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PSZ 19:16 (Pind.1/97)
UNIVERSITI TEKNOLOGI MALAYSIA
BORANG PENGESAHAN STATUS TESIS♦
JUDUL:
_ _____ _
SESI PENGAJIAN: 2006/ 2007 / 01_ Saya: _______________ __________________ ___
(HURUF BESAR)
mengaku membenarkan tesis (PSM / Sarjana / Doktor Falsafah)* ini disimpan di Perpustakaan Universiti Teknologi Malaysia dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Teknologi Malaysia. 2. Perpustakaan Universiti Teknologi Malaysia dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. ** Sila tandakan ( ) (Mengandungi maklumat yang berdarjah keselamatan atau SULIT kepentingan Malaysia seperti yang termaktub di dalam ATKA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat Tetap:
_____________ _ _ _ ___________________________ Nama Penyelia
Tarikh: ___6 NOVEMBER 2006_____ Tarikh: ____6 NOVEMBER 2006___ __
769, TAMAN KOTAMAS, 70200 SEREMBAN, NEGERI SEMBILAN.
ONG CHEE HUAT
PERFORMANCE OF CONCRETE CONTAINING METAKAOLIN AS CEMENT REPLACEMENT MATERIAL
P.M. DR. ABDUL RAHMAN MOHD. SAM
TERHAD
CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu
dikelaskan sebagai SULIT atau TERHAD. ♦ Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara
Penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
“I/We hereby declare that I/we have read this project report and in my/our opinion this
report is sufficient in terms of scope and quality for the award of the degree of Master of
Engineering (Civil - Structure).”
Signature :
Name of Supervisor : Assoc. Prof. Dr. Abdul Rahman Mohd. Sam
Date : 6 November 2006
PERFORMANCE OF CONCRETE CONTAINGING METAKAOLIN AS
CEMENT REPLACEMENT MATERIAL
ONG CHEE HUAT
A project report submitted in partial fulfillment of
the requirements for the award of the degree of
Master of Engineering (Civil - Structure)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
NOVEMBER, 2006
ii
I declare that this project entitled “Performance of Concrete Containing Metakaolin
As Cement Replacement Material” is the result of my own research except as cited in
the references. The report has not been accepted for any degree and is not
concurrently submitted in candidature of any other degree.
Signature :
Name of Author : Ong Chee Huat
Date : 6/11/2006
iii
To my beloved parents and family
iv
ACKNOWLEDGEMENT
I would like to express my greatest appreciation to my supervisor, Assoc.
Prof. Dr. Abdul Rahman Mohd. Sam, for his generous guidance, advice and
motivation throughout this research.
A special thank dedicated to my beloved parents and family, for their
continuing financial and morale supports throughout my studies. Finally, my sincere
appreciation also extends to all my friends, the structural laboratory personnel, those
who were directly or indirectly involved in the process of producing this research
report, for their generous assistance, useful views and tips.
Without their support and contribution, this research project would not have
been possible.
v
ABSTRACT
Concrete is probably the most extensively used construction material in the
world. However, environmental concerns both in terms of damage caused by the
extraction of raw material and CO2 emission during cement manufacture have
brought pressures to reduce cement consumption by the use of supplementary
materials. The utilization of calcined clay, in the form of metakaolin (MK) in
concrete has received considerable attention in recent years. On this matter, a study
has been conducted to look into the performance of metakaolin as cement
replacement material in concrete. The study focuses on the compressive strength
performance of the blended concrete containing different percentage of metakaolin.
The cement is replaced accordingly with the percentage of 5 %, 10%, 15%, 20% and
30% by weight. Concrete cubes are tested at the age of 1, 3, 7, and 28 days. In
addition, the effect of calcination temperature to the strength performance is included
in the study. Finally, the strength performance of metakaolin-concrete is compared
with the performance of concrete blended with silica fume and slag. The results show
that the strength development of concrete blended with metakaolin is enhanced. It
was found that 10% replacement appears to be the optimum replacement where
concrete exhibits enhanced compressive strength at all ages comparable to the
performance of SF and GGBS. The study also reveals that optimum calcination
temperature of 750°C is important to improve the performance of metakaolin-
concrete.
