Types of SCMs Natural (ASTM C 618 Class N) Produced from natural mineral deposits (e.g., volcanic ash, diatomaceous earth) May require heat treatment (e.g., metakaolin) Processed / Manufactured Silica fume (ASTM C 1240) Slag (ASTM C 989) Fly Ash (ASTM C 215) Rice Husk Ash Benefits of SCMs Industrial by-products (waste utilization) Typically cheaper than cement (except for silica fume and metakaolin) Environmentally conscious No CO 2 emission during processing Less landfill waste Influence of SCMs Concrete Fresh State Heat of Hydration Water demand Workability Bleeding Setting time Concrete Hardened State Mechanical properties Durability Hydraulic vs. Pozzolanic Reaction (1) Latent Hydraulic Reactions: Pozzolanic Reactions: Hydraulic vs. Pozzolanic Reaction (2) Different SCMs React Differently Basic Cement Hydration 2C 3 S + 6H -> C-S-H + 3CH 2C 2 S + 4H -> C-S-H + CH Cement Chemistry Notation: C = CaO; S = SiO 2 ; H = H 2 O C-S-H; molar ratios can vary; strength-giving phase No cementitious properties (does not contribute to strength); easily leached; prone to chemical attack SCM Reactions C 3 S + H C-S-H + CH C 2 S + H C-S-H + CH FAST FAST SCMs + CH + H C-S-H SLOW Fly Ash Fly Ash 25% limit on cement replacement in Tennessee (15% in GA) Realistic cement replacement amounts of ~50% Class F Fly Ash Derived from anthracite or bituminous coals from eastern US. Pozzolanic reaction -> Typical composition: Class C Fly Ash Derived from lignite or sub-bituminous coals from western US (particularly Wyoming and Montana). Pozzolanic and hydraulic reactions -> Chemical composition: Physical Characteristics of Fly Ash Mainly solid sphere with some cenospeheres (hollow) or plerospheres (containing smaller spheres) Particle size ~ 5-20 m Surface area ~ 300-500 m 2 /kg Color ranges from off-white to light gray Shapes of Fly Ash Fly ash particles typically exhibit spherical and irregular shapes. Silica Fume Silica Fume Highly reactive pozzolan due to high SiO 2 content and extremely small particle size (i.e., large surface area). Approximately 200,000 tons/yr produced in US Silica Fume Product Forms As-produced (undensified; easily inhaled) Densified (agglomerated) Slurry Silica Fume Properties Physical Particle size ~0.1-0.3 m Surface area ~15,000-25,000 m 2 /kg Generally, black in color Chemical 85 - 98% SiO 2 SiO 2 content dependent upon alloy Shape of Silica Fume Silica fume is almost always spherical in shape Slag Slag Also known as ground granulated blast furnace slag. Slag is the residue from metallurgical processes, either from production of metals from ore or refinement of impure metals. As of 2005, cost is slightly lower than portland cement (was significantly less) Slag Production Slag Pelletization May be used as lightweight aggregate (>4 mm) To be used in concrete, pellets must be ground Slag Properties Chemical 35 - 45% CaO 32 - 38% SiO 2 8 - 16% Al 2 O 3 5 - 15% MgO Physical Particle size < 45m Surface area ~ 400-600 m 2 /kg Angular particle shape Generally, white to off-white color Slag at high cement replacement values may cause concrete to turn greenish! However, this is not why we call SCM-cement mixes green concrete! Metakaolin Metakaolin Calcined (700-900 C) clay Georgia is major source of kaolin (clay) Typical cement replacement amounts of <10% (similar to silica fume) More expensive than portland cement Metakaolin Al 2 Si 2 O 5 (OH) 4 + 700-900 C Al 2 Si 2 O 7 dehydroxylation, puckering of layers Metakaolin Average particle size: 1-2 m Chemical composition: 45-55% SiO 2 40-45% Al 2 O 3 Average surface area: 10,000-25,000 m 2 /g Other SCMs Rice Husk Ash 90 million tons of rice husks produced worldwide each year Particle size ~ 10-20 m High reactivity (85% SiO 2 ) Diatomaceous Earth Volcanic Ash Proprietary Blends Effect of SCMs on Cement and Concrete Properties Many of the beneficial effects of using SCM are related to the effect they have on the pore structure by: These effects refine the pore structure and reduce the permeabilty of concrete thereby making it more resistant to the penetration of deleterious agents. Micro-filler effect Increased C-S-H Wall effect Pore blocking Benefits of SCMs Heat of Hydration (1) Most SCMs reduce overall heat of hydration and rate of heat liberation Eliminated need for ASTM Type IV cement Setting Slag and Class C Fly Ash: setting (15-60 minutes for initial, 30-120 minutes for final) Class F Fly Ash: setting (more than Class C); dependent upon chemical composition Silica Fume: setting due to high reactivity 0 50 100 150 200 250 300 350 Control MK235 (8%) MK349 (8%) SF (8%) Sample T i m e
( m i n u t e s ) Initial Set Final Set Water Demand Fly Ash: water demand due to ball bearing effect of spherical particles For every 10% FA, ~2-3% reduction in water demand Silica Fume: at typical replacement amounts, water demand Slag: water demand Effect on Decreasing Water Demand: FA > Slag > SF Workability Silica fume containing concretes tend to be sticky and more difficult to finish, leading to decreased workability or the need for high-range water reducer. Slag and fly ash improve workability. Bleeding Fly ash: bleeding Slag: bleeding; depends upon fineness of slag particles (fine particles decrease bleeding and vice versa for coarse particles) Silica fume: bleeding and may eliminate it altogether, thus making finishing difficult Rate of Strength Gain (1) Rate of Strength Gain (2) 0 10 20 30 40 50 60 70 80 1 3 7 28 90 Age (days) S t r e n g t h
( M P a ) Control MK235 MK349 SF SF Redo Total Strength Gain Effect of Silica Fume Using smaller particle sizes than cement, SCMs improve particle packing, leading to decreased transition zone porosity and increased overall strength gain. Durability Pozzolanic materials improve concrete durability due to: Durability: Permeability (1) Durability: Permeability (2) 0 1000 2000 3000 4000 5000 6000 7000 8000 0.40 0.50 0.60 w/cm C h a r g e
p a s s e d
( C o u l o m b s ) Control MK235 MK349 SF HIGH MODERATE LOW VERY LOW