Effect of silica fume fineness on the improvement of Portland cement strength performance

doi:10.1016/j.conbuildmat.2015.07.092

Construction and Building Materials

Volume 96, 15 October 2015, Pages 55-64

https://doi.org/10.1016/j.conbuildmat.2015.07.092 Get rights and content

Highlights

•
Interaction between SF fineness and amorphous SiO₂ on mortars has been assessed.
•
The mortar compressive strength rises with the SF fineness increase.
•
SF size distribution is a key factor regarding the compressive strength development.
•
The addition of fine SF to PC improves the microstructure of hardened pastes.
•
Higher strength and lower permeability have been assessed.

Abstract

This paper presents both a study on the effect of silica fume (SF) fineness on the pozzolanicity of blended cement and a method for improving coarse SF performance in making high-strength and high-performance concrete. The coarse SF, having a 45 μm sieve residue of 32.11%, yields a low pozzolanic reaction. In order to enhance its quality, the coarse SF was ground until the average particle size was reduced to a 45 μm sieve residue of 4.13% and 0.98%. It was then mixed with Portland cement type CEM I 52.5 N-SR 3 by a weight of 25% to determine the strength activity index for it to be used to produce high-performance concrete.

The pozzolanic reaction and quantitative influence of SF fineness on the mechanical strength in the SF containing composite cement system were examined in detail. XRF results indicated that reactive SiO₂ content has a clear influence on pozzolanic performance, though not as important as the SF grain size. Several methods, including the pozzolanicity test (EN 196-5:2011), chemical analysis (XRF) and strength activity index techniques, were used comprehensively for evaluation of the SF containing composite cement system.

The results suggest that the SF with high fineness is suitable for use in making CEM II/A–D cement in percentages of SF lower than 10%, according to the European Standard EN 197-1:2011 in producing a good quality, high-strength and high-performance concrete.

Introduction

Silica fume (SF) composed of submicron particles of silicon dioxide is produced by an electric arc furnace as a by-product of the smelting process in the production of metallic silicon or ferrosilicon in the alloys industry. The reduction of high-purity quartz to silicon at temperatures up to 2000 °C produces SiO₂ vapours which oxidise and condense in the low-temperature zone to tiny particles consisting of 85–99% amorphous silica [2]. Then, SF is composed of submicron particles of silicon dioxide which occur as almost-perfect spheres with diameters ranging from 20 to 500 nm [1]. It is estimated that current global output of SF is, at most, between one and 1.5 million tonnes per year [58].

Portland cement (PC) is unquestionably the primary cementitious material now used in construction. However, SF has been used as a high pozzolanic reactive cementitious material to make high-performance concrete (HPC). Moreover, it may be said that SF is the key ingredient for producing such high-performance concrete. This addition in PCs, such as CEM II/A–D according to the European Standard EN 197-1:2011 [18] has been shown to give rise to physical and chemical effects on the microstructure of hardened pastes, leading to improved properties well recognised in concrete technology, such as higher strength [4], [10], [27] and lower permeability [63]. Therefore, HPC has increasingly been used in civil engineering work because it allows reduction of the size of structural elements, which is essential in high-rise building. In addition to this, such HPC use is now growing in conditions of a severe nature [48], [5]. In summary, the benefits obtained when utilising SF include substantial increases in compressive strength and increased durability of hardened concrete when added in optimum amounts [36], [50], [55], [35], [60], [10]. Particularly, the main advantages of using SF are higher mechanical strength (high early compressive strength, high tensile strength, high flexural strength and modulus of elasticity, increased toughness and high bond strength) [10], [61] and enhanced durability (sulphate resistance [61], [65], higher electrical resistivity, low permeability to chloride and increased resistance to chemical attack, seawater resistance [28], freeze–thaw resistance [64] abrasion resistance [49], controlling expansion due to alkali–silica reaction [12] and good fire resistance [47]).

