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Potential Use of Microsilica in Concrete: A Critical Review

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 5thInternational Conference on Advances in Civil Engineering 2020 (ICACE 2020)
21-23 December 2020
CUET, Chattogram, Bangladesh
www.cuet.ac.bd

POTENTIAL USE OF MICROSILICA IN CONCRETE: A CRITICAL

REVIEW

M. A. Rahman1, M. F. S. Zawad2* and S. N. Priyom3

1
UG Student, Department of Civil Engineering, CUET, Bangladesh, email:asifurmahin752@gmail.com
2
UG Student, Department of Civil Engineering, CUET, Bangladesh, email: f.shahriarzawad@gmail.com
3
PG Student, Department of Civil Engineering, CUET, Bangladesh, email: sudiptonathpriyom@gmail.com

*Corresponding Author

ABSTRACT
Durability and High-performance, the two most desirable properties of concrete, are always important for
sustainable infrastructure. After the invention of concrete, several steps have been taken to improve their quality and
performance. Cement, the key ingredient of concrete, has shaped much of our infrastructure but produces a huge
amount of carbon footprint. A huge amount of carbon is being emitted and becoming a major cause of global
warming by dint of the Cement Industry. Besides, several pozzolanic by-products producing from industries can
have a detrimental effect on the environment. But, effective and optimum use of these by-products in lieu of cement
may help to minimize the carbon emission on the environment. Microsilica or Silica fume, an industrial by-product
from the silicon and ferrosilicon alloy industry, has the significant ability to replace cement partially in the concrete
&improve the mechanical properties and durability as well. The extremely fine particles of microsilica (<1µm) act
as a filler that can fit into space among cement particles. Because of its cementitious property, a partial replacement
of cement with microsilica not only decreases the use of cement but also improves the mechanical properties of
concrete. From various researches, it is ensured that the use of microsilica improves the strength of concrete and
decreases the porosity. This paper represents the critical literature review on the partial use of microsilica in concrete
and the potential outcomes of microsilica induced concrete.

KEYWORDS: Microsilica; Mechanical properties, Pozzolanic by-products; Porosity

INTRODUCTION
Improvement of the performance of concrete as a material of construction is required for the advancement of the
construction industry. Several strides have been carried out during the past decades in order to improve the inert
properties of conventional concrete. The use of Microsilica or silica fume in the concrete as a partial replacement of
cement has an indispensable impact on the strength properties as well as the durability of the hardened concrete [1].
Silica fume or Microsilica has significant pozzolanic or cementitious property as like cement. The use of microsilica
in concrete has the ability to improve the various properties like strength, impermeability, durability, workability etc.
for both fresh and hardened concrete. A gradual increase in the amount of silica fume has been seen to decrease the
slump value of the fresh concrete [2]. This indicates that construction work where high abrasion resistance of
concrete has higher priority; the use of micro silica will be a wise choice in order to reduce the bleeding and
segregation.
Microsilica or silica fume before using as the mineral admixture in the concrete it is generally produced from the
silicon or Ferro-silicon alloys like ferro-manganese, ferro-chromium production. The smoke produced from the
electric furnace is being used as the microsilica [3]. During the chemical reaction of Portland cement in concrete, it
produces calcium hydroxides. Silica fume, being partially replaced with cement, react with the Calcium hydroxide
and form the Calcium Silicate Hydrate, which is the major cause for the hardening properties [4].

1
So far, several studies have been carried out to check the usefulness of this microsilica for advancing in the
construction technology. Use of silica fume about 5 to 12. 12.5%
5% in concrete increases compressive, flexural, split-
split
tensile strength significantly & as well as the slump value [5].During high high-performance
performance concrete construction,
micro-cracks
cracks may be generated around the surface of unun-reacted pozzolona and the expanded cement
ement paste. But this
can be remedied by replacing a certain amount of cement with microsilica [6]. Replacement of silica fume about
10% by the weight of cement, keeping the water
water-cement
cement ratio constant does not affect the concrete adversely; rather,
it improves
roves the concrete performance significantly [7].
Considering all the aspects, the primary objective of this review paper is to analyze the good quality literature based
on this specific material in concrete and find out the major outcomes that can be appl
applicable,
icable, paving the way of high
performance and more durable nature of the concrete.

MICROSILICA
Microsilica or Silica fume is a byproduct
product during the smelting process in the production of silicon metal and ferro-
ferro
silicon alloys. Having more than 90% of SiO2 as chemical constituents, its particle sizes are of the size of cement
particles. It is very fine non-crystalline
crystalline silica. According to American Concrete Institute (ACI) microsilica is “very
“
fine non-crystalline
crystalline silica produced in electric arc furnaces as a byproduct of the production of elemental silicon or
alloys containing silicon.”

