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What is Fly Ash? |
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Fly ash is a fine, glass powder recovered from the gases of
burning coal during the production of electricity.
These micron-sized earth elements consist primarily of silica,
alumina and iron. When mixed with lime and water the fly ash
forms a cementitious compound with properties very similar
to that of Portland cement. Because of this similarity, fly
ash can be used to replace a portion of cement in the concrete,
providing some distinct quality advantages. The concrete is
denser resulting in a tighter, smoother surface with less
bleeding.
Fly ash concrete offers a distinct architectural benefit with
improved textural consistency and sharper detail. Fly Ash is
also known as Coal Ash, Pulverized Flue Ash, Pozzolona.
Fly ash closely resembles volcanic ashes used in production
of the earliest known hydraulic cements about 2,300 years
ago. Those cements were made near the small Italian town of
Pozzuoli - which later gave its name to the term "pozzolan."
A pozzolan is a siliceous or siliceous / aluminous material
that, when mixed with lime and water, forms a cementitious
compound. Fly ash is the best known, and one of the most commonly
used, pozzolans in the world.
Instead of volcanoes, today's fly ash comes primarily from
coal-fired electricity generating power plants. These power
plants grind coal to a powder fineness before it is burned.
Fly ash - the mineral residue produced by burning coal - is
captured from the power plant's exhaust gases and collected
for use.
Fly ash is a fine, glass powder recovered from the gases
of burning coal during the production of electricity. These
micron-sized earth elements consist primarily of silica, alumina
and iron.
The difference between fly ash and portland cement becomes
apparent under a microscope. Fly ash particles are almost
totally spherical in shape, allowing them to flow and blend
freely in mixtures. That capability is one of the properties
making fly ash a desirable admixture for concrete
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The features of Fly Ash |
- Spherical shape : Fly ash particles
are almost totally spherical in shape, allowing them to
flow and blend freely in mixtures.
- Ball bearing effect :The "ball-bearing"
effect of fly ash particles creates a lubricating action
when concrete is in its plastic state.
- Higher Strength : Fly ash continues
to combine with free lime, increasing structural strength
over time.
- Decreased Permeability : Increased density
and long term pozzolanic action of fly ash, which ties up
free lime, results in fewer bleed channels and decreases
permeability
Increased Durability. Dense fly ash concrete helps keep
aggressive compounds on the surface, where destructive action
is lessened. Fly ash concrete is also more resistant to
attack by sulfate, mild acid, soft (lime hungry) water,
and seawater.
- Reduced Sulfate Attack : Fly ash ties
up free lime that can combine with sulfate to create destructive
expansion.
- Reduced Efflorescence : Fly ash chemically
binds free lime and salts that can create efflorescence
and dense concrete holds efflorescence producing compounds
on the inside.
- Reduced Shrinkage : The largest contributor
to drying shrinkage is water content. The lubricating action
of fly ash reduces water content and drying shrinkage.
Reduced Heat of Hydration :The pozzolanic reaction between
fly ash and lime generates less heat, resulting in reduced
thermal cracking when fly ash is used to replace portland
cement.
Reduced Alkali Silica Reactivity : Fly ash combines with
alkalis from cement that might otherwise combine with silica
from aggregates, causing destructive expansion.
- Workability: Concrete is easier to place
with less effort, responding better to vibration to fill
forms more completely.
Ease of Pumping. Pumping requires less energy and longer
pumping distances are possible.
- Improved Finishing : Sharp, clear architectural
definition is easier to achieve, with less worry about in-place
integrity.
- Reduced Bleeding : Fewer bleed channels
decreases porosity and chemical attack. Bleed streaking
is reduced for architectural finishes. Improved paste to
aggregate contact results in enhanced bond strengths.
- Reduced Segregation : Improved cohesiveness
of fly ash concrete reduces segregation that can lead to
rock pockets and blemishes.
- Reduced Slump Loss : More dependable
concrete allows for greater working time, especially in
hot weather.
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Key advantages of using fly ash |
- Improved workability
- Reduced permeability
- Reduced heat of hydration
- High sulphate resistance
- Increased long term strength
- High chloride corrosion resistance
- Grater resistance to alkali reactivity
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- Better concrete finish
- Reduced shrinkage
- Improved water to cement ratio
- Reduced bleed and segration
- Environment friendly
- Improved cementitious binder economics
- Higher later stage strength
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Production Facilities |
To produce dependably consistent concrete of high quality
and durability; it is accepted that only the finer particles
of the fly ash produced from Power Station combustion can be
used. Indeed, in some of the Thermal Power Stations in India,
the finest material – arising from the final banks of electro-static
precipitators – is collected for use. The problem with this
method of collection is that this material is still potentially
variable due to many causes within the generation process and
more importantly – it wastes the largest volume of fly ash which
then goes for disposal.
Power station fly ash output varies in grade due to the inconsistent
combustion process. To produce consistent product quality Petra
uses custom built mechanical twin drive air separator
in the processing. A far greater percentage of the fly ash can
be collected and bagged for use as Petra POZZO.– which will
then carry the guarantee of consistency and performance.
After extensive testing of the chemical and physical properties
of the raw product, Petra has established that the fly ash produced
in India is as good a product as can be found worldwide, the
fly ash produced from the burning of the vast reserves of indigenous
coal, is consistent and perfectly suited for processing to release
this major untapped resource for use in construction.
Processing the fly ash to produce Petra POZZO. involves accelerating
the material at high speed to separate the finer material from
the course, this, followed by extensive sampling and testing
then results in a stream of consistently fine material which
can be stored for onward despatch either in bags or by bulk
tanker to concrete producers at their sites or production units. |
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