vi
ABSTRAK
Konkrit merupakan salah satu bahan binaan yang paling banyak digunakan
dalam dunia. Akan tetapi, terdapat masalah pencemeran persekitaran yang
disebabkan oleh penggunaan simen dalam konkrit. Pencemaran berlaku semasa
pengekstrakan bahan mentah dan penghasilan karbon dioksida semasa pemprosesan
simen. Hal ini telah menimbulkan tekanan untuk mengurangkan penggunaan simen
dan diganti oleh bahan gantian. Penggunaan tanah liat terbakar dalam bentuk
metakaolin (MK) dalam konkrit telah mendapat perhatian yang lebih kebelakangan
ini. Dalam hal ini, satu kajian telah dijalankan untuk mengkaji prestasi metakaolin
sebagai bahan gantian simen dalam konkrit. Kajian ditumpukan ke atas kekuatan
mampatan konkrit yang mengandungi metakaolin dalam peratusan yang berbeza.
Simen digantikan dalam peratusan 5 %, 10%, 15%, 20% dan 30% mengikut berat.
Kekuatan konkrit diuji pada hari ke-1, 3, 7 dan 28. Pada masa yang sama, pengaruh
suhu bakaran ke atas kekuatan mampatan turut dikaji. Prestasi kekuatan konkrit-
metakaolin juga dibandingkan dengan prestasi konkrit yang mengandungi wasap
silika dan sanga relau bagas. Keputusan eksperimen menunjukkan gantian
metakaolin dalam konkrit telah meningkatkan perkembangan kekuatan mampatan
konkrit di mana gantian 10% merupakan peratusan gantian yang paling optima.
Kajian juga mendapati metakaolin adalah setara dengan bahan gantian simen yang
lain seperti wasap silika dan sanga relau bagas dalan perkembangan dan peningkatan
kekuatan mampatan konkrit. Suhu bakaran didapati mempunyai pengaruh yang
ketara terhadap kekuatan mampatan konkrit-metakaolin. Kajian menunjukkan Suhu
bakaran setinggi 750°C merupakan suhu yang paling sesuai bagi meningkatkan
prestasi konkrit-metakaolin.
vii
CONTENTS
CHAPTER SUBJECT PAGE
THESIS TITLE i
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF SHORTFORMS xvi
LIST OF APPENDICES xv
CHAPTER I INTRODUCTION 1
1.0 Introduction 1
1.1 Objective of Study 3
1.2 Significant of the Study 3
1.3 Scope of Study 4
viii
CHAPTER II LITERATURE REVIEW 6
2.0 Concrete 6
2.1 Cement 8
2.2 Cement Replacement Material 10
2.2.1 Pozzolanic Behavior 10
2.2.2 Types of Material 11
2.3 Kaolin 14
2.3.1 Classification 15
2.3.2 Mineralogy 16
2.4 Physical and Chemical Properties of Kaolin 16
2.4.1 Particle Size 17
2.4.2 Color and Brightness 18
2.4.3 pH 19
2.4.4 Chemical Composition 19
2.5 Application and Specification 20
2.5.1 Paper 20
2.5.2 Ceramic and Refractory 21
2.5.3 Rubber 22
2.5.4 Paints 22
2.5.5 Others Uses 23
2.6 Calcination 24
2.6.1 Temperature 26
2.6.2 Method of Calcination 28
2.7 Metakaolin 29
2.7.1 Sources for Metakaolin 30
2.7.2 High Reactivity Metakaolin 31
2.8 The Pozzolanic Reaction 33
CHAPTER III RESEARCH METHODOLOGY 35
3.0 Introduction 35
3.1 Materials 36
ix
3.1.1 Cement 36
3.1.2 Kaolin 37
3.1.3 Silica Fume 37
3.1.4 Ground Granulated Blast Furnace Slag 37
3.1.5 Sand and Aggregate 40
3.1.6 Water 40
3.2 Calcining Kaolin 41
3.3 Concrete Mixes 42
3.4 Mixing Procedure 43
3.5 Preparing Test Cubes 44
3.6 Curing 44
3.7 Compression Test 46
CHAPTER IV RESULT AND DISCUSSION 48
4.0 Introduction 48
4.1 Effect of MK to Compressive Strength 49
4.1.1 5% and 15% Replacement 49
4.1.2 10% Replacement 53
4.1.3 20% and 30% Replacement 55
4.2 Effect of Calcination Temperatures to Strength 60
Development
4.2.1 Effect of Calcination 60
4.3 Effect of Calcination Temperature 61
(10% Replacement)
4.4 Effect of Calcination Temperature 67
(20% Replacement)
4.5 Comparison between MK and Others Pozzolans 71
to the Strength Performance of Concrete
4.6 Further Discussion 75
x
CHAPTER V CONCLUSIONS AND RECOMMENDATIONS 80
5.1 Conclusion 80
5.2 Recommendations 81
REFERENCE 83
APPENDIX 86
xi
LIST OF TABLES
TABLE NO. TITLE` PAGE
2.1 Typical Properties of Normal-Strength Portland 7
Cement Concrete.
