EFFECT OF REPLACEMENT OF CEMENT BY SILICA FUMES

– A STUDY

R.PRAVEEN KUMAR

REG NO: P16ST902

M.TECH STRUCTURAL ENGINEERING

(PART TIME)

PROJECT PHASE - I REVIEW

GUIDED BY

MR.T.P MEIKANDAAN

ASSOCIATE PROFESSOR

DEPARTMENT OF CIVIL ENGINEERING

SYNOPSIS
 SYNOPSIS
Silica fume is a byproduct of producing silicon metal or ferrosilicon alloys. One of the most
beneficial uses for silica fume is in concrete. Because of its chemical and physical properties,
it is a very reactive pozzolan. Concrete containing silica fume can have very high strength
and can be very durable.

Silica fume is available from suppliers of concrete admixtures and, when specified, is simply
added during concrete production.

Silica fume consists primarily of amorphous (non-crystalline) silicon dioxide (SiO2).

The individual particles are extremely small, approximately 1/100th the size of an average
cement particle.

Because of its fine particles, large surface area, and the high SiO2 content, silica fume is a
very reactive pozzolana when used in concrete.

High performance concrete usually contains Portland cement. However, partial cement
replacement by mineral admixtures can be economically advantageous.

These minerals act as filler due to their small particle size that enables their penetration
between cement grains. This results in reduction in the water cement ratio to achieve a given
workability.

To determine the percentage this yields maximum compressive strength

To determine the most economical percentage of replacement this also gives maximum
compressive strength.

To compare strength of three combinations: (1) Control, (2) silica fumes at various dosages
of 5%,7% and 10%.
INTRODUCTION
 SILICA FUME
Silica fume, also known as micro silica, is a fine-grain, thin, and very high surface area
silica.

Figure No. 1 Silica fume

It is sometimes confused with fumed silica (also known as phylogenic silica) and colloidal
silica. These materials have different derivations, technical characteristics, and applications.

Proper introduction of silica fume in concrete improves both the mechanical and durability
characteristics of the concrete.

It emphasized the effect of silica fume on workability level and its maintenance of fresh
concrete; strength development, strength optimization and elastic modulus of hardened
concrete; and chemical and mechanical durability of mortar.

The experimental program comprised three levels of silica‐fume contents (as partial
replacement of cement by weight) at 0% (control mix), 5%, 7%, 10%, ).

Due to the slow development of pozzolanic effect, there was a drop in up to seven days and
late significant introducing silica fume to concrete.
PROPERTIES

The history of silica fume is relatively short, the first recorded testing of silica fume in
Portland cement based concretes was in 1952 and it wasn’t until the early 1970s that
concretes containing silica fume came into even limited use.

The biggest drawback to discovering the unique properties of silica fume and its potential
was a lack of silica fume to experiment with. Early research used an expensive additive
called Fumed silica, a colloidal form of silica made by combustion of silicon tetrachloride in
hydrogen-oxygen furnaces.

Silica fume on the other hand, is a by-product or a very fine pozzolanic material, composed
of mostly amorphous silica produced by electric arc furnaces during the production of
elemental silicon or Ferro silicon alloys. Before the late 1960s in Europe and the mid1970’s
in the United States, silica fume simply went up the stack as smoke vented into the
atmosphere.

Only with the implementation of tougher environmental laws during the mid-1970s did
silicon smelters begin to capture and collect the silica fume, instead of sending it to the
landfill. Thus the push was on to find uses for it.

Obviously, the early work done in Norway received most of the attention, since it had shown
that Portland cement based concretes containing silica fumes had very high strengths and low
porosities.

Since then silica fume usage and development has continued making it one of the world’s
most valuable and versatile admixtures for concrete and cementitous products. Typically
purchased by the refractory market in a 50 lb. bag this very fine gray powder has come a long
way.

Silica fume consists of fine vitreous particles with a surface area on the order of
215,280 ft²/lb (20,000 m²/kg) when measured by nitrogen adsorption techniques, with
particles approximately one hundredth the size of the average cement particle.[1]

PRODUCTION

Silica fume is a byproduct in the reduction of high-purity quartz with coke in electric arc
furnaces in the production of silicon and ferrosilicon alloys.
APPLICATIONS

CONCRETE
Because of its extreme fineness and high silica content, silica fume is a very effective
pozzolanic material. Standard specifications for silica fume used in cementations mixtures
are ASTM C1240, EN 13263.

Silica fume is added to Portland cementconcrete to improve its properties, in particular its
compressive strength, bond strength, and abrasion resistance. These improvements stem from
both the mechanical improvements resulting from addition of a very fine powder to the
cement paste mix as well as from the pozzolanic reactions between the silica fume and free
calcium hydroxide in the paste.

Addition of silica fume also reduces the permeability of concrete to chlorideions, which
protects the reinforcing steel of concrete from corrosion, especially in chloride-rich
environments such as coastal regions and those of humid continental roadways and runways
(because of the use of deicing salts) and saltwater bridges.

