Studies On Metakaolin Based Coir Fibre Reinforced Concrete

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
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ISSN 0976 6316(Online), VolumeJOURNAL
5, Issue 9, SeptemberOF
(2014),
pp. 190-210ENGINEERING
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ISSN 0976 6308 (Print)

ISSN 0976 6316(Online)
Volume 5, Issue 9, September (2014), pp. 190-220
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STUDIES ON METAKAOLIN BASED COIR FIBRE REINFORCED

CONCRETE
Khaza Mohiddin Shaik,
Prof. Vasugi K
B.tech Civil Engineering, Vellore Institute of Technologies, Chennai, Tamilnadu, India.

Assosiate professor, Civil Engineering Department, Vellore Institute of Technologies, Chennai,
Tamilnadu, India.
ABSTRACT
The advances of concrete technology proved that the use of mineral admixture such as Silica
fume, Fly ash and Ground Granulated blast furnace slag are necessary and essential for producing
high performance concrete. Further, utilization of these materials immensely help to address
environmental problem related to damage being caused by extraction of raw materials, CO2
emissions during production of cement and disposal of industrial waste by products. In recent years,
there has been a growing interest in utilization of metakaolin in concrete as partial substitution is
addition to cement due to its high pozzolanic activity.
In the present work an attempt has been made to study the suitability of metakaolin as a
mineral admixture and its effect on the properties concrete. Metakaolin was blended with cement in
various proportions to study the effect of strength on concrete. Concrete mixes were made using
Ordinary Portland cement alone as Control and also replacing cement by 5%, 10%, 15%, 20%, 25%
and 30% of metakaolin. The physical properties and compressive strength of concrete were
measured.
In this experimental investigation, workability, strength and durability of concrete mix with
partial replacement of cement by metakaolin and with and without coir fibres have been studied. The
results obtained shows that at 15% replacement of OPC with metakaolin have higher compressive
strength as compared to the other replacement levels. The maximum compressive strength attained
was 49.4N/mm2 which is higher than the reference concrete strength i.e. 39.4N/mm2. Maximum
strengths (i.e. compressive, flexural tensile, and split tensile) are observed at 0.5% coir fibre content
as compared to the other coir fibre contents. Unlike other strengths (i.e. compressive, flexural tensile,
and split tensile) the impact strength was maximum at 2% coir fibre content. The workability of
concrete has reduced due to the addition of coir fibres in the concrete. The durability (measured in
terms of above strengths) of the coir fibre reinforced concrete was affected in the alkaline exposure
(i.e. NaOH solution at pH value of 13) due to the deterioration of the matrix but not the coir fibres
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ISSN 0976 6316(Online), Volume 5, Issue 9, September (2014), pp. 190-210 IAEME
exist inside the matrix. Hence the coir fibre has stability in metakaolin based concrete, in resistance
the cracks even after exposure to the alkaline environment.
I. INTRODUCTION
The most important parameters described a fibre is its aspect ratio (length of fibre divided by
an equivalent diameter of fibre). The properties of fibre reinforcement concrete are very much
affected by the type of fibre. Fibres are secondary reinforcement material and act as crack arrester.
Prevention of propagation of cracks origination from internal flaws can result in improvements in
static and dynamic properties of the matrix. The concept of post cracking can be improved by the
illation of fibre was first put forward by Portor in 1910, but title progress was made in the
development of material until 1963 when Romualdi and Batson 1969 published their classic paper on
the subject.
Fibres are taken as new form of binder that combines Portland cement in the bonding with
cement matrix. Several kinds of fibres such as steel, poly propylene, nylon, coir, jute, sisal, glass and
carbon have been tried and these are available in variety of shapes, size and thickness fibres can be
broadly be classified in two groups as low modulus high elongation fibres and high modulus fibre.
Low modulus fibre has high elongation having large energy absorption characteristic and are capable
of imparting toughness and resistance to impact and explosive loadings. Fibre generals included in
this group are poly propylene, nylon, rayon and polyester fibre. High modulus fibre is capable of
producing strong composite. They are primarily impact strength and stiffness to the composite to
varying degree and resistance under dynamic loadings.
The main factors which imports the deterioration of natural fibre are:
1. Internal and external destructions of natural fibres due to the mechanical extraction force.
2. Dimensional instability of fibre during their serve in the cement matrix.
3. Due to the thermic changes in the matrix, create tensile force, which in terms exceed tensile
strength of the fibre.
4. Due to the fibril orientation of fibre during wetting and drying cycle of the fibre.
5. During wetting and drying of composite creates deboning of the fibre from the matrix. All the
above actions effects the durability and continuous reduce their resistance capacity.
6. Natural fibres from centuries, mankind has been used for various types of application including
building materials. These fibres are light weight, high strength to weight ratio and corrosion
resistance. Natural fibre, especially, coir, sisal, jute, etc. have the potential to be used as
reinforcement in cement composite.
In spite of such advantages and extended of large potential investigation on the suitability of
natural fibre reinforcement composite for developing various building materials have not been that
extensively carried out and reported, which is true not only in India, but also in other developing
countries. Two important reasons which are responsible for above situation.
1. Balling effects - reduce workability of mix.
2. Embrittlement decay of natural fibre in the alkaline medium. From the studies carried out so
far. Natural fibre composite the method adopted is:
1. Carbon of matrix
2. Immersion of fibre in slurry that is silicate coating
3. Partial replacement of OPC with various Pozalonas and
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4. Coating of fibres that is pore seeding of the above studies, matrix modification using pozalonic
material has been used to improve the durability of fibre and the fibre composites.
Natural fibres which are weakening in alkaline environment of cement and poor interface,
less durability due to high moisture and chemical absorption, generation of concrete cracks due to
swelling and volume changes.
So far in the literature fly ash and GGBFS are abundantly used as replacement to OPC to the
durability of cement matrix system. The use of various fibres with cementations system to check the
improvement in the durability of composite and hence in the present investigation that metakaolin is
used as pozalonic materials for the matrix modification to avoid the imprimatur of the coir fibre in
the alkaline condition.
The versatility of OPC attracted everyone in the construction industry and its application is
steadily increasing when compared to other material used in these days due to:
1. Rapid changes in the technology in the manufacture of cement.
2. Its early gain of strength and,
3. Progressive improvement in strength in the presence of moisture leading to an impervious mass.
But the product gives considerable shrinkage; creep etc., during and after setting and hardening.
Even after extensive utilization of OPC till date, the durability of OPC has been still being
investigated and it is questionable. With the present level of OPC production, it is not possible to
meet the dwelling needs of the country and also for pavement of roads, bridges, canal works etc. The
OPC can be substituted partially or fully by industrial waste materials to reduce cost with improved
performance. The answer to the above question has been realized in the form of natural pozzolans,
which have been proved to be successful to replace OPC up to 30%.
NON CONVENTIONAL MATERIALS
i)
ii)
iii)
iv)
Fly Ash
Silica Fume
Rice Husk Ash
Ground Granulated Blast Furnace Slag
SELECTION OF POZZOLANS
i)
ii)
iii)
iv)
v)
vi)
Benefits of pozzolans
Workability
Reduced heat of hydration
Increased Durability
Reduced Efflorescence
Pozzolans colour
OBJECTIVES
The present project entitled Studies on Metakaolin based coir fibre reinforced incorporated
cement and concrete has taken up with the objectives listed below:
i. To study the performance of concrete containing different percentages of metakaolin and to
identify the Proper replacement percentage.
ii. To investigate the effect on the strength and durability of metakaolin based concrete by
adding coir fibre.
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SCOPE OF THE PRESENT STUDY

i.
The aim of the present study is to carry out reliability analysis of concrete mix with partial
replacement of cement by metakaolin including (0%, 0.5%, 1%, 1.5% and 2%) amount of
coir fibres. The main research of this investigation is the properties of metakaolin and coir
fibre on concrete which it satisfies both strength and durability properties
ii.
The tests to be conducted are workability and strength of the concrete like compressive test,
split tensile strength, flexural strength and Impact test. In addition to this, XRD of metakaolin
and durability of concrete with metakaolin coir fibre reinforced concrete are also to be
included.
II. LITERATURE REVIEW