PRODUCTION
ODUCTION PROCESS OF MICROSILICA
Highly purity quarts are heated with the addition of coal, coke and wood chips in Electric Arc Furnace at a
temperature of 2000℃ or higher.

Alloys are collected from the bottom of Electric Arc Furnace.

SiO2 vapor oxidizes and condenses at the upper parts of the furnace.

Fumes are drawn from the furnace trough a cyclone by a powerful media.

After removal of large coarse particles of unburned wood and carbon, fumes are blown into the baghouse
filler (special filter bags in bag house).

Microsilica is produced.

Figure 1:: Schematic diagram showing production process of microsilica

In the furnace when the temperature is higher than 1500

1500℃, SiO2 reacts with carbon.

SiO2 + 3C = SiC + 2CO

At temperature higher than 1800℃,
3SiO2 + 2SiC = Si + 4SiO + 2CO
At last phase,, the unstable gas situated at the top of furnace reacts with Oxygen
Oxygen,
4SiO + 2O2 = 4SiO2
Thus silicon dioxide having very fine nonnon-crystalline silica which is widely known ass microsilica is produced [8, 9].
Microsilica is grey colored
red powder, much similar to fly ash. There are different forms of microsilica. It can be used
as densified, undensified, pelletized and slurry forms. Am Among
ong them the slurry form of microsilica has the greater
gr

2
specific gravity (1400 kgm-3) and it is produced by mixing undensified microsilica with equal amount of water
content by weight. This slurry in concrete mix results in better homogenous mixture.

PHYSICAL AND CHEMICAL PROPERTIES OF MICROSILICA

Physical and chemical properties of microsilica are given in Table 1 and Table 2.

Table 1: Physical properties of Microsilica Table 2: Chemical properties of Microsilica

Physical Property Percentage (%) Constituents Percentage (%)
Particle size Less than 1µm Silicon (as SiO2) > 90
Shape Mostly spherical Al2O3 <2
Mean diameter 0.2µm Fe2O3 <1
Surface area 15000 - 30000 m2kg-1 CaO <1
Bulk density 1350-1510 kgm-3 MgO <1
Specific gravity 2.2 Na2O <1
Color Grey K 2O <1
Odor No odor Cl2 < 0.3
SO4 < 0.3
Loss in ignition <4

LITERATURE REVIEW
Sl. Addition of Methodology Major outcomes Ref.
Microsilica
1. 5% and 10% Condensed microsilica 1)Maximum compressive strength, 67 MPa was [10]
(CSF) was added in achieved for PC + 10% CSF.
Portland cement by 2)PC + 10% CSF mixes showed optimum
replacing it by weight and performance in durability index test.
also as addition to the 3) CSF mixes were least sensitive to lack of
binder. moisture curing.

2. 0%, 12.5%, 13% M30, M35 and M40 grade
and 13.5% specimens were made by
partial replacement of
cement by microsilica.
1)Specimens having 13% microsilica showed [11]
better performance in all tests.
2)Specimens having 13% microsilica attained
44.4% compressive strength in 7 days of the
total 28 days strength.

3. 0%, 3%, 5%, Stated percentages of silica 1)Specimens having 7% microsilica of the [12]
7%, 10%, 15%, fume containing SiO2 cement content showed maximum compressive
20% and 25% about 94.10% were strength 54.88 MPa on 28 days.
partially replaced with 2)From the flexural strength test maximum
cement in the concrete. value of MOR was found for 5% replacement of
silica fume.
3)Increment of microsilica content up to 25% in
the concrete reduces porosity and permeability
drastically.
4)Addition of 5-7 % microsilica to concrete
coating has proven to resist aggressive marine
environment.

