulting fly ash concrete produced the same strength were added to the concrete mix. The fly ash used was obtained
as that of plain concrete at the end of 90 days. Mehta [19] had pre- from the Harduaganj power plant, Uttar Pradesh, India. It was class
sented a paper targeting different HVFA concrete properties such F fly ash having a specific gravity of 2.28.
3252 A.F. Hashmi et al. / Materials Today: Proceedings 26 (2020) 3250–3256

Table 1
Physical properties of Ordinary Portland Cement.

Characteristics Experimental Results Recommended values

Specific Gravity 3.15 3.15
Normal Consistency (% by weight of cement) 32 –
Setting time (minutes) Initial, Final 65,550 30 (min) 600 (max)
Soundness of cement (mm) 5 <10
Compressive strength (MPa) i) 3-days ii) 7-days iii) 28-days 23.5, 28.6, 43.5 22, 28, 43

Table 2 selected in the range of 0.4 to 0.55. The concrete for 0.4 water to
Chemical properties of Cement and Fly Ash. binder ratios was dry and have the least workability but gives
Compositions OPC (%) Fly Ash (%) higher strength. For increasing water to binder ratio in the range
of about 0.45, 0.5 & 0.55, the workability considerably increases
Lime (CaO) 62 3
Silica (SiO2) 22 60
whereas the compressive strength decreases. The concrete mixes
Alumina (Al2O3) 6 28 prepared to utilize W-B ratio as 0.45 magnitude has upgraded
Iron Oxide (Fe2O3) 4 8 workability and show good compressive strength. For higher W-B
Magnesia (MgO) 0.8 0.5 ratios having magnitudes in range 0.5 and 0.55, the workability
Sulphur (SO3) 1 –
increases too much while concrete’s compressive strength
decreases significantly. With the escalation in the quantity of fly
ash content, the concrete workability also increases. The contrac-
tion in the water winds up to the improvement in strength’s value.
3.2. Test program Fly ash contains less reactive particle in comparison to the Portland
cement, so significant hydration takes place in a longer time
The full factorial experimental technique with (4x4x4) concrete thereby giving elevated ultimate strength.
mixes was used for the optimization of the concrete mix. Various
trials were performed by making combinations on three parame- 4.2. Effects of.CA-TA ratio
ters i.e. W-B ratio, CA-TA ratio and four different percentages of
fly ash i.e. 0%, 25%, 40% & 60%. The loose density of the cement used Coarse aggregate to total aggregate (CA-TA) ratio performs an
in the experimental program was 400 kg/m3. The cement was important act in the compressive strength of concrete. For all W-
replaced by 0%, 25%, 40% & 60% of fly ash. The range of W-B ratio C ratios (showing slump range between 0 and 100 mm), the
used in the experimental work was 0.4, 0.45, 0.5 & 0.55 and the strength in compression of concrete increases as the CA-TA ratio
range of CA-TA ratio was 0.5, 0.55, 0.6 and 0.65. The total number upgraded from 0.5 to 0.6. But as CA-TA ratio increases beyond
of 64 mixes were formed and 192 specimens were cast (three 0.6, there is a reduction in the values of the compressive strength
cubes for each mix). Specimens were put in the mould for 24 h of concrete. This is because the surface area of aggregates in con-
at ambient temperature and after that it was demoulded. Test tact to cement decreases as the quantity of CAs increases. As a
specimens of 150 mm cube were tested for compressive strength result of which the cement is not able to coat all the surface of
after 28 days of curing in the compression testing machine. Two aggregates due to which the strength decreases. So, the strength
grades of concrete i.e. M20 and M30 were obtained from the exper- of concrete uplifts as the quantity of CA raised up to a certain limit
imental test. Table 4 summarizes the details of all the 64 mixes. but if it increases beyond further, segregation may take place and
the strength of the concrete also decreases considerably. Fig. 1
4. Results and discussion shows the compressive strength variation with the CA-TA ratio
for different values of W-B ratios and diverse percentages of fly
4.1. Effects of W-B ratio ash. It is clear by visualizing the graph that the optimum values
of the CA-TA ratio corresponding to the utmost strength in com-
Water to binder (W-B) ratio is highly sensitive for deciding con- pression of concrete lies close to 0.6 for all W-B ratio and for all
crete workability and strength values. It plays a very important substitution of the binder by fly ash.
role as long as the cement strengths in compression are exercised.
Higher the W-B ratio, lower the compressive strength of concrete 4.3. Effects due to fly Ash/Cement ratios
and vice versa. In this experimental program, the W-B ratio was
The existence of fly ash in the mix reduces the early compres-
sive strength’s values of concrete. The strength in compression is
considerably reduced at 40 & 60 percent of fly ash. The initial
Table 3
strength of fly ash concrete is quite low but gain considerable mag-
Physical properties of Fine Aggregate & Coarse Aggregate.
nitude with time durations. The significant advancement in the
Fine Aggregate strengths of fly ash concrete with the time is because of the fly
Characteristics Observed Test Values ash pozzolanic nature. During the presence of moisture, FA parti-
Grading zone II cles chemically bonds with Ca(OH)2, which is expelled due to
Fineness modulus 2.95 hydration to form calcium-silicate-hydrate (CSH) compounds,
Specific Gravity 2.30
Water.Absorption (%) 1.01
which possessing cementitious properties. During this experimen-
Coarse Aggregate tal program, the maximum strength in compression is 31 MPa that
Characteristics Observed Test Values was procured at 0.45 W-C ratio and 0% of FA and the least com-
Fineness modulus 6.95 pressive strength of 12.6 MPa was obtained at 0.55 W/C ratio and
Specific Gravity 2.75
60% of fly ash. As the percentages of fly ash has upgraded, the com-
Water.Absorption (%) 0.8
pressive strength’s of concrete decreases. However, the current
 A.F. Hashmi et al. / Materials Today: Proceedings 26 (2020) 3250–3256 3253