The surface chemistry and consequently the behavior of the particle can be altered through
chemical, mechanical, or thermal means. The surface transformations of kaolnite which occur on
thermal treatment as determined through microscopy, differential thermal analysis, weight loss,
density and gas absorption measurements. In general, Kaolinite is an inorganic polymer, with its
backbone chain made up of silicon and aluminum atoms. It is generally formed in soils as a result of
the chemical weathering of feldspar and other clay materials like illite and species.
2KlAlSi3O8 + 9H2O + 2H+Al2Si2O5 (OH) 4 + 2K + 4H2SiO4
Eq.
2KAl2 (AlSi3) O10 (OF) 2 + 5H2) 3 Al2Si2O5 (OH) 4 + 2KO
..Eq. (2.2)
(2.1)
When Kaolinite is heated to temperatures of about 500oC to 600oC, the water that was
chemically bound to it is lost leading to a highly disordered structure (Meta Kaolinite). The basic
Kaolinite particle is a hexagonal platelet formed from alternating two-dimensional silica and alumina
layers. The silica layer consists of interconnected tetrahedral composed of silicon atoms in a
tetrahedral coordination with oxygen atoms. These tetrahedral forms a hexagonally symmetric layer
with one surface composed of three of the tetrahedral oxygen and the other with one of the oxygen.
The silicon atoms are located in between two. The surface containing single tetrahedral oxygen
atoms is chemically connected to the alumina layer. The unbounded oxygen forms a hexagonally
open packed layer.
A typical DTA for kaolinite shows an endothermic and exothermic over the temperature
range of interest here between 4000-6000 C and endotherm develops as a result of dehroxylation of
the particle. With dehydroxylation there is concomitant change in aluminum coordination from six to
four fold. The aluminum-oxygen tetrahedral then becomes 'stretched out' over the unaltered siliconoxygen network. The particle retains its basic hexagonal shape with alterations in only one surface.
This structure has been termed 'Metakaolin'.The Metakaolin structure remains until the temperature
is increased to near 950 C. At this point an exothermic recrystallization takes place according to the
reaction.
Si4Al4O14 Si3Al4O12 + SiO2.... Eq. (2.3)
The resultant structure is an alumina-silica defect spinel plus free silica. In the spinel the
aluminum has reverted back to the octahedral coordinated state above 1050 Celsius the spinel
transforms to mallite with a further expulsion of silica. Gas absorption was chosen as the principal
means of monitoring surface changes in this work.
193
Applications of Metakaolin
a. High Performance, High Strength and Lightweight concrete.
b. Precast Concrete for Architectural, Civil, Industrial and Structural works.
c. Fibre cement and Ferro cement products, Glass Fibre Reinforced Concrete.
d. Mortars, Stuccos, Repair Material, Pool Plasters.
e. Manufactured Repetitive Concrete Products.
Benefits of Metakaolin on Concrete
a. Increased Compressive & Flexural Strengths.
b. Reduced Permeability & Efflorescence.
c. Increased Resistance to Chemical Attack & Prevention of ASR.
d. Reduced Shrinkage Improved Finish ability, Colour& Appearance.
Metakaolin Pozzolanic improvements
a. Improves strength, durability, and workability of Portland cement concrete.
b. Makes Portland cement easier to apply.
c. Provides smoother finish.
d. Has white colour for white and colour plasters.
e. Reduces permeability, efflorescence, and cracking.
f. Reduces the porosity of hardened concrete.
g. Readily disperses in cement-based systems.
h. It is safe and easy to handle.
REVIEW OF WORK DONE ON METAKAOLIN BY VARIOUS INVESTIGATORS
i) Workability
Jiping bai (2001) have determined a method for predicting the workability of concrete
incorporating Metakaolin from the standard workability tests. Bonakdar A (2010) approaches in
improving the workability of concrete to use blended cement materials as metakaolin incorporating
with different percentages of 0%-20% of MK. A poly-carboxilate based super plasticizer has been
used and achieved its desired workability. Zongjin (2011) have determined the workability of
different percentages of 0%, 5%, 10%, and 15% of metakaolin. The workability of concrete is little
influenced by small metakaolin contents 5% metakaolin. At higher metakaolin contents workability
has be controlled effectively by super plasticizer addition.
ii) Strength Characteristics
Wild and Khatib, (1996) reported results on strength development of concrete, where
cement was partially replaced with MK (5% to 30%). Sabir et al. (2001) carried out the review
regarding the use of claimed clays and metakaolin as a pozzolan for concretes. They found that the
use of met kaolin as partial cement replacement material in mortar and concrete has been studied
widely in recent years. Poon et al. (2006) studied the mechanical and durability properties of high
performance metakaolin (MK) concrete an silica fume concretes and found that the performance of
the MK used in this study was superior to the silica fume in terms of strength development of
concrete. Erhan Guneyisi (2007) investigated on the use of MK as a supplementary cementing
material to improve the performance of concrete. The results indicate that it increased the strengths
of the concretes in varying magnitudes, depending mainly on the replacement level.
AL-Mishhadani (2009) investigation studies the mechanical characteristics of carbon fibre
reinforced light weight concrete, containing different percentages of fibre. The effect of using high
194
range water reducing agent SP with 8% silica fume and 8% high reactivity Metakaolin as a partial
replacement by weight of cement.
Raya yaseen Mohammed (2011) investigates the effect of high reactivity met kaolin on the
properties of steel fibre reinforced concrete. Compressive strength, splitting tensile strength, flexural
strength and Impact resistance were investigated.
iii) Durability
Vuetal (2001) studied the effect of partial replacement of Portland cement by calcined kaolin
and concrete on compressive strength as well as on durability characteristics of concrete. The
additions of calcined kaolin to Portland cement increase the normal consistency of blended Portland
cement mixtures. High reactivity metakaolin (HRM) is manufactured pozzolan produced by thermal
processing of purified kaolinic clay.
K.A. Gruber et al (2003) have discussed laboratory evolution to assess the long term
performance of concrete containing HRM produce resistance to chloride penetration and reduction in
expansion due to alkali silica reaction. Michael Zeljkovic (2009) the durability performance of
metakaolin concrete to alkaline solution of magnesium sulphate and the replacement of cement by
MK at various percentages of 5%, 10% and 15%.The cube was casted and cured. After 28 days water
curing, the concrete specimens were kept magnesium sulphate for 90 days. The specimens were
removed and tested for their compressive strength. It was found that metakaolin showed better
performance in magnesium sulphate and improves the strength of concretes at 15% of metakaolin.
iv) Pozzolanic Activity
The role of Metakaolin in enhancing the strength of concrete is reviewed and the principal
mechanisms identified by S. Wild et al. (1996) metakaolin concretes with a range of MK contents (030 %) have been cured for periods of 1-90 days. The change in relative strength with both curing
time and metakaolin contents is discussed in relation to the filter effect , acceleration in OPC
hydration and the pozzolanic reaction. The observed results establish that there is an optimum OPC
replacement level of 0 % MK and the contribution which MK makes to strengths is restricted beyond
14 days. The positive contribution which metakaolin makes to strength enhancement of concrete
does not continue beyond about 14days irrespective of the replacement level.
v) Resistance to sulphate attack
Hooton (1993) concluded that the sulphate attack is generally attributed to the reaction of
Sulphate ions with calcium hydroxide and calcium aluminates hydrate to form gypsum and ettringite.
The gypsum and ettringite formed as a result of sulphate attack is significantly more voluminous (1.2
to 2.2 times) than the initial reactants. The formation of gypsum and ettringite leads to expansion,
cracking, deterioration and disruption of concrete structures. In addition to the formation of ettringite
and gypsum and its subsequent expansion, the deterioration due to sulphate attack is partially caused
by the degradation of calcium silicate hydrate(C-S-H) gel through leaching of calcium compounds.
This process leads to loss of C-S-H gel stiffness and overall deterioration of the cement paste matrix.
(Mehta, 1983)
Al Amoudi et al. (1995) and Mangat et al. (1995) studied the behaviour and concrete using
supplementary cementing material and found that the incorporation of supplementary cementing
materials such as blast furnace slag, fly ash, and silica fume as partial replacement of ordinary
cement has been found a beneficial technique of enhancing the resistance of concrete to sulphate
attack.
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vi) Coconut Fibre