Therefore, SF is used in construction to make HPC for highway bridges, marine structures, parking decks, and bridge deck overlays. Furthermore, SF is utilised to manufacture shotcrete for use in rock stabilisation, mine tunnel linings, and rehabilitation of deteriorating bridge and marine columns and piles. Furthermore, SF is applied for oil well grouting and in a wide variety of cementitious repair products, among other applications.

In the case of some pozzolanic materials such as fly ash, a correlation between pozzolanic properties determined by using the compressive strength of mortars and the fineness and the soluble silica was identified [62]; the effect of the soluble silica content was found to be more significant than the effect of their fineness at later ages [56].

The purpose of this study is to evaluate the influence of SF reactive SiO₂ and grain size on SF reactivity. The pozzolanicity test method was complemented by another widely accepted method, the strength activity index for strength performance quantification, with the aim of clarifying the pozzolanic reaction and effects of SF on the hydration process of SF-containing composite cement system. Hence, the study focused on two sections: the effects of SF fineness on the evolution of pozzolanic reaction and strength performance quantification.

Section snippets

Materials

Materials used in this study consisted of PC type CEM I 52.5 N-SR 3 according to the European Standard EN 197-1:2011 [18], fine aggregates (sand), silica fume and distiled water at 20 °C. Two brands of SF, namely SF I and SF II, in powder form were used. Both of them conformed to the mandatory requirements of the European Standard EN 13263-1:2005+A1:2009 [15] issued by the European Committee for Standardisation (Comité Européen de Normalisation, CEN). High-quality standardised sand was used as

Chemical composition of materials

The oxide analyses for cement CEM I 52.5 N-SR 3 and SF samples SF I and SF II are presented in Table 1. The fraction of SiO₂ which is active for pozzolanic reactions is also given (active silica). The Table 1 shows that SF has a significantly high content of amorphous silicon dioxide, with small amounts of iron, magnesium, alumina, calcium and alkali oxides being found too (Table 1).

ASTM C1240-12 [7] and EN 13263-1:2005+A1:2009 [15] issued by ASTM and the CEN, respectively, cover SF

Conclusions

The following conclusions have hence been drawn:

1.
The replacement of Portland cement with 25% of silica fume (45 μm sieve residue between 0.98%, for SF I (C) and 4.13%, for SF I (B)) produces high-strength mortar and such fineness gives the highest compressive strength. However, the coarser silica fume named SF I (A) does not exhibit a good performance when added in high amounts of 25% (45 μm sieve residue of 32.11%).
2.
Mortar made of silica fume that has a fineness of between 0.98% and 4.13%

Acknowledgement

The authors gratefully acknowledge the financial support provided by Ministry of Economy and Competitiveness of Spain by means of the Research Fund Project DPI 2011-24876.

References (68)

S. Bhanja et al.
Modified water–cement ratio law for silica fume concretes
Cem. Concr. Res.
(2003)
S. Bhanja et al.
Influence of silica fume on the tensile strength of concrete
Cem. Concr. Res.
(2005)
J. Bijen
Benefits of slag and fly ash
Constr. Build. Mater.
(1996)
A.M. Boddy et al.
The effect of product form of silica fume on its ability to control alkali–silica fume
Cem. Concr. Res.
(2000)
N. Bouzoubaa et al.
Mechanical properties and durability of concrete made with high-volume fly ash blended cements using a coarse fly ash
Cem. Concr. Res.
(2001)
N. Bouzoubaa et al.
The effect of grinding on the physical properties of fly ashes and a Portland cement clinker
Cem. Concr. Res.
(1997)
P. Chindaprasirt et al.
Influence of fly ash fineness on strength, drying shrinkage and sulfate resistance of blended cement mortar
Cem. Concr. Res.
(2004)
D. Damidot et al.
Thermodynamics and cement science
Cem. Concr. Res.
(2011)
A. Demirbaş
Optimizing the physical and technological properties of cement additives in concrete mixtures
Cem. Concr. Res.
(1996)
E. Douglas et al.
Prediction of compressive strength of mortars made with Portland cement-blast-furnace slag–fly ash blends
Cem. Concr. Res.
(1991)

M. Enders

Microanalytical characterization (AEM) of glassy spheres and anhydrite from a high-calcium lignite fly ash from Germany

Cem. Concr. Res.

