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USAGE OF THE FLY ASH IN HOT ASPHALT MIXES

Ivica, Androjić, mag.ing.aedif., Osijek – Koteks d.d., Croatia


31 000 Osijek, Croatia, ivica.androjic@osijek-koteks.hr

Gordana, Kaluđer, mag.ing.aedif., Kombel d.o.o. Belišće, Croatia


31 551 Belišće, Croatia, gordana.kaludjer@kombel.hr

Mario, Komljen, ing.građ., Osijek – Koteks d.d., Croatia


31 000 Osijek, Croatia, mario.komljen@osijek-koteks.hr

ABSTRACT

In highway engineering, consumptive use of natural mineral materials is significant in the construction of new roads, as well as in
renovations of the existing ones. A part of this material can be replaced by alternative materials which have been regarded as waste
for many years. One such material is fly ash, a byproduct of burning coal in power stations. Its annual output is measured by millions
of tonnes just in one power plant, whereas its deposition is spatial, economic and environmental problem. Observing the fly ash as a
waste to use-value, the authors conducted a study of its use as a filler in AC 8 surf 50/70 asphalt mixture. Used fly ash belongs to the
group of acid fly ash with low content of calcium oxide (CaO). The authors prepared mixtures of several models which are used for
optimization of the percentage content of all ingredient mixes which should satisfy the physical and mechanical properties of the
General Technical Conditions for road works; Croatian Road authority.

Key words: fly ash, hot asphalt mixes

1.INTRODUCTION

Fly ash (electrofilter ash) is a product of combustion of pulverized coal lignite, bituminized coal,
partially bituminized coal and anthracite in thermal power plants. American standards classify fly
ash into the classes F and C [1] depending on the type of coal used and what are the products of
combustion. Fly ash of the F class is the product of combustion of anthracite and bituminized coal,
which achieves its bonding characteristics only after adding water. Fly ash of the C class is the
product of combustion of lignite and partially bituminized coal which achieves its bonding
characteristics even without addition of the hydrate. The basic difference between the classes F and
C of fly ash lies in the percentage content of calcium (Ca), silicon dioxide (SiO2), aluminum oxide
(Al2O3), iron (Fe) and the loss while annealing (LOI), which constitutes a measure of the amount
of carbon residue retained in the fly ash. The fly ash is a silicate, i.e. an aluminosilicate material
which has binding properties and finds its application in road construction as structural fill in
pavements structures [2]. In the asphalt-concrete mixtures, it is used as mineral filling (filler) to fill
the voids and connect coarse aggregates by meeting conditions prescribed by ASTM D242 and
AASHTO M-17 standards, as well as an addition to bitumen [3to 6]. In 1931, the Detroit Edison
company conducted tests of benefits of fly ash by comparing physical characteristics with limestone
filler and the obtained results indicated the suitability of fly ash for filling cavities and water
resistance while reducing the possibility of leaching of asphalt binder from the surface of grain
stone aggregate [7.2]. The test of resistance to leaching of mineral filling of fly ash originated after
combustion of lignite coal, having been repeated at the North Dakota State University, has
confirmed the same or increased compressive strength to the strength test of water saturated sample
and it was discovered that the tested fly ash contributed to the slower binding of bitumen [8 to10].

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Fly ash must meet certain technological and technical characteristics that would be suitable for use
in the hot mix asphalt to produce asphalt surfacing pavement structures. When used as a filler, fly
ash has to be dry, which means it must be deposited in watertight silos. The physical requirements
are defined by the AASHTO M-17 standard, and are shown in Table 1. and they include
granulometric composition, organic matter content and plasticity. Among other important features
are finesse and specific gravity.

