Business Excellence With Sika

: Sika Fume for Durable Concrete

Presented by Kristianto Adjie
Technical Sales Engineer PT.Sika Indonesia
November 23, 2009

Sika Indonesia
 2

Content
1. Sika® - General Introduction
2. Sika Fume – Silica Fume
3. Others Products
4. Major Projects Reference

Sika Indonesia
 3

The Sika Business

Construction Division Industry Division

Concrete Business Contractors Business Distribution Business Industry Business

Sika Indonesia
 4

Sika Group - History

▲ Foundedin 1910 by
Kaspar Winkler

▲ Through constant growth became one

of the world’s leading suppliers of
construction chemicals

▲ Emphasis on innovative integrated

system solutions

▲ Committed to environment and people

▲ Added value for our customers

Sika Indonesia
 5

Sika Group – Research & Development

▲ Sika has a strong Research and
Development Department
▲ with dedicated Centres in Europe, the
USA and Japan.
Sika has Technology Centres
in Zurich (Switzerland)
in Stuttgart (Germany)
in Gournay (France)
in Madison Heights (USA)
in Hiratsuka (Japan)
Plus Additional Regional Technology
Centres
in Lyndhurst (North America)
in Madrid (Europe South)
in Kuala Lumpur (Asia Pacific)
in Santiago (South America)
A total of 300 people work in
Sika’s Corporate R&D Department.
▲ Sika invests at least 3% of our
total turnover in research and
development every year.

Sika Indonesia
 6

Sika Indonesia

1969-1970's 1970's 1986 1993-1997 1998-2003

Technocrete
Applicator and Agent
for Sika Technocrete awarded a
license to manufacture
Sika products P.T. Sika Indonesia
Joint Venture 70:30 New Liquids Plant 1998
Sika Indonesia 100%
Resin Plant H.Q.moves to factory

Small Packs 2003

Sika Indonesia
 7

Sika Factory

Production Facilities, Warehouse and Laboratories

Sika Indonesia
 8

Sika – Quality Comes First

▲ Firstconstruction chemical
company in Indonesia to
achieve ISO 9000 Quality
Assurance certification in
2001

▲ Has been ISO 14001

Environmentally Certified
since 2005

Sika Indonesia
 9

Logistic Sika Indonesia

Head Office and Production Facility

Sika Branches
Distributor
Sika Indonesia
 1

Content
0

1. Sika® - General Introduction

2. Sika Fume – Silica Fume
3. Others Products
4. Major Projects Reference

Sika Indonesia
 1

SIKA FUME 1

Densified Silica Fume

Base Material
Silica Fume
Complies and Tested as per
ASTM C 1240-00
REQUIREMENTS SIKA FUME
ASTM C 1240 - 03 Test Result

CHEMICAL REQUIREMENTS

1 SiO2 content, min 85.0% 92.52%

2 Moisture content, max 3.0% 0.55%

3 Loss on Ignition, max 6.0% 2.91%

Sika Indonesia
 1

SIKA FUME - Pozzolanic Material 2

Silica Fume (Micro Silica) is a waste or a by-product, which is

produced during the production of Ferro-silicon or silicon alloys.

Sika Indonesia
 1
3

Sika Fume

▲ Apa itu Sika Fume atau Silica Fume

Hasil Produk sampingan dari reduksi Quarsa Murni (SiO2) dengan
batu bara di tanur listrik dalam pembuatan campuran silikon metal dan
ferrosilikon.

▲ Bagaimana Karakteristik Sika Fume ?

- Strukturnya amorphous (bersifat reaktif dan tidak terkristalisasi).
- Butiran sangat halus s/d 0.05 Mikron atau 1/100 butiran semen.
- Partikelnya sangat halus, Surface area yang besar, mempunyai
Kadar SiO2 yang tinggi, maka menjadikan Silica fume adalah
pozzolan yang sangat Reaktif ketika digunakan dalam Beton.

Sika Indonesia
 1
4

Sika Fume

Apa Keuntungan Sika Fume ?

