Microsit – a new pozzolanic addition

Comparison of pozzolans

€ CEM I fly ash silica fume nanosilicahard coal

chemistry SiO2 18...24 40...60 92...98 100 Al2O3 M.-% 4....8 23...24 0,5...3,0 ---

Fe2O3 1...5 2...16 0,1...5,0 --- CaO 61...69 0,6...8,5 0,7...2,5 ---

average particle size µm ~ 10...20 ~ 10...20 ~ 0,1 ~ 0,015

specific surface m2 / g 0,3...0,6 0,3...0,8 18...22 180...230

State powder powder powder stable,slurry aqueous

(aqueous colloidaldispersion) solution

Particle size proportions

Density and fineness

density specific surface [cm2/g] [cm2/g]

pozzolans fly ash 2,28 3450 Microsit M10 2,49 6680 Microsit M20 2,47 5060

cements CEM I 52,5 3,08 5120 Lafarge Fondue 3,18 2990 Lafarge Secar 51 2,96 3800 Supracem 55 2,98 4030

Particle size distribution

0

10

20

30

40

50

60

70

80

90

100

0,01 0,1 1 10 100 1000

particle size in µm

Vol.-

% c

umul

ativ

e

silica fumefly ashMicrosit M10Microsit M20Macrosit

Frequency distribution

0,00

5,00

10,00

15,00

20,00

25,00

0,0 0,1 1,0 10,0 100,0 1000,0

particle size in µm

Vol.-

%

silica fumefly ashMicrosit M10

Microsit M20CEM I 52,5

Chemical composition of pozzolansfly ash Microsit quality control Mic M10

M10 min. average max. LOI % 2,48 2,28 2,2 3,1 3,8 LOI - free: SiO2 % 52,67 51,74 48,5 50,2 52,1 TiO2 % 1,27 1,29 Al2O3 % 27,72 28,7 22,8 25,7 27,4 Fe2O3 % 7,39 7,23 5,9 7,0 8,8 MnO % 0,12 0,13 CaO % 2,93 2,91 3,2 5,2 7,2 MgO % 2,24 2,22 1,5 2,0 2,7 Na2O % 1,02 1,14 0,1 0,9 1,2 K2O % 4,32 4,36 0,6 3,1 5,2 SO3 % 0,3 0,14 0,4 0,8 1,0 P2O5 % 0,15 0,19

sum % 100,13 100,05 Cl- % 0,003 0,002 0,00 0,00 0,00 SO3 gravim. % 0,49 1,02 CO2 % 0,79 1,76 H2O % 0,26 0,47 CaOfree % n.n. n.n.

KOH SiO2 in solution % 43,32 50,8

NaOH SiO2 in solution % 8,26 16,58

Water demand of CEM I (cement paste)

25,0

30,0

35,0

40,0

45,0

50,0

55,0

0 20 40 60 80 100

Microsit M10 against fly ash in Vol.-%

wat

er d

eman

d in

Vol

.-%

FA - EN 196-3FA - PuM10 - EN 196-3M10 - PuSF - EN 196-3SF - Pu

Frequency distribution : CEM I + Microsit M10

0

2

4

6

8

10

12

14

16

0 1 10 100 1000

particle size in µm

Vol.-

%

CEM I 52,580+2060+4040+6020+80flyash

Frequency distribution : CEM I + flyash

0

1

2

3

4

5

6

7

8

9

10

0 1 10 100 1000

particle size in µm

Vol.-

%

CEM I 52,580+2060+4040+6020+80flyash

Water demand of CEM I (mortar)

30

35

40

45

50

55

60

65

70

0 20 40 60 80 100

Microsit 10 against fly ash and silica fume in %

wat

er d

eman

d in

% b

inde

r

M 10 M.-%fly ash M.-%SF M.-%M 10 V.-%fly ash V.-%SF V.-%

Setting time retardation

0

100

200

300

400

500

600

0 20 40 60 80 100 0 20 40 60 80 100 0 10

M.-% Microsit M.-% fly ash M.-% silica fume

sett

ing

time

begi

n/en

d in

min

utes

begin - M10end - M10begin - f ly ashend - f ly ashbegin - SFend - SF

Strength development

0 ,0

10 ,0

20 ,0

30 ,0

40 ,0

50 ,0

60 ,0

70 ,0

80 ,0

90 ,0

100 ,0

0 20 40 60 80 100

Microsit M10 against fly ash and silica fume in M.-%

com

pres

sive

str

engt

h in

N/m

m^2

Wall effect

Microscopy CEM I - mortar

Microscopy CEM I with Microsit M10

Water demand of CAC (cement paste)

20,0

25,0

30,0

35,0

40,0

45,0

0 20 40 60 80 100

replacement of Secar 51 by Microsit M10 or fly ash Vol.-%

wat

er d

eman

d V

ol.-%

FA - EN 196FA - PuM10 - EN 196SM Pu

Water demand of CAC (mortar)

25

30

35

40

45

50

55

60

0 20 40 60 80 100

replacement of Secar in M.-%

wat

er d

eman

d in

M.-%

resp

. Vol

.-%

f ly ahs M.-%M10 M.-%fly ahs V.-%M10 V.-%

Setting time acceleration

0

50

100

150

200

250

0 10 20 30 40 50 60 70 80

replacement of Secar by Microsit in M.-%

min

utes

set begin: slump=const.set end: slump=const.set begin: w ater=const.set end: w ater=const.