Table 1. AASHTO M – 17 regulations for use of fillers in the making of asphalt surfacing [2,5]
Size of particles
Organic additives Plasticity index
Aperture / sieve number Percentage of passing (%)
0,006 mm (No.30) 100
Filer must not contain Filer may not have the
0,003 mm (No.50) 95 – 100
organic additives plasticity index> 4
0,075 mm (No.200) 70 - 100

Specific gravity of fly ash varies depending on the source and ranges from 1.70 to 3.0 g / cm³, while
the specific weight of stone dust ranges from 2.6 to 2.8 g / cc [27]. As the volumetric weight of fly
ash is generally less than the bulk weight of stone dust, the prescribed weight percentage of fly ash
will occupy a larger percentage of the total volume of asphalt mixtures than the corresponding
weight percent of conventional stone dust.
The fineness of fly ash is usually determined by the percentage weight of particles larger than 0.045
mm (sieve no. 325), but the most important is the uniformity in granulometry, especially the size
and shape of particles smaller than 0.075 mm (sieve no. 200). The fineness of fly ash affects the
reactivity of the ash and the level of carbon content. Most types of fly ash have the transience of
between 60 and 90% over a sieve with openings of 0.075 mm (sieve no. 200) [11].
Fly ash used in this study was supplied from a thermal power plant in Tuzla, the Republic of Bosnia
and Herzegovina. The decision on the selection of this fly ash was influenced by positive
experiences of the application of this waste material in road construction, and particularly its
suitability as mineral filler in asphalt-concrete mixtures.

2. Laboratory testing

In the road construction laboratory of the Osijek Koteks Inc.company, the physico-mechanical
properties of samples of asphalt mixtures to produce the wearing layer 8 AC surf 50/70 have been
examined according to the Croatian standard HRN EN 13108-1 [12], made of fly ash, stone chip
fractions of 0/2, 2/4 and 4/8 mm of igneous origin from the Vetovo quarry, stone dust of the
category labelled KB-I from the Veličanka quarry and road construction bitumen 50/70 of refineries
from Bosanski Brod, the Republic of Bosnia and Herzegovina. The required properties were tested
according to the European standard EN 12591:1999 [13].

2.1. The program of testings


The testing program anticipated a set of specimens of the mineral skeleton of equal granulometric
composition in asphalt mixture containing the largest grain of up to 8 mm. The three groups of
mixtures of different concentrations of bitumen and filler (stone dust and fly ash) were set. In each
group, the individual blends vary in type and proportion of filler in the stone material, so that the
make of a set of nine asphalt mixtures of different composition was anticipated. For each mix, the
making of laboratory test bodies was anticipated in a procedure described by a prescribed European
norm.
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2.1. Eksperimental part
2.1.1. The constituent materials of asphalt mix
Used fly ash is an acidic fly ash of expressed pozzolanic properties, by its composition, it is
classified into the F class anddoes not belong in radioactive materials, with the chemical
composition as shown in Table 2. Specific gravity of fly ash amounts to 1.9 to 2.1 g / cm ³, the
volumetric weight in the loose is 0.68 kgf / dm³ and, in the compacted state, the volumetric weight
is 0.91 kgf / dm³. In the tested samples of asphalt mixes, it replaces stone dust in the mass fractions
of 3% and 6.2%.
Table 2 The results of chemical analysis of samples of fly ash 14
PARAMETER RESULT ASTM C 618-94 a
Loss on ignition 0,36 max. 6
SiO2 45,01 -
Al2O3 17,82 -
Fe2O3 11,37 -
CaO 17,63 -
MgO 3,76 -
SO3 1,78 max. 4,0
Moisture - max. 3,0
SiO2 + Al2O3 + Fe2O3 74,20 min. 70%

Pozzolanic properties, tested according to the European standard EN 196-5, show that the
pozzolanicity is positive and the following values have been obtained:
[OH-] = 4,4 m mol OH-/1
[CaO] = 5,19 m mol/1
For the production of asphalt mixtures, the two types of stone materials were chosen, the stone from
the Vetovo quarry (eruptive material of silicate composition) and stone dust from the Veličanka
quarry (sediment of carbonate composition). For the make of samples of asphalt mixtures, the
selected granulometric composition and density of material of stone skeleton and fillers are
presented in Tables 3. and 4. [15,16].
Table 3. Granulometric composition of stone chip and stone dust
Quarry/Thermal
Veličanka Vetovo Vetovo Vetovo TE TUZLA
power plant
Stone dust
Tag Fraction 0/2 2/4 4/8 Fly ash
SD
Granulometric analysis of fractions of stone chip and fly ash
SIEVE ( mm ) mas% Σ mas% Σ mas% Σ mas% Σ mas% Σ
0,09 78,4 78,4 10,20 10,20 2,50 2,50 1,00 1,00 42,80 42,80
0,25 15,1 93,5 17,20 27,40 1,10 3,60 0,20 1,20 44,70 87,50
0,71 6,5 100,0 38,40 65,80 2,80 6,40 0,50 1,70 12,50 100,00
2,00 30,70 96,50 8,40 14,80 1,20 2,90
4,00 3,40 99,90 78,00 92,80 14,70 17,60
8,00 0,10 100,0 7,10 99,90 76,80 94,40
11,20 0,10 100,0 5,50 99,90
16,00 0,10 100,0
22,40
31,50