Dapat meningkatkan quality dari semua type Beton dan

Precast beton terdiri dari :
▲ Mengurangi konsumsi Semen ( High Strength Concrete ).
▲ Menaikkan Comp. Strength / Flexural Strength Beton
▲ Menaikkan Ketahanan Beton terhadap Korosif.
▲ Memperkecil Permeability Beton.
▲ Mengurangi Shrinkage Beton.
▲ Menaikkan Workability dan mengurangi Segregasi Beton.
▲

Sika Indonesia
 1
5

Sika Fume for Durable Structures

▲ Pada daerah tahan terhadap Korosif

Pelabungan, Jetty, dok kapal , pipa, piers, pondasi, bangunan industri,
bangunan pertanian, bangunan.
▲ Pada daerah yang punya Alkalinity Rendah
GRC, Beton yang dicat bahan Alkali Sensitive.
▲ Pada daerah tahan terhadap kimiawi
WWTP, bangunan pertanian, tempat Garam, bangunan industri, bangunan
yang terkontaminasi kimiawi.
▲ Pada daerah Low Permeability
Basement, Dams, reservoirs, Water tanks.
▲ Pada daerah yang tahan terhadap Abrasi
Pavement, Ramp, Lantai High Impact.

Sika Indonesia
 1
6

Ranking Diagram of Cement and Pozzolanic

Materials

Sika Indonesia
 1
7

Cement Hydration and Silica Fume

Sika Indonesia
 1
8

Comparation of Size

Sika Indonesia
 1
9

Sika Fume
Komposis Chemical Silica Fume terhadap :
Semen Slag Silica Fume Fly Ash
CaO 60 - 67 32 - 48 0.1 - 0.6 3-7
SiO2 17 - 25 28 - 40 85 - 96 40 - 55
Al2O3 2-8 10 - 22 0.2 - 0.6 20 - 30
Fe2O3 0-6 4 0.1 -1.0 5 - 10
MgO 0.1 - 4.0 2 - 16 0.3 - 3.5 1-4
SO3 1-4 3 0.4 - 2.0
Na2O 0.2 - 1.5 <3 0.8 - 1.8 1-2
K2O 0.2 - 1.5 <3 1.5 - 3.5 1-5

Sika Indonesia
 2
0

Sika Fume

Komperasi Properties dari Silica Fume

Semen Slag Silica Fume Fly Ash
Density, kg/m3 1200 - 1400 1000 - 1200 200 - 300 900 - 1000
Loss of Ignotion, % 2-4 12
Surface Area, m2/gr 0.2 - 0.5 > 20 0.2 - 0.6
SG 3150 2900 2100 2100

Sika Indonesia
 2

SIKA FUME - Pozzolanic Material 1

Latent Hydraulic Pozzolanic - Fly-ash (low Ca)

- Slag, Fly-ash (high
- Micro Silica
Ca)

Fillers: Hydraulic: - Cement

- Limestone Powder - Hydraulic Lime

Sika Indonesia
 2
2

Silica Fume -- Physical Properties

Particle size (typical) <1µm

Bulk density
(as-produced) 130 to 430 kg/m3
(slurry) 1320 to 1440 kg/m3
(densified) 480 to 720 kg/m3
Specific gravity 2.2
Surface area (BET) 13,000 to
30,000 m2/kg

Sika Indonesia
 2
3

100.0
Percent passing 80.0
Typical particle
60.0 size distribution

40.0
20.0
0.0
0.1 0.3 0.5 0.7 0.9
Diameter, micrometers

Sika Indonesia
Comparison Cement and Silica Fume at the same
Magnification

▲ Cement Silica Fume

Sika Indonesia
 2
5

Comparison of Chemical and Physical

Characteristics -- Silica Fume, Fly Ash and
Cement
Silica Fume Fly Ash Cement

SiO2 Content 85- 97 35 - 48 20 -25

Surface Area m2/kg 17,000 - 30,000 400 - 700 300 - 500

Pozzolanic Activity
(with cement, %) 120 - 210 85 - 110 n/a

Pozzolanic Activity
(with lime, psi) (MPa) 1,200 - 1,660 800 - 1,000 n/a
(8.3 - 11.4) (5.5 - 6.9)

Sika Indonesia
 2
6

How Does Silica Fume Work in Concrete?

