Strength activity and microstructure of blended ultra-fine coal bottom ash-cement mortar

Replacing Portland cement with reutilized coal combustion products can have substantial benefits to the environment as well as infrastructure. In this study, a sub-bituminous coal bottom ash is re-utilized as a cement replacement. The bottom ash was pulverized using a high energy vibratory ball mill at two different milling times to achieve a particle fineness approximately two and three-times finer, respectively, than type I cement. The workability and final setting time were found to increase by 21% and 14%, respectively, and the highest strength activity was observed to be 120% at 90 days. After normalization for particle fineness, age, and binder replacement using a general linear regression model, the data suggested the bottom ash blended cement mortar had 6.8% less strength activity than a comparative fly ash blended cement mortar. Blended bottom ash-cement paste samples were observed to have densely packed CSH product composed of relatively lower Ca/Si ratio (1.37) compared to that of fly ash blended cement paste (1.43) and the control (2.27). The CH content was also observed to be significantly lower in the bottom ash blended cement paste (19.1%) when compared against the control (27.2%) and fly ash blended paste (23.3%). Within the range of experimental conditions considered here, the results suggest that a coal bottom ash can be pulverized with a high energy ball mill to produce a re-utilizable pozzolan that, depending on the powder fineness, can significantly increase the strength activity, improve the microstructure of cement mortar, and increase the cement replacement tolerances without significant reduction to compressive strength activity.