5.

(CONDENSED) SILICA FUME

Asst. Prof. Dr. Sevket BOSTANCI

 Silica Fume
• Silica fume (SF), also called condensed silica fume (CSF), is a
mineral admixture, mostly composed of submicron
particles of amorphous silicon dioxide.

• The term “silica fume” is adopted by the American

Concrete Institute.

• The first use of SF in Portland cement based concretes was

in 1952.

• Comparing to other supplementary cementitious materials

such as FA and GGBS, it is relatively new material and thus
its use in concrete has a short history.
 5.1 Introduction
• SF or CSF is a by-product of silicon or silicon alloy industries.
The total world production is about more than 1 million tons.
Leading producers are US, Norway, France, Switzerland,
Germany. Turkey produces about more than 7000 tons of CSF.

• It is extremely fine (100-150 times smaller compared to PC)

non-crystalline material with dark in colour consisting of very
fine vitreous materials.

• Unlike natural pozzolans & fly ash, CSF rapidly reacts with lime
to produce C-S-H gel.
• It contains  75% amorphous silica (SiO2). It consists of
extremely fine spherical particles.

• CSF has a mean particle diameter of 0.1 m. Therefore being

composed of amorphous silica in extremely fine form, CSF
exhibits excellent pozzolanic properties (particle diameter of
cement is 10m).

• Due to these characteristics, it is very pozzolanic material

(much more reactive), which means it does not gain strength
when mixed with water.
• When added to concrete, SF acts in two ways.

- As a filler it improves the physical structure, occupying the space

between hydrated cement particles,

- and as a pozzolan, it reacts chemically with the calcium hydroxide

released during the hydration of cement, forming strength-giving
compounds to impart greater strength and durability to concrete.
 Types of Silica Fume
• SF, as obtained after condensation from the furnace, is grey in
color, somewhat similar to cement or PFA.

• SF particles appear to be agglomerated and round.

• SF is commercially available in the following four types.

1. Undensified SF
• bulk density, up to 350 kg/m3

• It occupies a large volume due to low bulk density.

• It is sticky and self agglomerating, hence inconvenient to

handle and transport pneumatically.

• It also generates more dust.

• It is mainly used in making pre-bagged products like grouts or

repair mortars.
2. Densified
• Bulk density, 480–720 kg/m3

• The densification of SF is done in the storage silos installed

at the smelting plant.

• As the particles rub, the naturally occurring van der Waals

forces on their surface cause adherence to each other.

• The value of the densification process is most evident in

shipments over long distances and especially for off-shore
customers because high bulk density reduces the cost of
transport.

• The particles of densified SF produce very little dust

3 - Pelletized SF
• Bulk density, around 1000 kg/m3

• The pelletized form is not suitable for direct use in concrete,

as the hard pallets do not break and disperse in a concrete
mixer.

• It can be interground with Portland cement clinker to produce

blended SF cement.

• The densified SF should not be confused with pelletized SF.

4 – SF Slurry
• Bulk density, 1300-1400 kg/m3

• Transporting SF as a water based slurry is easy and more

economical. The slurry contains 50%–50% SF (mass basis)
dispersed in water and transported in bulk tankers.

• The storage tanks may require agitation to prevent slurry from

stiffening and protection from freezing.
 5.2 Production of CSF
• In the production of metal or alloys, quartz is reduced by carbon at
very high temperatures.
• Although the reactions in the furnace are very complex, one of
these involves the oxidation of SiO2 vapor, this vapor then
condenses to form CSF.
• CSF thus produced is taken out from the furnace by flue gasses and
collected in bag house filters.

Types of CSF depends on the source of the material;

• Si - CSF
• FeSi – CSF
• FeCrSi – CSF
• CaSi – CSF
• SiMn – CSF
 5.3 Handling & Transportation
• As-produced

• Compacted (using high pressure air)

• Slurry (using water)

• Pelletized (pressing)-used to produce SF blended cements.