3
Sl. Addition of Methodology Major outcomes Ref.
Microsilica
4. 5.5% of the total Two mixtures M1 & M0, 1)Samples containing silica fume exhibited [13]
cement content containing silica fume better performance in terms of leaching of
were designed and Ca2+& Si4+ rather than conventional concrete.
prepared for several tests 2)Leachable fractions were 2.9- and 2.3-fold
lower in terms of Si4+& Ca2+ amid the exposure
of H2SO4
3)In terms of Biological exposure leachable Si4+
fraction was 5.2- and 3.3- fold higher for
concrete without silica fume.
4)Due to significant resistant against the
chemical attack of sewer leachate, concrete with
microsilica is preferable for sewer and outfall
pipe construction.
5. 0, 16 and 25 Cement mortar and cement 1)Addition of microsilica has no impact in [14]
percent by paste were made having 5 increasing strength of the cement paste.
weight of cement different w/c ratios. 2)Cement mortars having 16 and 25 percent
Microsilica (95.75% SiO2) microsilica showed better strength performance
was used with the addition for all w/c ratios than conventional one.
of super-plasticizer. 3)For cement mortar, w/c ratio 0.22 showed
maximum strength performance for both 16 and
25 percent addition of microsilica: 110 MPa and
103 MPa.
6. 0%, 10% and Concrete specimens were 1)Concrete specimens having microsilica [15]
15% as partial made by using low quality showed better performance.
replacement of coarse aggregates of 4 2)Specimens having 15% microsilica and steel
cement types with microsilica as a slag as coarse aggregate showed maximum
partial replacement of compressive strength 63.55 MPa.
cement. 3)Specimens having steel slag with 10% and
15% microsilica showed better result in split
tensile test. The results were 4.54 and 4.59 MPa.
4)Specimens having 15% microsilica and steel
slag as coarse aggregate showed better
performance in modulus of elasticity test. For 28
days curing result was 40 GPa.
7. 8% of the 3 types of concrete 1)Concrete having gravel aggregate showed less [16]
cement weight formulae were produced entrapped air which had ensured relatively
using natural gravel and higher compressive strength.
crushed basalt aggregates 2)In case of thermal conductivity gravel
to investigate the effect of aggregate concrete also showed better result.
aggregate shapes on 3)The attempt of improving concrete by basalt
mechanical and thermal aggregate and silica fume in terms of
properties. mechanical and thermal properties is a failure
and not beneficial to use.
8. 0%, 5% & 10% Concrete samples were 1)Slight increment in the unit weight due to the [17]
replacement of prepared with partial addition of silica fume.
cement by Silica replacements of FA and 2)Silica fume addition increases the impact
fume cement by rubber and energy absorbance of concrete by 2.62 times for
microsilica. first crack & 3.06 times for failure.
3)From the SEM analysis it’s proved that
addition of microsilica increases hydration of
cement and helps to improve bond between
rubber and cement paste.

4
Sl. Addition of Methodology
Microsilica
9. 5%, 10%, 15%, C2, C3, C4, C5 concrete
20% replacement samples having varying
of cement by silica fume, cement and
silica fume constant fly ash contents
along with C-1 concrete as
the reference one having
only silica fume & cement
contents are tested for
mechanical and nano-
structural properties both
to analyze the UHPC.
10 10% by the Silica fume mortar (SFmo)
weight of cement along with three different
repairing materials was
applied in hydraulic
structure’s surfaces
subjected to high velocity
water flow.
11. 0%, 6%, 10% Concrete specimens were
and 15% cement prepared by addition of
was replaced by microsilica with different
microsilica percentages.
12. 10% replacement Two mixes, one having
of total cement silica fume content and
weight with another free of this where
silica fume in the each of the two contains
mix three different fractions of
steel fiber were made in
the preparation of SIFCON
& 28 days’ mechanical
properties tests.
Major outcomes Ref.
1)C4 concrete having 20% silica fume and 30% [18]
fly ash exhibited highest flexural and
compressive strength.
2)For UHPC construction the highest efficiency
factor(k): 1.03 was obtained for C4 sample
3)Sample having highest flexural and
mechanical strength has the similar correlation
to maximum compactness & low capillary
pores.
4)The ANN model has proved to be the accurate
model for strength prediction of UHPC.
1)At 28 days, the SFmo gained 44 MPa [19]
compressive strength with high system
compatibility.
2)Resistance classification after tests showed
that SFmo showed moderate to high
performance in all aspects but it was a little
weak in abrasion resistance.
3)SFmo showed compatible mechanical
performance.
4)The application and handling process of SFmo
concrete was easy than others.
5)SFmo needs a longer period for its complete
hardening.
6)Depending on performance evaluation SFmo
was at the top.
1)Specimens containing 15% microsilica [20]
showed 70 MPa compressive strength at the age
of 28 days, about 21% more than that of
conventional one.
2)Increment of the proportion of micosilica
decreased the workability but on the contrary
mechanical properties and the secant modulus
improved.
3)Microsilica enriched concrete specimens
showed better compressive strength performance
in both dry and moist state at the age of 400
days.
4)For 15% microsilica enriched concrete creep
of concrete decreased by about 20-30%.
5)To minimize autogenous shrinkage and
cracking probability of high strength concrete
inclusion of microsilica should not extend 10%
1)SF replacement has shown increase in the [21]
viscous properties which eventually indicates
the proper flowing and filling ability of the
SIFCON.
2)10% SF replacement leads to the 9.4%
increment in the compressive strength test.
3)For the same replacement 18.5% increment
was achieved in splitting tensile strength test.
4)Use of Silica fume & iron fiber in this manner
has positive impact in preparation of SIFCON.
5
 Sl. Addition of Methodology Major outcomes Ref.
Microsilica
13. 5% & 10% Three types of cement 1)Cement grouts containing SF contents have [22]
partial grouts containing Sulfate more refined microstructures than the one made
replacement of resisting OPC, 5% silica with sulfate-resisting Portland cement.
cement by silica fume replacement, 10% 2)Micropiles grouts having SF contents up to
fume silica fume replacement 10% have similar or even better results than the
respectively were prepared one having sulfate resisting cement.
for assessing the durability 3)In terms of compressive strength the two types
under harsh sulfate attack. don’t show any significant differences.
14. 0%, 7%, 10% Three different 1)The pores were filled by silica fume which [23]
replacement of water/binder ratios: 0.35, reduces the sorptivity and reduces the depth of
cement with 0.4, 0.45 have been used water penetration.
silica fume by whereas for each of the 2) For sample having w/b ratio: 0.35 and SF:
weight of the ratio 0%, 7% & 10% silica 10% had water penetration depth 16mm which
cement fume have been added in is 10% lower than that of the control concrete.
place of same amount of 3) Silica fume has filled up the pores inside both
cement contents & tested physically & chemically which ensures less
for simultaneous carbonation as well as less chloride ingression.
carbonation and chloride 4) Reduction in pH indicates the production of
ingress. CaCO3 and Ca(OH)2 inside.

