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Filler in Concrete
Filler in Concrete
ABSTRACT RI~SUMI~
The purpose of this investigation has been to evaluate L'objectif de cette recherche a OtO d'Ovaluer l'effet de la
the effect of quartz filler on concrete strength and charge au quartz sur la r~sistance et la microstructure du
microstructure, and to see if it is possible to replace cement b~ton, et de voir s 'il est possible de remplacer le ciment par
with filler without loss of strength. Fillers are materials une charge, sans perdre de rdsistance. Les charges sont des
whose function in concrete is based mainly on size and matikres dont la fonction au sein du b~ton d@end
shape. They can interact with cement in several ways; to essentiellement de la tuille et de la forme. Elles peuvent
improve particle packing and give the fresh concrete other interagir avec le ciment de plusieurs manibres ; pour
properties, and even to reduce the amount of cement in augmenter le compactage des particules et donner d'autres
concrete without loss of strength. Quartz was chosen as propri~tOs au bOton frais, et mOme pour rdduire la quantitO de
filler material, since it is inert and is available both as a by- ciment dans le bOton sans perdre de r~sistance. Le quartz a ~td
product and a natural raw material. Different amounts of choisi comme matOriau de charge, car inerte et disponible
filler were used in the various experiments, as well as aussi bien en tant que sous-produit qu'en tant que matikre
different particle size distributions. The results are positive: premiere naturelle. Diffdrentes quantit~s de charge ont ~t~
fillers can partially replace cement and at the same time utilisOes lors des diffOrentes expOriences, ainsi que diffOrentes
improve the properties and the microstructure of the r@artitions entre les tailles des particules. Les rOsultats sont
concrete. This research is part of a larger project that aims positifs: les charges peuvent remplacer le ciment et en mOme
to find uses for by-products in concrete. temps amOliorer les propriOtOs et laj microstructure du bOton.
Cette recherche fait partie d'un projet majeur dont le but est
de trouver des utilisations pour les sous-produits contenus
dans le bOton.
75
Moosberg-Bustnes, Lagerblad, Forssberg
A superplasticizer dissolves flocks and disperses the finer than cement and significantly finer than cement, d50
particles, which results in a looser but more homogenous are 14, 4 and 2.2 microns respectively.
particle packing. Particles of ultrafine powder, which form The by-product was used for the rheology tests. The
an electric double layer after adsorbing superplasticizer, material was classified by SINTEF in Norway. The
will be more effective in filling in the spaces between the classification was done using an INPROSYS air classifier,
cement particles and dispersing these particles. As a result, type IAC 200. The quartz was divided into six different size
the fluidity of the cement paste increases. According to fractions, three of them were used in the experiments. The
Nehdi [7], the workability is obtained with the densest 0-125 micron fraction was used as base-filler and 0-31 and
particle packing, since the adsorbed water will not only fill 125-250 micron fractions were used for replacement.
voids, it will increase the thickness of the water layer
around particles, which in turn decreases viscosity and 3.2 Methods
improves flow properties. In a cement-filler system, the
amount of free water is decreased, and most of the water is 3.2.1 Mixing
adsorbed on the surface of grains or entrapped inside flocks
The concrete was mixed in a paddle mixer, in
of particles. Through its action on the surface charges a
accordance with the SS-ENV 206, in batches of 25 litres.
superplasticizer can partially liberate the water adsorbed as
First, cement and filler were mixed dry, then the aggregates
a surface layer, but not decrease the amount of free water.
were added. The water and superplasticizer were mixed and
Thus, a superplasticizer is more efficient in a dense
then added to the dry components.
particulate system with high surface area, and has only
limited effect in a porous low-density system. 3.2.2 Slump test
At the initial stage of hydration the physical and surface The concrete flowability was measured according to the
chemical effects are important for the fresh and young SS 13 71 23 procedure.
concrete, while eventual pozzolanic reactions start later and
affect the hardened concrete. Silica, in principle, is unstable 3.2.3 Compressive strength
in the high pH in concrete. Amorphous silica, disordered In order to test the compressive strength, concrete cubes
quartz and meta-stable cristobalite are classical pozzolans. of 0.15 x 0.15 x 0.15 m 3 were cast in steel moulds
Normally, quartz is considered an inert material, but fine- according to the procedure in SS 13 11 12. Demoulding
grained ordered quartz will also react if it has a very high took place after 24 hours and the cubes were cured and
surface area, i.e., very fine particles. According to Benezet stored under 100 percent relative humidity (RH). The cubes
and Benhassaine [8], it is the size of the quartz particles that were measured and weighted before the compressive
determines the occurrence of a pozzolanic reaction, i.e., the strength was tested with uniaxial compression at 7 and 28
surface area is the important factor. Quartz particles have to days, according to the procedure in SS 13 72 10. The press
be a lot smaller than 5 microns to contribute to a pozzolanic used for the tests is in accordance with SS 13 11 10.
