INTRODUCTION

1. The world ecosystem is constantly facing with

severe ecological problems.
2. The effect of extremities to environmental aspects.
3. Use of SCMs( supplementary cementitious
material) as replacement of cement.(most of the
SCMs are waste product which possesses
pozzolonic activity.
4. Thus SCM has been an ultimate solution to concrete
world and by time has proved its worth.
5. This following work is also an attempt to make
concrete healthier and durable.

OBJECTIVE OF PROJECT
1) To finalize percentage of fly ash and metakaolin
to make ternary blended cement concrete.
2) To check workability of concrete by using
supplementary cementitious material by various
methods of workability and comparison to
conventional concrete.
3) Effect of ternary blended cement concrete in
flexural,compressive and split tensile strength of
concrete in comparison with conventional
concrete.
4) To select best combination of cementitious
material of fly ash and metakaolin

MATERIALS AND METHODOLOGY

The materials used are ;

1. Cement
: Ultratech OPC-53
2. Fly Ash
: Class F fly-ash
3. Metakaolin
: Zigma Internationals,
Khopoli
4. Water
: Potable Water
5. Fine aggregates : Locally available
6. Coarse aggregates : Locally available

a. Fly Ash
1. Fly ash, also known as flue-ash, is one of the
residues generated in combustion, and comprises
the fine particles that rise with the flue gases.
2. Fly ash is produced from the combustion of
pulverized coal in industrial boilers or electric
utility boilers.
3. The physical and chemical characteristics of fly
ash depend on (i) combustion methods, (ii) coal
source, and (iii) particle shape.
4. There are basically two classes of fly ash as
defined by ASTM C618 as:1. Class F Fly ash
2. Class C Fly ash

b. Metakaolin
1. Metakaolin is classified as a new generation of
supplementary cementitous material. Supplementary
cementitious materials (SCMs) are finely ground solid
materials that are used to replace part of the clinker
in a cement or cement in a concrete mixture .
2. It is derived from a naturally occurring mineral Kaolin, and is manufactured specifically for
cementing applications.
3. Metakaolin is usually produced by thermal
treatment, i.e., calcination of kaolin clays within a
definite temperature range. The process is known as
dehydroxylation .

Chemical Properties of Materials used

Chemical Property

OPC(ultratech-53)

Fly- Ash

Metakaolin

dioxide

20.25

49-67

60-65

oxide

63.61

1-4

0.2-0.8

oxide

4.56

0.2-2

0.2-0.8

Sodium oxide (NaO)

0.08

--------

0.5-1.2

Potassiumoxide(K2

0.51

--------

Loss on ignition

3.12

0.5-3.0

<1.4

Alumina (Al2O3)

-------

16-29

---------

Silicon
(SiO2)
Calcium
(CaO)
Magnesium
(MgO)

O)

Concrete Mixes Prepared as Test Specimen

Conventional

Fly-ash

Metakaolin

100% cement

0%

0%

95%

90

10

85

15

80

20

95%

90

10

85

15

80

20

concrete

Conventional concrete
90

Fly-ash

Metakaolin

(by mass)

(by mass)
5

85

10

80

15

75

20

85

10

80

10

75

15

70

20

80

15

75

10

70

15

65

20

75

20

70

10

65

15

60

20

Lab Tests conducted

A. Cement tests :
1. Fineness Test (IS 4031-Part-III)
2. Standard Consistency(IS 4031-Part-IV)
3. Initial and Final setting time (IS 4031-Part V)
B. Aggregates tests :
1. Aggregate impact value(IS 2386-Part-IV)-1963
2. Aggregate Crushing Value(IS 2386-Part-IV)-1963
3. Shape Test-(IS 2386-Part-I)-1963
4. Specific Gravity(IS 2386 Part-III)-1963
5. Moisture content of aggregates(IS 2386-Part-III)-1963
C. Concrete tests :
1. Fresh Concrete tests : Workability tests
2. Hardened Concrete tests : strength tests

