The study of using rice husk ash to produce ultra high performance concrete
Nguyen Van Tuan
a, , Guang Ye a , Klaas van Breugel a , Alex L.A. Fraaij a , Bui Danh Dai b a Microlab, Faculty of Civil Engineering and Geosciences, Delft University of Technology, P.O. Box 5048, 2600 GA Delft, The Netherlands b Department of Building Materials, National University of Civil Engineering, 55 Giai Phong Road, Hanoi, Viet Nam a r t i c l e i n f o Article history: Received 17 April 2010 Received in revised form16 September 2010 Accepted 13 November 2010 Available online 17 December 2010 Keywords: Compressive strength Fineness Rice husk ash Silica fume Ultra high performance concrete a b s t r a c t The limited available resource and the high cost of silica fume (SF) in producing ultra high performance concrete (UHPC) give the motivation for searching for the substitution by other materials with similar functions, especially in developing countries. Rice husk ash (RHA), an agricultural waste, is classied as a highly active pozzolan because it possesses a very high amount of amorphous SiO 2 and a large sur- face area. The possibility of using RHA to produce UHPC was investigated in this study. The result shows that the compressive strength of UHPC incorporating RHA, with the mean size between 3.6 lm and 9 lm, can be achieved in excess of 150 MPa with normal curing regime. The interesting point is that the effect of RHA on the development of compressive strength of UHPC is larger than that of SF. Besides, the sample incorporating the ternary blend of cement with 10% RHA and 10% SF showed better compressive strength than that of the control sample without RHA or SF. This blend proved to be the optimum combination for achieving maximum synergic effect. 2010 Elsevier Ltd. All rights reserved. 1. Introduction Ultra high performance concrete (UHPC) refers to materials with a cement matrix and a characteristic compressive strength in ex- cess of 150 MPa, possibly attaining 250 MPa, and containing steel bers in order to achieve ductile behavior under tension and, if pos- sible, to dispense with the need for passive (non-prestressed) rein- forcement [1]. Because of these outstanding properties, UHPC offers new and sometimes exiting possibilities: lighter structures, larger structures, hybrid structures, new design and new products with a potential for a better economy and resource consumption than with traditional concrete, steel and other building materials [24]. In UHPC, silica fume (SF) with extreme neness and high amor- phous silica content plays a very important role with physical (ller, lubrication) and pozzolanic effects. However, the limited available resource and the high cost constrain its application in modern construction industry, especially in developing countries. For these reasons, it gives a motivation for searching for other materials to substitute SF with similar functions. One possibility is using rice husk ash (RHA), which is obtained by burning rice husk, an agricultural waste. Rice husk constitutes about one fth of the 690 million metric tons of rice paddy pro- duced annually in the world [5]. When completely incinerating the husk in controlled conditions, the residue, RHA, contains 9096% silica in amorphous form. The average particle size of RHA ranges in general from 5 lm to 10 lm with a very high spe- cic surface area (even more than 250 m 2 /g) [6]. This high surface comes from the porous structure of RHA [7,8]. Meanwhile the spe- cic surface area of SF is 1820 m 2 /g, which mainly comes from the very ne particles. Both SF and RHA are considered as highly active pozzolans [9]. When incorporated in cement, both SF and RHA affect the rate and the extent of hydration [10,11]. The addition of RHA in concrete, similar to SF, can lead to reduced porosity and Ca(OH) 2 content in the interfacial transition zone (ITZ) between the aggre- gate and the cement paste, as well as the ITZs width compared with the control sample [12]. Furthermore, RHA has been studied to replace SF for achieving high strength/performance concrete [13,14]. However, its effects still remain unclear for UHPC. In this study, the effect of RHA in combination with and without SF on the compressive strength of UHPC was experimentally eval- uated. Besides, the effect of neness of RHA was also considered. 