Coir fibre has the potential to be used as reinforcement in internal wall panelling system with
binder component of cement and gypsum. Coconut cultivation can be found spreading across the
tropical and Subtropical regions between the latitudes 20oN and 20oS. It can be seen in most of Asia
countries especially Thailand, Indonesia and India and Malaysia and the tropical climate countries
like Hawaii and Fiji Islands. Coconut fibre is extracted from the outer shell of a coconut. The
common name, scientific name and plant family of coconut fibre is Coir, Cocos nucifera and
Arecaceae (Palm), respectively.
vii) Properties of Natural fiber Reinforced Concrete in Fresh State
The incorporation of natural fibre into a mix decreases the workability and increase the void
content due to entertainment of additional air. The decrease in workability is basically due to the
shape of fibers in relation to the other constituent particles in concrete. Unworkable mixes generally
lead to non-uniform fibre distribution resulting in variation in properties between specimens from the
same mix. The increase in void content is also due to the in adequate compaction of the unworkable
mixes. The amount of fibers that can be added to a mix is limited by the phenomenon of (balling)
where the fibers have a strong tendency to intermesh and form fibre ball which cannot be easily
separate. The balling of fibers results in an unworkable and segregated mix which ultimately
produces a highly porous and honeycombed concrete. The balling of fibers when large volume
fractions are used can be reduced by reducing the coarse aggregate content however, there is a limit
to the volume of fibers that can be add to a mix beyond which the balling of fibers takes place and
this mainly depends up on the nature of fibers, type and the mix proportion. Mixing methods have
also been developed that minimizes the balling problem at a great extent. In order to improve the
workability or to keep it constant, Aziz and Jorillo suggested the following:
Increase the water/cement ratio of the mix at the expense of compressive strength.
Use certain admixtures which can improve the workability and strength properties of
concrete.
Properties of Natural Fiber Reinforced Concrete in Hardened State

Important properties of the hardened fiber reinforced composites are strength, deformation
under load, crack arrest energy absorption, durability, permeability and shrinkage. In general, the
strength is considered to be the most important property and the quality of fiber reinforced concrete
is judged mainly by their strength. Ultimate strength depends almost entirely up on the fiber type,
length and volume fraction of fibers and also on the properties and proportion of other constituent
materials.
Natural fiber reinforced concrete behaves as a homogeneous material within certain limits.
The random distribution and high surface to volume ratio (specific surface) of the natural fibers,
results in a better crack arresting mechanism. With low fiber contents that are normally used in
cement composites (from 2% to 4% by volume) or (from 1% to 5% by volume) the strain at which
the matrix cracks is little different from that observed in plain cement paste, mortars and concrete.
However, once cracking has started the fibers act as crack arresters and also absorb a significant
amount of energy, if they are pulled out from the matrix without breaking.
SUMMARY OF LITERATURE
This chapter has reviewed that the pozzolans and natural fibres has been used in the concrete
technology and it shows the types, origin and how they react with the Portland cement to improve the
properties of concrete. The critical review of literature shows that the characteristics of pozzolans
196
and natural fibre proportions are essential aspects to be considered to make a desired quality of
concrete. Extensive research work has been done by several researchers regarding the suitability of
metakaolin as pozzolanic material to use in concrete. It plays a significant role which affects its
suitability as a pozzolanic material.
The properties of natural fibre reinforced concrete are affected by a large number of factors
due to the type and length of fibres, as well as the volume fraction is the most significant factors.
Natural fibres have disadvantages like weakening in alkaline environment of cement and poor
interface, less durability due to high moisture and chemical absorption, generation of concrete cracks
due to swelling and volume changes. Improvement key properties in concrete are workability,
strength characteristic, durability and Resistance attack.
III. EXPERIMENTAL INVESTIGATIONS
MATERIALS
Cement
Chetinadu Cement, 43 grade OPC confirming to IS: 8112[13] was used for the present study.
The properties of cement were tested in accordance with IS 403[6] and given in Table 3.1.
Coarse Aggregate
The coarse aggregate used was a normal weight aggregate with a maximum size of 20mm
and was obtained from the local supplier and it was tested in accordance with IS: 2386-1964. The
results are given in Table 3.2.
Fine Aggregate
Good quality river sand, free from silt and other impurities and which is locally available,
was used in this study. Salient properties of the fine aggregate determined by standard tests
accordance with IS 2386 (part II & III) -1963 and results are given in Table 3.3.
Metakaolin
The Metakaolin is used for the investigation. The physical properties of metakaolin such as
specific gravity and surface area were measured using the procedure presented by IS 1727-1969. The
particle size of the metakaolin was referred with the help of scanning electron microscope. The
physical properties of metakaolin are given in table 3.4. The chemical properties of metakaolin are
obtain from the supplier and it is given in Table 3.5.
Coir Fibre
The coir used for this work is from the local village, Tamilnadu region. The fibres are
available in processed and ready-to- use form. Fig 3.1 shows the fibres from as available form (i.e.
plant) to ready to use form. Uniform length of fibres was obtained by using cutting machine.
Salient physical and mechanical properties of coir were determined in their natural form. Length of
coir fibres was measured by a vernier scale and the diameter by the micrometer. Specific gravity and
density of coir fibres were determined using a pycnometer. Since the coir fibres have a tendency to
absorb water especially during the first few hours after immersion in water, the specific gravity and
density were calculated after 24hrs of immersion in water. The physical and mechanical properties of
the coir fibres are presented in Table 3.6.
197
Water
Water is an important ingredient of concrete as it actively participates in the chemical reaction
with cement. Since it helps to form the strength giving cement gel, the quantity and quality of water
is required to be looked into very carefully. Potable water is generally considered satisfactory. In the
present investigation, tap water was used for both mixing and curing purposes.
Chemical Admixture
Metakaolin concrete requires super plasticizer and it has be noticed through experimentally
that at which stage of replacement of metakaolin concrete requires super plasticizer. In order to
obtain suitable workability, super plasticizer will be added.
IV. PREPARATION AND TESTING OF SPECIMEN
A reference mix (i.e. without coir fibres and metakaolin using the above materials was
proportional for M30; using IS 10262 2009. The mix proportion is obtain is 1:1.73:3.08 (cement:
sand: graded coarse aggregate of maximum size 20mm) with water cement ratio of 0.45. The detail
mix design procedure for reference (i.e. M30 grade) is given in Appendix A. OPC was replaced by
metakaolin (5%, 10%, 15%, 20%, 25% and 30 by weight) in the above mix without coir fibre
investigated. The maximum replacement level (within the above range at the range) which the
maximum benefit of compressive strength of M30 grade concrete can be achieved. The mix details
of OPC with various replacement levels of metakaolin are given in Table 3.7
An XRD-analysis are also carried out to the above concrete mixes to study the pozzolanic activity in
terms of Ca (OH) and CH peaks. The above study i.e. both compressive strength and XRD- analysis
will bring the advantage of using the pozzolanic material i.e. metakaolin, to produce stable and
durable.
Coir fibre cement composite for a longer service life. The results of compressive strength and
the XRD- analysis are discussed in the next chapter. After obtaining the better mix proportion for
M30 grade concrete with metakaolin, of same mix was used, with coir fibres of length20mm at
various levels of the volume fractions of 0.5%, 1%, 1.5%, 2%, by volume of concrete. A typical mix
proportion using coir fibres is given in Appendix-B.
Using the above mix proportions (i.e. 4 combinations in the coir fibre + 1 combination
without coir fibres, the workability, strength and durability of the coir fibre reinforced concrete was
arrived;
The workability of the coir fibre reinforced concrete is measured by the inverted slump cone
test as per ASTM C995 01. Following tests were conducted on the hardened concrete of coir fibre
composites, after 28 days normal curing;
1. Compressive strength (cube)
2. Split tensile strength (cylinder)
3. Flexural strength (prism) and
4. Impact strength (circular slab)
The size of the specimen, number of specimens to be cast for both strength and durability and
the standard of testing the above specimens are given Table 3.8. Compressive and split tensile
strength tests are carried out on 2000kN capacity compression testing machine, whereas flexural
strength was determined using a locating frame of capacity 1000 KN under two point loads (the point
loads are applied at 1/3 of span).
Impact strength was determined using impact testing machine, which is available in the
department of civil engineering The available impact testing machine has a dropping hammer of
198
weight 4.5kg falling from a height of 45cm the energy per blow is joule. For the study of the
durability of coir fibre reinforces concrete, the above specimens, which are cured already for 28
days, are immersed in the sodium hydroxide solution for another 28 days. During the above period,
the pH of the sodium hydroxide was maintained to 13. After 28 days of immersion curing, in the
alkaline medium (i.e. NaOH solution), the compressive strength, flexural strength, split tensile
strength and impact strength were evaluated and compared with the respective strength of composite
before immersion in the above alkaline medium. The results and discussion are given in chapter4.
The testing of the coir fibre reinforced concrete both in fresh and hardened stage are shown below.
Table 3.1: Physical Properties of Cement
Property
Value
Specific gravity
3.12
Standard consistency
31%
Initial setting time
128
Final setting time
260
Compressive Strength
Mpa
3 days
24.9
Mpa
7days
35.7
Soundness, Lechatlier (mm)
1.89
Fineness, m2/kg
306
Sl.No.
1
2
3
4
5
6
7
Table 3.2: Properties of Coarse Aggregate