 Physical effect
 Chemical effect

Sika Indonesia
 2
7

Silica Fume: Physical Effect

The presence of any type of very small particles

will improve concrete properties. This effect
is termed either “particle packing” or “micro
filling”.

Sika Indonesia
 2
8

Sika Indonesia
 2
9

Silica Fume: Chemical Effect

Silica fume is simply a very effective pozzolanic

material

Sika Indonesia
 3
0

What is a Pozzolan?

A siliceous or siliceous and aluminous material, which in itself

possess little or no cementitious value but will, in finely
divided form and in the presence of moisture , chemically
react with calcium hydroxide at ordinary temperatures to form
compounds possessing cementitious properties.

-- ACI 116R

Sika Indonesia
 3
1

portland cement + water

=
calcium silicate hydrate
+
calcium hydroxide

Sika Indonesia
 3
2

pozzolan + calcium hydroxide

+
water
=
calcium silicate hydrate

Sika Indonesia
 3
3

Pozzolan Reaction

Sika Indonesia
 3
4

Formation Cement Stone with Silica Fume

Sika Indonesia
 3
5

Sika Indonesia
 3
6

The Transition Zone

The transition zone is a thin layer between the bulk hydrated

cement paste and the aggregate particles in concrete. This
zone is the weakest component in concrete, and it is also the
most permeable area. Silica fume plays a significant role in the
transition zone through both its physical and chemical effects.

P. K. Mehta describes the transition zone in his textbook, Concrete: Structure, Properties, and Materials.

Sika Indonesia
 3
7

Sika Indonesia
▲ Socket where a sand grain has been pulled away from cement paste in 1-day old mortar. The sand grain was originally at the
top of the picture.
▲ “The formation of this zone may be the result of the presence of some water-filled gaps around the sand grains in the fresh
mortar. These gaps may be the result of bleeding and inefficient filling with cement particles of the 20-µm space around the
grain surface.”

▲ Arnon Bentur and M. D. Cohen, “Effect of Condensed Silica Fume on the Microstructure of the Interfacial Zone in Portland Cement Mortars,” Journal of the
American Ceramic Society, Vol. 70, No. 10, pp. 738-743, 1987.

Sika Indonesia
▲ Socket where a sand grain has been pulled away from cement paste in 28-day old mortar containing silica fume. The sand grain
was originally at the top of the picture. Note the dense structure without the gaps and crystals seen in the previous photo.
▲ These changes can be the result of the suppression of bleeding in the fresh mortar and the ability of the CSF particles to fill the
space in the vicinity of the sand grain surface much more efficiently than the bigger cement particles.”
▲ Arnon Bentur and M. D. Cohen, “Effect of Condensed Silica Fume on the Microstructure of the Interfacial Zone in Portland Cement Mortars,” Journal of the
American Ceramic Society, Vol. 70, No. 10, pp. 738-743, 1987.

Sika Indonesia
▲ The improvement in the structure of the transition zone can be seen when broken test specimens are examined. Usually for
high-strength, silica-fume concrete, most of the aggregate particles will be fractured, very few will be pulled out of the matrix.
The better bonding of the aggregate into the matrix results in higher concrete strength and modulus.

Sika Indonesia
 4
1

Sika Indonesia
 4
2

Using Silica Fume in Concrete

1. Enhancing Mechanical Properties

1. Increased Concrete Strength
2. Improving Durability
1. Decreased Permeability for Corrosion-Resisting Concrete
1. Parking structures
2. Bridge decks
3. Marine structures
3. Enhancing Constructability
1. Increase Early Strength
2. Control Temperature
4. Producing High-Performance Concrete Bridges