Table 4
Fly Ash Concrete Mix.

Mix No. W-B ratio CA-TA Ratio Fly ash/Cement Ratio Measured Compressive strength (MPa) Computed Compressive strength (MPa)
1. 0.4 0.5 0 29.8 29.14
2. 0.4 0.5 1/3 25.06 26.8
3. 0.4 0.5 2/3 20.3 24.6
4. 0.4 0.5 3/2 16.67 18.8
5. 0.4 0.55 0 29.4 29.0
6. 0.4 0.55 1/3 26.3 26.7
7. 0.4 0.55 2/3 21.4 24.4
8. 0.4 0.55 3/2 17.8 18.7
9. 0.4 0.6 0 30.4 28.8
10. 0.4 0.6 1/3 25.8 26.5
11. 0.4 0.6 2/3 22.4 24.3
12. 0.4 0.6 3/2 18.6 18.6
13. 0.4 0.65 0 28.0 28.7
14. 0.4 0.65 1/3 24.8 26.4
15. 0.4 0.65 2/3 22.5 24.12
16. 0.4 0.65 3/2 17.4 18.4
17. 0.45 0.5 0 30.2 27.08
18. 0.45 0.5 1/3 26.2 24.8
19. 0.45 0.5 2/3 22.0 22.5
20. 0.45 0.5 3/2 17.5 16.8
21. 0.45 0.55 0 29.3 27.0
22. 0.45 0.55 1/3 25.4 24.6
23. 0.45 0.55 2/3 21.1 22.4
24. 0.45 0.55 3/2 18.23 16.7
25. 0.45 0.6 0 31.0 26.8
26. 0.45 0.6 1/3 27.1 24.6
27. 0.45 0.6 2/3 23.8 22.23
28. 0.45 0.6 3/2 18.9 16.5
29. 0.45 0.65 0 28.4 26.6
30. 0.45 0.65 1/3 26.0 24.4
31. 0.45 0.65 2/3 23.0 22.07
32. 0.45 0.65 3/2 17.5 16.4
33. 0.5 0.5 0 26.6 25.03
34. 0.5 0.5 1/3 22.4 22.78
35. 0.5 0.5 2/3 18.0 20.4
36. 0.5 0.5 3/2 16.0 14.8
37. 0.5 0.55 0 27.4 24.8
38. 0.5 0.55 1/3 23.3 22.6
39. 0.5 0.55 2/3 19.8 20.3
40. 0.5 0.55 3/2 16.9 14.6
41. 0.5 0.6 0 25.5 24.7
42. 0.5 0.6 1/3 22.3 22.48
43. 0.5 0.6 2/3 18.9 20.1
44. 0.5 0.6 3/2 16.5 14.5
45. 0.5 0.65 0 23.9 24.6
46. 0.5 0.65 1/3 20.06 22.34
47. 0.5 0.65 2/3 19.03 20.0
48. 0.5 0.65 3/2 16.6 14.35
49. 0.55 0.5 0 23.8 23.0
50. 0.55 0.5 1/3 18.5 20.7
51. 0.55 0.5 2/3 15.8 18.4
52. 0.55 0.5 3/2 13.9 12.74
53. 0.55 0.55 0 24.4 22.8
54. 0.55 0.55 1/3 20.4 20.58
55. 0.55 0.55 2/3 15.0 18.26
56. 0.55 0.55 3/2 13.0 12.6
57. 0.55 0.6 0 23.5 22.7
58. 0.55 0.6 1/3 20.3 20.4
59. 0.55 0.6 2/3 16.9 18.11
60. 0.55 0.6 3/2 13.5 12.4
61. 0.55 0.65 0 20.09 22.5
62. 0.55 0.65 1/3 17.06 20.2
63. 0.55 0.65 2/3 16.03 17.9
64. 0.55 0.65 3/2 12.6 12.3

