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Concrete Construction Article PDF - How Microsilica Improves Concrete PDF
Concrete Construction Article PDF - How Microsilica Improves Concrete PDF
improves concrete
Finer than fly ash, this pozzolan increases strength
and density, reduces concrete permeability
Pozzolanic action
Addition of microsilica to a concrete mix alters the ce-
ment paste structure. The resulting paste contains more
of the strong calcium-silicate hydrates and less of the
weak and easily soluble calcium hydroxides than do or-
dinary cement pastes. Because the microsilica particles
are so small—their average diameter is about 1⁄100 that of
cement particles—they disperse among and separate
the cement particles. The resulting fine, uniform matrix
can give markedly higher compressive, flexural, and
bond strength. Compressive strengths as high as 15,000
psi with ordinary aggregates and 30,000 psi or more with
special aggregates have been reported.
Protection of reinforcement
Concrete’s ability to protect embedded steel against
corrosion depends mainly on the alkalinity of the pore
water. As long as the water is highly alkaline, a passive
oxide film on the steel protects it.
If the passivity is destroyed by aggressive ions, either
carbonates or chloride ions, the steel will corrode at
a rate depending on the concrete’s electrical resistivity
Relationship between strength and water-cement ratio for and rate of oxygen transport through water- s a t u ra t e d
two microsilica concretes and a reference concrete. Curves concrete.
are similar in shpae, but microsilica concretes reach Fortunately, microsilica—thanks to its pore-filling ca-
significantly higher levels, up to nearly 14,000 psi (from pabilities—reduces (in some if not all cases) the rate of
Reference 1). carbonation, decreases permeability to chloride ions,
imparts high electrical resistivity, and has little effect on
oxygen transport (Reference 1, page 719). Therefore, mi-
Freeze-thaw durability crosilica concrete can be expected to be strongly pro-
The small microsilica particles are very good at infil- tective of reinforcement and embedments.
trating and plugging capillary pores in concrete—mak-
ing pores smaller and fewer and concrete more dense. Sulfate resistance, reduced aggregate reactivity
This gives the concrete good resistance to freezing and Probably because it has a finer pore structure and less
thawing. calcium hydroxide, microsilica concrete has improved
resistance to sulfate attack (Reference 1, page 698). In little bleeding. This may cause problems for floors or
addition, microsilica binds the potassium and sodium slabs cast in hot, windy weather because there is no wa-
oxide alkalies present in cement, thus reducing detri- ter film at the surface to compensate for evaporation.
mental effects with alkali-reactive aggregates. Plastic shrinkage cracking can readily develop unless
precautions are taken. It is important to finish the con-
Aids strength gain of fly ash concretes crete promptly and apply a curing compound or cover
immediately. With lean concrete mixes or mixes con-
Preliminary indications suggest that microsilica may
taining fly ash replacement of cement, different effects
be useful in controlling heat generation in mass con-
have been reported. For example, Reference 4 re p o rt s
crete. It has also been found useful in combination with
that mixes with less than 380 pounds of cement per cu-
fly ash. Early-age strength development of concrete in
bic yard plus 10 percent microsilica are both more co-
which fly ash replaces cement tends to be slow because
hesive and more plastic so no extra water is needed to
fly ash is relatively inert during this period of hydration.
maintain slump.
Adding microsilica, which is more reactive in early hy-
dration, can speed the strength development. Concrete color effects
MIXING AND PLACING CONSIDERATIONS Freshly mixed concrete containing microsilica can be
almost black, dark gray, or practically unchanged, de-
Handling the microsilica pending on the dosage of microsilica and its carbon con-
tent. The more carbon and iron in the admixture, the
Because of its extreme fineness, microsilica presents
darker the resulting concrete. Hardened concretes are
handling problems. A cement tanker that could ordi-
not much darker than normal concretes when dry.
narily haul 35 metric tons of cement accommodates on-
Sometimes there is a faint bluish tinge, but when the mi-
ly 7 to 9 tons of dry microsilica and requires 20 to 50 per-
crosilica concrete is wet, it looks darker than normal.
cent more time for discharging. Some producers mix
microsilica with water on a pound-for-pound basis to Silicosis danger doubted
form a slurry that is transportable in tank trailers de-
Microsilica is essentially noncrystalline. Cu r re n t l y
signed to handle liquids. The water of the slurry replaces
available data indicate it has no tendency to cause sili-
part of that ordinarily added to the mix.
cosis, the lung disease associated with inhalation of
One supplier prepares a slurry which, used at the rate
crystalline SiO2. Howe ve r, because of possible cumula-
of 1 gallon per 100 pounds of cement, will provide about
tive long-term effects, Norwegian standards restrict dust
5 percent microsilica by weight of cement. In 1984, that
in the air of the workplace to the same level as that of
supplier was quoting a price of $1.70 per gallon at a plant
other dusts such as natural diatomaceous earth, mica,
in West Virginia. In Canada, patented methods have
and soapstone.
been used to densify the microsilica for shipment to
ready mix producers. Some concrete producers also use RECENT USES OF MICROSILICA
the loose microsilica just as it is collected. CONCRETE IN THE U.S.