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Table 4. Density of subfractions of constituent materials tested
Opening of the Fly ash (g/cm³) Stone dust (g/cm³) Stone chippings
sieve (mm) (g/cm³)
<0,063 2,019 2,848 2,928
0,063-0,25 2,022 2,849 2,889
0,25-1,00 2,066 2,896
1,00-2,00 2,885
2,00-4,00 2,938
4,00-8,00 2,938
8,00-11,00 2,939

The selected binder is a paving grade bitumen type BIT 60 (50/70) produced in the Bosanski Brod
oil refinery, in the Republic of Bosnia and Herzegovina. Standard properties of bitumen are ρB =
1,016 g/cm3, PK = 49,9°C and PEN = 51,7 1/10 mm [17 to 19].

2.1.2. Projecting of the set composition of asphalt mixtures


To explore the influence of fly ash on the physico-mechanical properties of asphalt samples, the
following mixtures of equal granulometric composition were made, which differ by the mass ratio
and the type of filler in the asphalt mixture:
- Asphalt mixture of Group I , which in its composition contains stone fractions of 0/2 mm,
2/4 mm, 4/8 mm, paving grade bitumen BIT 60 (50/70) and filler - stone dust in the mass
ratio of 3%,
- Asphalt mixture of Group II, which in its composition contains stone fractions of 0/2 mm,
2/4 mm, 4/8 mm, paving grade bitumen BIT 60 (50/70) and filler – fly ash in the mass ratio
of 6,2%,
- Asphalt mixture of Group III, which in its composition contains stone fractions of 0/2 mm,
2/4 mm, 4/8 mm, paving grade bitumen BIT 60 (50/70) and filler - fly ash in the mass ratio
of 3%.
Granulometric composition of stone mixture is determined according to the HRN EN 12697-2 [20],
and the soluble ratio of paving grade bitumen according to the HRN EN 12697-1 [21].
Figure 1. shows the granulometric composition of stone skeleton and fillers for the production of
asphalt mixes.

Figure 1. Granulometric composition of stone skeleton and fillers of asphalt mixes


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In the further projecting process, the paving grade bitumen was added into the asphalt mixes of specific
groups. The projected composition of asphalt mixtures are shown in Table 5. (SD - stone dust, BB - bitumen
binder, FA - fly ash).

Table 5. Composition of designed asphalt mixtures


GROUP I. GROUP II. GROUP III.

SD BB 0-2 2-4 4-8 FA BB 0-2 2-4 4-8 FA BB 0-2 2-4 4-8


(mas %)
Gradivo

[%] [%] [%] [%] [%] [%] [%] [%] [%] [%] [%] [%] [%] [%] [%]

AM 3,0 5,2 35,0 21,0 41,0 6,2 5,2 31,8 21,0 41,0 3,0 5,2 35,0 21,0 41,0
1

AM2 3,0 5,5 35,0 21,0 41,0 6,2 5,5 31,8 21,0 41,0 3,0 5,5 35,0 21,0 41,0

AM3 3,0 5,8 35,0 21,0 41,0 6,2 5,8 31,8 21,0 41,0 3,0 5,8 35,0 21,0 41,0

Table 6. shows the projected granulometric composition of stone mixture (stone skeleton and filler of stone
dust and / or fly ash), in asphalt mixtures groups from which a minimum deviation is visible, mostly on the
sieves of aperture smaller than 1,0 mm. Figure 2. shows the overall granulometric grading curve for all
groups of samples.