Sika Indonesia
 4
3

1. Enhancing Mechanical Properties

- Increased Concrete Strength

Compressive Strength, MPa 70 15%

10%
60

5%
50

40 0%

30
Control mixture
20 cement: 390 kg/m3
w/c: 0.41
10 air: 5%

0 3 7 28 60

Age, days

SI
Sika Indonesia
 4
4
Effect of Silica Fume on Comp. Strength of Concrete

▲ References : ACI 234R-96, Use of Silica Fume in Concrete, page 18

Sika Indonesia
 4
5
Effect of Silica Fume on Comp. Strength of Concrete

▲ References : ACI 234R-96, Use of Silica Fume in Concrete, page 18

Sika Indonesia
 4
6

2. Improving Durability

- Decreased Permeability for Corrosion-Resisting Concrete

 Parking structures
 Bridge decks
 Marine structures

 Within the general area of improving durability, by far the greatest use of
silica fume has been in concrete susceptible to corrosion caused by
chloride ion attack of the reinforcing steel. This category includes
concrete exposed to either deicing salt or to marine salts. The
protection mechanism in this case is primarily the reduction of the
permeability of the concrete, which significantly increases the time that it
takes for the chlorides to reach the level of the reinforcing steel.

Sika Indonesia
 4
7

Deicing salt induced damage to the underside of a bridge.

Sika Indonesia
 4
8

Concrete in marine structures is also susceptible to chloride-induced corrosion.

Sika Indonesia
 4
9

Silica-Fume Concrete:
Corrosion Protection

 5-10% silica fume added by mass of cement

 Mixture may include fly ash or slag
 w/cm < 0.40: use HRWRA
 Total cementitious materials < 415 kg/m3
 Permeability estimated using ASTM C 1202

Sika Indonesia
 5
0
3. Enhancing Constructability
- Increase Early Strength
- Control Temperature

▲ On this project silica fume was added primarily to enhance constructability. The exterior
concrete walls in this structure are 4.5 ft (1.4 m) thick. To prevent thermally induced
cracking, the designer specified very tight control over the maximum temperature rise allowed
in the concrete. To meet the requirements for concrete temperature, the contractor elected
to use a Class F fly ash in the concrete. While the fly ash did help to reduce temperature
development, the early strength gain characteristics of the concrete were such that form
removal was delayed. Addition of silica fume to the concrete provided additional early
strength to facilitate form removal on a satisfactory schedule.

Sika Indonesia
 5

SIKA FUME - Pozzolanic Material 1

Cement Hydration Process (after addition of water)

Sika Indonesia
 5

SIKA FUME - Pozzolanic Material 2

Silica Fume (Micro Silica) is a waste or a by-product, which is

produced during the production of Ferro-silicon or silicon alloys.

Micro silica forms hydration products with Ca(OH)2 (hydrated

lime).

Reaction of micro silica with hydrated lime

SiO2 +Ca(OH)2 = C.S.H (calcium silicate hydrate)

Sika Indonesia
 5

SIKA FUME 3

ADVANTAGES
 Improves durability and ultimate strength
 Less prone to segregation and better stability of the concrete
mix
 Improves density

DISADVANTAGES
 Higher water demand
 Requires correct curing

Sika Indonesia
 5
4

Sika Indonesia
 5
5

Sika Indonesia
 5
6

Sulphate Resisting Cements (Type V)

Semen Tahan Sulfat (Semen Type 5)

Mempunyai Kandungan C3A yang rendah untuk meminimise

Resiko dari Serangan Sulfat, tapi tidak menyediakan ketahanan
yang cukup, yaitu diantara nya :
 Semen Kandungan C3A yang rendah dapat dimasuki oleh Serangan
Korosi Tulangan.
 Semen Type 5 harus disimpan dalam jumlah cukup besar karena
terbatas Ketersediaanya.
 Semen Type 5, untuk Compressive Strength 28 hari lebih rendah dari
type 1, dan perkembangan kekuatannya lebih lambat.

Using Microsilica for Sulphate Resistance : F.Papworth

Sika Indonesia
 5

SIKA FUME - Sulfate Attack 7

Reaction of Alumina phase (C3A) with sulfate

C3A + 3CSH2 + 26H  C3A.3CS.H32 (ettringite)

C3A + C3A.3CS.H32 + 4H  3C3A.CS.H18 (monosulfate)

In the presence of sulfates, the monosulfate can form

ettringite
which may lead to expansion

Reaction of Calcium Hydroxide with sulfate

Na2SO4 +Ca(OH)2 +2H2O = CaSO4.2H2O + 2NaOH
Formation of gypsum that weaks and prone to
chemical attack !