(1995)

B. Felekoğlu et al.

Optimization of fineness to maximize the strength activity of high-calcium ground fly ash – Portland cement composites

Constr. Build. Mater.

(2009)

W.A. Gutteridge et al.

Filler effects: the effects of secondary component on the hydration of Portland cement

Cem. Concr. Res.

(1990)

S. Hanehara et al.

Effects of water/powder ratio, mixing ratio of fly ash, and curing temperature on pozzolanic reaction of fly ash in cement paste

Cem. Concr. Res.

(2001)

S. Ivorra et al.

Effect of silica fume particle size on mechanical properties of short carbon fiber reinforced concrete

Mater. Des.

(2010)

Ch. Jaturapitakkul et al.

Use of ground coarse fly ash as a replacement of condensed silica fume in producing high-strength concrete

Cem. Concr. Res.

(2004)

B.W. Jo et al.

Characteristics of cement mortar with nano-SiO₂ particles

Constr. Build. Mater.

(2007)

K. Kiattikomol et al.

A study of ground coarse fly ashes with different finenesses from various sources as pozzolanic materials

Cem. Concr. Compos.

(2001)

D. Li et al.

The influence of alkalinity on activation and microstructure of fly ash

Cem. Concr. Res.

(2000)

M. Mazloom et al.

Effect of silica fume on mechanical properties of high-strength concrete

Cem. Concr. Compos.

(2004)

D.R.G. Mitchell et al.

Interaction of silica fume with calcium hydroxide solutions and hydrated cement pastes

Cem. Concr. Res.

(1998)

V.G. Papadakis

Experimental investigation and theoretical modeling of silica fume activity in concrete

Cem. Concr. Res.

(1999)

J. Paya et al.

Enhanced conductivity measurement techniques for evaluation of fly ash pozzolanic activity

Cem. Concr. Res.

(2001)

P. Pena et al.

Solid-state ²⁷Al and ²⁹Si NMR characterization of hydrates formed in calcium aluminate–silica fume mixtures

J. Solid State Chem.

(2008)

B. Persson

Seven-year study on the effect of silica fume in concrete

Adv. Cem. Bas. Mat.

(1998)

R.V. Ranganath et al.

Influence of size fraction of ponded ash on its pozzolanic activity

Cem. Concr. Res.

(1998)

D. Ravina

Optimized determination of PFA (fly ash) fineness with reference to pozzolanic activity

Cem. Concr. Res.

(1980)

D.M. Roy

Alkali activated cements opportunities and challenges

Cem. Concr. Res.

(1999)

R.C. Sharma et al.

Semi-theoretical method for the assessment of reactivity of fly ashes

Cem. Concr. Res.

(1993)

H.-W. Song et al.

Estimation of the permeability of silica fume cement concrete

Constr. Build. Mater.

(2010)

Y. Wang et al.

Effects of sand and silica fume on the vibration damping behavior of cement

Cem. Concr. Res.

(1998)

A. Weinberg et al.

Hydration and weathering reactions in by-products from clean coal technologies: effect on material properties

Fuel

(1997)

S. Wild et al.

Factors influencing strength development of concrete containing silica fume

Cem. Concr. Res.

(1995)

V. Yogendran et al.

Hydration of cement and silica fume paste

Cem. Concr. Res.