 5.4 Physical & Chemical
Characteristics of CSF
• Colour: pale to dark grey.
• Loose unit weight: 200 kg/m3
• Compacted unit weight: 500 kg/m3
• Specific gravity: 2.2
• Size (mean-micron): 0.1
• Specific surface: 13 000-30 000 m2/kg
• Specific surface of OPC: 260-400 m2/kg
Table 5. Physical Characteristics of CSF

Characteristic American Turkish (Antalya)

Si-CSF FeSi-CSF FeSi-CSF
Fineness (% passing 45 micron sieve) 94.6 98.2 98.4*
Specific surface (m2/kg) 20 000 17 200 22 200**
Pozzolanic activity index (with OPC) 102.8 96.5 97
% of control
Pozzolanic activity index (with lime) 8.9 -- 6.9
(MPa)
Specific gravity 2.23 2.26 2.28
Water requirement 138.8 139.2 144.7
(for 110% flow) %

*30 micron sieve was used

** A = (6)/[Dx(SG)]
D: mean diameter (micron)
SG: Specific gravity
A: m2/gr

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Table 6. Chemical composition of CSFs

Oxide Si-CSF FeSi-CSF North America Turkish

FeCrSi-CSF SiMn-CSF FeSi-CSF
SiO2 94 90 83 25 85.5
Fe2O3 0.03 2.9 1.0 1.8 2.11
Al2O3 0.06 1.0 2.5 2.5 2.51
CaO 0.5 0.1 0.8 4.0 1.53
MnO -- -- -- 36.0 --
Cr2O3 -- -- -- -- 0.89

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5.5 Physical & Chemical Mechanisms in Cement –
CSF System

5.5.1 Physical Mechanisms

• Increasing the strength of the bond between the paste and
the aggregate by reducing the size of CH crystals. CSF particles
act as nuclei for the CH crystals formation, however they are
dispersed.

• By reducing bleeding and by increasing the cohesiveness of

the mix, for both mechanisms CSF particles must be
distributed throughout the body. Therefore use of
superplasticisers with CSF is mandatory.
 Physical Characteristics
• SF is essentially amorphous silicon dioxide and is dark gray in
colour.

• It takes part in the pozzolanic reactions occurring during

hydration of cement, due to its amorphous nature.

• It does not have cementitious characteristics but in the

presence of moisture and finely divided form, it reacts with C-
H and provides extra C-S-H.
 Physical Characteristics
• Besides its amorphous nature, the reactivity of SF in concrete
depends upon the size of particles, size distribution and how
well the particles get dispersed in concrete after mixing.

• The sand present in concrete is also silicon dioxide, chemically

similar to SF but crystalline in nature, hence does not react
with hydrated cement.
 Particle Size and Size Distribution
• The undensified SF particles are spherical in shape and on
average 0.02–0.25 μm in diameter, nearly 100 times smaller
than the average cement particle.

• It is amorphous (85%–98%) and glassy.

5.5.2 Chemical Mechanisms

• Lime silica systems mixtures: Silica goes into solution and

within one hour or less it forms an amorphous silica-rich gel
on the surface of the particles. In time this gel dissolves and
CSF particles start to react with CH to produce CSH gel. In 1:1
mixtures, lime was determined to be consumed in at most 28
days.
• Cement-CSF mixtures: CSF particles absorb water to produce
silica rich gel. This gel forms in the interstices between
cement particles and covers them to form a large mass. Any
lime produced by the hydration is immediately consumed by
the silica rich gel to produce CSH.
 5.6 Properties of Fresh CSF-
incorporated Concretes
1. Water requirement:
When used alone (without superplasticiser) CSF increases the
water requirement. However, when superplastisiser (SP) is
used, water demand is reduced for all levels of CSF inclusion
due to the dispersion effect of SP. In superplastisized silica fume
concretes, the water demand is governed by the amount of SP
rather than the CSF content.

2. Bleeding:
Bleeding in SF concretes is lower than OPC concretes. The
extremely fine particles of CSF attack themselves to cement
particles, thus reducing the channel size for bleeding. Therefore,
they leave very little free water available for bleeding.
• e.g. Bleeding was reduced by 50% and 90% through 5% and 10%
CSF incorporation, respectively.
3. Workability:
CSF concrete is more cohesive because solid – to – solid contact
points are increased. Therefore CSF concretes are more resistant
to segregation than OPC concretes.

On the other hand, CSF concretes loose slump more rapidly.

Therefore, a higher initial slump is necessary. This is true for rich
concretes.