2. Experiments 2.1. Materials The materials used in this study were silica sand with a mean particle size of 225 lm, Portland cement (CEM I 52.5N) with a Blaine specic surface area of 4500 cm 2 /g, condensed silica fume, rice husk ash, and polycarboxylate based superplasticizer with 30% solid content by weight. The SF has an amorphous SiO 2 content of 97.2% and its mean particle size is about 0.10.15 lm. The particle size distribution and the mean particle size of materials in this study were determined by laser diffraction. Rice husk, from Vietnam, was burnt in a drum incinerator developed by Pakistan Council of Scientic & Industrial Research [15] under uncontrolled combustion conditions. Details of the oven and rice husk combustion process were described 0950-0618/$ - see front matter 2010 Elsevier Ltd. All rights reserved. doi:10.1016/j.conbuildmat.2010.11.046
E-mail address: t.vannguyen@tudelft.nl (V. T. Nguyen). Construction and Building Materials 25 (2011) 20302035 Contents lists available at ScienceDirect Construction and Building Materials j our nal homepage: www. el sevi er . com/ l ocat e/ conbui l dmat elsewhere [6]. The obtained ash was ground in a vibrating ball mill for 90 min. The ash contains 87.96% amorphous SiO 2 , 3.81% loss on ignition and its mean particle size (d RHAmean ) is 5.6 lm. The particle size distribution of these materials is shown in Fig. 1. The Scanning Electron Microscopic (SEM) images of typical RHA and SF particles are shown in Fig. 2. It can be seen that RHA particles are angular and still keep the porous structure after grinding (Fig. 2b and c). Other three different mean particle sizes of RHA, i.e., 9, 6.3 and 3.6 lm was used to evaluate the effect of neness of RHA on compressive strength of UHPC. 2.2. Packing and composition Optimizationof granular mixture is one of the keys in UHPCmix design. The opti- mization of granular mixtures in this study was achieved by using the packing model developed by de Larrard [16] with the compaction index of 12.5 [17]. Firstly, the per- centage of SF was xed at 20% by weight of binder. The combination of cement and SF hence was considered as one material. The packing of ternary system, sand cementSF, was only calculated for two materials, sandbinder. The optimized pack- ing of this systemwas achieved with sand to binder ratio of 1. Secondly, water to bin- der (w/b) ratio of UHPC was xed at 0.18. SF was replaced partially or fully by RHA. To deal with some aspects, i.e., the effect of RHA replacement, neness of RHA and the synergic effect of RHAand SF, a set of 15 mixtures were prepared as shown in Table 1. 2.3. Experimental methods All materials were prepared in a 20 l Hobart mixer. The volume of each batch was 3.5 l. Fig. 3 shows the mixing procedure. The workability of all mixtures was determined by means of ow table test. The ow measurements were controlled between 210 and 230 mm. For very low water to binder (w/b) ratio mixtures, i.e., w/b ratio of 0.15, the maximum ow measure- ment was achieved only from 170 to 185 mm. This may be caused by the effective- ness of superplasticizer. The same phenomenon was observed for the mixtures incorporating high amount of cement replacement, i.e., over 20%. Besides, the workability of some mixtures was determined by mini V-funnel test in order to check the viscosity of fresh UHPC mixtures. Mixtures were cast into the 40 40 40 mm 3 cubes for compressive strength test. All mixtures were vibrated for 1 min using a vibrating table with a frequency of 2500 cycles/min. 0 10 20 30 40 50 60 70 80 90 100 0.01 0.1 1 10 100 1000 Particle Size (m) C u m u l a t i v e
p a s s i n g ,
b y
v o l .
