A High-Volume Fly-Ash Concrete Mixture for Tennessee Bridge Decks

High Volume Fly Ash (HVFA) portland cement concrete (PCC) was developed to compete with the Tennessee Department of Transportation (TDOT) Class D PCC. HVFA PCC is PCC with at least 50 percent of portland cement (PC) replaced with Class C fly ash. The current TDOT allowable PC replacement rate is 25 percent for Class C fly ash. A higher PC replacement rate would greatly increase the use of an industrial byproduct thus making more efficient use of natural resources. However, performance and economy cannot be sacrificed for environmental concerns. This paper addresses HVFA PCC performance and not environmental benefits. HVFA PCC has lower total cementing materials and water contents than TDOT Class D PCC. HVFA PCC is similar in material costs below a placement temperature of 85°F (29.4°C) and cheaper at a placement temperature of 85°F (29.4°C) and above. The results of the research show first that HVFA PCC meets all TDOT 604.03 Class D PCC property requirements. Second, that HVFA PCC is statistically superior to TDOT Class D PCC in compressive strength (at 7 to 182 days), static modulus of elasticity (28 to 182 days), hardened concrete absorption (28 to 182 days) and rapid chloride permeability (at 91 days). Finally, that above 85°F (29.4°C), hot HVFA PCC hardened properties and rapid chloride permeability are statistically superior to hot TDOT Class D PCC (at 7 to 182 days).

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