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HIGH PERFORMANCE CONCRETE UTILIZING METAKAOLIN AND SPENT
GARNET
NAZIRAH BINTI AHMAD SHUKRI
A thesis submitted in fulfilment of the
requirements for the award of the degree of
Master of Philosophy in Structural and Material
School of Civil Engineering
Faculty of Engineering
Universiti Teknologi Malaysia
FEBRUARY 2020
iv
DEDICATION
Tomybelovedparentsfortheirendlesssupportandlove.Tomysiblingswhoalwaysencouragemealongtheroad.Tomysupervisorforalltheguidanceandunderstandings.
Tomyclosefriendsforalwaysbeingthere.
v
ACKNOWLEDGEMENT
Firstly, I would like to thank Allah for His mercy, I am able to complete this
journey, Alhamdulillah.
I would like to express my sincere gratitude to my supervisor Dr Roslli Bin
Noor Mohamed for the his continuous support, patience, motivation, knowledge and
understanding. I am very grateful for the given opportunity to work with him. I would
also like to show my appreciation to Dr Yunus Bin Ishak for his guidance and
encouragement.
I thank my fellow lab mates for their assistance, sharing session and
experiences. I am really blessed to know all of you and your kindness will never be
forgotten. I would also like to dedicate my special gratitude to all the people who have
helped me directly and indirectly along the journey.
Last but not the least, a special thank you to my beloved family for everything
that they had done for me.
vi
ABSTRACT
This study deals on the utilization of metakaolin and spent garnet as part of
cementitious and fine aggregates replacement in high performance concrete (HPC).
HPC offers many benefits especially towards application of structures which sustain
higher loads and exposed to harsh environment at the same time such as piers. HPC
usually been produced by applying supplementary cementitious material as an
admixture to enhance the quality of HPC. Metakaolin is known as one of the common
material that has been proven to produce good qualities of HPC. Spent garnet is one
of the industrial waste materials which had been recognized as suitable fine aggregates
substitution in concrete. Apart from sand mining issue which had been highlighted,
excessive amount of spent garnet in the landfill had also seems to jeopardize the
environment. Thus, the study on the utilization of spent garnet and metakaolin in
producing HPC is performed. Physical properties test of the materials had been
conducted and trial mixes had been executed afterwards with replacement of spent
garnet in percentage amount of 10%, 20%, 30%, 40%, 50% and 60% by weight. The
workability test results showed that at the replacement of 60%, the fresh concrete bled.
Compressive strength, flexural strength, splitting tensile strength and modulus of
elasticity tests were carried out to determine mechanical properties of the mix
proportion. The morphology of the HPC was identified by completing Scanning
Electron Microscope (SEM) with Energy Dispersive X-Ray Analysis (EDX) and X-
Ray Diffraction Analysis Test (XRD). The durability test was conducted to observe
the resistance of HPCM and HPCMG50 towards chloride penetration and elevated
temperature test. HPC with 50% of spent garnet replacement (HPCMG50) indicated
the highest value of compressive strength with 92.3 MPa as compared to 65.4 MPa for
HPC without any spent garnet replacement (HPCM). As conclusion, this study found
that 50% utilization of spent garnet is effective in producing HPC with better
mechanical properties and chloride resistance. Hence utilization of 50% of spent
garnet as fine aggregates replacement is a good approach in fighting the issue of sand
deficit as well as betterment of landfill management.
vii
ABSTRAK
Kajian penggunaan metakaolin dan sisa garnet sebagai bahan gantian simen
dan agregat halus dalam konkrit berprestasi tinggi (HPC) telah dijalankan. HPC
selalunya dihasilkan melalui penggunaan bahan simen tambahan sebagai bahan
campuran untuk meningkatkan kualiti HPC. Metakaolin dikenali dan telah dibuktikan
sebagai salah satu bahan yang sering digunakan dalam menghasilkan HPC yang
berkualiti. Sisa garnet merupakan salah satu bahan buangan industri yang telah
dikenalpasti sebagai bahan yang sesuai untuk digunakan sebagai bahan gantian agregat
halus dalam konkrit. Selain daripada isu perlombongan pasir, lambakan sisa garnet di
tapak pelupusan juga dilihat sebagai perkara yang dapat menjejaskan alam sekitar.