Table 6. Granulometric composition of stone skeleton and fillers by groups of asphalt mixtures
Granulometric composition of stone mixture determined by HRN EN 12697-2
SIEVE (mm) 0,063 0,25 1,00 2,00 4,00 8,00 11,2 16,0
GROUP I. 6,9 13,6 28,1 41,1 64,7 97,7 100 100
GROUP II. 6,8 15,4 29,2 41,2 64,7 97,7 100 100
GROUP III. 5,8 13,5 28,1 41,1 64,7 97,7 100 100
Average 6,5 14,2 28,5 41,1 64,7 97,7 100 100

Figure 2. The average granulometric composition of stone skeleton and fillers

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2.1.3. Creating a set of samples of asphalt mixtures
For each group of asphalt mixtures, three samples were made according to the standardized
procedure of compacting onto the tamper with falling mallet. The temperature of asphalt mixtures
was 155 ° C. After cooling to room temperature of the prepared asphalt samples, the following
physical properties were determined:

Density of the asphalt sample according to the HRN EN 12697-6 [22],


Density of asphalt mixtures according to the HRN EN 12697-5 [23],
Share of voids according to the HRN EN 12697-8 [24],
Voids in stone mixture according to the HRN EN 12697-8 [24],
Voids filled with bitumen according to the HRN EN 12697-8 [24],
Stability / strain / stiffness according to the HRN EN 12697-34 [25]

3. Test results

For a tested set of asphalt samples, which consists of the three groups of asphalt mixtures, the
required parameters are determined, i.e. physical and mechanical properties and the boundary
conditions of share of voids in the range from 3.0 to 6.0% and the fillings of voids with bitumen
within the range of 65 to 83% [26]. Test results are shown in Table 7. and Figure 3. presents asphalt
samples with filler from fly ash in the mass content to 6.2%; samples photographed after the testing
of stability.

Table 7. Physico-mechanical properties of asphalt samples tested


PROPERTY

Density of
Share of Voids in stone Voids filled
Stability Deform. asph. Density
Mixture Stiffness voids mixture with bitumen
Group sample
mark [kN/mm] [%(v/v)] [%(v/v)] [%(v/v)]
[kN] [mm] [kg/m³]
[kg/m³]

AM1 10,4 3,2 3,3 2488 2667 6,7 19,4 65,4

AM2 11,9 3,2 3,6 2505 2648 5,4 18,9 71,4


GROUP I.

AM3 10,5 3,1 3,4 2516 2639 4,7 19,0 75,4

average 2503 2651,33 5,6 19,1 70,73

AM1 6,5 2,6 2,5 2250 2624 14,3 25,7 44,6

AM2 9,0 3,1 2,9 2287 2611 12,4 24,7 49,8


GROUP II.

AM3 10,2 3,4 3,0 2339 2598 10,0 23,3 57,2

average 2292 2611 12,23 24,57 50,53

AM1 10,2 3,1 3,3 2398 2642 9,2 21,5 57,0


GROUP

AM2 12,2 3,0 4,2 2426 2629 7,7 20,8 62,9


III.

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AM3 14,2 3,2 4,4 2455 2616 6,2 20,1 69,4

average 2426,33 2629 7,7 20,8 63,1

Figure 3. Asphalt samples –filler of fly ash in the mass ratio of 6,2%

3.1. Comment on the results of testing of physical and mechanical properties


The analysis of delievered results of the required parameters of physico-mechanical properties of
asphalt mixtures for the preparation of the wear layer 8 AC surf 50/70 (Table 7.) showed the
following:
1. Samples of asphalt mixtures from the Groups II and III achieve lower densities compared to
the samples of mixtures in which stone dust was used as filler,
2. Share of voids in samples of asphalt mix Groups II and III is larger than the set value (3.0 to
6.0%),
3. Filling of voids with bitumen in samples of the Groups II and III does not meet the required
conditions (65.0 to 83, 0%), except for the asphalt mixture in which the filler is from fly ash
in the mass ratio to 3.0% and bulk bitumen concentration of 5.8%,
4. The average density of asphalt samples of the Group II amounts to 2.292 kg / m³ and is
lower than the average density of asphalt samples from the Group I for 8.43%,
5. The average density of asphalt samples from the Group III amounts to 2.426,33 kg / m³ and
is lower than the average density of asphalt samples from the Group I for 3.06%,
6. Filler from fly ash of the Group II resulted in a higher volume fraction of voids in the
asphalt sample, which affects the realization of smaller, i.e. lower spatial masses of asphalt
samples,