S.NO
Property
Value
1
2
3
4
S.NO
1
2
3
4
5
S.NO
1
2
3
Specific gravity of
coarse aggregate
Water absorption
Bulk density
Fineness modulus
2.72
0.33 %
1420 kg/m3
6.98
Table 3.3: Properties of Fine Aggregate

Property
Value
Specific gravity of
2.61
fine aggregate
Water absorption
1%
Bulk density
1560 kg/m3
Fineness modulus
2.62
Zone
II
Table 3.4: Properties of Metakaolin

Property
Value
Specific gravity of metakaolin
2.51
Specific Surface Area
10180 cm2/g
Particle size ( average )
2.4 um
199
Table 3.5: Chemical properties of Metakaolin

Species
SiO2
Al2O3
Fe2O3
CaO
MgO
Na2O
K2 O
TiO2
LOI
52.0
44.0
1.0
0.40
0.20
2.0
1.10
Table 3.6: Properties of Coir Fibre

Property
Fibre Length
(mm)
Fibre Diameter
(mm)
Specific Gravity
Water Absorption for 24

hrs duration
Value
300
0.05
1.12
98%
Table 3.7: Mix Details for Concrete

Materials
0%
Mk
5%
Mk
10%
Mk
15%
Mk
20%
Mk
25%
Mk
30%
Mk
Cement (kg/m3)
380
361
342
323
304
285
266
Metakaolin (kg/m3)
Coarse aggregate
(kg/m3)
Fine aggregate
(kg/m3)
19
38
57
76
95
114
1169
1169
1169
1169
1169
1169
1169
656
656
656
656
656
656
656
Water
171
171
171
171
171
171
171
W/C ratio
0.45
0.45
0.45
0.45
0.45
0.45
0.45
SP
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Table 3.8: Details of Elements Cast for Strength and Durability Studies (M30 grade;
for 28 days)
Sl.No
3
4
Type of Element
Cube
(100mm x 100mm x
100mm)
Beam
(100mm x 100mm x
500mm)
Cylinder
(100mm x 200mm )
Circular slab
(150mm x 63.5mm )
No. of
specimens for
Strength
Studies
No. of
specimen for
Durability
Studies
Total no. of
specimens cast
for the total
no. of mixes
(i.e. 5)
30
15
45
IS 516 - 1959
15
15
30
IS 516 - 1959
15
15
30
IS 5816 - 199
15
15
30
ASTM
C995 01
Test standard
Note: Specimens cast for durability study were immersed in NaOH solution (0.1N, pH: 13) for
28 days after 28 days of normal curing in water
200
Fig 3.1: Stages in the Processing of Coir Fibres

From Plant to ready to use Form
(a) Slump Cone Test
(b) Inverted Slump Cone Test
(c) Compression Test
(d) Flexural Test
(e) Split Tensile Test
(f) Impact Test
Fig 3.2: Testing of the Coir Fibre Reinforced Concrete both in

