EXPERIMENTAL STUDIES ON HIGH

PERFIRMANCE CONCRETE USING

METAKAOLIN

BY
C SANDEEP REDDY

13E71D2004
 MATERIALS IN CONCRETE:-

Cement (Partial replacement of Quarry dust and Metakaolin)

Fine aggregate

Coarse aggregate

Admixtures

Water
METAKAOLIN:-Metakaolin is a dehydroxylated form of clay mineral

kaolinite( Al2Si2O5(OH)4). Stone that are rich in kaolinite that are known as china clay

traditionally use in the manufacture of porcelain.The particle size of Metakaolin is smaller

than cement but not as fine of silica fume.

 Calcium hydroxide accounts for up to 25% of the hydrated Portland cement, and calcium hydroxide

does not contribute to the concrete strength or durability. Metakaolin combines with the calcium

hydroxide to produce additional cementing compounds, the material responsible for holding concrete

together. Less calcium hydroxide and more cementing compounds means stronger concrete.

The raw material in the manufacture of Metakaolin is kaolin clay. Kaolin is fine, white, clay mineral

that has been traditionally used in the manufacture of porcelain.

Metakaolin is neither the by-product of an industrial process nor is it entirely natural. It is derived

from naturally occurring mineral and is manufactured specially for cementing applications
Physical Properties of Metakaolin Chemical composition of Metakaolin

Properties Value Constituents Values

Silica 53%
Density (gm./cm3) 2.17

Alumina 43%

Bulk density (gm./ cm3) 1.26

Iron oxide 0.5%

Sulphate 0.1%
Particle shape Spherical
Calcium oxide 0.1%

Colour White
Sodium oxide 0.05%

Specific gravity 2.7 Potassium oxide 0.4%

TESTS DONE ON CONCRETE:-

• Initial setting time test.

• Final setting time test.
• Specific gravity test.
• Workability test.
• Slump test.
• Compressive strength test.
Initial and final setting time:-

The period elapsing between the time when water is added to the cement and the time at which

the needle penetrates the test block to a depth equal to 33-35 mm from the top is taken as initial setting

time.

Replace the needle of the Vicatsappartus by a circular attachment. The cement shall be

considered as finally set when, upon, lowering the attachment gently cover the surface of the test block,

the Centre needle makes an impression, while the circular cutting edge of the attachment fails to do so.

In other words the paste has attained such hardness that the center needle does not pierce through the

paste more than 0.5 mm.

Specific gravity apparent(initial setting time) Vicats apparatus(Final setting time)
Specific gravity:-Specific gravity of aggregate is also required in calculating the compacting factor

in connection with the workability measurements. Similarly, specific gravity of aggregate is required to

be considered when we deal with light weight and heavy weight concrete. Average specific gravity of

the rocks vary from 2.6 to 2.8.

Slump test:-Slump test is the most commonly used method of measuring consistency of concrete

which can be employed either in laboratory or at site of work. It is not a suitable method for very wet or

very dry concrete. It does not measure all factors contributing to workability, nor is it always

representative of the playability of the concrete.

Methodology:- SELECTED TITLE

STUDIED LITERATURE

MIX DESIGN NORMAL

DIFFERENT TYPES OF MIX DESIGN WITH QUARRY DUST AND METAKAOLIN

TESTS ON CONCRETE

COMPARISON BETWEEN NORMAL MIX AND QUARRY DUST

RESULT
 STRENGTH AND DURABILITY PROPERTIES OF HIGH

PERFORMANCE CONCRETE INCORPORATING HIGH REACTIVITY

METAKAOLIN:-

Since 1990s, HPC has become very popular in construction works. At present, the use of HPC has

spread throughout the world. In 1993, the American Concrete Institute (ACI) published a broad

definition for HPC and is defined as the concrete which meets special performance and uniformity

requirements that cannot always be achieved by using only the conventional materials and mixing,

placing and curing practices.

 Mineral admixtures such as fly ash, rice husk ash, Metakaolin, silica fume etc. are more commonly

used in the development of HPC mixes. They help in obtaining both higher performance and economy.

These materials increase the long term performance of the HPC through reduced permeability resulting

in improved durability.

Addition of such materials has indicated the improvements in the strength and durability properties

of HPC. High reactivity Metakaolin, which is a relatively newer material in the concrete industry, is

effective in increasing the compressive strength, reducing the sulphate attack and improving air-void

network.
USE OF METAKAOLIN IN HIGH STRENGTH CONCRETE (HSC): -

The use of Metakaolin becomes ample ingredients in the production of concrete of more than 40MPa or

where service environments, exposure conditions or life cycle cost considerations dictate the use of

High Performance concrete. For High Strength Concrete Silica Fume/Micro Silica is used. When these

are replaced by Metakaolin, concrete of equivalent strength and durability properties developed along

with several additional features like reduced water permeability, workability and pump ability.