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7. A higher proportion of bitumen binder in asphalt mixtures results in greater filling of voids
in the stone skeleton, and in the mixtures in which fly ash was used as filler, volume
concentration of the bitumen binder is greater than 0.5% than its use in a standard mixture.
Curves of stiffness of bitominous specimens (Figure 4.) indicate that the bitominous specimens
from the Group I achieve maximum value of the required quality parameter at a concentration of
5.5% bitumen. Bitominous mixtures of Group II and III achieve the maximum value of the required
quality parameter at concentration of bitumen greater than 5.8%.

Figure 4 Stiffness of bituminous specimens

4. Conclusion

On a set of samples of bituminous mixtures for making the wearing layer of asphalt paving, AC 8
Surf 50/70, tested were the physical - mechanical properties of conventional stone skeleton,
bitumen binder and filler from stone flour and fly ash. The results of laboratory tests indicated the
suitability of fly ash as a filler in asphalt mixture and the results are in compliance with the
requirements set out on the aggregate according to the Croatian and European legislation. The
suitability of fly ash as a filler in asphalt mixtures in the tested samples is conditioned by higher
concentration of bitumen binder, which increases the price of production, but from an
environmental point of view the convenience is unquestionable. In an effort to emphasize the
exhaustiveness of natural resources,and the costs of the exploitation of the same, as well as the
costs of disposal of industrial waste generated, tests were made on the possibility of recovery and
utilization of fly ash as an aggregate. The results represent a contribution to the possibility of using
this waste material as a filler in asphalt mixes for making wearing layers of pavement overlay, that
would help to preserve the environment, natural resources and land, i.e. the landfill site.

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5. List of references

[1] ASTM C 618:1994 Standard Specification for Fly ash and raw or calcined natural pozzolan for
use as Mineral admixture in concrete. In: Annual book of ASTM standards.
[2] Federal Highway Administration (FHWA), American Coal Ash Associatio (ACAA). Fly ash
facts for highway engineers. Federal Highway Administration (FHWA); 2003 06-13-2003. Report
nr FHWA – IF – 03-019.
[3] Butul, B.: Performance characteristic of coal fly ash and wood ash-modified asphalt binder.
United States – Florida: Florida Atlantic University; 2000:ID:192.
[4] ASTM D242 Standard Specification for Mineral Filler for Bituminous Paving Mixtures. In:
Annual book of ASTM standards.
[5] AASHTO M-17 Standard specification for mineral filler for bituminous paving mixtures.
Washington, DC 20001: American Association of State Highway and Transportation Officials;
2007. Report nr M-17-07.
[6] Simms, S.A.: Use of coal fly ash in asphalt concrete mixes. Canada: DalTech – Dalhousie
University (Canada); 1998:ID190.
[7] Zimmer, F.V.: Fly ash as a bituminous filler. In: Proceedings of the second ash utilization
symposium. Pittsburgh, Pennsylvania: U.S. Bureau of Mines; 1970.
[8] Carpenter, C.A.: Cooperative study of fillers in asphaltic concrete. Public Roads 1952;27:101-
10.
[9] Galloway, B.M. A review of the use of mineral filler in asphalt-aggregate mixtures. Fly ash
applications in 1980 conference, 1980.
[10] Rosner, J.C., Chehovits, J.G., Morris, G.R.: Fly Ash as a Mineral Filler and Anti-Strip Agent
for Asphalt Concrete. Challenge of change -6th international ash utilization symposium
proceedings. Reno, NV;United States Department of Energy, Morgantown Energy Technology
Center.
[11] Di Gioia, A.M., Nuzzo, W.L.: Fly ash as structural fill. Journal of the power Division 1972
June; 98 (1): 77-92
[12] HRN EN 13108-1:2007 Bitumenske mješavine – Specifikacije materijala – 1. dio: Asfaltbeton
(EN 108-1:2006) [Bituminous mixtures -- Material specifications -- Part 1: Asphalt concrete]

[13] Opći tehnički uvjeti za radove na cestama 2001 – KNJIGA III. [General technical conditions
for work on roads, Croatian Civil Engineering Institute, Zagreb, 2001. Book III.]