(1991)

Cited by (93)

Effect of various additives in activating early age properties of phosphorus furnace slag blended cement
2024, Journal of Building Engineering
Phosphorus furnace slag (PFS) is an industrial by-product of yellow phosphorus production which causes environmental and landfill problems. Researchers have recently shown increased interest in the environmental benefits of incorporating PFS into mortar and concrete mixes. However, the low early strength and extended setting time of PFS restrict its use as a supplementary cementitious material (SCM). Considering this, the effect of different additives, namely sodium sulfate (Na₂SO₄), calcium sulfate anhydrite, calcined alumina (CA), and calcium aluminate cement (CAC) at up to 5 %, on the setting time, soundness, and early strength (2d) of 25 % and 50 % phosphorus furnace slag blended cement (PFSC) paste and mortar have been investigated. It is observed that chemical activation of PFSC paste is more critical in reducing the setting time. The addition of 3 % Na₂SO₄ to PFSC mortar resulted in the most significant improvement in early strength, with a 20 % increase in 25 % PFSC and a 27 % increase in 50 % PFSC compared to the reference PFSC mortar. Additionally, the microstructure analysis revealed the additional formation of calcium silicate hydrate (CSH) and ettringite in the 3 % Na₂SO₄ added PFSC paste compared to the reference PFSC paste. It is established that the relationship between microstructural changes and the enhancement of early strength in PFSC mortar is due to the chemical activation of PFSC paste.
Upcycling of lime mud into lightweight artificial aggregates through the crushing technique
2024, Journal of Cleaner Production
Lime mud (LM), a solid waste generated in the paper-making industry, was proposed to manufacture lightweight artificial aggregates (LAAs) via the crushing technique. LAAs with a loose bulk density of 765–885 kg/m³, an apparent density of 1270–1445 kg/m³, and a strength of 5.7–7.2 MPa were achieved. To optimize the crushing-consumption energy and the mechanical properties, the mix proportions and curing ages of the LAAs before crushing were comprehensively investigated through mineralogy and microstructure analyses. In addition, the embodied carbon and material costs of the manufactured LAAs were estimated. Results showed that the early-crushed LAAs (curing till 28 days) enabled achieving the higher 28-day strength compared to the 28-day-crushed LAAs; however, the early-crushed LAAs tended to produce more contents of powder. The incorporation of silica fume (SF) reduced the contents of crushing powder and refined the pore characteristics of the LAAs. An optimized mix proportion (LM:cement:SF = 5:3:2) of the LAAs crushed on day 3 showed the best comprehensive properties, considering the mechanical properties, material costs, energy consumption, and embodied carbon. Overall, this study offers insight into the LAA production via the crushing technique and the value-added use of LM in the construction industry.
Pozzolanic attributes of hydraulic cement paste hybridized with agricultural by-product and Nano-carbon
2024, Construction and Building Materials
The increased consumption of construction materials has created a global movement toward the use of eco-friendly materials, including agricultural and industrial by-products. Similarly, research on nano-particles for improving concrete performance and lowering clinker impact has intensified. The primary objective of this research is to examine the pozzolanic reactivity and microstructure analysis of cement paste fortified with Graphene Nanoplatelets (GNPs) and rice husk ash (RHA). The Fratini test and strength activity index are used to assess the pozzolanic reactivity of RHA burnt at different temperatures, and the microstructure of RHA with exceptional pozzolanic reaction is further examined. RHA burnt at high temperature (750ºC) shows poor pozzolanic activity than RHA burnt at 500ºC. For the development of a sustainable cement matrix, 15 % of RHA is substituted with cement, and GNPs are added in varying proportions, such as 0.1 %, 0.2 %, and 0.3 %. The chemical properties and changes in the microstructure of the hybrid composites are determined using SEM, XRD, and FTIR. A series of experiments are conducted to evaluate the fresh and mechanical performances of graphene and rice husk ash reinforced cement. It is observed that the GNP-reinforced cement showed a compressive strength enhancement of up to 19.4 % and a maximum strength improvement of 28.7 % is attained in the composite blended with 0.3 % GNP and 15 % RHA.
Volcanic ash from La Palma (Canary Islands, Spain) as Portland cement constituent
2023, Journal of Building Engineering