2.2 Properties of Kaolin. 17
2.3 Chemical Properties of Kaolin 19
3.1 Properties of Cement, Kaolin, SF and GGBS 38
3.2 Mix Proportions 43
4.1 Cube Test Results for Different Mix Ratios 51
4.2 Cube Test Results for Mixes with Different Calcination 62
Temperatures
4.3 Cube Test Results for Mixes with Different Calcination 67
Temperatures
4.4 Strength Comparison between MK, SF and GGBS Concrete 71
4.5 Compression Test Results for Cubes Cured In Water 75
4.6 Compression Test Results for Cubes Cured Using Sacks 76
xii
LIST OF FIGURES
FIGURE NO. TITLE` PAGE
2.1 Fly Ash. 11
2.2 Silica Fume. 13
2.3 Kaolin. 14
2.4 Structure of Kaolinite. 15
2.5 Kaolin Particle Size. 18
2.6 Crystalline of Kaolinite. 24
2.7 DTA Curve. 25
2.8 SEM Photographs of Calcined Kaolin at Temperature 27
(a) 550°C, (b) 650°C, (c) 800°C and (d) 900°C.
2.9 Rotary Kiln. 28
2.10 Metakaolin Particle. 30
3.1 Flow Chart of the Study. 36
3.2 Kaolin. 39
3.3 Silica Fume. 39
3.4 Ground Granulated Blast Furnace Slag. 39
3.5 Oven for Heating the Aggregates. 40
3.6 Calcining Kaolin. 41
3.7 Kaolin Before Calcination and After Calcination. 42
3.8 Curing Using Sacks. 45
3.9 Covering the Sacks with Plastic Sheets. 45
3.10 Concrete Cubes. 46
3.11 Compression Test 47
3.12 The Tested Cubes 47
xiii
4.1 Compressive Strength For 5% And 15% Replacement 52
Compared to Control
4.2 Compressive Strength For 10% Replacement Compared 54
to Control
4.3 Compressive Strength For 20% And 30% Replacement 56
Compared to Control
4.4 Strength Development for Various Mixes 59
4.5 Strength Performance With 10% MK Calcined at Various 63
Temperatures
4.6 XRD Pattern of Kaolin 64
4.7 Strength Performance With 20% MK Calcined at Various 68
Temperatures
4.8 Strength Comparison for MK, SF and GGBS Concrete 72
4.9 Compression Test Results For Cubes Cured In Water and 77
Cured Using Sacks
4.10 White Sediment Forming On The Top of the Cube 78
4.11 Bubbles on the Surface of the Cube 79
xiv
LIST OF SHORTFORMS
% - percentage
°C - Celcius
GGBS - Ground Granulated Blast Furnace Slag
kg - kilograms
m - meter
m3 - meter cubes
MK - Metakaolin
MPa - Mega Pascal
SF - Silica Fume
xv
LIST OF APPENDICES
APPENDIX TITLE` PAGE
A Silica Fume 86
1
CHAPTER 1
INTRODUCTION 1.0 Introduction
Concrete is one of the most common materials used in the construction
industry. In the past few years, many research and modification has been done to
produce concrete which has the desired characteristics. There is always a search for
concrete with higher strength and durability. In this matter, blended cement concrete
has been introduced to suit the current requirements. Cementitious materials known
as pozzolans are used as concrete constituents, in addition to Portland cement.
Originally the term pozzolan was associated with naturally formed volcanic ashes
and calcined earths will react with lime at ambient temperatures in the presence of
water. Recently, the term has been extended to cover all siliceous/aluminous
materials which, in finely divided form and in the presence of water, will react with
calcium hydroxide to form compounds that possess cementitious properties. The
current area of research in the concrete is introducing clay (metakaolin) in the
concrete. Clays have been and continue to be one of the most important industrial
minerals. Clays and clay minerals are widely utilized in our society. They are
important in geology, agriculture, construction, engineering, process industries, and
environmental applications. Traditional applications of clay including ceramics,
2
paper, paint, plastics, drilling fluids, chemical carriers, liquid barriers, and catalysis.