EFFECT OF MICROSILICA ON THE CONCRETE PROPERTIES

 Workability: Addition of microsilica in concrete mix improves the cohesiveness of concrete mix. As a
result the mix becomes much stiffer. So, for maintaining the desired slump value addition of admixture is
important. Depending on the amount of microsilica used the dosage of super-plasticiser varies in order to
have the desired slumps. [20]
 Permeability: The very fine particles of microsilica fill the small pores in the concrete microstructure.
From research work it was seen that the water penetration depth of concrete specimens containing
microsilica is 6 times lower than the conventional concrete. [24]
 Setting time: Up to a limited extent (about 10% addition) microsilica has no significant impact on the
setting time of concrete.
 Curing: Concrete specimens microsilica shows significantly reduced bleeding. So, amount of water left in
the concrete is too little for bleeding. Proper water curing and a longer curing time is necessary for concrete
specimens containing microsilica to possess the desired qualities. [19]
 Compressive strength: Inclusion of microsilica in concrete improves the aggregate-paste bond. So, a
significant amount of compressive strength increases. Addition of microsilica increases the mortar strength
up to 30-50% than that of plain concrete at 28 days. [25]
 Corrosion: Use of microsilica as a partial replacement of cement reduced the level of long term corrosion
of concrete. From electrochemical test on concrete samples it was found that using microsilica ( upto 15%)
improved the long term corrosion resistance of concrete. [26]
 Freezing and thawing: Microsilica enriched concrete shows better resistance towards freezing and
thawing condition. Test results showed that PCC failed ASTM C 666 (Procedure A), after 58 cycles, while
all concrete containing microsilica (10%, 15% and 20%) had durability factor in excess of 90% after 300
cycles. [27]

MAJOR OUTCOMES FROM LITERATURE ANALYSIS

 Microsilica increases the cohesiveness and adhesiveness of concrete mixture. Thus, for maintaining
workability use of water reducing admixture is recommended.
 Addition of microsilica reduces the porosity and permeability of concrete.
 Low quality coarse aggregate can be used effectively by using definite amount of microsilica in concrete.
 Microsilica and Fly ash as a partial replacement of cement in concrete possess better strength performance.

6
  Addition of microsilica in concrete increases the modulus of elasticity of concrete.
 Microsilica addition increases the impact energy consumption of the concrete significantly which
eventually shows the effectiveness of using it for airport pavement construction.
 Concrete specimens containing microsilica gives better resistance against chemical attack.
 Definite amount of microsilica addition in concrete can give better performance. So, for practical
implementation some guidance should be followed in order to eradicate the future problems.

CONCLUSION
Use of microsilica is becoming famous for producing durable and high-strength concrete. In this work, some
prominent published articles were reviewed where main focus was kept on the potential use of microsilica in
concrete. Various countries have specific usage manual of microsilica in concrete for the construction purposes. But
for developing countries such kind of pozzolanic by-products can play an important role for reducing cement usages
as well as carbon emission which eventually ensures sustainable infrastructure development. But the effect of
microsilica in concrete on different atmospheric condition should be considered. Several researches have been
carried out on this topic for a long time. But potential practical implementation has not started yet. Although some
researches showed good possibility of using this constituent for developing structure exposed to harsh ambience.
Apart from that, a good amount of researches are needed on such pozzolanic by-products considering the practical
implementation of it.

ACKNOWLEDGEMENT
The authors declared no conflict of interest. The authors would like to gratefully acknowledge the supports provided
by Suborno Debnath, former Research and Testing Assistant at Memorial University of Newfoundland, Canada and
Md. Ibrahim Mostazid, PG student, The University of Tokyo, Japan.

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