( % ) SF RHA (3.6 m) Silica sand Cement (CEM I 52.5 N) RHA (9.0 m) RHA (6.3 m) RHA (5.6 m) Fig. 1. Particle size distribution of materials used in this study. (d) (a) (b) (c) 20 m 5 m 2 m 20 m Fig. 2. SEM images of RHA before grinding (a); RHA after grinding with some magnications: 1250(b); 5000(c); and SF (d). Table 1 UHPC compositions used in this study. Water to binder ratio (by weight) Sand to binder ratio (by weight) RHA (% by weight) SF (% by weight) The mean particle size of RHA (d RHAmean ), lm 0.18 1 01020 5.6 0.18 1 102030 0.18 1 102030 10 5.6 0.18 1 20 9.06.35.63.6 0.18 1 5 15 5.6 0.18 1 15 5 5.6 0.150.180.200.23 1 10 10 5.6 V. T. Nguyen et al. / Construction and Building Materials 25 (2011) 20302035 2031 After casting, samples were cured in a fog room (20 2 C, RH > 95%) for one day. After demoulding, the samples were still stored in the fog room until the day of testing. 3. Results and discussion 3.1. The workability of UHPC mixtures The amount of superplasticizer of mixtures for achieving a con- stant ow value from 210 mm to 230 mm are shown in Fig. 4. It can be seen that cement replacements by SF between 10% and 20% have a positive effect on the workability of the mixtures. This may be resulted from the ne spherical particles of SF, which act as a lubricant. However, when more than 20% cement is replaced by SF, the amount of superplasticizer increases dramatically to 1.43% and 2.38% for 30% and 40% SF, respectively. The cement used in this study has the specic surface area of 0.45 m 2 /g. The surface area of SF is about 20 m 2 /g. Therefore, the total surface area of the blend of cement and SF depends on the SF replacement percentage. For example, when cement is replaced by 20% SF, the total surface area of 1 g of this blend is 4.36 m 2 . This value will be almost double, 8.27 m 2 /g with 40% cement replace- ment by SF. Thus, the lubricant effect may not compensate the ef- fect of its surface area when more cement is replaced by SF. On the contrary, the amount of superplasticizer of UHPC in- creases with an increase of RHA replacement. Fig. 4 also shows that the RHA replacement of cement can be in- creased to 40% when combined with 10% SF. If the RHA replacing percentage is higher than 40%, the maximum ow value is achieved less than 170 mm even when using a high amount of superplasticizer. This also was caused by the high specic surface area of RHA. The mixture was observed to be very difcult to be cast in this case. Thus, the cement replacement by 30% RHA and 10% SF was con- sidered as the maximum replacement amount in this study. 3.2. The effect of the percentage of cement replacement by RHA on compressive strength of UHPC Fig. 5 shows that compared to the control sample, the compres- sive strength of UHPC was improved signicantly with 10% SF or 20% RHA. Moreover, the compressive strength enhancement levels of the samples with binary blends were comparable. For samples containing SF, the highest compressive strength of UHPC was achieved with 10% SF replacement of cement. The high- er replacement level, especially beyond 20%, led to reduction in compressive strength. The use of RHA as a partial replacement of cement revealed the different behavior of compressive strength development. The compressive strength of UHPC was obtained highest by using 10% RHA at 3 and 7 days, but by using 20% RHA at 28 and 91 days. Based on this result, it is clear that RHA can be used to produce UHPC for a replacement level less than 30%. 3.3. The effect of combination of RHA and SF on compressive strength of UHPC Based on the workability result of UHPC, the possibility of using RHA rose when combined with 10% SF. Fig. 6 shows the effect of RHA replacement percentage on the compressive strength of UHPC when the percentage of cement replacement by SF was xed at 10%. It is interesting to see that the compressive strength of UHPC with 0 and 10% RHA was higher than that of the control sample. It should be noted that the total cement replacement percentages were 10 and 20%, respectively in this case. The compressive strength of UHPC decreases when the amount of cement replace- ment by RHA is higher than 20%. It also can be seen that the 28 days compressive strength of all samples was in excess of 150 MPa. Powder + 70% Water Scrape and stir SP + 25% Water Scrape and Stir 2 min. mixing speed 2 1 min. mixing speed 2 1-2 min. mixing speed 2 Add 5% water End of mixing 2-5 min. mixing speed 3 Sand + Cement + RHA + SF 3 min. mixing speed 2 Fig. 3. Mixing procedure for UHPC. 0.0 0.5 1.0 1.5 2.0 2.5 3.0 0 10 2 30 40 50 RHA; SF or (RHA and SF) (% by weight of total binder) S u p e r p l a s t i s i z e r
