IMPACT: International Journal of Research in

Engineering & Technology (IMPACT: IJRET)

ISSN(E): 2321-8843; ISSN(P): 2347-4599
Vol.Effective
4, Issue 3,Utilization
Mar. 2016,
of7-16
Industrial by- Products in Construction Industry
Impact Journals

EFFECTIVE UTILIZATION OF INDUSTRIAL BY- PRODUCTS IN

CONSTRUCTION INDUSTRY
PARVATHY A NAIR1 & APARNA ASHOK2
1

post Graduate Scholar, Department of Civil Engg, Indira Gandhi Institute of Engg &
Technology, Nellikuzhi, Kerala, India
2

asst Professor, Department of Civil Engg, Indira Gandhi Institute of Engg &
Technology, Nellikuzhi, Kerala India

ABSTRACT
Now a days large number of studies are going on to improve the performance of concrete with the help of
innovative chemical admixtures and supplementary cementitious materials .These materials used are majority by- products
or industrial waste from other processes. This paper presents results of experimental investigations on effect of addition of
industrial by products as partial replacement of cement on the mechanical properties of concrete. In this research the
Ordinary Portland Cement (OPC) has been replaced by industrial waste/by products (namely fly ash, micro silica,
metakaolin) accordingly in the range of 0%, 5%, 10%, 15% 20%, & 25% by weight. Concrete mixtures were prepared,
tested and compared in terms of compressive strength to the conventional concrete. Experimental results showed that
addition of supplementary cementitious materials increased strength of concrete up to certain percentages and then
decreased. Use of metakaolin imparted highest strength compared to other two materials. This experimental study also
compares the strength by adding replacement materials separately in varying proportions and also in combination to obtain
three types of triple blend mix .Compressive strength obtained for the triple blend mixes are also compared.

KEYWORDS: Compressive Strength, Flexural Strength, Split Tensile Strength, Fly Ash, Micro silica, Metakaloin
INTRODUCTION
In many of the countries huge amount of waste materials are produced annually. Most of these waste materials or
by products are not reusable or if they are, their recycling leads to wasting energy and pollution which in turn increase the
risk of these materials to the environment. Generally obtained by products or waste materials may or may not be further
processed for use in concrete .Majority of them are pozzolonic materials which by themselves do not have any
cementitious property ,but when used with Portland cement react to form cementitious compounds .The main benefits of
using alternative materials for cement replacement is to reduce the consumption of cement by a considerable amount and
still shows ability to display cementitious property and thus reducing the overall cost in construction. Moreover
replacement is a good strategy to achieve the two purposes of removing the waste materials and also obtaining the positive
qualities of concrete. This project mainly emphasis on the comparison of mechanical properties and development of
suitable concrete with partial replacement of cement by industrial wastes or by-products, (fly ash. Microsilica, metakaolin).

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Parvathy A Nair & Aparna Ashok

MATERIALS USED
Cement: Grade-53 Ordinary Portland Cement conforming to IS specifications was used in this study. Properties of
cement used is tabulated below
Table 1: Properties of Cement
Sl No
1
2
3
4

Properties
Standard consistency
Average compressive strength
Specific Gravity
Initial/Final setting time

Values obtained
35%
53.1
3.15
127/320 min

Fine aggregate: Manufactured sand with specific gravity 2.63, fineness modulus 2.53 was used. The maximum
size of fine aggregate was taken to be 4.75 mm.
Coarse Aggregate: Coarse aggregate with 20 mm nominal size and specific gravity 2.85, and fineness modulus 6.9
were used.
superplasticizer: A commercially available superplasticizer Master Rheobuild 1125 was used as admixture
Replacement materials used:
Fly ash also known as flue-ash is one of the residue generated in combustion of coal in thermal power plants. Fly
ash is generally captured by electrostatic precipitators or other particle filtration equipment before the flue gases reach the
chimneys. In this study low-calcium fly ash (Class F), having specific gravity 2.05 was used .Fly ash was collected from
Mettur thermal power plant.
Microsilica also known as silica fume is an amorphus polymorph of silicon dioxide. It is an ultra fine powder
collected as a by-product in the carbothermic reduction of high-purity quartz with carbonaceous materials like coal, coke,
wood chips in electric arc furnaces in the production of the silicon and ferrosilicon alloy and consist of spherical particles
with an average particle diameter of 150 nm. Commercially available micro silica were used to prepare specimens.
Specific gravity of micro silica used was 2.35.
Metakaolin is white, amorphous, highly reactive aluminium silicate pozzolan forming stabile hydrates after
mixing with lime stone in water and providing mortar with hydraulic properties. It is a dehydroxylated form of clay
mineral (aluminium silicate) and is obtained by thermal activation of kaolin clay. Particle size is less than fly ash (FA) and
greater than silica fume (SF).Metakaolin having specific gravity 2.6 was used for the study. Obtained from English India
Clay Ltd, Thonnakal, Kerala
Mix Proportions
Mix proportions were made for each set of replacement materials. First was control mix (without any replacement
material), and the other four mixes each contained cement replaced with fly ash, microsilica and metakaolin by weight.The
proportions of cement replaced were 5%, 10%, 15%, 20% & 25%.The control mix without replacement materials was
proportioned as per Indian standard Specifications IS: 10262-1982.M30 mix design is adopted in the experimental study
.Average compressive strength f 37.83 MPa was obtained for the control specimen. Mix proportion for control specimen
and replaced materials are given in the tables below
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Effective Utilization of Industrial by- Products in Construction Industry