Fresh and Hardened Stage
201
V. RESULTS AND DISCUSSIONS

Workability compressive strength and XRD analysis of concrete incorporated with
Metakaolin
(i) Workability
Slump test was used to measure the workability of concrete with and without metakaolin. It
is found that the slump (or) workability decreases, as the percentage of metakaolin increases. The
percentage decrease in workability at 30% of replacement of OPC with metakaolin is 40% with
respect to the reference concrete. The variation of workability is graphically represented with
respect to metakaolin replacement in Fig. 4.1.
(ii) Compressive Strength
The results of the compressive strength of concrete with and without admixing metakaolin
are given in Table 4.1. The variation of the above strength is also given in Fig. 4.2. From the result
it show that the compressive strength increases with increase in the percentage of metakaolin, up to
15%, beyond which the compressive strength decreases. The maximum compressive strength
obtained is 20.2% higher than the reference concrete compressive strength. From the above study,
the best mix proportion was found at 15% replacement of metakaolin for further study i.e. for the
coir fibre reinforced concrete.
(iii) XRD Analysis
The results of the XRD pattern of concrete at the replacement levels of 0%, 5%, 10%, 15%
and 20% by metakaolin are shown in Fig.4.3. From the XRD patterns, it shows that the Ca (OH),
(CH) peaks are lowest in the concrete with metakaolin as compared to the reference concrete.
Among the replacement levels of metakaolin, 15% replacement has lowest peak of Ca(OH), (CH),
due to the reaction of CH and MK. CH cannot directly produce strength to the cement paste; only
after it was translated to C-S-H gel by pozzolanic reaction with active minerals MK can observe CH
to form C-S-H, making the micro structure denser. CH often occurs in the form of crystal and
produce interfaces (weak combinations) inside the cement matrix. However, C-S-H has been
tremendous specific surface, which produces a greater combination force inside the paste, and it is a
continuum structure (there is no interface).
Most of CH was consume, the more C-S-H was formed, and higher strength of concrete.
This is very helpful to the early strength development of cement mortars. So XRD analysis indicates
that more Ca (OH) was consumed after adding mineral ad-mixture.
Workability of coir fibre reinforced concrete
The results of the workability of coir fibre reinforced concrete are given in Table 4.2. It
shows that the workability decreases with increase in fibre content.
Compressive strength of coir fibre reinforce concrete
Compressive strength of coir fibre reinforced concrete, (M30 grade; Vf = 0%, 0.5%, 1.5%, 2%, at
fibre length of 20mm) at 7 and 28 days of normal curing are given in table 4.3 and its variation is
show in Fig. 4.4
Following are the inferences drawn from the results obtained.
1) The compressive strength of coir fibre reinforced concrete has shown considerable increase
relative to the reference concrete, up to 0.5% fibre content, beyond which the strength
decreases.
202
2) The compressive strength obtained at 0.5% fibre content is 58.6 N/mm2 which is 18.62%
higher than the reference concrete strength.
3) The compressive strength at 1.5% fibre content is 51.9 N/mm2, which is 5% higher than the
reference concrete strength.
(iv) Flexural strength of coir fibre reinforced concrete.
Flexural strength of coir fibre reinforced concrete, (M30 grade; Vf = 0%, 0.5%, 1.5%, 2%,
at fibre length of 20mm) at 28 days are presented in table 4.4 and its variation shown in Fig 4.5.
1) Flexural strength of coir fibre reinforced concrete is also maximum, when the fibre content is
0.5%, when compared to the other fibre contents.
2) The maximum flexural strength obtained at 0.5% fibre content is 6.4 N/mm2, which is 17.64%
(v) Split tensile strength of coir fibre reinforced concrete
Split tensile strength of coir fibre reinforced concrete (M30 grade; Vf = 0%, 0.5%, 1.5%,
2%, at fibre length of 20mm) at 28 days are presented in table 4.5 and its variation shown in Fig. 4.6.
1) Split tensile behavior of coir fibre reinforced concrete is similar to that of compressive and
flexural strength within the range of fibre content (i.e. 0% to 2% at fibre length of 20mm) and
fibre length considered.
2) Split tensile strength of coir fibre reinforce concrete is also maximum, when the fibre content is
0.5%, when compared to other fibre contents.
3) The maximum split tensile strength attained at 0.5% fibre content is 4.93 N/mm2, which is
15.18% higher than the reference concrete strength.
VI) Impact strength of coir fibre reinforced concrete
Impact strength of coir fibre reinforced concrete (M30 grade; Vf = 0%, 0.5%, 1% 1.5%,
2%, at fibre length of 20mm) at 28 days are presented in Table 4.6 and its variation shown in
Fig. 4.7.
1)
2)
3)
4)
The impact strength of coir fibre reinforced concrete increases with increase in fibre content
(i.e. 0% to 2% at fibre length of 20mm) and fibre length considered.
The above behavior may be related to the ability of coir fibres in absorbing the energy to
produce failure. The fibre addition causes more closely spaced cracks, with a reduced crack
width leading to the absorption of large energy.
The maximum impact energy at 2% fibre content is (energy per blow) which is 36.9% higher
than the reference concrete.
In the case of reference concrete (i.e. without coir fibres) the energy required to completely
fail the specimen is (energy per blow), which is 1.2 times higher than the impact energy
required for the initial crack in the specimen.
203
5)
6)
7)
Whereas in the case of coir fibre reinforced concrete specimen at 2% fibre content, the energy
requires to completely fail the specimen is (energy per blow), which is 1.75 time higher than
the impact energy required for the initial crack in the specimen.
Along with the impact strength of the specimen, total length of crack is also observed. It is
found that the lateral length of crack also increases wit increase in the fibre content.
Based on the above total crack length (i.e. for the complete failure of the specimen), the
energy required for millimetre crack length was calculated. It is found that the energy
required in joules per millimetre length of cracks is 56.7J/mm at 2% fibre content which 36.9
% higher than the reference concrete. This show the role of coir fibres in resisting the cracks
in the concrete.
(vii) Durability evaluation of coir fibre reinforced cement composite

Durability of coir fibre reinforced concrete is evaluated in terms of compressive strength,
flexural strength, split tensile strength and impact strength, after exposure in NaOH solution for 28
days. The result of the above strength parameters after explore in NaOH solution as follows
(viii) Compressive strength of coir fibre reinforced concrete after exposures in NaOH solution
(for 28 days)
The result of compressive strength of coir fibre reinforced concrete after exposure in NaOH
solution is given in table 4.7. And its variation is shown in Fig. 4.8.
From the result the following inference are drawn:
1) Compressive strength of coir fibre reinforced concrete and reference concrete decreases after
exposure in NaOH. Since there is no much chance in the strength loss between the reference
concrete and the coir fibre reinforced concrete, the strength loss id due to the interaction
between the matrix and the medium under condition.
2) The maximum strength loss is at 2% fibre content which is equal to 3.4%.
3) The maximum compressive strength is 57N/mm2 at 0.5 fibre content, which is 15.38% higher
than the reference concrete strength, before explore in the NaOH solution.
(ix) Flexural strength of coir fibre reinforced concrete after exposures in NaOH solution (for 28
days)
The result of Flexural strength of coir fibre reinforced concrete after exposure in NaOH
solution is given in Table 4.8. And its variation is shown in Fig. 4.9.
1) Flexural behavior of coir fibre reinforced concrete is similar to the compressive strength, after
exposure in to alkaline environment.
2) Flexural strength decreases when exposed to NaOH solution for 28 days, irrespective of the
fibre content. The maximum loss in strength was found at 2% fibre content, which is equal to
14.54%.
3) The flexural strength at 0.5% fibre content is 5.57 N/mm2 which is 2.38% higher than the
reference concrete strength, before exposure in NaOH solution.
(x) Split tensile strength of coir fibre reinforced concrete after exposures in NaOH solution (for
28 days)
The result of Split tensile strength of coir fibre reinforced concrete after exposure in NaOH
204
1) Split tensile strength behavior of coir fibre reinforced concrete is similar to that of compressive
and flexural strength, when exposed to alkaline environment. The maximum loss in strength
was found at 2% fibre content, which is equal to 11.52%.
2) Split tensile strength at 0.5% fibre content is 4.62N/mm2, which is 7.94% higher than the
reference concrete strength, before exposure in NaOH solution.
(xi) Impact strength of coir fibre reinforced concrete after exposures in NaOH solution (for 28
days)
The result of Impact strength of coir fibre reinforced concrete after exposure in NaOH
1) Impact strength of fibre reinforced concrete and the reference concrete decrease after exposure
in NaOH solution.
2) The maximum Impact strength loess per millimeter crack length is at 2% fibre content, which
is equal to 2.8%.
3) Impact strength of fibre reinforced concrete (i.e. without coir fibre) the energy required per mm
crack length completely fails the specimen is reduced to 0.38 J/mm, where is7.31 less than the
energy required per millimeter crack length before exposure in NaOH solution.
1) After exposure in NaOH solution the coir fibre reinforced concrete at 2% fibre content, the
energy required completely fails the specimen is 52.6 J, which is 1.62 times higher than impact
energy required for the initial crack in the specimen.
2) It is also found that the impact specimen exposed in NaOH solution has reduced total crack
length, as compare to that of impact specimen total crack length before exposure in NaOH
solution.
3) Based on the above discussion, it is found that the matrix is damaged much in the alkaline
exposure, but not the coir fibres exist inside the matrix. Hence the coir fibre has stability in
metakaolin based concrete, in resistance the cracks due to impact energy.
Table 4.1 Compressive strength of concrete incorporating with Metakaolin
(7 and 28 days ages)
COMPRESSIVE
MIX
Workability
STRENGTH
CODE
Value in
terms of
(N/mm2)
Slump
7 DAYS
28
(mm)
DAYS
100
23.7
39.4
Control
5Mk
95
27.6
42.7
10Mk
83
31.4
46.1
15Mk
80
34.8
49.4
20Mk
70
33.1
48.4
25Mk
30Mk
72
60
32.1
30.4
47.3
45.1
205
Table 4.2: Workability of Coir Fibre Reinforced Concrete