Sika Indonesia
 5
8

Sika Indonesia
 5

SIKA FUME – How It Works to Prevent Sulfate Attack 9

Convert Hydrated Lime to C.S.H

SiO2 +Ca(OH)2 = C.S.H (calcium silicate hydrate)

C.S.H (calcium silicate hydrate) is much chemically inert

Reduce Permeability of Concrete

Due to its very fine particle, micro silica reduce the permeability of
concrete.
The pozzolanic reaction also creates denser C.S.H matrix than
Ca(OH)2 .

Reduce Bleeding
This results from the low bleed eliminating permeable paths around
aggregate and the impermeable nature of the paste. In addition the
low bleed gives a low water:cement ratio of slab surfaces. This
leads to lower penetrability of contaminants.

Sika Indonesia
 6

SIKA FUME – How It Works to Prevent Sulfate Attack 0

The permeability of concrete plays a fundamental role in

determining the rate of deterioration due to destructive
chemical actions such as the alkali-aggregate
expansion and attack by acidic or sulfate solution.

Sika Indonesia
 6
1

Sulfate Permeability

Recommendation for normal concrete subject to sulfate attack

(SO4) in (SO4) in Water

Sulphate Soil Water Cement
Exposure persent ppm Cement Maximum
Mild 0.00 - 0.10 0 - 150 - -
Moderate 0.10 - 0.20 150 - 1500 Type II 0.50
Savere 0.20 - 2.00 1500 - 10,000 Type V 0.45
Very Savere over 2.00 Over 10,000 Type V + Slag or 0.45
Ponzzolan
* Tabel 2.2.3 ACI - Guide to Durable Concrete

Sika Indonesia
 6
2

Sulfate Permeability

Sika Indonesia
 6
3

Sika Indonesia
 6
4

Sika Indonesia
 6
5

OTHER PRODUCTS

Concrete Admixture
Retarder
Plastocrete / Plastiment
▲ Digunakan untuk mencegah
supaya beton tidak kering
selama dalam perjalanan.
▲ Memperlama workability dari
beton (slump retention)
▲ Menaikkan mutu beton
▲ Beton lebih ekonomis
▲ Mencegah cold-joint

Sika Indonesia
 6
6

OTHER PRODUCTS
Curing Compound
Antisol E-125 / E-White
▲ Mencegah plastic shrinkage
▲ Hidrasi beton di permukaan
lebih sempurna

Sika Indonesia
 6
7

OTHER PRODUCTS

Cementitious Grouting
SikaGrout series
▲ Untuk angker & pondasi
mesin yang tidak banyak
bergetar
▲ Untuk base plate kolom

Sika Indonesia
 6
8

OTHER PRODUCTS

Epoxy Grouting
SikaDur 42 MP series
▲ Untuk pondasi mesin yang
banyak getaran
▲ Suhu di permukaan grouting
tidak boleh lebih dari 60 C

Sika Indonesia
 6

Content
9

1. Sika® - General Introduction

2. Sika Fume – Silica Fume
3. Others Products
4. Major Projects Reference

Sika Indonesia
 7
0

Project Name : Surabaya Madura Bridge

Location : Surabaya, East Java

Supplied Products : Concrete admixture, Grouting & Fixing, Concrete Repair and Protection

Sika Indonesia
 7
1

Project Name : Steam Power Plant Tanjung Jati B Project

Location : Desa Tubanan Bangsri, Jepara, Central Java
Schedule : 2004 - 2005
Supplied Products : • Concrete & Mortar Production, • Grouting & Fixing, • Repair & Protection,

• Waterproofing, • Elastic Sealing & Bonding, • Floor & Containment Lining,

• Rigid Bonding Sika Indonesia

 7
2

Project Name : PLTU SURALAYA

Location : Banten
Schedule : 2007 - 2009
Supplied Products : • Concrete & Mortar Production, • Grouting & Fixing, • Repair & Protection,

• Waterproofing
Sika Indonesia
QUESTION ?
Thank you for your attention

Sika Indonesia