Water demand and setting time of accelerated mortar

0

10

20

30

40

50

60

0 10 20 30 40 50 60

replacement of OPC+CAC by Microsit, FA and SF in M.-%

set i

n m

inut

es a

nd w

ater

dem

and

in %

set begin: M10set end: M10set begin: f ly ashset end: f ly ashset begin: SFset end: SFw ater demand M10w ater demand f ly ashw ater demand SF

Strength development of accelerated mortar

50

55

60

65

70

75

80

85

90

95

100

0 5 10 15 20 25 30 35

replacement of OPC+CAC by Microsit M10, fly ash or SF in M.-%

com

pres

sive

str

engt

h in

N/m

m^2

M10 28 dfly ash 28 dSF 28 dM10 90 dfly ash 90 dSF 90 d

Water demand and setting time of mortar with SUPRACEM

0

5

10

15

20

25

30

35

40

45

50

0 20 40 60 80 100

replacement of Supracem by Microsit, fly ash or SF in %

setti

ng ti

me

and

wat

er d

eman

d in

Vol

.-%

WA [Vol.-%]E B [Min]E E [Min]WA [Vol.-%]E B [Min]E E [Min]WA [Vol.-%]E B [Min]E E [Min]

Rheological properties of mortar with SUPRACEM

100

150

200

250

300

350

0 10 20 30 40 50 60

replacement of Supracem by Microsit, fly ash or SF in %

slum

p-te

st in

mm

Microsit M10 - w /b 0,40Microsit M10 - w /b 0,45Microsit M10 - w /b 0,50fly ash - w /b 0,40silica fume - w /b 0,50silica fume - w /b 0,45

Frequency distribution : SUPRACEM + Microsit M10

0

2

4

6

8

10

12

14

16

0 1 10 100 1000

particle size in µm

Vol.-

%

SUPRACEM 5595+590+1080+2070+30Microsit M10

^̂

Factors influencing pozzolanic additions

physical effect particle size and particle size distributionshape of particles (spheres)make up and surface of particlesadditional detrimental components (coke, ...)

chemical effect glass content = content of amorphous constituentschemical composition of the glass available surface of the glass, exposed to the solution

Effects and advantages of Microsit compared with purecement and fly ash

reduces water demandimproves rheological properties: flowability workabilityslightly retards the setting time of OPC, with CAC accelerated OPC, SP 55accelerates the setting time of CAC

increases the strength development after 28 days and moredecreases the capillar porosity neutral on shrinkage

Optimum of Microsit – addition level

70

72

74

76

78

80

82

84

86

88

90

0 5 10 15 20 25

replacement of OPC by Microsit M10 or M20 in M.-%

N/m

m^2

aft

er 9

0 da

ys

Microsit M10

Microsit M20

Properties with Microsit: grout

CEM I fly ash Microsit M10 Microsit M10 silica fume

CEM I 52,5 % 100 90 90 90 90fly ash % 10Microsit M10 % 10 7,5Microsit M20 % 10silica fume % 2,5

w/c 0,32 0,36 0,36 0,36 0,36w/b 0,32 0,32 0,32 0,32 0,32

slump t= 5 min. mm 322 351 350 331 290slump t=30 min. mm 229 258 257 252 202slump loss mm 93 93 93 79 88

compr. strength1d N/mm2 69 62 60 58 62

28 d N/mm2 96 103 116 106 11090 d N/mm2 100 102 120 117 114

Properties with Microsit: coating mortar

CEM I 52,5 Microsit M10 silica fume M10 + SF

CEM I 52,5 % 100 90 90 90Microsit M10 % 10 5silica fume % 10 5

water % 320 320 320 320w/c 0,33 0,39 0,39 0,39w/b 0,33 0,33 0,33 0,33

slump 5 Min. mm 157 166 120 143

compressive strength1 day N/mm2 57,0 51,6 52,7 49,6

28 days N/mm2 93,1 98,6 91,0 88,990 days N/mm2 91,3 110,7 103,5 97,2

porosity % 8,94 5,42 5,34 6,07relative porosity % 100 61 60 68

Market of mortars in Germany

Annual consumption in 2003 6.178.000 t/a

cementitious mortars for building construction 5.356.326 t/a

renders 2.539.158 t/a brick laying mortars 1.871.934 t/a flooring 945.234 t/a

special modified mortar systems 821.674 t/a

assumed cement content 30 % 246.502 t/a assumed replacement of 10 % cement by Microsit M10 24.650 t/a

Microsit - advantageous in modified mortar systemsanchor mortarcoating mortar for drinkwater system for sewage system and sewage treatment plantconcrete repair mortarcrack filling compoundcrack injection groutgroutindustrial flooringpolymer modified mortarrepair mortarsealing compound (brush applied)sealing mortar shotcrete

ceramic tile adhesiveself levelling compoundsmoothing compoundtile grouttrawling compound

and more ....

Microsit M10