Workability of coir fibre
Fibre Content
reinforced concrete using Inverted Slump Cone Test
(Seconds)
Control
22
5%
24
10%
25.5
15%
27
20%
28
Table 4.3: Flexural strength of coir fibre reinforced concrete (M30; 28 days)
Sl.No
Fibre Length
(mm)
1.
2.
3.
4.
5.
20
Fibre
Content (%)
0
0.5
1
1.5
2.0
Flexural Strength
(MPa)
5.44
6.4
5.88
5.20
4.95
Table 4.4: Compressive strength of coir fibre reinforced concrete (M30; at 7 days and 28 days)
SI.
No.
Fibre content
%
Compressive Strength MPa

7days
1
2
3
4
5
0
0.5
1
1.5
2
28 days
34.8
43.9
42.4
37.8
31.9
49.4
58.6
55.9
51.9
44
Table 4.5: Split tensile Strength of Coir Fibre Reinforced Concrete (M30; 28Days)
Sl.No
1.
2.
3.
4.
5.
Fibre
Length
(mm)
Fibre
Content (%)
0
0.5
1
1.5
2.0
20
206
Split
Tensile
Strength
(MPa)
4.28
4.93
4.53
4.03
3.73
Table 4.6: Impact strength of Coir Fibre Reinforced Concrete (M30; 28Days)
NO OF
NO OF BLOWS
TOTAL
Impact
SI. FIBRE%
BLOWS
Joule
FOR THE
Joule LENGTH
strength
FOR THE
No
FINAL
OF
per mm
FIRST
FAILUARE
CRACK
length of
CRACK
crack
1
0
5
10.1
6
12.1
29
0.41
2
0.5
8
16.2
14
28.3
33
0.42
3
1
11
22.2
20
40.5
36
0.55
4
1.5
13
26.3
24
48.6
40
0.6
5
2
16
32.5
28
56.7
43
0.65
Table 4.7: Effect of Exposure in NaOH on the Compressive Strength and Flexural Strength of
Coir Fibre Reinforced Concrete (M30; 28 days in normal curing and 28 days in NaOH)
Compressive
Sl.No
Fibre
Fibre
Strength
Length Content
(MPa)
% loss in
(mm)
(%)
strength
A
B
1.
0
49.4
47.88
3
2.
0.5
58.6
57
2.73
20
3.
1
55.9
54.9
1.78
4.
1.5
51.9
50.7
2.31
5.
2
44
42.5
3.4
Sl.No
Fibre
Length
(mm)
1.
2.
3.
4.
5.
20
Fibre
Content
(%)
0
0.5
1
1.5
2
Flexural
Strength
(MPa)
A
B
5.44
4.98
6.4
5.57
5.88
5.37
5.2
4.62
4.95
4.23
% loss in
strength
9.23
12.96
8.67
11.15
14.54
Table 4.9: Effect of Exposure in NaOH on the Split tensile Strength of Coir Fibre Reinforced
Concrete (M30; 28 days in normal curing and 28 days in NaOH)
Sl.No
1.
2.
3.
4.
5.
Fibre Length
(mm)
20
Fibre
Content (%)
0
0.5
1
1.5
2
207
Split Tensile Strength

(MPa)
A
B
4.28
4.02
4.93
4.62
4.53
4.23
4.03
3.82
3.73
3.30
% loss in
strength
6.07
6.28
6.62
5.21
11.52
Table 4.10 Effect of Exposure in NaOH on the Impact Strength of Coir Fibre Reinforced
Concrete (M30; 28 days in normal curing and 28 days in NaOH)
SI.
No
1
2
3
4
5
FIBRE
%
0
0.5
1
1.5
2
NO OF
BLOWS FOR
THE FIRST
CRACK
4
8
10
12
14
NO OF
BLOWS
FOR THE
FINAL
FAILUARE
5
12
19
23
26
Joule
8.1
16.2
20.2
28.3
32.4
TOTAL
LENGTH
OF
CRACK
26
30
33
37
41
Joule
10.12
24.3
38.4
46.5
52.6
Impact
strength
per mm
length of
crack
0.38
0.81
1.09
1.22
1.28
120
100
Slump in mm
80
60
40
20
0
0% 5% 10% 15% 20% 25% 30%

MK MK MK MK MK MK MK
Slump 100
95
83
80
70
72
60
Fig. 4.1: The variation of workability is graphically represented With respect to metakaolin
replacement
Compressive strength (N/mm2)
60
50
40
30
20
7 Days
10
28 Days
0
Fig. 4.2: Variation of Compressive Strength of Concrete Incorporated with Metakaolin

208
(a) X-ray
ray Diffraction (XRD) pattern for (0%) 0f metakaolin
(b) X-ray
ray Diffraction (XRD) pattern for (5%) 0f metakaolin
209
(c) X-ray Diffraction (XRD) pattern for (10%) 0f metakaolin
(d) X-ray Diffraction (XRD) pattern for (15%) 0f metakaolin
210
(e) X-ray Diffraction (XRD) pattern for (20%) 0f metakaolin

Fig. 4.3: XRD- Patterns of concrete Incorporated with Metakaolin
Compressive strength (N/mm2)
70
60
50
40
30
20
10
7 days
28 days
0
0%
0.50%
1%
1.50%
2%
Fibre content
Fig. 4.4: Compressive strength of coir fibre reinforced concrete of various fibre content (M30;
Fibre content = 0.5%, 1%, 1.5% and 2%)
211
Flexural strength (N/mm2)
7
6
5
4
3
2
28 Days
1
0
0%
0.50%
1%
1.50%
2%
Fibre content
Fig. 4.5: Flexural strength of coir fibre reinforced concrete of various fibre content (M30; Fibre
content = 0.5%, 1%, 1.5% and 2%)
Split tensile strength