reaction. As a comparison, silica fume has a particle size of
3.2.4 Microscopy analyses
0.1 microns and shows a distinct pozzolanic reaction as
early as one to three days after mixing with Portland After 91 days 14 samples were chosen for scanning
cement or up to one year after mixing when slag-cement is electron microscopy (SEM) analysis in order to verify the
used [9]. Knauss and Wolery [10] reports that the experimental results. The samples were impregnated with
dissolution rate of quartz is approximately 2-3 times higher epoxy resin, cut, polished and then analysed with a SEM in
at pH 12 compared to pH 7. order to investigate the structure. Silica mapping was also
done on the samples to determine the distribution of the
filler particles in the cement paste. Thin sections were also
3. E X P E R I M E N T A L STUDY made of the above-mentioned samples and they were
analysed with an optical microscope.
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Materials and Structures / Matdriaux et Constructions, Vol. 37, March 2004
The experimental starting-point is an ordinary concrete extended with further experiments; 300 kg o f M300, M500
recipe with 433 kg cement, 950 kg sand (0-8 mm), 722 kg and M6000, which have different particle size distributions,
gravel (8-16 mm) per cubic metre and a water/cement ratio were added to each mixture.
o f 0.48, without addition o f filler material. The cement used The first and second experiments were repeated with
in this investigation is a standard Portland cement from M300 and M500 to determine the effect o f the different
Sweden, Slite Standard (CEM I 42.5R). Natural sand and mean particle sizes o f the materials.
gravel (granite) were used as aggregates. To be able to mix The experimental mix design is given in Table 1. The
the components properly and increase the fluidity o f the slump was measured for all mixes. 10 g of superplasticizer was
cement paste it is necessary to add a superplasticizer. The added at a time tmtil the slump measured 0.100 mm or more.
superplasticizer used in the experiments is a naphthalene- Scanning electron microscopy was used to investigate the
based poly-condensate. microstructures o f some of the hardened specimens.
To see the effect o f filler on concrete, cement was Rheology measurements were performed on mortar
replaced with quartz filler, with a mean particle size o f 10- mixes. The mortar consisted o f cement, water and quartz
12 micron. Replacement levels o f 10, 20, 30, 40 and 50 filler with a size range o f 0-125 microns. Table 2 presents
volume percent (of the cement volume) were chosen. The the experimental data. This "base-filler" was replaced with
quantities o f water and aggregates were kept constant. quartz that had a size range o f 0-31 microns. The
Further experiments were conducted on the 40 and 50 replacement levels were 10, 20, 30, 40 and 50 volume
percent replacement
Table 2 - Experimental data and compressive strength from the rheology tests.
levels, i.e., 260
The mortar is made of 658 g cement and has a w/c-ratio of 0.40
respective 216 kg
Replacement Base-filler Filler Strength MPa
cement per cubic metre,
where aggregates are level (0-125) (0-31) or 7 days 7 days 7 days 28 days 28 days 28 days
replaced with quartz (125-250) (o-31) (0-31) SP (125-250) (0-31) (0-31) SP (125-250)
% g g
filler by 10, 20, 30, 40
and 50 volume percent 0 205.0 0 35.4 40.9 35.3 42.1 46.3 41.9
(of the original cement 10 184.5 20.5 36.1 41.4 34.0 43.5 48.9 39.9
volume). In order to 20 164.0 41.0 37.1 43.6 33.4 44.8 51.7 38.1
achieve proper mixing
30 143.5 61.5 38.9 46.2 31.8 45.7 54.4 39.7
of the materials and
acceptable visco-sity, a 40 123.0 82.0 39.9 47.7 33.1 48.6 57.2 39.5
superplasticizer was 50 102.5 102.5 40.7 48.9 33.6 50.0 60.2 39.8
added. The experiment
with 260 kg cement was
Table 3- Compressive strength for concrete where aggregates are replaced with quartz
repeated with a higher
216 kg cement w/c = 0.96 260 kg cement w/c = 0.81 260 kg cement w/c = 0.96
w/c-ratio (w/c=0.96).