[14] Imamović, A., Osmanović,H., Ljaljić, M.: Laboratorijska i eksperimentalna istraživanja


primjene elektofilterskog pepela i šljake u izgradnji saobraćajnica, Zbornik radova sa savjetovanja
o primjeni elektrofilterskog pepela i šljake u izgradnji putne infrastrukture, Tuzla 2003.
[Laboratory and experimental research application fly ash and slag in the construction of roads,
Proceedings, Tuzla 2003.]
[15] HRN EN 1097-7:1999 Ispitivanje mehaničkih i fizičkih svojstava agregata – 7.dio:
Određivanje gustoće punila – piknometarska metoda (EN 1097-7:1999) [Tests for Mechanical and
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Physical Properties of Aggregates - Part 7: Determination of the Particle Density of Filler -
Pyknometer method]
[16] HRN EN 1097-6:2000 Ispitivanje mehaničkih i fizičkih svojstava agregata – 7.dio:
Određivanje gustoće i upijanje vode (EN 1097-6:2000+AC:2002) [Tests for mechanical and
physical properties of aggregates - Part 6: Determination of particle density and water absorption]

[17] Olard, F.: Properties of Bituminous Mixtures at Low Temperatures and Relations with Binder
Characteristics.ibid.str.450-457.

[18] HRN EN 1425:2012 Bitumen i bitumenska veziva-Karakterizacija vidljivih svojstava (EN


1425:2012) [Bitumen and bituminous binders. Characterization of perceptible properties]

[19] HRN EN 1426:2008 Bitumen i bitumenska veziva-Određivanje penetracije iglom (EN


1426:2007) [Bitumen and Bituminous Binders – Detemination of Needle Penetration]
[20] HRN EN 12697-2:2003 Bitumenske mješavine – Ispitne metode za asfalt proizveden vrućim
postupkom – 2. dio: Određivanje granulometrijskog sastava [Determination of particle size
distribution]
[21] HRN EN 12697-1:2003 Bitumenske mješavine – Ispitne metode za asfalt proizveden vrućim
postupkom – 1. dio: Topljivi udio veziva [Soluble binder content]
[22] HRN EN 12697-6:2003 Bitumenske mješavine – Ispitne metode za asfalt proizveden vrućim
postupkom – 6. dio: Određivanje gustoće asfaltnih uzoraka [Determination of the bulk density
bituminous specimens]
[23] HRN EN 12697-5:2003 Bitumenske mješavine – Ispitne metode za asfalt proizveden vrućim
postupkom – 5. dio: Određivanje gustoće asfaltnih mješavina [ Bituminous mixtures -- Test
methods for hot mix asphalt -- Part 5: Determination of the maximum density]
[24] HRN EN 12697-8:2003 Bitumenske mješavine – Ispitne metode za asfalt proizveden vrućim
postupkom – 8. dio: Određivanje šupljina u asfaltnim uzorcima [Determination of void
characteristics of bituminous specimens]
[25] HRN EN 12697-34:2004 Bitumenske mješavine – Ispitne metode za asfalt proizveden vrućim
postupkom – 34 – Marshallovo ispitivanje [Marshall test]

[26] Razrada tehničkih svojstava i zahtjeva za građevne proizvode za proizvodnju asfaltnih


mješavina i za asfaltne slojeve kolnika, Hrvatske Ceste d.o.o., Zagreb, ožujak 2012. [Elaboration of
technical characteristics and requirements for construction products for the production of asphalt
mixtures and asphalt pavement, Zagreb, 2012.]

[27]http://www.rmrc.unh.edu/tools/uguidelines/cfa51.asp

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