( s o l i d ) ( %
b y
w e i g h t
o f
b i n b e r ) Flow values between 210 and 230 mm RHA (No SF) SF (No RHA) SF + RHA (SF fixed at 10%) Fig. 4. The amount of superplasticizer of UHPC mixtures vs. % RHA, % SF or % (RHA + SF), for achieving a constant ow value of mixtures between 210 and 230 mm; w/b ratio = 0.18, d RHAmean = 5.6 lm. 70 90 110 130 150 170 190 210 0 10 20 30 SF or RHA (% by weight in binder) C o m p r e s s i v e
s t r e n g t h
( M P a ) RHA (91 days) SF (28 days) SF (7 days) RHA (7 days) SF (3 days) RHA (3 days) SF (91 days) RHA (28 days) Fig. 5. Compressive strength of UHPC samples vs. % SF (dotted line) or % RHA (solid line), w/b ratio = 0.18, d RHAmean = 5.6 lm. 2032 V. T. Nguyen et al. / Construction and Building Materials 25 (2011) 20302035 This result shows the benet of using RHA in combination with SF to produce UHPC. The amount of SF replacement is only 10% but the total cement replacement percentage can increase to 40% by weight. 3.4. The effect of RHA neness on compressive strength of UHPC One of the most important aspects using RHA to produce UHPC is particle size of RHA. This concerns the energy required for grind- ing rice husk to appropriate neness. Grinding energy increases with neness of RHA. If long periods of grinding are required either the production output will be reduced or larger milling capacity will be required for a given output, the latter obviously results in higher capital costs for plant, especially in the developing countries [8]. Because of the porous structure, RHA is easy to grind. For exam- ple, the mean size of RHA from 12 mm can be reduced to 9 lm only with 30 min ground by vibrating ball mill. These mean sizes of 6.3, 5.6 lm can be achieved with grinding times of 60 and 90 min, respectively. However, the efciency of this mill does not increase with grinding time [18]. It was also found when the grind- ing time increases, the pore structure of RHA is gradually collapsed [19]. This collapsibility can affect the properties of concrete. Thus the effect of RHA neness on properties of UHPC, especially, the compressive strength is studied thereafter. Four different particle size of RHA with the mean size smaller than that of cement, namely 9, 6.3, 5.6, and 3.6 lmwere chosen. The mean size of cement, CEMI 52.5N, is 13.7 lm. The replacement percentage of cement by RHA was xed at 20%. Fig. 7 shows that the superplasticizer dosage needed for a given workability is reduced proportionally with the decrease of RHA particle size. In this study, the mean particle size of RHA of 3.6 lm can be achieved by grinding in planetary ball mill after 3 h. The compressive strength of these UHPCs is shown in Figs. 8 and 9. It can be seen that the compressive strength decreases linearly when increasing the mean size of RHA particle. The 28 days com- pressive strength of 150 MPa can be achieved with the mean size of RHA particle of about 8 lm at 20 C curing. It means that 1 h grinding time by vibrating ball mill can be considered optimum in this study. However, the coarser the RHA, the higher the amount of the superplasticizer is required and the higher the viscosity is. Although the ow values were controlled between 210 mm and 230 mm, the viscosity measured by the mortar funnel is different. The ow funnel times of mixtures increase with an increase of the mean particle size of RHA (see Fig. 7). The mixture with ow time mortar funnel over 115 s was observed to be difcult to be cast. Besides, the grinding energy cost increases dramatically, from 3.0 kW h/kg to 7.5 kW h/kg when the mean size of RHA particle reduces from 5.6 lm to 3.6 lm. From this result, the reasonable mean size of RHA particle was proposed to be 5.6 lm. 3.5. The synergic effect of RHA and SF on compressive strength of UHPC Interestingly, in Fig. 6, the UHPC sample made by the blend of 10% RHA and 10% SF shows better compressive strength results than that of the control sample without RHA or SF and samples using other blends. There must be a synergic effect between RHA and SF on the compressive strength of UHPC. To investigate this ef- fect, the total cement replacement percentage by blend of RHA and SF was kept at 20%. The ratio, RHA/(RHA + SF), varies from 0% to 100%. Fig. 10 shows the amount of superplasticizer of UHPC mixtures, for achieving a constant ow value. The more cement was replaced by RHA, the higher the amount of superplasticizer was needed. The compressive strength of UHPC samples vs. RHA/(RHA + SF) and vs. time are shown in Figs. 11 and 12, respectively. It is found that the highest compressive strength of UHPC sam- ples from 3 days to 91 days was achieved using the blend of 10% 50 70 90 110 130 150 170 190 210 230 0 10 20 30 RHA (% by weight of binder) C o m p r e s s i v e