Metakaolin functions by converting an undesirable by product of the cement hydration process, calcium

hydroxide (Free lime) to various forms of calcium aluminate. These materials can be described as

cementitious, as they contribute to the strength of the concrete. In its pure form, Metakaolin reacts with

up to 1.6 times its mass of CH.

ADVANTAGES HIGH STRENGTH CONCRETE WITH METAKAOLIN :-
a) Facilitate finishing concrete surfaces by rubbing and smoothing due to the lack of stickiness of
concrete to the tool and good thixotropy.
b) It reduces the amount of cement in the formation of concrete, especially in concrete with high
requirements for water resistance.
c) Can significantly increase the residual strength of refractory concrete after firing, typically lose 50%
of its strength after heating to 8000C.
d) The strength and durability of concrete increases.
e) Use of Metakaolin accelerates the initial set time of concrete.
f) Compressive strength of concrete increases @ 20 % with Metakaolin.
g) The cross sectional areas of structural members can be reduced safely, so saving in concrete and can
be economically used for high rise buildings, dams, bridges etc.
h) It Imparts improved water-tightness, so safely used for water retaining structure, off shore structure.
APPLICATIONS: - High Strength Concrete with Metakaolin as admixtures offers many

advantages as mentioned above. So it can be used for – a)Dams, b) Bridges c) Water retaining structures

d) High rise buildings e) Off shore structures f) industrial flooring g) Warehouses h) Container Depots i)

Roads j) Lining k) Mass concreting l)aqueducts m) Nuclear power stations n) structural members where

cross section required to be small etc.

MIX DESIGN
NOMINAL MIX DESIGN
STEP1: stipulations for proportioning
Grade designation :M30
Type of cement :OPC53 grade ( IS: 8112 )
Maximum nominal size of aggregate :20mm
Minimum cement content :320Kg/m3
Maximum water cement ratio :0.45
Workability :100mm slump
Exposure condition : severe (for reinforced concrete)
Method of concrete placing : pumping
Degree of super vision : good
Type of aggregates : crushed angular aggregates
Maximum cement content :450Kg/m3
STEP2: Test data for materials
Cement used :OPC 53 grade ( IS:8112 )
Specific gravity of cement :3.15
Specific gravity of
A) Coarse aggregate : 2.98
B) Fine aggregate : 2.55
Water absorption
A) Coarse aggregate : 0.5%
B) Fine aggregate : 1.0%
STEP3: target strength for mix proportioning
f1ck=fck+1.65s
f1ck=target average compressive strength at 28 days
fck =characteristic compressive strength at 28 days
s=standard deviation
s=5N/mm2 (from pg-23 table8)
f1ck=30+1.65*5
f1ck=38.25N/mm2
STEP4: selection of water-cement ratio
Maximum water cement ratio=0.45(from pg-20 table5)
Adopt water cement ratio=0.40
0.40<0.45
STEP5: selection of water content

Maximum water content for 20mm aggregates=186 litre

(From 25 to 50mm slump from IS: 10262table2)

Estimated water content for 100mm slump
=186+ (6/100) (186) (6% is due to usage of 100mm slump)
=197 litre
STEP6: calculation of cement content

Water content ratio=0.40

Cement content =197/0.40=492.5Kg/m3

But maximum cement content is 450Kg/m3
Hence adopt 450Kg/m3
STEP7: proportion of coarse aggregate & fine aggregates content
Volume of coarse aggregate=0.62*0.9=0.56
Volume of fine aggregate=1-0.56=0.44
STEP8:
(A). Volume of content=1m3
(B). Volume of cement= (mass of cement/sp.gravity of cement)*(1/1000)
=450/3.15*(1/1000)
=0.142m3
(C). Volume of water=mass of water/sp.gravity of water*(1/1000)
=197*(1/1000) = 0.197
(D). Volume of all in aggregates=1-0.142-0.197
c=0.66/m3
(E). mass of coarse aggregate =c*volume of coarse aggregates*specific gravity of coarse
aggregates
=0.661*0.56*2.98*1000
=1103.07Kg
(F). mass of fine aggregate=c*volume of coarse aggregate*specific gravity of fine
aggregates
=0.661*0.44*2.55*1000
=741.64Kg
STEP9: Mix proportion
Cement: 450Kg/m3
Water: 197Kg/m3
Fine aggregates: 741.64Kg
Coarse aggregates: 1103.07Kg
W/c ratio: 0.4
C: FA: CA = 450:741.64:1103.07
=1:1.64:2.45
CUBES
Volume of 1 cube = 150*150*150
9 cubes =0.030m3
R.C.C unit weight = 24KN/m3
Weight =24*0.3075*103=72.9Kg
CYLINDER
Volume of 1 cylinder =𝜋r2h
= (22/7)*7.52*35
=5.3*10-3m3
Volume of 3 cylinders=0.016m3
R.C.C unit weight=24KN/m3
Weight =24*0.016*103=38.4Kg

For M30=1:1.64:2.45
Cement=21.864Kg
Fine aggregate=35.85Kg
Coarse aggregate=53.56Kg
W/c ratio=8.736liters