(N/mm2)
6
5
4
3
28 Days
2
1
0
0%
0.50%
1%
1.50%
2%
Fibre content
Fig. 4.6: Split tensile strength of coir fibre reinforced concrete of various fibre content (M30;
Fibre content = 0.5%, 1%, 1.5% and 2%)
0.7
Impact strength (N/mm2)
0.6
0.5
0.4
0.3
28 Days
0.2
0.1
0
0%
0.50%
1%
Fibre content
1.50%
2%
Fig 4.7: Impact strength of coir fibre reinforced concrete of various fibre content
(M30; Fibre content = 0.5%, 1%, 1.5% and 2%)
212
Compressive strength
(N/mm2)
70
60
50
40
30
20
28 Days normal water curing
10
28 days in NaOH solution
0
0%
0.50%
1%
1.50%
2%
Fibre content
Fig 4.8: Compressive strength of coir fibre reinforced concrete in NaOH solution of various
fibre content (M30; Fibre content = 0.5%, 1%, 1.5% and 2%)
Flexural strength (N/mm2)
7
6
5
4
3
28 Days in NaOH Solution
2
1
0
0%
0.50%
1%
1.50%
2%
Fibre content
Fig: 4.9 Flexural strength of coir fibre reinforced concrete in NaOH solution of various fibre
content (M30; Fibre content = 0.5%, 1%, 1.5% and 2%)
Split tensile strength (N/mm2)
6
5
4
3
2
1
0
0%
0.50%
1%
Fibre content
1.50%
2%
Fig 4.10: Split tensile strength of coir fibre reinforced concrete in NaOH solution of various
fibre content (M30; Fibre content = 0.5%, 1%, 1.5% and 2%)
213
Impact strength (N/mm2)
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0%
0.50%
1%
Fibre content
1.50%
2%
Fig 4.11: Impact strength of coir fibre reinforced concrete in NaOH solution of various fibre
content (M30; Fibre content = 0.5%, 1%, 1.5% and 2%)
VI. CONCLUSION
Salient conclusions, based on the comprehensive experimental investigations carried out the
parameters considered in the present study, are summarized below.
i) Workability and Compressive Strength of Concrete incorporated with Metakaolin
1) Workability decreases, as the percentage of metakaolin increases.
2) The maximum compressive strength obtained is 49.4N/mm2 at 15% replacement of OPC with
metakaolin, which is 20.2% higher than the reference strength.
3) At 15% replacement of OPC with Metakaolin in XRD analysis, most of CH was consumed,
and the more C-S-H was formed, leads to higher strength of concrete. This is very helpful to
the early strength development of cement mortars.
4) XRD analysis indicates that more Ca (OH) was consumed after adding metakaolin ad-mixture.
5) From the above study, the best mix proportion was chosen at 15% replacement of metakaolin
for further study i.e. for the coir fibre reinforce concrete.
ii) Strength Behavior of Coir Fibre Reinforced Concrete:1) Compressive, flexural and split tensile strength of coir Fibre Reinforced Concrete are
maximum at 0.5% fibre content with 20mm fibre length.
2) Impact strength of coir Fibre Reinforced Concrete are maximum at 2% fibre content.
3) The compressive strength obtained at 0.5% fibre content is 58.6 N/mm2 which is 18.62%
4) The maximum flexural strength obtained at 0.5% fibre content is 6.4 N/mm2, which is 17.64%
5) The maximum split tensile strength attained at 0.5% fibre content is 4.93 N/mm2, which is
15.18% higher than the reference concrete strength.
6) The maximum impact energy at 2% fibre content is (energy per blow) which is 36.9% higher
than the reference concrete.
214
7) The energy required in joules per millimeter length of cracks is 56.7 J/mm at 2% fibre content
which 36.9 % higher than the reference concrete. This show the role of coir fibres in resisting
the cracks in the concrete.
iii) Durability Behavior of Coir Fibre Reinforced Concrete
1) Compressive, Flexural, Split tensile and impact strength of coir fibre reinforced concrete
decreases after the exposure in NaOH medium.
2) Based on the durability study, it is found that the matrix was deteriorated much in the alkaline
exposure, but not the coir fibres exist inside the matrix. Hence the coir fibre has stability in
metakaolin based concrete, in resistance the cracks due to impact energy.
SCOPE OF FUTURE STUDIES
1) It is necessary to characterize the natural fibres in the cementations composites, to ensure
durability and develop fibre reinforced quality concrete.
2) Natural fibres like coir fibres are to be established, so that concrete thickness can be reduced
with high cracking resistance.
VII. MIX DESIGN FOR THE REFERENCE CONCRETE (M30) GRADE
a) Grade
(As per IS: 10262-2009)

Mix design for metakaolin concrete
: M 30
b) Type of cement
: OPC 43
c) Max normal size of aggregate : 20 mm

d) Mix cement content
: 380 kg/m3
e) Max W/C
: 0.45
f) Workability
: 50-100mm
g) Mineral admixture
: metakaolin
Step 1:
Target strength for mix proportion
Fck+1.65(s)
[From table 1 of IS 10262:2009, sd =5.0]
30+1.65(5) =38.25 N/mm2
Step 2:
Selection of W/C ratio= 0.45
[From table 5 of IS 456:2000 for reinforced concrete of severe exposure conditions]
215
Step 3:
Selection of water content
Max water content=186 liters [As per IS code 10262:2009 from TABLE 2 for 20mm size of coarse
aggregate, the water content will be 186]
Step 4:
Calculation of cement content
186/0.45= 413.33 kg/m3 [adopted 380 kg/m3]
Step 5:
15% of metakaolin = 380x15/100
MK Content = 57 kg
Cement = 380-57
Cement content = 323 kg
Step 6:
Water content
Cement + MK x W/C [323+57 x 0.45] =171 liters
Step 7:
Estimation of coarse and fine aggregate content
Vol. of coarse agg: 0.62 + 0.01= 0.63
Vol. of fine
agg: 0.63 1
= 0.37
Mix calculation: a) Vol of concrete = .98M3

b) Vol of cement =
(Mass of cement/Sp.g of cement) x 1/1000
=323/3.12 x 1/1000
=0.1035 M3
c) Vol. of Water =
216
Mass of Water /Sp.g of Water x 1/1000

=171/1 x 1/1000
=0.171 M3
d) Vol. of metakaolin =
Mass of MK/ Sp.g of MK x 1/1000
= 57/2.5x1/1000
= 0.0228 M3
e) Vol of aggregate = [a-(b+c+d)]
= [.98-(0.1035+0.171+0.0228)]
= 0.6827 M3
f) Mass of C.A = Vol of agg x vol. of C.A x Sp.g of C.A x 1000
= 0.6827 x 0.63 x 2.72 x 1000
= 1169. Kg
g) Mass of C.A = Vol of agg x vol of F.A x Sp.g of F.A x 1000
= 656. Kg
= 0.6827 x 0.37 x 2.6 x 1000
Mix proportion
Material
Water
Cement
Fine aggregate
(Sand)
Coarse
aggregate
Kg/m3
171.
380
656
1169
Ratio
0.45
1.72
3.07
VIII. MIX DESIGN FOR COIR FIBRE REINFORCED CONCRETE (M30) GRADE
(As per IS: 10262-2009)
Mix design for Fibre reinforced concrete
a) Grade
b) Type of cement
: M 30
: OPC 43
c) Max normal size of aggregate : 20 mm

d) Mix cement content
: 380 kg/m3
e) Max W/C
: 0.45
f) Workability
: 50-100mm
217
g) Mineral admixture
: metakaolin
e) Fibre
: Coir
Step 1:
Target strength for mix proportion
Fck+1.65(s)
[From table 1 of IS 10262:2009, sd =5.0]
30+1.65(5) =38.25 N/mm2
Step 2:
Selection of W/C ratio= 0.45
[From table 5 of IS 456:2000 for reinforced concrete of severe exposure conditions]
Step 3:
Selection of water content
Max water content=186 liters [As per IS code 10262:2009 from TABLE 2 for 20mm size of coarse
aggregate, the water content will be 186]
Step 4:
Calculation of cement content
186/0.45= 413.33 kg/m3 [adopted 380 kg/m3]
Step 5:
15% of metakaolin = 380x15/100
MK Content = 57 kg
Cement = 380-57
Cement content = 323 kg
Step 6:
0.5% of coir fibre = 323 x 0.5/100 = 1.61
Step 7:
Water content Cement + MK x W/C [323+57 x 0.45] =171 liters
Step 8: Estimation of coarse and fine aggregate content
Vol of coarse agg: 0.62 + 0.01= 0.63
Vol of fine agg
: 0.63 1
= 0.37
218
Mix calculation
a) Vol of concrete = .98M3
b) Vol of cement = Mass of cement/ Sp.g of cement x 1/1000
c) Vol of water
= 323 /3.12 x1 /1000