Table 2: Mix Proportion for 1 M3 Control Mix

Cement
384Kg

Coarse Aggregate
1240Kg

Fine Aggregate
763Kg

Water
153 l

Admixture
2.88 Kg

Table 3: Mix Proportion for Cement Replacement by Fly Ash

For 1 M3 of Concrete
Cement(kg)
Water(litres)
Coarse aggregate(kg)
Fine aggregate(kg)
Slump obtained(mm)

5%
364.8
153
1231.86
757.85
65

% Replacement of Fly Ash

10%
15%
20%
345.6
326.4
307.2
153
153
153
1228.32 1224.77 1221.2
755.67
753.48
751.3
65
65
70

25%
288
153
1217.7
749.12
65

Table 4: Mix Proportion for Cement Replacement by Micro silica

For 1 M3 of Concrete
Cement(kg)
Water(litres)
Coarse aggregate(kg)
Fine aggregate(kg)
Slump obtained(mm)

% Replacement of Micro silica

5%
10%
15%
20%
25%
364.8
345.6
326.4
307.2
288
153
153
153
153
153
1231.86 1228.32 1224.77 1221.2 1217.7
757.85
755.67
753.48
751.3 749.12
65
65
65
70
65

Table 5: Mix Proportion for Cement Replacement by Metakaolin

For 1 M3 of Concrete
Cement(kg)
Water(litres)
Coarse aggregate(kg)
Fine aggregate(kg)
Slump obtained(mm)

5%
364.8
153
1231.86
757.85
65

% Replacement of Metakaolin
10%
15%
20%
25%
345.6
326.4
307.2
288
153
153
153
153
1228.32 1224.77 1221.2 1217.7
755.67
753.48
751.3 749.12
65
65
70
65

Experimental Procedures
Concrete cubes of size 150mm 150 mm 150 mm were cast for testing compressive strength, 150300 mm
cylinders for splitting tensile strength, 500mmx100mmx100mm beams for testing flexural strength.The machine was first
loaded with aggregates, cement and other replacement materials, mixed in dry condition. Half of total water was added
immediately after the initial rotation of the drum. The remaining water was added along with super plasticizer just after
drum is started. The period of mixing was not less than two minutes. After proper mixing concrete was tested for desired
slump and after casting, all the test specimens were finished with a Steel trowel. The specimens were carefully placed, and
allowed to settle. Later they were unmoulded and taken for curing after setting. Specimens were tested for 7 day and 28
day strength.
Triple Blend Mix
After obtaining the optimum percentages for cement replacement a new mix was developed by combining two
replacement materials simultaneously. Three set of mix design was developed by combining fly ash, micro silica and
metakaolin.
Type 1: partial replacement of cement by fly ash and micro silica (10+10) %
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Parvathy A Nair & Aparna Ashok

Type 2: partial replacement of cement by fly ash and metakaolin (10+10) %

Type 3: partial replacement of cement by micro silica and metakaolin (10+10) %
Compressive strength for 7 days and 28 days is determined
Table 6: Triple Blend Mix Fly Ash + Micro silica (10+10) %
Materials
concrete
Cement (kg)
Fly ash (kg)
Micro silica (kg)
Water (litre)
Coarse aggregate (kg)
Fine aggregate (kg)
Slump obtained (mm)
Superplasticizer added (% weight of total cementatious material)

Amount
1m3
307.2
38.4
38.4
153
1217.13
748.79
38
.98

Table 7: Triple Blend Mix Fly Ash + Metakaolin (10+10) %

Materials
concrete
Cement (kg)
Fly ash (kg)
Micro silica (kg)
Water (litre)
Coarse aggregate (kg)
Fine aggregate (kg)
Slump obtained (mm)
Superplasticizer added (% weight of total cementatious material)