For lean concretes, CSF incorporation increases workability (more

cement paste increases workability).
4. Air Entrainment:
The amount of air entraining agent (AEA) increases considerably
with CSF incorporation. For example, to obtain 6% entrained air,
the AEA dosage was tripled for 10% CSF incorporation,
quadrupled for 15% and it was more than 5 times for 20% CSF.

• The reduction in entrained air by CSF incorporation is more

pronounced in low w/c+CSF ratios.

• For example, [w]/[C+CSF] = 0.5 and 0.6, air entraining dosage was
twice and four times less than that for [w]/[C+CSF] = 0.4
5. Shrinkage Cracking:

Shrinkage occurs in fresh concrete by the removal of water from the

exposed surfaces thus creating stresses beyond the early age strength
of the concrete. Since CSF concretes exhibit little or no bleeding, the
risk of cracking is high.

To prevent cracking do the following:

• Use plastic sheets
• Use wet burlaps
• Use curing compounds.
6. Setting Time:
No significant change if CSF is used together with
superplaticiser. If not, CSF has an accelerating effect.

7. Heat of hydration:
Total heat of hydration remains unchanged.
 5.7 Properties of Haredened CSF-
incorporated Concretes
1. Compressive Strength:
The contribution of CSF to compressive strength development of concrete is
important because of:
• its filler effect,
• its excellent pozzolanic properties.

Factors on which CSF-contribution to high strength depends;

• --amount of silica fume
• --[w]/[C+CSF] ratio
• --cement composition
• --type & amount of SP
• --temperature
• --curing conditions
• --age.
• The water requirement is proportional to the CSF content if no SP is
used.

• In such cases, the contribution of CSF is offset by the high water

content.

• In general, the SP use is a prerequisite in order to achieve both a

proper dispersion of the particles and to fully utilize its strength
potential.

• The major contribution of CSF on strength is observed prior to 28

days.
• The temperature is another important parameter which affects the
strength development in CSF - concretes.

• Pozzolanic reactions of CSF are very temperature sensitive. High

temperatures accelerate the beneficial effect.

• 7-15% CSF was found to be optimum for strength development.

2. Flexural & tensile Strengths:
• The patterns of f and t developments are essentially the same
as those of OPC concretes.

3. Bond strength:
• CSF improves bond strength because of reduced porosity, which is a
result of;
- reduced free-water,
- reduced CH (calcium hydroxide)
- densified interface.
4. Elastic modulus & Poisson’s ratio:

• There is not much difference between the CSF & OPC concretes.

• For concretes of 80-100 MPa compressive strength, Elastic

modulus will be 40-45 GPa and Poisson’s ratio will be 0.22.
5. Creep:
• Less creep strains.

6. Drying Shrinkage:
• Not much difference but the curing period is important.

7. Durability:
• Permeability is reduced.
• Carbonation is reduced.
• Freezing-thawing resistance is increased.
• Alkali-aggregate reactivity is not very well known yet.
 Toxicity and Occupational Health
• SF comes under the category of hazardous materials. The national
organizations of health and safety of most of the countries mandate
the supply of information necessary to ensure the health and safety
of personnel handling hazardous materials.

• At the ambient temperature, SF is stored dry in closed containers.

Dust generation should be avoided while handling.
 Toxicity and Occupational Health
• SF is generally considered a nuisance dust of low toxicity;
consequently, it is considered to pose minimal risk of pulmonary
fibrosis (silicosis).

• SF may cause skin irritation in some cases hence, adequate skin

protection (gloves) and similarly eye protection (goggles) to prevent
possible irritation and damage are recommended.

• Repeated exposure may cause lung damage (fibrosis).

 Toxicity and Occupational Health
• Due to its extreme fineness, it may cause serious health problems.
Therefore, it is used in slurry form in some countries.

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 Environmental Concerns
• Concrete is the most beneficial use of SF considering that
environmental concerns and durability have become crucial as SF
smoke vented into the atmosphere until late 1960’s in Europe.

• As with the environmental concerns and growing demand on the

high strength concretes in 1970’s, silica fume concretes came into
action with limited use.
Addition of SF to Cement and Concrete
• Its use in concrete is specified in European normatives in “EN 13263-
1+A1 – Silica fume for concrete. Definitions, requirements and
conformity criteria”.

• It is used as a replacement material in concrete up to maximum

amount of 10% by mass under CEM II type under EN 197-1.

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