= 0.1035 M3
= Mass of water/ Sp.g of water x 1/100 = 171/1 x 1/1000 = 0.171 m3
d) Vol of metakaolin =
Mass of MK/ Sp.g of MK x 1/1000
= 57/2.5x1/1000
= 0.0228 M3
e) Vol of coir fibre
= Mass of coir fibre/ Sp.g of coir x 1/1000

= 1.61/1.12 x 1/1000
=0.00143 M3
e) Vol of aggregate = [a-(b+c+d+e)]

= [.98-(0.1035+0.171+0.0228 + 0.00143)]
= 0.6812 M3
f) Mass of C.A
= Vol of agg x vol of C.A x Sp.g of C.A x 1000
= 0.6812 x 0.63 x 2.72 x 1000

= 1167 kg
g) Mass of C.A
= Vol of agg x vol of F.A x Sp.g of F.A x 1000

= 0.6812 x 0.37 x 2.6 x 1000
= 655 kg
Mix proportion
Material
Water
Cement
Fine aggregate (Sand)
Coarse
aggregate
Kg/m3
171.
380
665
1167
Ratio
0.45
1.75
3.07
219
REFERENCE
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ash and Metakaolin. Magazine of Concrete research, Vol.51, No 2, 1999, pp.207-216.
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Cement and Concrete Research, Vol.33, 2003, pp.1473-1479.
Zinging Li, Zhu Ding., Property improvement of Portland cement by incorporating with
Metakaolin and slag. Cement and Concrete Research, Vol.33, 2003, pp.579-584.
Kumbhar Pd, Strength and workability properties of High Performance Concrete
Incorporating High Reactivity Metakaolin Modern Engineering Research, Vol.2, 2012 pp1099-1104.
Vu D.D, Stroven.P, Bui. V.B Strength and Durability aspects of Calcined Kaolin-blended
Portland cement concrete, Cement and Concrete Composites Vol.23, 2001, pp.471-478.
Gruber K.A., Terry Ramlochan, Andrea Boddy, Hooton R.D, M.D.A Thomas., Increasing
Concrete Durability with high-reactivity Metakaolin, Cement and Concrete Composites,
Vol.23,2001,pp.479-484.
Michael Zeljkovic, Metakaolin effects on concrete durability, University of toronato (2009)
Sudarsana H, Durability studies on metakaolin based glass fibre reinforced concrete,
Advance scientific research and technology, Issue 2, volume 2 2012
ISSN: 2249-9954.
Poon, C.S., Lam L, Kou, S.C., Wong, Ron Wong Y.L., Rate of pozzolanic reaction of
Metakaolin in high-performance in cement pastes Cement and Concrete Research,
Vol.31,2001, pp.1301-1306.
Sabir B.B and Kinuthia J.M., Strength developed in concrete incorporating PFA and
Metakaolin, Magazine of Concrete Research, Vol.52, No.3, 2000, pp.153-162.
Erhan Guneyisi, Improving strength, drying shrinkage and pore structure of concrete using
metakaolin, Material and structure DOI 10.1617/s11527-007-9296-z.
Mishhadani AL, Metakaolin properties of light weigth concrete containing carbon fibre,
Iraqi journal of civil engineering, Vol 6 NO: 1 2009.
Raya yaseen Mohammed, Properties of high performance steel fibre reinforced concrete
containing high reactive metakaolin, Iraqi journal of civil engineering, Vol 8 NO: 1 2010.
Frias M., Sanchez de Rojas M.I., Cabrera, J., The Effect that the Pozzolanic reaction of
Metakaolinite has on the heat evolution in Metakaolin-cement Concrete, Cement and
Concrete Research, Vol.30, 2000, pp.209-216.
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1996, pp.1537-1544.
N.Krishna Murthy, N.Aruna, A.V.Narasimha Rao, I.V.Ramana Reddy, B.Madhusudana
Reddy and M.Vijaya Sekhar Reddy, Influence of Metakaolin and Fly Ash on Fresh and
Hardened Properties of Self Compacting Concrete, International Journal of Advanced
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ISSN Print: 0976-6480, ISSN Online: 0976-6499.
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Studies On Metakaolin Based Coir Fibre Reinforced Concrete

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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),

ISSN 0976 6308 (Print)

STUDIES ON METAKAOLIN BASED COIR FIBRE REINFORCED

B.tech Civil Engineering, Vellore Institute of Technologies, Chennai, Tamilnadu, India.

SCOPE OF THE PRESENT STUDY

II. LITERATURE REVIEW

2KAl2 (AlSi3) O10 (OF) 2 + 5H2) 3 Al2Si2O5 (OH) 4 + 2KO

vi) Coconut Fibre

Properties of Natural Fiber Reinforced Concrete in Hardened State

Table 3.2: Properties of Coarse Aggregate

Table 3.3: Properties of Fine Aggregate

Table 3.4: Properties of Metakaolin

Table 3.5: Chemical properties of Metakaolin

Table 3.6: Properties of Coir Fibre

Water Absorption for 24

Table 3.7: Mix Details for Concrete

Fig 3.1: Stages in the Processing of Coir Fibres

(a) Slump Cone Test

(b) Inverted Slump Cone Test

(c) Compression Test

(d) Flexural Test

(e) Split Tensile Test

(f) Impact Test

Fig 3.2: Testing of the Coir Fibre Reinforced Concrete both in

V. RESULTS AND DISCUSSIONS

(vii) Durability evaluation of coir fibre reinforced cement composite

Table 4.2: Workability of Coir Fibre Reinforced Concrete

Compressive Strength MPa

Split Tensile Strength

0% 5% 10% 15% 20% 25% 30%

Compressive strength (N/mm2)

Fig. 4.2: Variation of Compressive Strength of Concrete Incorporated with Metakaolin

(c) X-ray Diffraction (XRD) pattern for (10%) 0f metakaolin

(d) X-ray Diffraction (XRD) pattern for (15%) 0f metakaolin

(e) X-ray Diffraction (XRD) pattern for (20%) 0f metakaolin

Compressive strength (N/mm2)

Flexural strength (N/mm2)

Split tensile strength

28 Days normal water curing

28 days in NaOH solution

Flexural strength (N/mm2)

Split tensile strength (N/mm2)

28 days in NaOH solution

Impact strength (N/mm2)

(As per IS: 10262-2009)

c) Max normal size of aggregate : 20 mm

Mix calculation: a) Vol of concrete = .98M3

Mass of Water /Sp.g of Water x 1/1000

= 0.6827 x 0.37 x 2.6 x 1000

c) Max normal size of aggregate : 20 mm

= 323 /3.12 x1 /1000

= Mass of coir fibre/ Sp.g of coir x 1/1000

e) Vol of aggregate = [a-(b+c+d+e)]

= Vol of agg x vol of C.A x Sp.g of C.A x 1000

= 0.6812 x 0.63 x 2.72 x 1000

= Vol of agg x vol of F.A x Sp.g of F.A x 1000

Fine aggregate (Sand)

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