Effect of Fly Ash as Partial Replacement of Cement on Mechanical and Durability Properties of Concrete: An Experimental Investigation
Abstract
This paper presents an experimental study on the influence of fly ash (FA) as a partial cement replacement material on the mechanical and durability characteristics of ordinary Portland cement concrete. Five mix designs incorporating FA at 0%, 5%, 10%, 15%, and 20% replacement levels by weight of cement were prepared and tested for compressive strength at 28, 56, and 90 days curing, flexural strength, split tensile strength, water absorption, and rapid chloride permeability (RCPT). Workability was assessed through slump cone tests and compacting factor tests. Microstructural investigation was conducted through scanning electron microscopy (SEM) imaging at 28 days. Results indicate that 10% FA replacement yields the optimum combination of strength and durability, achieving a 28-day compressive strength of 25.0 MPa, a 90-day value of 33.1 MPa, water absorption of 3.4%, and RCPT charge of 890 Coulombs. The slow pozzolanic reactivity of FA produces progressive strength gain between 56 and 90 days that partially offsets the early-strength deficit relative to the control mix. Replacement levels exceeding 15% result in measurable strength reduction at 28 days but remain within acceptable limits at 90 days for low-demand structural applications. SEM imaging confirms formation of denser calcium silicate hydrate (C-S-H) gel and reduced porosity at the interfacial transition zone (ITZ) in FA-modified mixes at 28 days. The study demonstrates that FA incorporation at optimum dosage simultaneously reduces embodied carbon by approximately 9% and improves long-term durability performance, making it suitable for sustainable concrete construction in Indian conditions.
Keywords: fly ash, supplementary cementitious material, compressive strength, pozzolanic reaction, chloride permeability, SEM, durability, sustainable concrete, partial cement replacement
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