Filler 7 days 28 days 7 days 28 days 7 days 28 days
To examine the kg MPa MPa MPa MPa MPa MPa
effect o f the amount o f 216 24.4 32.6 16.5 17.3
filler on concrete
260 12.0 17.7 24.6 33.0 19.5 20.9
strength concrete with
260 kg cement was 300 15.5 21.9 24.3 32.3 19.8 21.2
made and 0, 86, 172 343 16.8 23.1 27.0 36.4 21.2 22.2
and 300 kg quartz filler
386 17.5 24.2 28.9 38.0 20.5 22.1
added to the different
mixes. This series was 433 18.9 26.6
77
Moosberg-Bustnes, Lagerblad, Forssberg
percent. The test was repeated with filler that had a particle filler that replaced aggregates the higher strength were
size of 125-250 microns. A second test was made with the obtained. The results are similar for the 260 and 216-kilo
0-31 micron filler, but this time a superplasticizer was cement levels. When the w/c-ratio was increased from 0.81
added to show the importance of dispersion. Prisms of each to 0.96 for the concrete with 260-kg cement was the
mixture were cast to determine influence of the different decrease in compressive strength significant. This decrease
particle sizes on the compressive strength. is due to the looser particle packing that is the result of an
increased amount of water.
Concrete with 260 kg cement, 50 percent filler and a w/c-
5. RESULTS AND DISCUSSION ratio of 0.81 has 9.6 MPa higher compressive strength than
the concrete without filler. This compressive strength
correlates to a w/c-ratio of 0.65. The compressive strength
5.1 Cement replacement tests for the concrete with 216 kg cement, 50 percent filler and a
Replacement of cement with quartz-filler leads to a w/c-ratio of 0.96 is 5.1 MPa higher then the ordinary
decrease in compressive strength and an increase in the concrete. This value corresponds to a w/c-ratio of 0.90.
water/cement-ratio (w/c-ratio), as could be expected, see This extrapolation of strength and w/s-ratio, in Figure 4,
Fig. 3. shows that it is possible to raise the w/c-ratio without losing
strength.
Table 4 show the effect of different amounts of filler
added to concrete with 260 kg cement. The amounts of
added filler are 0, 86, 172 and 300 kg. The figures in
Table 4 shows that the strength increases with the
increase in filler addition. Unfortunately, the
superplasticizer that is needed to disperse cement and
filler and give the concrete proper viscosity acts as a
retarding agent when added in higher dosages. This
phenomenon influences the early strength negatively, but
not the long-term strength. The 7-day strength for the
concrete with 300 kg filler is lower than it should be, but
the 28-day strength is back to the expected level.
The effect of the particle size distribution of the
filler on concrete strength is shown in Table 5.
Concrete with 260 kg cement was mixed with 300 kg
Fig. 3 - Compressive strength. of filler with different particle sizes. Quartz and M300
have the same particle size as cement, d50 is 12 and
The effect of replacing cement with filler is the same as 14 microns, respectively, while M500 is slightly smaller
if the water/cement-ratio were raised. Concrete strength is and can be considered ultra-fine filler with a d50 of 4
dependent on the w/c-ratio, which in this case provides a microns. M6000 is significantly smaller than cement with a
suitable basis for comparison. In Fig. 4 the relation between d50 of 2.2 microns. Quartz and M300 have the same
w/c-ratio and compressive strength at 28 days is plotted
together with the curve for standard concrete [13]. The Table 4 - Compressive strength, the effect
concrete with filler shows a slightly steeper decrease in of different amounts of filler in concrete
strength than the standard concrete. 260 kg cement w/c = 0.81
The following experiments see Table 3, where
aggregates was replaced with filler, shows that the more Filler kg 7 days 28 days
MPa MPa
80, 0 20.8 25.7
+Quartz 1
70 = t 9 260 kg cement, 340 kg filler~-----~ 86 22.2 27.0
-- ~ / " 216kgcemellt, 340 kg filler[ 172 24.8 29.4
60 84
N 300 25.1 30.4
50-
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Materials and Structures / Matdriaux et Constructions, Vol. 37, March 2004
Table 6 - Strength development for concrete where cement is replaced viscous and sticky. The
respectively with M300 and M500 superplasticizer was added 10 grams
Cement w/c- Filler M300 7-day M300 28-day M500 7-day M50028-day at a time and the concrete was
kg rNio kg MPa MPa MPa MPa thoroughly mixed before the slump
433 0.48 0 45.0 53.2 45.5 55.3 was measured. This procedure was
389 0.54 43 40.8 49.4 41.4 53.0 performed after each addition of
346 0.61 86 35.0 40.5 40.7 49.6 superplasticizer until the slump
measured at least 100 mm or the
300 0.69 129 27.2 35.0 33.9 42.9
concrete started to flow. The effect of
260 0.81 172 22.9 28.4 26.5 35.7 the superplasticizer on the concrete
216 0.96 216 16.2 21.2 20.3 28.l with high filler content was
substantial, from an extremely
viscous consistency to free-flowing
strength development, while the addition of M500 and when the last 10 grams was added. The addition to the
M6000 increases the strength significantly. different concrete-filler mixtures varied from 0 to 310
Strength development for concrete in which cement is grams.
