Practical use of Microsilica in Concrete Recommendations and hints Mr. Robert Lewis, Dr. Tor S. Hansen Elkem Materials When a contractor or a concrete ready mix producer for the first time have to use microsilica because it has been specified for the project, one has to leam how to add this material and how to place it and cure it correctly so all the beneficial properties is achieved. Faulty mixing and use may reduce all the desired effects. But do not be scared, it is not difficult at all. Other who has learned how to do these things, likes this microsilica concrete. It is because it gives many advantages to the contractor using it since as for example, one gets a good result the first time. Therefore, before delivering a completed structure to the owner, the need for post grouting, repairs and patch-work finishing is almost eliminated. ‘So what are the tricks? ‘There are no triks, but there are a few things that needs to be understood and which might seem to be new for this concrete, when compared to ordinary concrete. ‘We shall look at these in the following order: © Why is microsilica specified? Can such concrete be made by anyone? What is the delivery form and how should one get hold of microsilica? How should one handle and doze microsilica into the concrete mix. How to cast and cure microsilica concrete? Specification of microsilica concrete. Let us make one thing clear. A concrete mix cannot be made cheaper by adding microsilica Microsilica concrete is therefore not used commonly in all applications. But there are normally some minor premiums to the RMC plant delivering this concrete. All in all: the concrete must be specified by owner/consultant or by contractor. Microsilica concrete has found its use in almost all applications one can imagine. High strength/high rise, precast elements for buildings, hollow core slabs, beams, foundations, bridges, flat works, harbours, dams, tunnels, airports, underwater casting, shotcrete, mortars, grouts, special cements, etc. etc. Due to its impact on workability and handling of the fresh concrete and other contractor benefits, there are cost savings to the contractor who has leamed to benefit from these advantages. If permission is granted from the owner, microsilica could be used, as there is no harm to a concrete structure by containing microsilica, On the contrary. Same situation might be the —al—situation for subcontractors producing precast elements where productivity and quality are ‘major factors in applying microsilica. A contractor specifying microsilica in a concrete will normally call for a concrete with high slump, no ability to separation, which sets fast but not too early in order to finish off, hardens quickly but without causing heat of hydration cracks, ete. Shoterete should be sticky and concrete being pumped through long pipclines or high up should be cohesive and have no ability for separation. Same goes for concrete to be placed under water. ‘The most common reason for using microsilica concrete is due to the vast variety of durability benefits it gives to a concrete structure. There are also situations where ‘strength benefit is used to design the structure quite differently for user benefits or visual aspects. In other terms, a microsilica concrete is specified because it makes a concrete structure much stronger and to last much longer, to call for much less costly repair works in the future and thereby give a much higher maintained value and lower lifetime cost. Depending on application, on location and on severity of the clements attacking the concrete, we can here be talking of huge money. ‘The specification should normally call for measures, which is according to the type of durability the structure is designed to withstand. For bigger projects this is done at trial stages during receipt development and later during execution. This could be permeability tests, chloride diffusion tests, alkali aggregate tests, frost resistance tests, ctc. Unfortunately such test procedures are not available all over and may cause engineers to find other measures in order to cut comers. As common practice always calls for compressive strength. For a microsilica concrete there is a relation between the above criterias and strength since microsilica has an impact on strength as well. Compressive strength may therefore be used as a practical measure, but it is a risk in it. We are here normally talking of compressive strengths, often way beyond what the structural strength design calls for, unless utilised, and contractors can therefore be tempted to reduce cement to save money. One should therefore make it clear that reduction of cement must be tested out during test trial stage to verify if reduction of cement can be tolerated in meeting the initial criterias, such as chloride diffusion tests etc. In many cases it can, in others not. As microsilica is often specified as % of cement weight, reduction of cement will also have an impact on the amount of microsilica. All in all: Investing in microsilica concrete mix in projects where contractor skill can utilise benefits and where owner utilises the benefits microsilica has on strength and durability will give a payback with high interests. That it is why it has found its use in growing field within concrete structures world wide RMC requirement ‘Any RMC plants are capable of mixing a microsilica concrete as long as they have will to do so and meets normal standard otherwise. For high performance concrete there are needs for high quality aggregate or sands, and since many RMC’s are located to a certain resource this might give limitations to that plant. It is an advantage to have personnel who is open for making new types of concrete and willing to learn, especially when it comes to management. Order idling of micro: By ordering of microsilica, one should always make sure the product conforms to a standard for such materials, Some standards are made in order to suit certain national producers, which does not have classification equipment. The silica fume might therefore contain as much as up to10% impurities. Some sources will also have a lower content of Si02 or higher amounts of alkali -82-elements, These will normally bind up SiQ2 into silicate and therefore make the