Use of Hydrated Fly Ash as a Flexible Base Material

Common uses for fly ash, such as soil stabilization and cement replacement, account for less than 20 percent of the fly ash produced in the United States. Therefore, finding other bulk uses for fly ash is important. One such potential application is hydrated fly ash as a base material. The Texas Department of Transportation (TxDOT) is working to produce specifications to incorporate hydrated fly ash as a flexible base material. High-calcium Class C fly ash has a self-hydrating capability in the presence of moisture. Class C fly ash produced from coal power plants using lignite and subbituminous coal is mixed with water, dumped in large pits, and left to hydrate for a period of 3 to 6 weeks. The result is a hard, homogeneous mass of hydrated fly ash that can be mined to produce a construction aggregate much like limestone. TxDOT has used this material on several test projects. It has a desirable compressive strength, but in some instances its adhesion to seal coats has been a problem. Laboratory studies indicate that hydration water content has a significant influence on its strength. Microscopic investigations on hydrated Class C fly ash indicate that the hydration products may depend on the curing conditions. Hydrated Class C fly ash has a potential as a flexible base material provided that the curing process is carefully managed.