s t r e n g t h
( M P a ) 3 days 7 days 91 days 28 days 7 days 28 days (SF fixed at 10%) Fig. 6. Compressive strength of UHPC samples vs. % RHA (solid line); the control sample without RHA or SF (dotted line), the percentage of SF replacement was xed at 10%, w/b ratio = 0.18, d RHAmean = 5.6 lm. 235 165 115 75 55 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 15.5 9.0 7.8 6.3 5.6 3.6 The mean size of RHA particle (m) S u p e r p l a s t i c i z e r
d o s a g e
( s o l i d ) ( %
b y
w e i g h t
o f
b i n d e r ) 0 50 100 150 200 250 V - f u n n e l
t i m e
( s e c . ) R E F
S F Flow values between 210 and 230 mm Fig. 7. The amount of superplasticizer and V-funnel time of UHPC mixtures incorporating 20% RHA with different particle sizes from 15.5 lm to 3.6 lm; ow values between 210 mm and 230 mm. 6.3 9.0 40 60 80 100 120 140 160 180 200 220 3.6 4.6 5.6 6.6 7.6 8.6 The mean size of RHA particle (m) C o m p r e s s i v e
s t r e n g t h
( M P a ) 7 days 3 days 28 days 91 days 1 day Fig. 8. Compressive strength of UHPC samples using 20% RHA vs. the mean particle size of RHA (solid line); the control sample without RHA or SF (dotted line), w/b ratio = 0.18. V. T. Nguyen et al. / Construction and Building Materials 25 (2011) 20302035 2033 RHA and 10% SF. The SF shows the strong effect at a very early age, i.e., at 1 day. However, the effect of RHA is more pronounced in the later ages, i.e., after 3 days (see Fig. 11). 3.6. Discussions From the results presented above, the use of RHA improves the properties of UHPC. Firstly, the incorporation of the RHA in UHPC can gain higher compressive strength than that of the control sam- ple. When more cement is replaced by RHA, i.e., 20% replacement, the compressive strength of the RHA sample even surpasses that of the SF sample. Secondly, the combination of RHA and SF improves the workability of UHPC mixtures and compressive strength of UHPCs. Especially, the combination of 10% RHA and 10% SF shows the synergic effect on the compressive strength of UHPC. This result can be explained rstly by the improvement of pack- ing of granular mixtures. The result from the work [20] shows that the mixtures with water to cement ratio of 0.20, up to 50% of the cement will remain unhydrated. In this aspect, cement becomes very expensive aggregates, and the substitution of cement by other materials is helpful. Moreover, the addition of ner materials can give better packing density, thus improves of the properties of concrete. As demonstrated earlier by Detwiler and Mehta [21], cement-blending can even be successful when an inert type of mineral admixture is used, provided the size ranges of the Portland cement and the mineral admixture are properly designed. The gap between cement size (1015 lm) and silica fume size (0.11 lm) is very large, about 100150 times. In this case, the amount of ce- ment was replaced by SF was 20%, which may be not enough to ll all the empty spaces in the system, as proposed by Richard and Cheyrezy [3]. On the other hand, the size of RHA is not small enough to ll all the small spaces. Therefore, the combination of RHA and SF can make the packing of UHPC denser. Besides, the combination of RHA and SF can reduce the amount of superplasti- cizer of mixture when the same workability is kept (see Fig. 4). It means the better packing may also improve the workability of the mixture, also suggested from Popovis [22]. Secondly, the positive effect of RHA on cement hydration can improve the compressive strength of UHPC. The previous result [19] shows that the effect of RHA on cement hydration, determined by isothermal calorimetry, is more pronounced than that of SF with the low w/b ratio, especially in the later ages. Therefore when RHA is used in UHPC, it can stimulate the cement hydration. Moreover, it can also be seen in this work that the behavior of the blended ce- ment hydration is different with the addition of RHA and SF. The hydration degree of cement blended with RHA is low at the early period and high at the later period, but vice versa in case of cement blended with SF. It means that the combination of RHA and SF can 3 7 14 28 91 40 60 80 100 120 140 160 180 200 220 100 10 1 Time (days) C o m p r e s s i v e