Water requirements of the mix Bridge deck overlay
When no water reducing agent is used, the addition Ohio transportation engineers are testing their theory
of microsilica to a concrete mix calls for more water to that microsilica concrete is suitable for bridge deck over-
maintain a given slump. Water content can be held the lay work. With the same construction equipment used to
same by using a water reducer or superplasticizer along place latex-modified concrete, they installed an experi-
with the microsilica. Water reducing agents appear to mental section late in 1984 on a bridge on State Route
have a greater effect on microsilica concrete than on 511, north of Ashland, Ohio. The purpose is to compare
normal concrete. Thus water demand for a given mi- placeability, cost, resistance to deicing salt, and other as-
crosilica concrete can be controlled to be either greater pects of durability of the microsilica mix with latex mod-
or smaller than for the reference concrete. ified concrete.
The admixture used for the microsilica concrete was
Placing and finishing, curing a slurry containing both microsilica and a water-reduc-
The gel that forms during the first minutes of mixing ing agent. Microsilica-cement ratio was 0.15 by weight.
microsilica concrete takes up water and stiffens the mix- Water-cement ratio was 0.4 not including the microsili-
ture, necessitating adjustment of the timing of charging ca with the cement. Design compressive strength was
and placing. Scandinavian researchers (Reference 1) 7500 psi. Slump was 6 to 8 inches, and there was no air
have concluded that microsilica concretes often require entrainment.
1 to 2 inches more slump than conventional concrete for Mobile batcher-mixers were used to mix on site and
equal workability. When cement content and microsili- place 1.5-inch overlays of microsilica concrete on the
ca dosage are relatively high, the mixture is so cohesive southbound lane and latex-modified concrete on the
that there is virtually no segregation of aggregates and northbound lane. The microsilica concrete was mixed
for only 60 seconds, then placed and promptly finished. tory at Fa i rc h a n c e, Pennsylvania in the spring of
Wet burlap was used for curing. 1983. Conventional embedded mesh reinforcement was
One crew handled both concretes and found them not used.
equally easy to place and finish. Careful observation The wet mix was delivered straight from mixer trucks
showed no shrinkage cracking. to a remote-controlled truck-mounted shotcreting rig,
The job required about 16 cubic yards of each of the capable of reaching a height of 63 feet. Only two work-
two types of concrete. Ohio officials estimate the mi- ers were needed—one to operate the control panel and
crosilica concrete cost about $50 per cubic yard less than one to monitor the concrete mix. Rebound loss was less
the latex-modified concrete. than 5 percent. Specified 28-day strength of the
shotcrete was 9000 psi in compression and 1500 psi
Repair of a dam stilling basin in flexure.
The U.S. Army Corps of Engineers specified microsili-
ca concrete for repair of the stilling basin of the Kinzua
Dam in northern Pennsylvania. The job required 2000
cubic yards of microsilica concrete, placed during a 7- References
week period in late 1983 and early 1984. The concrete 1. Fly Ash, Silica Fume, Slag & Other Mineral Products in
was trucked 8 miles to the dam, and pumped into place Concrete, edited by V. M. Malhotra; ACI Publication SP-
79,1983, available from American Concrete Institute, Box
through a 100-foot boom. Measured compressive 19150, Detroit, Michigan 48219 at $90 ($70 to ACI mem-
strength exceeded the specified values of 10,000 psi at 7 bers). Pertinent information appears in Volume I, pages 1-
days and 12,500 psi at 28 days. 46, 221-233, 255-265, 539-557; and in Volume II, pages
The 204- by 108-foot basin, lined with 5-foot thick 625-829, 847-865, 923-942, and 1165-1176.
slabs, had been placed in operation in 1966. By 1973,
debris had eroded the basin’s surface and caused pits as 2. D. W. Christiansen Jr., E. V. Sorensen, and F. F. Radjy,
deep as 3 feet. Slabs were then repaired with steel-fiber- “Rockbond: A New Microsilica Concrete Bridge Deck Over-
reinforced concrete. Nine years later, divers found that lay Material,” International Bridge Conference and Exhibi-
tion, June 1984, Pittsburgh, Pennsylvania.
not only had the 1-foot overlay of steel-fiber-reinforced
concrete been worn away in places but in some areas as
much as 2 feet of the underlying original slab had been 3. V. M. Malhotra and G. G. Carette, “Silica Fume—A Poz-
zolan of New Interest for Use in Some Concrete,” CON-
worn away also. CRETE CONSTRUCTION, May 1982, pp. 443-446.
Abrasion-erosion tests in the laboratory suggested to
the Corps of Engineers that microsilica concrete would
4. Condensed Silica Fume, edited by Pierre-Claude Aitcin,
be a suitable repair material, but full scale field tests 52 pages, 1983. Available from the editor, University of
were ordered to be sure the repair concrete could be Sherbrooke, Sherbrooke, Quebec, Canada J1K 2R1 at $20
placed and finished satisfactorily. Slumps as high as even (Canadian) plus $5 for postage and handling.
10 inches were used to facilitate placing and finishing. A
membrane curing compound was applied immediately
after final finishing.