Oleh itu, kajian mengenai penggunaan sisa garnet dan metakaolin dalam menghasilkan
HPC dijalankan. Ujian sifat fizikal bahan-bahan ini dan seterusnya percubaan
mendapatkan campuran konkrit dengan penggantian peratusan jumlah sisa garnet
berdasarkan berat sebanyak 10%, 20%, 30%, 40%, 50% dan 60% telah dijalankan.
Ujian kebolehkerjaan menunjukkan berlakunya penjujuhan pada penggantian sisa
garnet sebanyak 60%. Ujian kekuatan mampatan, kekuatan lenturan, kekuatan
tegangan dan modulus keanjalan dijalankan bagi mendapatkan sifat mekanikal
campuran konkrit terbabit. Morfologi HPC dikenalpasti melalui ujian peingimbasan
mikroskop electron (SEM) bersama ujian analisis penyebaran tenaga X-Ray (EDX)
dan ujian analisis pembelauan X-Ray (XRD). Ujian ketahanan telah dijalankan bagi
mengenalpasti tahap rintangan HPC terhadap penembusan klorida dan suhu tinggi.
HPC dengan penggantian 50% sisa garnet menunjukkan kekuatan mampatan tertinggi
dengan nilai 92.3 MPa berbanding 65.4 MPa bagi HPC tanpa sebarang gantian sisa
garnet Sebagai kesimpulan, kajian ini mendapati bahawa penggantian sisa garnet
sebanyak 50% adalah efektif dalam menghasilkan konkrit berprestasi tinggi yang lebih
berkualiti dari segi sifat mekanikal dan rintangan klorida. Oleh itu, penggantian50%
sisa garnet adalah merupakan salah satu pendekatan yang baik dalam menangani isu
penguranagn pasir disamping penambahbaikan pengurusan tapak pelupusan.
viii
TABLE OF CONTENTS
TITLE PAGE
DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENT v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES xiii
LIST OF FIGURES xiv
LIST OF ABBREVIATIONS xvii
LIST OF SYMBOLS xix
LIST OF APPENDICES xxi
CHAPTER 1 INTRODUCTION 1
1.1 Introduction 1
1.2 Problem statement 3
1.3 Aims and Objectives 4
1.4 Significance of Study 4
1.5 Scope of Study 5
CHAPTER 2 LITERATURE REVIEW 7
2.1 Introduction 7
2.2 High Performance Concrete 7
2.2.1 Mix Design of HPC 9
2.2.2 Fresh Properties of HPC 10
2.2.2.1 Segregation and Bleeding In Concrete. 11
2.2.3 Mechanical Properties of HPC 12
2.2.4 Microstructure Properties of HPC 14
ix
2.2.4.1 Phase Identification 15
2.2.4.2 Morphology Properties 17
2.2.5 Durability of HPC 19
2.2.5.1 Impact Of Chloride On Concrete 20
2.2.5.2 Chloride Penetration On HPC 20
2.2.5.3 Impact of Elevated Temperature On Concrete. 23
2.2.5.4 Impact Of Elevated Temperature On HPC. 25
2.3 Garnet 28
2.3.1 Application of Garnet 29
2.3.2 Properties of Garnet 31
2.4 Metakaolin 33
2.5 Critical Summary 34
CHAPTER 3 RESEARCH METHODOLOGY 37
3.1 Introduction 37
3.2 Research Framework 38
3.3 Raw Materials 41
3.3.1 Cementitious Materials 41
3.3.2 Aggregates 42
3.3.3 Super Plasticizer 42
3.3.4 Water 43
3.4 Physical Properties Of Raw Materials. 43
3.4.1 Sieve Analysis 43
3.4.2 Particle Size Analysis (PSA) 44
3.4.3 Bulk Density 45
3.4.4 Specific Gravity 46
3.4.5 Water Absorption 48
3.5 Trial Mix and Fresh Properties of HPC. 48
3.5.1 Trial Mixes of HPC 48
3.5.2 Preparation and Casting Of Samples 51
3.5.3 Fresh Concrete Properties 52