The last volcanic eruption on the island of La Palma (Spain) took place in 2021. Significant activity started in September of that year with the vigorous emission of volcanic gases and ash and lasted for three months. It is estimated that the Cumbre Vieja volcano emitted more than ten million cubic meters of ash comprising pyroclastic materials like those found in many parts of the world. Some of these volcanic ash deposits are untapped, despite their potential construction industry applications. Since the chemical composition and mineralogy of the ash depends on the type of magma from it originates, this paper characterizes this material and evaluates its suitability as a major constituent of Portland cement. This volcanic ash is rich in silica (45%) and alumina (15%), meaning it reacts with portlandite. The blended cements with up to 40% replacement content meet the standardized chemical, physical, and mechanical requirements and present good intrinsic durability values (resistivity and capillary absorption), making them viable for the manufacture of low-carbon-footprint eco-cements. This paper seeks to provide society with lasting technical, environmental, and social benefits through recovery of this ash.
An overview of mechanical, permeability, and thermal properties of silica fume concrete using bibliographic survey and building information modelling
2023, Construction and Building Materials
The present paper discussed the silica fume (SF) as the SCM to replace cement partially in concrete. The paper aims to summarize till date literature findings and suggest necessary gaps in utilizing SF as SCM. The study’s necessity and framework are highlighted through bibliographic analysis using VOS viewer software and Scopus search engine data and found a lack of research in the field of SCM in the last 5 years. The production process of SF and its physical and chemical properties are studied location-wise. The range of these properties is analysed, and it found that SF mean particle size is 10 times finer than cement which enhances the mechanical and durability of concrete. The mechanical properties studied reported that the optimum percentage of silica fume generally ranges between 7.5 and 12%. However, it is not constant and found to be dependent on w/c. An adverse effect on the characteristics of concrete was observed on excess addition of SF over the optimum limit. The feasibility of SF with other SCM and fibers was found effective in improving the concrete properties. The different properties based on the action of water transport through the concrete are studied, such as permeation, diffusion, migration, convection, void formation, sorption, wick action, absorption, and adsorption. The permeability properties were optimum between 7.5 and 10% SF. Further, the thermal performance of the building with and without SF-added concrete was performed using Revit software (BIM). It was reported that SF concrete is effective by 2.25 % and 4.30 % for cooling and heating load, respectively. Very few papers were found on the utilization of silica fume for the development of different construction products. The review concludes with recommendations for future research, aiming to stimulate more studies in this field.
Multifunctional cementitious blends containing zirconia nanoparticles: Mechanical characteristics, gamma attenuation behavior, and self-cleaning performance
2023, Journal of Building Engineering
Marble dust (MD) is an industrial solid waste that has a low recycling rate which triggers in much serious environmental pollution. This study focused on evaluating the possibility of recycling MD as a partial replacing material for Portland cement. To overcome the expected negative impact of MD on the mechanical characteristics of the investigated cement blend because of its inert pozzolanic character, silica fume (SF) was incorporated with it. Hence, this article interested with evaluating the effects of replacing Portland cement with 10 and 20 (mass %) of MD and SF on the mechanical behavior, stability against fire (SAF), bulk density and water absorption of hardened blended pastes. Composite containing 10% of SF and 10%MD showed slight depletion in compressive strength. So, for economic and environment benefits this composition was selected to be the optimum composition for different application and try to elaborate its mechanical characteristics using minor doses of nano ZrO₂ (0.25,0.5 and 1%). The formed hydration products and the microstructure of the hardened composites were identified using TGA/DSC, XRD and SEM techniques. γ-rays shielding % of some hardened composites was identified using two intensities (661.6Kev & 1332.5 Kev) γ-rays radiation and results clarified that inclusion of 1%nano ZrO₂ significantly elaborate the shielding capability of the hardened composites. Agar diffusion test (ASTM D4300-1) revealed that composite containing 1% nano ZrO₂ possessed an excellent antimicrobial activity (self-cleaning) with various microorganisms. The overall outcomes indicated that inclusion of different doses of nano ZrO₂ increase the SAF of SM20 composite; being higher for 1% nano ZrO₂ and clarified that 80 %OPC +10%SF+10%MD composite admixed with 0.5% ZrO₂ exhibited significantly the best mechanical properties. So, this investigation recommended this composition to be the optimum for various special applications.

View all citing articles on Scopus

View full text