replaced with M300 and M500, respectively, is presented in
Table 6. The results are similar to the one obtained with
quartz: strength decreases with the increase in w/c-ratio and 5.3 M i c r o s c o p y a n a l y s e s
the added filler amount. In Fig. 5 the relation between w/c- The influence of the filler addition on the microstructure
ratio and compressive strength at 28 days is plotted for both of the hardened concrete was investigated by scanning
M300 and M500. To establish a basis for comparison, the electron microscopy. The pictures, Figs. 6-9, show how
quartz curve (numbers from Fig. 3) was also inserted in the filler with different particle sizes affects the microstructure
diagram. The M300 and quartz curves correspond in shape of concrete made with 260 kg cement. The filler addition is
and strength, as can be expected, since they have 300 kg in each case. Figs. 6 and 7 show concrete made with
approximately the same particle size. The strength increases quartz filler and M300 respectively. Both filler materials
significantly when cement is replaced with M500 and even have the same particle size and the SEM pictures confirm
more when M6000 is used. This is due to the smaller that they have the same microstructure. Figs. 8 and 9
particle sizes of the materials. M6000 was difficult to mix present concrete in which M500 and M6000 were used as
properly with cement, even though superplasticizer was filler material. The cement paste is significantly denser in
used. One mixture was made to give an estimation of the
increase in strength. To be able to utilise materials like
M6000 properly it is necessary to change the
superplasticizer into a so-called third generation type of
sterically hindrance acting superplasticizer. The M6000
mixture has high strength and gives a good estimate of the
strength level that can be achieved by using this ultra-fine
filler.
5.2 S l u m p tests
Slump tests were performed when the concretes were
mixed; it was impossible to predict the necessary amount of
superplasticizer in advance. The added amount of
superplasticizer was increased with increasing filler
additions, since larger amounts of filler makes the concrete Fig. 7 - Concrete with an addition of 300 kg of M300.
79
Moosberg-Bustnes, Lagerblad, Forssberg
Fig. 8 - Concrete with an addition of 300 kg of M500. Fig. 10 - Silica mapping of the sample containing 10 %
M500. The silica particles are shown in white colour.
Fig. 9 - Concrete with an addition of 300 kg of M6000. Fig. 11 - Silica mapping of the sample containing 50 %
M500. The silica particles are shown in white colour.
both samples than in the above mentioned specimens. It is
also clearly evident that the M6000 addition gives the viscosity and strength. Fig. 12 shows how the yield stress
densest and most even structure to the paste, which is as changes with the amount of fine or coarse filler used to
expected. replace the base filler. The water demand increases with the
Silica mapping o f the specimens with M500 shows how increasing amount o f fine material in the cement pastes.
evenly the filler has been dispersed in the cement paste. The coarse material has a very limited effect on the yield
Figs. 10 and 11 show the 10 and 50% replacement levels. stress. The prisms that contained the finer material had
The white and light grey areas contain
80-
s i l i c a in different proportions. r
~ 50
~ 4o
l - ~--I -~ 01125pm + 250pm
-*--0
////
sizes and the more even distribution o f the -~
pores. Both the SEM-analysis and optical ~- ao;
microscopy analysis show that cement
pastes containing fine particles have a 2o
denser and more homogenous structure,
10
the result is in accordance with the
findings o f F e n g et al. [14].
0 10 20 30 40 50 60
5.4 Rheology % Filler
The rheology experiments were Fig. 12 - Yield stress versus percent replaced filler. 0-125 pm is the base filler which is
performed to show the importance o f fine replaced with the fractions 0-31 gm and 125-250 pm respectively. Superplasticizer
(SP) is used in one experimental series.
particles and their influence on mortar
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Materials and Structures / Matdriaux et Constructions, Vot. 37, March 2004
81