Research and development activities by researchers in higher education and industry
are continually resulting new and innovative clay products.
Metakaolin is one of the innovative clay products developed in recent years.
It is produced by controlled thermal treatment of kaolin. Metakaolin can be used as a
concrete constituent, replacing part of the cement content since it has pozzolanic
properties. The use of metakaolin as a partial cement replacement material in mortar
and concrete has been studied widely in recent years. Despite of the recent studies,
there are still many unknowns with the use of metakaolin. Study is needed to
determine the contribution of metakaolin to the performance of hardened concrete.
There are great concerns on the strength and durability of metakaolin-concrete when
used as construction materials in the construction industries. If it is proven that the
concrete is durable and strong, this will lead to the use of metakaolin to replace part
of the cement.
3
1.1 Objective of Study This study is conducted to accomplish some predefined objectives. These
objectives are:
i) To study the performance of concrete containing different percentages
of metakaolin and to identify the optimum replacement percentage. ii) To investigate the effect of calcination temperatures to the strength
performance of metakaolin-concrete.
iii) To compare the performance of metakaolin with other cement
replacement materials (CRMs).
1.2 Significant of the Study Concrete has been used in the construction industry for centuries. Many
modifications and developments have been made to improve the performance of
concrete, especially in terms of strength and durability. The introduction of pozzolans as cement replacement materials in recent
years seems to be successful. The use of pozzolan has proven to be an effective
solution in enhancing the properties of concrete in terms of strength and durability.
The current pozzolans in use are such as fly ash, silica fume and slag. Development
and investigation of other sources of pozzolan such as kaolin will be able to provide
more alternatives for the engineer to select the most suitable cement replacement
4
material for different environments.
Unlike other pozzolans, metakaolin is not a by-product which means its
engineering values are well-controlled. Therefore, using metakaolin should promise
some advantages compared to other cement replacement materials. In this case,
studies are needed to study the performance of concrete using metakaolin. The
performance of metakaolin-concrete will be compared to the cost of production of
metakaolin to determine whether metakaolin is worthy to be developed as a new
cement replacement material. In addition, the use of metakaolin is not common in the Malaysian
construction sector. This study will be able to enhance the understanding on the
suitability of metakaolin as cement replacement material. 1.4 Scope of Study
This study focuses on the strength performance of concrete with metakaolin.
Strength is the most important property of concrete since the first consideration in
structural design is that the structural elements must be capable of carrying the
imposed loads. Strength characteristic is also important because it is related to
several other important properties which are more difficult to measure directly. With regard to this matter, the development of compression strength of
metakaolin concrete is studied. Cement replacements by 5%, 10%, 15%, 20% and
30% with metakaolin are studied. Concrete tests are conducted on the concrete
samples at the specific ages. All the strength tests are limited to the ages of 28 days.
5
In the study of the effect of calcination temperatures to the strength
performance of metakaolin, the temperatures is set within the range of 600°C-800°C.
The temperatures interval used is 50°C. For the performance comparison study, the cement replacement materials
used are silica fume and ground granulated blast furnace slag. These two cement
replacement materials are chosen as they are the most common replacement
materials nowadays and will be good comparisons to metakaolin. The comparison is
made on the compressive strength performance of metakaolin, silica fume and slag
concrete.
6
CHAPTER 2
LITERATURE REVIEW 2.0 Concrete
Concrete is known to be a simple material in appearance but with a very
complex internal nature. In contrast to its internal complexity, versatility, durability,
and economy of concrete have made it the most frequently used construction
material in the world. Concrete is a mixture of cement, water, and aggregates, with or without
admixtures. The cement and water will form a paste that hardens as a result of a
chemical reaction between the cement and water. The paste acts as glue, binding the
aggregates (sand and gravel or crushed stone) into a solid rock-like mass. The quality
of the paste and the aggregates dictate the engineering properties of this construction
material. During hydration and hardening, concrete will develop certain physical and
chemical properties, among others, mechanical strength, low permeability and
chemical and volume stability. Concrete has relatively high compressive strength,
but significantly lower tensile strength (about 10% of the compressive strength).
Table 2.1 shows the typical properties of normal strength Portland cement concrete
(Hewlett, 1998).