Prior to the mid-1970s, nearly all silica fumes were discharged into the atmosphere. After
environmental concerns necessitated the collection and land filling of silica fume, it became
economically viable to use silica fume in various applications, in particular high-performance
concrete effect of silica fume on different properties of fresh and harden concrete:-

Workability: With the addition of silica fume, the slump loss with time is directly
proportional to increase in the silica fume content due to the introduction of large surface
area in the concrete mix by its addition. Although the slump decreases, the mix remains
highly cohesive.

Segregation and Bleeding: Silica fume reduces bleeding significantly because the free water
is consumed in wetting of the large surface area of the silica fume and hence the free water
left in the mix for bleeding also decreases. Silica fume also blocks the pores in the fresh
concrete so water within the concrete is not allowed to come to the surface.

MICRO SILICA

It is very reactive and effective pozzoloanic material due to its fine particle size and high
purity of sio2 (99.5%). It enhances the mechanical properties, durability and constructability
in concrete.

It used in the production of high strength & high performance concrete. It is used in the
production of high performance concrete structures like bridge’s where the strength and
curability properties of the concrete are required.
It can be used to build marine structure as it reduces due to the reaction of chloride and
various chemicals; it helps in the protection and increases the life of the structure.

The recommended dosage is 5% 7% 10% of the cement weight added to the concrete. Silica
fume or micro silica is the most commonly used mineral admixture in high strength concrete.

It has become the chose favorites for high strength concrete and is a good pozzolan& can be
used in a big way. Adding to the concrete mix will dramatically enhance the workability,
strength & impermeability of concrete mixes while, making the concrete durable to chemical
attacks.

Abrasion & reinforcement corrosion increasing the comprehensive strength. There is a

growing demand in the production of concrete mixes, high strength, and low permeability
concrete for use in bridge, marine environment, and nuclear plants ECT.
NEED FOR STUDY
NEED FOR STUDY

 Silica fume can make a significant contribution to early-age strength of concrete. One
pound of silica fume produces about the same amount of heat as a pound of Portland
cement, and yields about three to five times as much compressive strength.

 Silica fume improves concrete in two ways the basic pozzolanic reaction, and a micro
filler effect. Addition of silica fume improves bonding within the concrete and helps
reduce permeability, it also combines with the calcium hydroxide produced in the
hydration of Portland cement to improve concrete durability.

 As a micro filler, the extreme fineness of the silica fume allows it to fill the
microscopic voids between cement particles.This greatly reduces permeability and
improves the paste-to-aggregate bond of the resulting concrete compared to
conventional concrete.

 Compressive Strength test results are primarily used to determine that the concrete
mixture as delivered meets the requirements of specified strength.

 Strength test results may be used for quality control, acceptance of concrete, or for
estimating concrete strength in a structure for the purpose of scheduling construction
operations such as formwork removal or adequacy of curing.
1: METHODOLOGY
1.1 COMPRESSIVE STRENGTH

AIM:
To determine the compressive strength of the concrete specimens prepare and to verify the
strength requirement as the desired in the mix design and stipulated in the IS code.

APPARATUS:

FIGURE NO :1.1.1

COMPRESSION TESTING MACHINE

MATERIAL REQUIREMENT CALCULATION:

Quantity of materials required is calculated as below:

Grade=m20-cement value =256 kg/m3

Ratio=1:1/5:3
Cube dimension
1.15x0.15x0.15=3.75x10-3 m 3
Total cube = 12

Control cube 3
Silica fume cube 5% 3
Silica fume cube 7% 3
Silicafume cube 10% 3
12 cubes = 0.045 m 3
Total cement = 11.52 kg
Per day 3 are cubes casting = 3x3.75x10-3
Per day use of concrete to 3 cubes = 0.011 m 3
Dosage of micro silica fume for 5% = 140 g
Dosage of micro silica fume for 7% = 197 g
Dosage of micro silica fume for 10% = 281.6 g

SPECIMEN:
12 cubes of 15 cm size mix. M20

HAND MIXING:
Mix the concrete and fine aggregate on a water tight none-absorbent platform until the
mixture is thoroughly blended and is of uniform color.
Add the coarse aggregate and mix with cement and fine aggregate until the coarse aggregate
is uniformly distributed throughout the batch
Add water and mix until the concrete appears to be homogenous and of the desired
consistency .

SAMPLING:
Clean the mould and apply oil
Fill the concrete in the mould in layers approximately 5 cm thick
Compact each layer with not less than 35strocks per layers using a tamping rod (steel bar
16mm diameter and 60 cm long, bullet pointed al lower end)
Level the top surface and smoothen it with a trowel

CURING:
The test specimens are stored in moist air for 24 hours and after this period the specimens are
marked and removed from the moulds and kept the submerged in clear fresh water until take
out prior to test

PRECAUTIONS:

The water for curing should be tested every 7 days and the temperature of water must to be at
27 +-20C.

PROCEDURE:
remove the specimen from the water after specified curing time and wipe out excess water
from the surface.
Take the dimension of the specimen to the nearest 0.2m

Clean the bearing surface of the testing machine

Place the specimen in the machine in such a manner that the load should be applied to the
opposite side of the cube cas.

Align the specimen centrally on the base plate of the machine.

Rotate the movable portion gently and so that it touches the top surface of the specimen.