Amount
1 m3
307.2
38.4
38.4
153
1219.8
750.43
45
1

Table 8: Triple Blend Micro silica + Metakaolin (10+10) %

Concrete
concrete
Cement (kg)
Fly ash (kg)
Micro silica (kg)
Water (litre)
Coarse aggregate (kg)
Fine aggregate (kg)
Slump obtained (mm)
Superplasticizer added (% weight of total cementatious material)

Amount
1 m3
307.2
38.4
38.4
153
1223.92
752.95
48
.95

Standard cubes of size 150x150x150mm were casted and cured, compressive strength was determined. Cement is
replaced by 20% with the addition of supplementary cementitious materials (fly ash, microsilica and metakaolin) to form a
ternary blend using the above said mix proportions.

RESULTS AND DISCUSSIONS

A.Compressive Strength
Standard cubes casted were loaded to failure in compression testing machine .The cubes were tested for 7 day
strength and 28 day strength. Load values obtained for each specimen was noted. These load values divided by surface area

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Effective Utilization of Industrial by- Products in Construction Industry

11

gives compressive strength of concrete. The test results are plotted in the figure given below.

Figure 1: Comparison of Compressive Strength for Replacement by Fly Ash

Figure 2: Comparison of Compressive Strength for Replacement by Micro silica

Figure 3: Comparison of Compressive Strength for Replacement by Metakaolin

It is clear from the graph that fly ash and metakaloin gave maximum strength at 10% replacement level and
microsilica at 15% replacement level. A comparison of the strength obtained for different, materials used is given in the
table below.
Table 9: Comparison of Compressive Strength Achieved for Different Materials
Replacement %Age by Weight of Cement
0%
5%

28 Day Strength Achieved (MPA)

Control Mix Fly Ash Micro silica Metakaolin
37.83
----46.45
40.89
52.13

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Parvathy A Nair & Aparna Ashok

10%
15%
20%
25%

-----

51.11
45.77
35
25.11

46.89
47.55
39.33
38.44

58.06
55.9
57.5
55.78

Maximum compressive strength ( 58.06 MPa) achieved for 10% replacement of cement by metakaloin
.Replacement of cement increased compressive strength appreciably upto 10% replacement level and then begin to
decrease.
B. Split Tensile Strength
The tensile strength of concrete cylinders (control mix and with different replacement materials) were determined
at 7 and 28 days. Variation of 28 day tensile strength of various mixes are plotted in the graphs below.

Figure 4: Comparison of Split Tensile Strength for Replacement by Flyash

Figure 5: Comparison of Split Tensile Strength for Replacement by Micro silica

Figure 6: Comparison of Split Tensile Strength for Replacement by Metakaolin

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Table 10: Comparison of Split Tensile Strength Achieved for Different Materials
Replacement %Age by Weight of Cement
0%
5%
10%
15%
20%
25%

28 Days Split Tensile Strength (MPA)

Control Mix Fly Ash Micro silica Metakaolin
2.4
----3.85
3.19
4.71
-3.56
4.05
5.1
-3.75
3
4.55
-3.45
2.4
4.1
-3.25
2.33
3.99

Table above shows split tensile strength of concrete mixes replaced by supplementary materials .Optimum
strength of 5.1 MPa is obtained for 10% replacement of weight of cement by metakaloin. Variation of tensile strength
shows a similar pattern as that of compressive strength.
C. Flexural Strength
Beams of size 500mmx100mmx100mm were loaded to failure in flexural strength testing machine .flexural
strength at 28 days was calculated ,comparison of the strength for various percentages of fly ash, silica fume and
metakaloin is plotted in the graphs below.

Figure 7: Comparison of Flexural Strength for Replacement by Flyash

Figure 8: Comparison of Flexural Strength for Replacement by Micro silica

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Parvathy A Nair & Aparna Ashok

Figure 9: Comparison of Flexural Strength for Replacement by Metakaolin

Table 11: Comparison of Flexural Strength Achieved for Different Materials
Replacement %Age by Weight of Cement
0%
5%
10%
15%
20%
25%

28 Days Flexural Strength (MPA)

Control Mix Fly Ash Micro silica Metakaolin
4.67
----5.5
5.4
5.1
-5.9
5.1
6.4
-3.9
5.3
7
-4
4.7
6.1
-5.2
4.2
5.7

CONCLUSIONS
Effect of Fly Ash

The compressive strength of concrete replaced with fly ash increases as the amount of replacement increased,
upto a certain percentage (10% in the present study, the initial strength development was less compared to that of
the control mix. The mix with 10 % replacement of cement with fly ash showed an increase of compressive
strength by 22 %. For replacement beyond 20% the compressive strength obtained was less than the control mix.