Mix Design for M 40 Grade of Concrete

Quantity of materials for 1 m3 of concrete;
a)cement-443.25kg/m3
b)sand-668.0625 kg/m3
c)coarse aggregate-1188.28 kg/m3
d)water-177.3kg/m3
f)chemical admixture-8.88kg/m3

Results and Discussions

Workability of individual blend of cement
Mix Combination

Slump of concrete

Compaction factor Flow test

Workability

Conv.Concrete

89

0.89

70%

Medium

70%

workability
Medium

5 % FA

90

0.86

10 % FA

95

0.89

77%

workability
Good workability

15 % FA

107

0.92

90%

High workability

20 % FA

121

0.97

92%

High workability

5 % MK

78

0.85

75%

Medium

10 % MK

75

0.8

68%

workability
Low workability

15 % MK

67

0.76

65%

Low workability

20 % MK

58

0.75

59%

Poor workability

140

120

height in mm

100

80

60

40

20

0
5.000000000000001E-2

0.1

0.15000000000000016

0.2

100%
90%
80%
70%
60%

% flow values

50%
40%
30%
20%
10%
0%
0.05

0.1

0.15000000000000016

0.2

1.2

0.8

0.6
compaction factor values

0.4

0.2

0
0.05

0.1

0.15000000000000016

0.2

Workability of Ternary blended cement concrete.

Mix Combination

Conv.Concrete
5%FA+5%MK
5%FA+10%MK
5%FA+15%MK
5%FA+20%MK
10%FA+5%MK
10%FA+10%MK
10%FA+15%MK
10%FA+20%MK
15%FA+5%MK
15%FA+10%MK
15%FA+15%MK
15%FA+20%MK
20%FA+5%MK
20%FA+10%MK
20%FA+15%MK

Slump of concrete

Compaction factor

Flow test

Workability

89

0.887

70%

Medium workability

66

0.87

79%

Medium workability

58

0.85

73%

Medium workability

50

0.77

65%

Low workability

42

0.75

58%

Poor workability

79

0.89

69%

Medium workability

68

0.83

74%

Medium workability

61

0.80

74%

Medium workability

45

0.76

62%

Low workability

113

0.92

89%

High workability

104

0.95

92%

High workability

89

0.86

73%

medium workability

81

0.84

70%

medium workability

120

0.97

94%

High workability

109

0.97

95%

High workability

93

0.90

76%

medium workability

87

0.85

75%

medium workability

140
120
100
80
60
40

20 % FA

20

15 % FA
10 % FA

0
0 % MK

5 % MK

5 % FA
10 % MK

15 % MK

0 % FA
20 % MK

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
20 % FA

0.2

15 % FA

0.1

10 % FA

0
0 % MK

5 % MK

5 % FA
10 % MK

15 % MK

0 % FA
20 % MK

100
90
80
70
60
50
40
30

20 % FA

20

15 % FA

10

10 % FA

0
0 % MK

5 % MK

5 % FA
10 % MK

15 % MK

0 % FA
20 % MK

Compressive Strength of cubes

Sr. No.

Replacement
(%)

Levels

Compressive Strength (MPa)

3 days

7 days

28 days

PCC

25.78

32.44

41.78

5 % FA

23.56

35.56

41.33

10 % FA

22.89

34.22

40.44

15 % FA

21.78

32.22

38.67

20 % FA

20.89

30.67

37.78

5 % MK

25.56

33.33

42.22

10 % MK

27.11

35.11

44.89

15 % MK

28.22

36.44

47.11

50
45
40
35

compressive strength
30
25

3 days strength

20
15

7 days strength

10

28 days
strength

5
0

Replacement Levels (%)

Split Tensile Strength of Concrete of

individual Blend
Sr.No.

Replacement levels (%)

Split
Tensile
test result

Fly Ash for Cement

Metakaolin for Cement

28 days

1.

4.53

2.

4.84

3.

10

4.73

4.

15

4.56

5.