Apply the load gradually without shock and continuously at the rate of 140kg/cm2 /minute
till the specimen fails.

Record the maximum load and note any unusually features in the type of failure.

COMPRESSIVE STRENGTH
COPRESSIVE STRENGTH is the capacity of material or structure to with stand axially
directed pushing forces. When the limit of compressive strength is reached material is
crushed.

Concrete can be made to have high compressive strength, e.g. many concrete structures have
compressive strength is excess of 50 mpaMPawhere as material such as soft sandstone may
have a compressive strength as low as 5 OR 10 N/mm2

Compressive strength after measured on a universal testing machine; this range from very
small table top systems to ones with over 53 MN capacities. Measurements of compressive
strength or affected by the specific test method and condition of measurements. Compressive
strength is usually reported in relationship to specific technical standard.

When a specimen of material is loaded in such way that is extends it is said to be in tension.
One the other hand is material compresses and shortens it is said to be compression.

On an atomic level, the molecules are atoms are forced apart when in tension whereas in
compression they are forced together. Since atoms in solids always try to find an equilibrium
position, and distance between other atoms, forces arise throughout the entire material which
oppose both tension are compression.
The phenomena prevailing on an atomic level are there force similar. On a macroscopic
scale, these aspects are also reflected in the fact that the properties of most common material
in tension and compression are quite similar.The major difference between the two types of
loading is the strain which would have opposite signs for the tension (positive + it gets
longer) on compression (negative – it gets shorter). Another major difference is tension tends
to pull small sideways deflections back in to alignment, while compression tends to amplify
such deflection into buckling.

By definition, the compressive strength of the material is that valve of uniaxial compressive
stress reached when the material fails completely. The compressive strength usually obtained
experimentally by the means of a compressive test.

The apparatus used for the experiment is the same as that used in a tensile test. However,
rather than applying a uniaxial tensile load, a uniaxial compressive load is applied. As can be
imagined, the specimen (usually cylindrical) is shortened as well as spread laterally. A stress
– strain curve is plotted by the instrument and would look similar to the following. The
compressive strength of the material would correspond to the stress at the red point shown on
the curve.

Even in a compression test there is a linear region where the at material follows Hooke’s law.
Hence for this the region  = E€ where this time E refers to the young’s modulus for the
compression.

There is difference between the engineering stress and true stress. By its basic definition the
uniaxial stress is given by:
= F/A
Where:
F = load applied (N)
A = area (m2)
As stated, the area of the specimen varies on compression. In reality therefore the area is
some functions of the applied load i.e. A = f (F). Indeed, stress is defined as the force divided
by the area at the start of the experiment. This is known as the engineering stress and is
defined by
e = F /Ao where: Ao = original specimen area (m2)
These cylinders are cured for 28 days and tested by compression until they are crushed. This
will give the contractor or the engineer the compressive strength for that batch of concrete.
He or she can then compare that value to the design value used to make sure that the structure
was constructed properly.
Once the concrete has been placed for a particular structure, there is nondestructive test
which can be performed to estimate the strength of the concrete.
PRODUCT INFORMATION
 CERTIFICATE OF ANALYSIS

MICROSILICA

(SILICA FUMED – 920D)

(HIGH DENSITY SILICA)

Sio2 99.5%
AI2O3 0.08%
TiO2 0.04%
CaO 0.01%
MgO 0.01%
L.O.I 0.28%
ALKALIES 0.29%
PARTICLE SIZE 800 M

CERTIFICATE OF ANALYSIS

(LOW DENSITY SILICA FUMED)

APPEARANCE WHITE FREE FLOWING POWDER

Moisture (105 DEG.C for 2 hrs) 4.28% Max
Ignition loss on anhydrous basis (AT 1000 4.12% max
DEG.C. for 2 hrs)
Bulk density (tapped)(while materials 54 gm/lit
packed)
PH value (in 5% aqu. Suspension) 6.68
Residue on 325 mesh (wet sieving) Nil
Sio2 on an hydrous basis 98.59% min
Soluble salts 0.58% max
Water absorption 248% Max
Iron content (Fe + 3) 170 ppm
Average particle size 4.72 Micorn
SURAFE AREA – BET (SINGLE POINT 2
184.26 M /gm
METHOD)
LINSEED OIL ABORPTION 244
 CERTIFICATE OF ANALYSIS
FUMED SILICA – AC 200

TEST ITEM STANDARD TEST RESULT

REQUIREMENT
SPECIFIC SURFACE AREA 200 + 20 202
(M2 /G)
PH VALUE 3.7- 4.5 4.12
LOSS ON DRYING @ 105 < 1.5 0.47

DEG.C(5)

LOSS ON IGNITION @ 1000 <2.0 0.66

DEG. C (%)
SIEVE RESIDUE (5) <0.04 0.02
TAMPED DENSITY g/L 40- 60 44
Sio2 CONTENT > 99.8 99.88
CARBON CONTENT (%) < 0.15 0.06
CHLORIDE CONTENT (%) < 0.0202 0.009
AI2O3 < 0.03 0.005
TiO2 < 0.02 0.004
Fe 203 < 0.003 0.001