The enhancement of compressive strength was (22%, 30%, 20%) at 28 days of (5%,10%,15%) replacement of fly
ash respectively

The compressive strength in these mixes is attributed to both the continued hydration of Portland cement and
pozzolanic reaction between fly ash and calcium hydroxide component of Portland cement

Maximum split tensile strength of 3.85 N/mm 2 was obtained at 5% replacement level. Even after the replacement
of cement by 25% the split tensile strength was greater than control mix.

Effect of Micro silica

When cement was replaced with micro silica in different percentages, it has been observed that there is an
increase in compressive strength up to 15% replacement with an increase of 25% strength as compared to control
mix.

Increase in strength for (5,10,15)% replacement levels were (8,20,25)% respectively. Beyond 15% replacement of
cement by micro silica, the compressive strength showed a slight reduction, but greater than the control mix.
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Effective Utilization of Industrial by- Products in Construction Industry

15

Slight increase in the split tensile strength though not in a definitive manner. maximum value for split tensile
strength of 4.05 N/mm2 was obtained at 10 % replacement

The gain in strength can be attributed to the formation of calcium silicate hydrate (C-S-H) gel which is stronger
than the normal C-H gel. This silica-fume gel C-SH forms in the voids of the C-S-H produced by cement
hydration, thus producing a very dense structure.

In hardened concrete, silica-fume particles increase the packing of the solid materials by filling the spaces
between the cement grains in much the same way as cement fills the spaces between the fine-aggregate particles,
and fine-aggregate fills the spaces between coarse-aggregate particles in concrete

Effectof Metakaolin

Metakaolin effectively increased the mechanical strength of concrete including compressive and tensile strength.
The 28 day compressive strength of concrete has been increased by 40% for 10 % replacement of cement by
metakaolin. Beyond that the strength slightly decreased

.Unlike other two replacement materials addition of metakaolin showed remarkable increase in compressive
strength. Also the strength does not decrease considerably with 20% and 25 % replacement compared to the
control mix. The splitting tensile strength increased with the increase in metakaolin content at all ages.

The increase in the splitting tensile strength was smaller compared to that obtained in the compressive strength.
Split tensile strength was maximum (5.1 N/mm 2) at 10 % replacement level, beyond which the value start to
decrease.

The enhancement in compressive strength of concrete incorporating metakaolin may be attributed to the filling
effect, pozzolanic reaction of metakaolin, and acceleration of cement hydration.

When replacing cement with metakaolin the calciumhydroxide (CH) is reduced, thus leading to an increase in
sulphate resistance. This is in addition to the pore refinement due to inclusion of metakaolin that restricts the
ingress of sulphate ions.

Strength Achieved for Triple Blend Mix

On comparison of the compressive strength of triple blend with single material replacement specimens ,it was
observed that out of the three mix Combinations(FA+MS,FA+MK,MS+MK),type three i,e MS+MK yielded maximum
strength. Metakaolin gave maximum strength compared to other two replacement materials individually as well as in
combination.

REFERENCES
1.

Md. Moinul Islam , Md. Saiful Islam, [2010], Strength Behaviour of Mortar Using Fly Ash as Partial
Replacement of Cement , Concrete Research Letters,Volume 1(3) pp. 98-106

2.

D Tensing, C Freeda Christy, [2010], Effect of Class-F fly ash as partial replacement with cement and fine
aggregate in mortar, Indian Journal of Engineering & Materials Sciences , vol 17 ,pp 140-144

Impact Factor(JCC): 1.9586- This article can be downloaded from www.impactjournals.us

16

Parvathy A Nair & Aparna Ashok

3.

Faseyemi Victor Ajileye,[2012], Investigations on Microsilica (Silica Fume) As Partial Cement Replacement in
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4.

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Beulah M ,Prahallada M. C,[2012], Effect Of Replacement Of Cement By Metakalion On The Properties Of

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6.

P. Dinakar, Pradosh K. Sahoo, and G. Sriram,[2013], Effect of Metakaolin Content on the Properties of High
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7.

Arfath Khan Md, Abdul Wahab, B. Dean Kumar, [2013], Study of Strength Properties of Fibrous Concrete
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8.

Mini Soman1 Sobha.K, [2014], Strength and Behaviour of High Volume FlyAsh Concrete, International Journal
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9.

Amar Devendra Shitole, Sandhya Mathapati,[2014],The Use of Micro-silica to Improve the Compressive and
Flexural Strength of Concrete International Journal of Mechanical and Production Engineering, volume- 2, issue8

10. K.V.Pratap, M.Bhasker, P.S.S.R.Teja ,[2014], Triple Blending of Cement Concrete With Fly Ash and Ground
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