effect is not more significant at a 25% alteration of the content of fly of fly ash at all CA-TA ratios. For 0.45 W-B ratios and 0.5 CA-TA
ash with cement. In Fig. 2, i.e. strengths in compression versus Fly ratios, the strength in compression gets reduced by 13.2%,
Ash / Cement graphs, the steep downfall of the graph indicates that 27.15%, 42% for 25% , 40%, 60% cement replacement by fly ash
the compressive strength reduces with the increase in the quantity respectively. For 0.55 CA-TA ratio, the compressive strength gets
3254 A.F. Hashmi et al. / Materials Today: Proceedings 26 (2020) 3250–3256

Fig. 1. Compressive strengths distribution while altering CA-TA and W-B ratios.

reduced by 13.3%, 26.6%, 37.7% for 25% , 40%, 60% cement replace- sive strength with that of values obtained experimentally. A good
ment by fly ash respectively. For 0.60 CA-TA ratio, the compressive agreement has been obtained between the measured and the exper-
strength gets reduced by 12.6%, 23.2%, 39% for 25% , 40%, 60% imental values for compressive strength fly ash concrete having the
cement replacement by fly ash respectively. For 0.65 CA-TA ratio, error in the range between ±10%. The computed values of compres-
the compressive strength gets reduced by 8.4%, 19.0%, 38.3% for sive strength are approximately the same as the values obtained
25%, 40%, 60% cement alteration by fly ash respectively. experimentally.

5. Regression analysis 6. Conclusion

The findings of the strengths values for the cubes were sub- The present experimental analysis deals with the optimization
jected to regression using a computer program. Various combina- of a concrete mix containing fly ash by carrying out full factorial
tions were carried out to represent W/B, CA/TA & FA/C analysis considering three parameters i.e. water-cement ratio,
parameters in the equation. The model is given by Eq. (1) shows CA-TA ratio, and fly-ash cement ratio. These parameters were so
the best fit for the cubic strengths in compression (fc) of fly ash selected that it gives meaningful results for compressive strength.
concrete. Following main outcomes are drawn-

f c ¼ k1 þ k2 ðW=BÞ þ k3 ðCA=TAÞ þ k4 ðFA=CÞ ð1Þ

 On the ground for regression investigations for experimental
where k1 , k2 , k3, and k4 refers to the regression coefficients pro- values, the equation has been suggested to represent compres-
cured after performing the investigations and are given in Table 5. sive strength in terms of the variables considered. It is con-
The equation has been utilized in procuring 28th-day strengths in cluded that the binder replacement with that of fly ash
compression for fly ash concrete mixes. A plot has been devised decreases the 28th-days strength when the content of fly ash
in Fig. 3 for the purpose of comparing computed values of compres- is above 25%.
 A.F. Hashmi et al. / Materials Today: Proceedings 26 (2020) 3250–3256 3255

Fig. 2. Compressive strength distribution while altering FA/Cement and W-B ratios.

Table 5
Regression Equation.

Regression Constant Values

k1 47.01
k2 41.02
k3 2.93
k4 6.830

 The experimental values of compressive strength were used to

develop a regression equation for predicting failure at any per-
cent of fly ash content. The values obtained from the general
regression equation shows a higher degree of accuracy with
that of compressive strength’s values gained by performing
the in-depth experimental study.
 The maximum value of strengths in compression was procured
at 0.45 W-B ratio and 0.6 CA-TA ratio with minimum content of
fly ash while the least strengths in compression was obtained at
0.55 W-B ratio, 0.65 CA-TA ratio and highest FA/ Cement ratio. Fig. 3. Comparison of measured and analytical values.
3256 A.F. Hashmi et al. / Materials Today: Proceedings 26 (2020) 3250–3256

 The optimum value of the CA-TA ratio has been found around [7] C.H. Huang, S.K. Lin, C.S. Chang, H.J. Chen, Mix proportions and mechanical
properties of concrete containing very high-volume of Class F fly ash, Constr.
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constituent materials and mix proportioning, Mater. J. 93 (3) (1996) 233–241.
[15] F.A. Oluokun, Fly ash concrete mix design and the water-cement ratio law,
The authors declare that they have no known competing finan- Mater. J. 91 (4) (1994) 362–371.
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development. Proceedings of the international workshop on sustainable
Department of Civil Engineering, Aligarh Muslim University, Ali- development and concrete technology 2004 May 20 (pp. 3-14). Ames, IA,
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[21] M. Shariq, J. Prasad, A.K. Ahuja, Optimization of concrete mix proportioning,
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