7
Table 2.1: Typical Properties of Normal-Strength Portland Cement Concrete
Characteristic
Compressive strength 20–40 MPa
Flexural strength 3–5 MPa
Tensile strength 2–5 MPa
Modulus of elasticity 14,000–41,000 MPa
Permeability 1x10–10 cm/sec
Coefficient of thermal expansion 10–5/°C
Drying shrinkage 4–8 x 10–4
Drying shrinkage of reinforced concrete 2–3 x 10–4
Poisson’s ratio 0.20–0.21
Shear strain 6000–17,000 MPa
Density 2240–2400 kg/m3
Concrete is used to make pavements, building structures, foundations, roads,
overpasses, parking structures, brick/block walls and bases for gates, fences and
poles. Over six billion tons of concrete are made each year, amounting to the
equivalent of one ton for every person on Earth, and powers a US$35 billion industry
which employs over two million workers in the United States alone (Kosmatka,1999).
Over 55,000 miles of freeways and highways in America are made of concrete.
8
2.1 Cement
Cements may be defined as adhesive substances capable of uniting
fragments or masses of solid mater to a compact whole (Lea, 1970). Portland cement
was invented in 1824 by an English mason, Joseph Aspdin, who named his product
Portland cement because it produced a concrete that was of the same color as natural
stone on the Isle of Portland in the English Channel. Raw materials for manufacturing cement consist of basically calcareous and
siliceous (generally argillaceous) material. The mixture is heated to a high
temperature within a rotating kiln to produce a complex group of chemicals,
collectively called cement clinker (Neville, 1987). Cement is distinct from the
ancient cement. It is termed hydraulic cement for its ability to set and harden under
water. Briefly, the chemicals present in clinker are nominally the four major potential
compounds and several minor compounds. The four major potential compounds are
normally termed as tricalcium silicate (3CaO.SiO2), dicalcium silicate (2CaO.SiO2),
tricalcium aluminate (3CaO.Al2O3) and tetracalcium aluminoferrite (4CaO.
Al2O3.Fe2O3). The American Society for Testing and Materials (ASTM) Standard C 150,
Specification for Portland cement, provides for the following types of Portland
cement:
Type I General Portland cement
Type II Moderate-sulfate-resistant cement
Type III High-early-strength cement
Type IV Low–heat-of-hydration cement
Type V High-sulfate-resistant cement
9
Type I Portland cement is a general cement suitable for all uses where
special properties of other cements are not required. It is commonly used in
pavements, building, bridges, and precast concrete products.
Type II Portland cement is used where precaution against moderate sulfate
attack is important where sulfate concentrations in groundwater or soil are higher
than normal, but not severe. Type II cement can also be specified to generate less
heat than Type I cement. This moderate heat of hydration requirement is helpful
when placing massive structures, such as piers, heavy abutments, and retaining walls.
Type II cement may be specified when water-soluble sulfate in soil is between 0.1
and 0.2%, or when the sulfate content in water is between 150 and 1500 ppm. Types
I and II are the most common cements available. Type III Portland cement provides strength at an early age. It is chemically
similar to Type I cement except that the particles have been ground finer to increase
the rate of hydration. It is commonly used in fast-track paving or when the concrete
structure must be put into service as soon as possible, such as in bridge deck repair. Type IV Portland cement is used where the rate and amount of heat
generated from hydration must be minimized. This low heat of hydration cement is
intended for large, massive structures, such as gravity dams. Type IV cement is
rarely available. Type V Portland cement is used in concrete exposed to very severe sulfate
exposures. Type V cements would be used when concrete is exposed to soil with a
water-soluble sulfate content of 0.2% and higher or to water with over 1500 ppm of
sulfate. The high sulfate resistance of Type V cement is attributed to its low
tricalcium aluminate content.
10
2.2 Cement Replacement Material With the extensively use of cement in concrete, there has been some
environmental concerns in terms of damage caused by the extraction of raw material
and CO2 emission during cement manufacture. This has brought pressures to reduce
the cement consumption in the industry. At the same time, there are getting more
requirements for enhancement in concrete durability to sustain the changing
environment which is apparently different from the old days.
With the development in concrete technology, cement replacement materials
(CRM) have been introduced as substitutes for cement in concrete. Several types of
materials are in common use, some of which are by-products from other industrial
processes, and hence their use may have economic advantages. However, the main
reason for their use is that they can give a variety of useful enhancements or
modifications to the concrete properties. All the materials have two common features
(Malhotra, 1986): i) Their particle size range is similar to or smaller than that of Portland
cement. ii) They are pozzolan material.
2.2.1 Pozzolanic Behavior
A common feature of nearly all CRM is that they exhibit pozzolanic behaviour.
Pozzolanic materials the materials which contains active silica (SiO2) and