s t r e n g t h
( M P a ) RHA (6.3 m) RHA (3.6 m) RHA (5.6 m) RHA (9.0 m) SF REF Fig. 9. Compressive strength of UHPC samples using 20% RHA with different mean particle sizes from 3.6 lm to 9.0 lm vs. time, w/b ratio = 0.18. 0.76 0.85 1.00 1.10 1.20 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 0.00 0.25 0.50 0.75 1.00 RHA / (RHA + SF) S u p e r p l a s t i s i z e r
( s o l i d ) ( %
b y
w e i g h t
o f
b i n b e r ) Flow values between 210 and 230 mm Fig. 10. The amount of superplasticizer of UHPC mixtures vs. RHA/(RHA + SF), for achieving a constant ow value of mixtures from 210 mm to 230 mm, w/b ratio = 0.18, d RHAmean = 5.6 lm. 60 80 100 120 140 160 180 200 220 0.00 0.25 0.50 0.75 1.00 RHA / (RHA+SF) C o m p r e s s i v e
s t r e n g t h
( M P a ) 3 days 1 day 91 days 28 days 7 days Fig. 11. Compressive strength of UHPC samples vs. RHA/(RHA + SF) (solid line); the control sample without RHA or SF (dotted line), w/b ratio = 0.18, d RHAmean = 5.6 lm. 60 80 100 120 140 160 180 200 220 100 10 1 Time (days) C o m p r e s s i v e
s t r e n g t h
( M P a ) 3 7 14 28 91 REF 20% SF 20% RHA 10% SF+10% RHA Fig. 12. Compressive strength of UHPC samples using different combinations of RHA and SF vs. time, w/b ratio = 0.18, d RHAmean = 5.6 lm. 2034 V. T. Nguyen et al. / Construction and Building Materials 25 (2011) 20302035 give a synergic effect in the whole period of cement hydration. The increased hydration of cement blended with RHA at the later per- iod was suggested to be due to the internal curing of RHA in the ce- ment paste. Because RHA has the porous structure, the pores in RHA particles may act as water wells. RHA may also absorb cer- tain amount of free water into its pores during mixing. This water is released from these pores when the relative humidity in the paste decreases with progress of cement hydration process, and therefore increases the hydration degree of blended cement. This effect is larger when the w/b ratio of mixtures is lower. This mech- anism is similar to that proposed by Weber and Reinhardt [23] and van Breugel et al. [24] when using the water saturated lightweight aggregates or proposed by Jensen and Hansen [25,26] when using superabsorbent polymer (SAP) particles for internal curing of con- crete. Besides, the porous structure of RHA may allow water to store in its pores. Therefore, the w/b ratios of RHA mixtures are lower than those of SF mixtures although the workability of all mixtures was kept constant with the same w/b ratio. As conse- quence, a higher compressive strength can be obtained. 4. Conclusion Nowadays, the environmental pollution is one of the most important world wide issues. The agricultural waste, such as rice husk, has been affecting on the environment. The use of rice husk ash in construction is one of the solutions to reduce the environ- mental pollution. Besides, the limited availability and the high cost constrain the application of SF, especially in developing countries. This study showed the potential of using RHA to produce UHPC. From this study, some conclusions can be drawn: RHA can be considered as a supplementary cementitious mate- rial using for producing UHPC. The addition of RHA does not signicantly decrease the com- pressive strength of UHPC compared to that of SF, when less than 30% RHA is added. Compared to SF, the neness of RHA has a favorable effect on compressive strength when cured in the normal condition. The optimum mean RHA particle size for producing UHPC was found to be 5.6 lm. The ner RHA can improve signicantly the compressive strength of UHPC. The compressive strength of UHPC using the nest RHA with the mean particle size of 3.6 lm can reach to 180 MPa and 210 MPa at ages of 28 and 91 days. The combination of SF and RHA can increase the total cement replacement percentage up to 40% to produce UHPC. There is a synergic effect between SF and RHA on the compres- sive strength. 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