amount of free reactive silica less. As the powder is 100 times finer than ordinary cement there are certain transportation, storage and dispensing considerations to be taken into account. To accommodate some of these difficulties the microsilica is commercially available in various forms. The differences between these forms are related to the shape and size of the particles and do not greatly affect the chemical make-up or reaction of the material. These differences do however have an influence on the areas of use and careful thought should be given to the type of microsilica chosen for a specific application. ‘The main forms of microsilica are as follows: Undensified. Bulk Density : 200 - 350 kg/m3 Available mainly in 25kg bags. Due to the very low bulk density and the fact that it is generally only available in small bags, undensified microsilica is considered impractical to use in normal concrete production. The areas where it is currently being used successfully are in formulated bagged materials such as grouts, mortars, concrete repair systems and protective coatings. Most of these products contain 80 much fine particle materials so there is not energy enough during dry premixing to disperse properly a densified product and undensified must therefore be applied. Densified. Bulk Density : 500 - 650 kg/mm? Available in 25kg and 1000kg bags and bulk. In the densification process the ultrafine particles become loosely agglomerated making the particulate size larger. This makes the powder easier to handle, with less dust, than the undensified form. Areas where this material is successfully used are in those processes that utilise high shear mixing facilities such as pre-cast works, concrete roof tile works or ready mixed concrete plants with ‘wet’ mixing units. Micropellitised. Bulk Density : 700 - 1000 kg/m? Available in 25kg and 750kg bags and bulk. Micropellitisation involves forming the microsilica powder into small compacted spheres about 0.5 - Imm in diameter, The material in this form does not readily break down in conventional concrete mixing and therefore is best suited to very powerful mixing facilities or inter-grinding with cement clinker to produce a composite cement. Icelandic cement is made in this fashion and contains 7.5% microsilica. Sluny. Specific Gravity : 1400 kg/m} Available in 210L and 1000 containers and bulk. This material is produced by mixing the undensified powder and water in equal proportions by ‘weight to produce a stable slurry. Mixing and maintaining a stable slurry requires expensive hi-tech equipment and hence cannot be done easily, therefore all slurries should be obtained from one specific supplier to maintain quality. In this form the material is easily introduced into the concrete mix. It is also the most practical form for dispensing by weight or volume. It can be used for virtually all forms of conerete from semi-dry mixes for pre-cast products to super-flowing concretes and is ideally suited to the ready mixed industry. Certain semi-mobile units and necessary technology and know how is available in order to produce slurry locally at larger projects. -83-In cases where slurry is not available locally, the most practical delivery form is densified microsilica in big bags or small bags for the RMC-plants. It is also in most cases the most cost effective product to purchase as it has less freight costs due to its less bulky character compared to undensified. Undensified microsilica is also much more difficult to handle through dozing system unless especially built. Due to the variety of aggregates that are available, mix designs will always need to be tested before any major production. The microsilica has two actions in the concrete mix: The first is to act as a filler, giving the mix greater cohesion, zero bleed and a thixotropic theology. Thus a mix may look ‘stiffer’ than expected but the superfine spherical particles of microsilica will ‘lubricate’ the mix making it flow better. This will improve the concretes pumpability and ease of placing. ‘As the bulk density of the microsilica is one fifth that of cement, it can be scen that a 10% dosage on a 400 kg cement content would be the equivalent of adding some 200 kg of extra coment. If simply added to the mix, this will cause a radical change in the rhcology of the concrete ~ making it very ‘fatty’. The rule of thumb that is often used in first designs is to reduce the sand percentage by half of the percentage of the microsilica. This will not only ‘improve the workability of the mix but will reduce the tendency to add more water. It should be remembered that in order to achieve maximum dispersion of the microsilica within a mix, a superplasticiser is often used. This is good practice. It will also increase the workability of the mix while maintaining a low water cement ratio. This is imperative to produce high performance concrete in the first place, but also serves to reduce the potential for excess water in the mix, which could lead to shrinkage and cracking. In this context ‘low’ means a ratio between 0.35 and 0.50. Mixes lower than 0,35 will need special attention and design assistance, The second action of the microsilica is pozzolanic. It reacts with the calcium hydroxide released by the cement hydration and forms more of the calcium silicate hydrates that bind the concrete together, Due to the fine size of the microsilica particles the CSH crystals formed are much finer and stronger and produce a very refined and dense matrix. This increases the strength and impermeability of the microsilica conerete giving it greater durabil Thus it can be expected that the microsilica concrete will gain strength more rapidly ~ although it does not accelerate the ‘set’ - which can induce any expected shrinkage at an earlier age. Again because the microsilica concrete does not bleed, once it has been placed and compacted, any finishing actions can be started. Once the desired finish has been achieved, the exposed surfaces must be cured immediately ~ see section on Curing, Starting points for mix designs and dosages of microsilica have been determined over the years. The ranges given allow for achieving the required strength at the relative performance. The microsilica percentages given