Type

OPC
MK

Sio2
21.8
52.3

Al2O3
4.8
44.9

Fe2O3
3.8
0.4

CaO
63.3
0.5

SO3
2.2
<0.1

MgO
0.9
0.2

Na2O
0.21
0.12

K2O
0.46
0.02

FAs
h

9.91

20.8

49.0

1.92

0.21

<0.01

4.11

<0.01

Chapter 3
Materials and testing
3.1. Materials
The following are the materials that were used in this investigation. The chemical composition of
ordinary Portland Cement (OPC), Metakaolin (MK) and Fly Ash are presented in Table 1.

Ordinary Portland Cement (OPC), 53 Grade conforming to BIS: 12269 1987 (specific

gravity: 3.15).
Metakaolin as mineral admixture in dry densified form was obtained from ASHWIN
CERAMICS, Chennai conforming to ASTM C 1240 (specific gravity: 2.54).
FlyAsh as mineral admixture in dry densified form was obtained from RMC plant,
Tatuguni, Bengaluru conforming to ASTM C 1241 (specific gravity: 2.06).
Superplasticizer (chemical admixture) based on Polycarboxy ethylene PC 20 was
obtained from MYK SCHOMBERG INDIA PVT LTD, Bengaluru conforming to BIS:
9103 1999 and ASTM C-494.
Locally available quarried and crushed granite stones confirming to graded aggregate of
nominal size 12.5 mm as per table 2 of BIS: 383 1970 (specific gravity: 2.82) as Coarse
aggregates (CA).
Locally available river sand confirming to grading zone II of table 4 BIS: 383-1970
(specific gravity: 2.60) as fine aggregates (FA).
Table1. Chemical Composition of OPC, MK and FlyAsh

Cement (g)

FAsh (g)

MK (g)

Water (ml)

w/c ratio

325.5
322.0
318.5
325.5
322.0
318.5
325.5
322.0
318.5

24.5
28.0
31.5
24.5
28.0
31.5
24.5
28.0
31.5

32.55
32.20
31.85
35.81
35.42
35.04
39.06
38.64
38.22

126.24
133.77
133.64
138.90
145.24
146.31
132.28
139.92
139.78

0.33
0.35
0.35
0.36
0.38
0.38
0.34
0.36
0.36

Penetration
( mm)
6
7
5
6
7
7
7
6
6

Normal
consistency
0.33
0.35
0.35
0.36
0.38
0.38
0.34
0.36
0.36

Na2

O
K2O
Ig. loss

2.0

0.8

3.2. Testing
Normal consistency on binder materials i.e. Cement, Metakaolin, Flyash were carried out as per
BIS: 269 1989 and IS: 4031 1988 ( Part 4) by adding metakaoin by 10, 11, 12 percent and
replacing Flyash by 7, 8 ,9 percent. The details of the mix proportions and normal consistency
are given in table2 and detailed procedure is given in Appendix B.1.

Table2. Details of mix proportion for normal consistency

Initial and final setting time were carried out as per BIS: 269 1989 and IS: 4031 1988 ( Part
5) by adding metakaoin by 10, 11, 12 percent and replacing Flyash by 7, 8 ,9 percent. Initial and
final setting time conforms to IS specifications. The details of the mix proportions and initial and
final setting time are given in Table3 and detailed procedure is given in Appendix B.2.
Table3. Details of mix proportion for initial and final setting time
Cement
(g)
325.5
322.0
318.5
325.5
322.0
318.5
325.5
322.0
318.5

FAsh
(g)
24.5
28.0
31.5
24.5
28.0
31.5
24.5
28.0
31.5

MK (g)
32.55
32.20
31.85
35.81
35.42
35.04
39.06
38.64
38.22

Water
(ml)
126.24
133.77
133.64
138.90
145.24
146.31
132.28
139.92
139.78

w/c ratio
0.33
0.35
0.35
0.36
0.38
0.38
0.34
0.36
0.36

Penetration(
mm)
6
7
5
6
7
7
7
6
6

Initial setting
time (min)

final setting
time (min)

11.50

Specific gravity of Cement was carried out as per BIS: 269 1989 and IS: 4031 1988 on OPC
53 Grade cement conforming to BIS: 12269 1987. Test results showed a specific gravity of 3.15
which conforms to the IS specifications. Detailed procedure are given in Appendix B.3.
Compressive strength of binder materials i.e. Cement, Metakaolin, Flyash was carried out as per
BIS: 269 1989 , IS 12269 1987, IS: 4031 1988( Part4) and IS: 4031-1988) on cube moulds
of size 75 x 75 x 75mm by varying mix proportions of binder materials. The test results showed
confirmation of binder materials to IS specifications under constant compressive load and it was
able to develop the required compressive strength of concrete. The details of the mix proportions
of compressive strength of binder material are given in table4 and detailed procedure are given in
Appendix B.4.

Table4. Details of mix proportion for compressive strength of Binder materials

Aggregate crushing value of coarse aggregates was carried out as per BIS:2386- 1963(Part 4) on
aggregates passing through 12.5 mm and retaining on 6.3 mm. Test results showed low crushing
values under a uniform loading of 4 tonne per minute until the total loading of 40 tonne. The

325.5
322.0
318.5

Cement (g)
24.5
28.0
31.5

32.55
32.20
31.85

FAsh
(g)
126.24
133.77
133.64

M
K
(g)

Wa
ter w/c
(ml rati
)
o
0.33
0.35
0.35

325.5
322.0
318.5

24.5
28.0
31.5

35.81
35.42
35.04

138.90
145.24
146.31

0.36
0.38
0.38

325.5
322.0
318.5

24.5
28.0
31.5

39.06
38.64
38.22

132.28
139.92
139.78

0.34
0.36
0.36

Lo
ad
(K
N)

Compressive
strength (N/mm2)

details of the aggregate crushing value procedure are given in Appendix B.5.
Specific gravity of coarse aggregate and water absorption test was carried out as per BIS: 383
1970 on Locally available quarried and crushed granite stones confirming to graded aggregate of
nominal size 12.5 mm. Test results showed a specific gravity of 2.82 which conforms to the IS
specifications. Detailed procedure is given in Appendix B.6.
Aggregate impact value of coarse aggregates was carried out as per BIS:2386- 1963(Part 4) on
aggregates passing through 12.5 mm and retaining on 6.3 mm. Test results showed low impact
value which implies high resistance to impact load. The details of the aggregate crushing value
procedure are given in Appendix B.7.
Specific gravity of Metakaolin was carried out confirming to ASTM C 1240 on MK. Test results
showed a specific gravity of 2.54 which conforms to the IS specifications. Detailed procedure are
given in Appendix B.8.
Specific gravity of Flyash was carried out confirming to ASTM C 1241 on Flyash. Test results
showed a specific gravity of 2.06 which conforms to the IS specifications. Detailed procedure are
given in Appendix B.9.

Marsh cone test was carried out confirming to ASTM C 1263 from which the optimum dosage of
Superplasticizer PCE based (PC20) was found to be 1.5% by weight of OPC 53 Grade cement.
Variation of marsh cone time is given in fig 1. Detailed procedure are given in Appendix B.10.

450
400
350
300
250
Marsh cone time in sec

200
150
100
50
0
1.1000000000000001

Superplasticizer dosage percent by weight of cement

Fig 1. Typical Relationship between Marsh Cone Time and Dosage

Summary
Yet to be written