20

4.10

6.

3.75

split tensile strength

5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0

split tensile
strength

Compressive strength and split tensile strength of ternary blended concrete

Sr.

Replacement levels (%)

Compressive Strength (MPa)

Split

No.

Tensile
Strength
Fly

Ash

Cement

forMetakaolin
cement

for
3 days

7 days

28 days

28 days

1.

25.78

32.44

41.78

4.53

2.

24.56

34.45

41.78

3.89

3.

10

25.34

35.34

43.11

4.13

4.

15

25.89

38.67

49.78

4.67

5.

20

25.45

36.65

45.89

5.77

6.

10

24.22

34.78

41.33

5.45

7.

10

10

25.34

34.67

42.67

4.97

10

15

25.56

35.67

46.34

6.23

10

20

25.11

34.89

43.56

5.67

10

15

23.67

32.78

41.45

4.89

11

15

10

24.45

34.78

41.67

5.13

12

15

15

25.33

34.45

45.12

4.45

13

15

20

24.56

33.89

42.56

4.05

Comparative study of comp. strength of ternary blend for various durations of curing

50
45
40
35
30
25
20
compressive strength
15
10
5
0

Comparative study of split tensile test for

ternary blended concrete
7

split tensile
strength
5
4

Flexural strength of individual blend of

concrete
Sr. No.

Concrete designation

Avg flexural strength (N/mm2)

Conventional Conrete

6.39

5% by mass of FA

5.49

10% by mass of FA

5.46

15% by mass of FA

5.44

20% by mass of FA

4.70

5% by mass of MK

6.59

10% by mass of MK

6.93

15% by mass of MK

7.20

20% by mass of MK

6.39

Impact test results for individual blend of concrete

Sr. No.

Concrete designation

Avg failure strength (blows)

Conventional Conrete

31

5% by mass of FA

34.5

10% by mass of FA

41

15% by mass of FA

47

20% by mass of FA

46.5

5% by mass of MK

55.5

10% by mass of MK

76

15% by mass of MK

81.5

20% by mass of MK

94

Water Absorption test for blended concrete

Mix Designation

Concrete Grade

Weight of Concrete Weight of Concrete Increase in mass of

blocks

before blocks

immersion in water days

(kg)

after

30 concrete

immersion

(kg)

(%)

OPC

M40

8.130

8.750

7.085

5%MK

M40

8.180

8.560

4.439

10%MK

M40

8.230

8.600

4.302

15%MK

M40

8.195

8.550

4.152

20%MK

M40

8.200

8.500

3.529

5%FA

M40

8.310

8.650

3.931

10%FA

M40

8.180

8.560

4.439

15%FA

M40

8.124

8.520

4.126

20%FA

M40

8.115

8.510

4.223

Conclusion
From the study, it can be concluded that:
Metakaolin is an effective pozzolana and results in enhanced early strength and
ultimate strength of concrete.
At initial stages use of plasticizers were made and results regarding strength, split
tensile and workability were studied.
It was found that use of plasticizers gave nearly similar value of compressive
strength but split tensile slightly improved.
Placing and finishing concrete becomes easier because of the improved workability
from the spherically shaped fly ash particles. Lower slump concrete can be placed
more easily (and at lower water content) because of the plasticity provided by fly
ash spheres. Segregation and bleeding are reduced because of to the increased
cohesiveness of fly ash concrete, so form finish and sharpness of detail are
enhanced. And coarse, clean sands can be used in concretes utilizing fly ash and
still have good workability.
Various workability tests reveal that concrete used with fly-ash and metakaolin
provides quite better results against abrasive environments. The use of ternary
blend ensures lesser permeability which was proved by moisture test on hardened
concrete after 60 days.
The split tensile test results shows that though MK improves the compressive
strength but when FA was added as an admixture the split tensile was improved as
compared to OPC.
Thus it proves that when cement is blended with certain pozzolanic materials it
gives better results against durability and is safer than the normal cement concrete
.