Experimental Study on the Effect of Silica Fume on Strength and Durability of M40 Grade Ready Mix Concrete - A Review

Abstract

Concrete is the most consumed construction material worldwide, and improving its strength and durability remains a critical research focus. The inclusion of mineral admixtures such as silica fume has emerged as an effective solution to enhance performance. This review paper presents an in-depth study of the effect of silica fume on the strength and durability characteristics of M40 grade Ready Mix Concrete (RMC). A total of twenty published research studies has been critically analyzed to understand the influence of silica fume replacement levels, ranging from 5% to 20%, on mechanical and durability parameters. The review identifies significant improvement in compressive, tensile, and flexural strength, along with enhanced resistance to chloride and sulfate attack. The identified research gap indicates a need for systematic experimental evaluation of silica fume with modern admixtures under RMC conditions, focusing on microstructural characterization and long-term durability.

Introduction

Concrete is the most widely used construction material due to its versatility and cost-effectiveness. However, the production of Ordinary Portland Cement (OPC), a key component, significantly contributes to global CO? emissions (5–7% of total). To address environmental concerns and enhance concrete performance, supplementary cementitious materials (SCMs) like silica fume (SF)—a by-product from silicon alloy production—have been studied extensively.

Silica fume is highly reactive with a fine particle size, enhancing pozzolanic activity, which improves concrete’s microstructure and strength by producing additional calcium silicate hydrate (C–S–H) gel. Research shows that partial replacement of cement with silica fume (typically 5–10%) significantly improves mechanical properties (compressive, tensile, and flexural strength) and durability (resistance to chemical attacks, sulphates, and chloride penetration).

Studies also explore combining silica fume with other industrial by-products (fly ash, GGBS, copper slag, PVC waste) and nano-additives (nano-silica) to develop sustainable, high-performance concrete suitable for structural and specialized applications. However, challenges remain in optimizing replacement levels, ensuring long-term durability, and evaluating new concrete technologies like fiber-reinforced and 3D printable concretes.

Extensive literature reviews covering various experiments confirm that silica fume improves concrete strength and durability up to an optimal replacement limit (often around 8–10%). Beyond this, issues like reduced workability and microcracking may occur. The use of admixtures like superplasticizers helps maintain workability.

Overall, incorporating silica fume as a partial cement replacement contributes to sustainable construction by reducing CO? emissions and enhancing concrete performance, with ongoing research aimed at refining mixes and broadening application scopes.

Conclusion

The reviewed literature highlights the significant role of silica fume as a supplementary cementitious material in enhancing the mechanical and durability properties of concrete. Studies consistently indicate that partial replacement of cement with silica fume improves compressive, tensile, and flexural strength, while also refining the microstructure, reducing porosity, and enhancing resistance to chemical attacks, sulphate exposure, and chloride penetration (Rukhsana Rashid et al., 2016; Andrabi et al., 2019; Cornelius Kanmalai Williams et al., 2020). Optimal replacement levels generally range between 7–12%, beyond which excessive silica content may lead to reduced workability and microcracking (?ahin et al., 2024; Nadim et al., 2024). Recent investigations emphasize the synergistic effects of combining silica fume with other industrial by-products or nano-additives, such as fly ash, GGBS, PVC waste powder, copper slag, and nano-silica, to produce sustainable and high-performance concrete (Manjunatha et al., 2021; Niket Singh et al., 2023; Gajre et al., 2024). Furthermore, emerging technologies, including fiber-reinforced concrete, polymer-modified concrete, and 3D printable concrete, benefit from the incorporation of silica fume, though challenges remain in balancing mechanical performance, workability, and long-term durability. Despite extensive research, gaps still exist in understanding the long-term performance of silica fume-based concretes under aggressive environmental conditions, the combined effects of multiple supplementary materials, and the practical application in large-scale and 3D printable structures. Addressing these gaps through further experimental and microstructural studies will be crucial for developing sustainable, high-performance concrete solutions that meet the evolving demands of modern construction practices.

References

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Copyright

Copyright © 2025 Mohd. Ammaruddin, Harshit Bhilawe, Abhay Sahare, Sanket Narnaware, Prof. Atul D Gautam. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.