are dry weight by cement weight, Application Microsilica % Pumping aid 2103 Improved durability* 4107 * Onan equal strength basis. High strength** Tto 15 ** + high impermeability/chemical resistance. Underwater 12to 15 Sprayed 81012 —84-The above figures do not take into account the potential to use another pozzolanic material such as blastfurnace slag or fly ash. Both of these materials are compatible with microsilica and the “triple blends’ have been used on many projects. Triple blend designs are being specified for high durability concretes for long lifetime structures ~ in excess of 125 years. Batching. Microsilica powder should be stored exactly as cement. Itis possible to store powder microsilica in a standard cement silo. Certain precautions must be taken in terms of moving the material around ~ using airslides and pneumatic conveyors, or low angle slow drive screw feeds, gravity feeds and rubber transport pipes. Additional data on plant equipment is available. ‘The main concern with batching the microsilica is that the material gets into the concrete mix as soon as possible and mixes for as long as possible, to get the maximum dispersion, The microsilica must go into ‘something’. That is, it must go into the aggregate or the initial flow of concrete material. It should not go into the empty pan mixer or truck mixer. Most especially microsilica powder should never be added to a full readymix truck. It will not disperse in this fashion and will probably just create a solid brick in the last cubic metre. ‘The best trial mix sequence has been found to be: + All coarse aggregate + 75% water + 50% of the fine aggregate into the mixer and start mixing, Add the microsilica, continue mixing ‘+ When aggregate is evenly coated, add cement and then superplasticiser (dispersed in some of the water), continue mixing, + Add remainder of fines, then slowly add remaining water until correct workability is achieved throughout the mix. Obviously, this pattem cannot be directly translated to a batching plant, but the basic format should be followed as closely as is possible. Incomplete dispersion of the microsilica may result in ‘pockets’ of material in the concrete, ‘which will have the same detrimental effects as cement balling and will not give the expected performance, Slurrified microsilica should be added in exactly the same fashion. Even though it is in liquid form it should not be added to an empty mixer. It will ‘weld’ to the metal and be very difficult to mix into the concrete, Equally, the superplasticiser should not be mixed with the microsilica. This coats the microsilica in the admixture, which will then not react as efficiently with the cement. Microsilica is compatible with most admixtures but, as with cement, some work better than others. The admixture companies can give the best advice here. 2. and Compacting. A properly designed and mixed microsilica concrete will be as easy to place and compact as ordinary concrete. Because of the thixotropic nature of the concrete, it may even be easier. As has been stated, the cohesiveness may make the concrete appear to be a lower workability. ‘This should not be countered with the immediate addition of water (standard UK site practice!) ‘The theology of the concrete will give better flow and once the subjected to energy, vibrating poker, screeding beam etc. the concrete will move a lot more freely than expected. This means that concretes can be pumped further, cither horizontally or vertically. It does mean that care —85 -should be taken to ensure complete consolidation of the concrete as compaction may secm to be finished sooner than All normal forms of placing and compacting techniques are usable with microsilica concrete. Mechanical vibration appears to be most effective due to the physical supply of energy. Care should be taken with rolling beam compaction on slabs, as the vibration may not penetrate deeply into the concrete. As such the slab should be compacted by other means before being finished with the roller. ‘Once compacted the concrete should be ‘finished’ as soon as possible. This is because there will be no bleed water rising to any exposed surface. Thus the surface should be finished and then cured immediately to prevent drying out and potential cracking, Steel equipment is recommended for this work. Trowelling, power-floating and all other normal finishes can be applied. It should be noted that due to the considerable strength that can be gained by microsilica concrete, a brush finish should be just enough for the purpose and not excessive — often done in order to allow for ‘wear down’, as this may not happen. Equally any joint cutting or duct cutting in the concrete should be done within the first few days to prevent excessive damage to cutting tools, It is sometimes an advantage to inform the ‘end user’ of the structure, that cutting may not be easy in the long term, When power-floated, a glass like finish can be obtained. Unless this is required, a very fine brush finish will introduce a non-slip, non-dusting surface. Curing. ‘The most important aspect of a high performance microsilica concrete. This concrete must be cured. There will be no moisture coming to any exposed surface. If this is left ‘open’ the surface will dry, setting up stresses that may cause surface cracking. It will also cause lack of reaction and thus weaken the surface, which is just the place where the impermeability and strength are required for environmental resistance Depending on the surface finish of the exposed concrete, most of the normal curing techniques are effective with microsilica concrete. ‘These include: Fogging, mist spraying, ponding, wet hessian, plastic shecting and curing membranes. Where the conerete is external or ‘weather exposed’, shading, wind breaks or even tenting are advantageous. Curing regimes should be carried out for the maximum time possible, within the constraints of the construction timetable. However, due to the fact that the microsilica concrete will gain strength at a faster rate than a normal concrete, most curing regimes need only be applied for about 7 days. This, as always, is dependent on the ambient conditions, the quality of the concrete and the required performance of the finished unit,