x
3.6 Hardened Concrete Properties 53
3.6.1 Compressive Strength Test 54
3.6.2 Flexural Strength Test 55
3.6.3 Splitting Tensile Strength Test 56
3.6.4 Modulus of Elasticity 57
3.6.5 Ultrasonic Pulse Velocity (UPV) Test 58
3.7 Morphology Properties 60
3.7.1 Scanning Electron Microscope (SEM) and X-ray Spectroscopy (EDX) 61
3.7.2 X-ray Diffraction (XRD) 62
3.8 Durability 62
3.8.1 Colorimetric Test 63
3.8.2 Elevated Temperature Test 64
CHAPTER 4 RESULTS AND DISCUSSIONS ON PHYSICAL PROPERTIES, MIX DESIGN AND HARDENED PROPERTIES 65
4.1 Introduction 65
4.2 Physical Properties Of Materials 65
4.2.1 Specific Gravity, Water Absorption and Bulk Density of Spent Garnet and Sand 65
4.2.2 Physical Of Material Observation Through SEM 66
4.3 Particle Size of Materials 67
4.3.1 Sieve Analysis of Spent Garnet and Sand 68
4.3.2 Particle Size Analysis of Metakaolin. 69
4.4 Mix Design 70
4.5 Fresh Properties 74
4.6 Hardened Properties 75
4.6.1 Compressive Strength 76
4.6.2 Flexural Strength 78
4.6.3 Splitting Tensile Strength 78
4.6.4 Modulus of Elasticity 79
4.6.5 Ultrasonic Pulse Velocity (UPV) and Dry Density 80
xi
4.7 Summary 81
4.7.1 Summary On Physical Properties of Materials 81
4.7.2 Summary On Mix Design of HPC 81
4.7.3 Summary On Fresh Properties of HPCM and HPCMG 82
4.7.4 Summary On Hardened Properties of HPCM and HPCMG 83
CHAPTER 5 MORPHOLOGY AND DURABILITY OF HPCM AND HPCMG50 85
5.1 Introduction 85
5.2 Morphological Characteristics of HPCM and HPCGM50 85
5.2.1 Scanning Electron Microscope (SEM) and Energy Disperse X-ray (EDX) 85
5.2.2 X-ray Diffraction of HPCM and HPCMG50 89
5.3 Performance of HPCM and HPCMG50 90
5.3.1 Characteristics of HPCM and HPCMG50 Towards Elevated Temperature Test 90
5.3.1.1 Physical Characteristics of HPCM and HPCMG50 After Exposed To Elevated Temperature. 90
5.3.1.2 Residual Compressive Strength of HPCM and HPCMG50 After Exposed to Elevated Temperature 93
5.3.1.3 Mass Loss of HPCM and HPCMG50 After Exposed to Elevated Temperature 95
5.3.1.4 UPV of HPCM and HPCMG50 Due to Elevated Temperature 96
5.3.2 Characteristics of HPCM and HPCMG50 Towards Chloride Penetration 97
5.3.2.1 Colorimetric Test of HPCM and HPCMG50 98
5.3.2.2 Reduction in Compressive Strength Due to Chloride Penetration 99
5.4 Summary on Morphology and Performance of HPCM and HPCMG50 100
xii
CHAPTER 6 CONCLUSION AND RECOMMENDATIONS 103
6.1 Introduction 103
6.2 Conclusion By Objectives 103
6.3 Overall Summary. 105
6.4 Recommendations. 106
REFERENCES 107
xiii
LIST OF TABLES
TABLE NO. TITLE PAGE
Table 2.1 Criteria of HPC by Strategic Highway Research Program 9
Table 2.2 Chemical composition of spent garnet from XRF analysis (Muttashar et al., 2017) 32
Table 2.3 Presence of heavy metals in spent garnet determined using TCLP analysis (Muttashar et al., 2017) 32
Table 2.4 Chemical composition comparison between metakaolin and OPC (Shahidan et al., 2017) 33
Table 3.1 Mix Design HPCM and HPCMG50 49
Table 4.1 Physical Properties of Spent Garnet and Sand 66
Table 4.2 Sieve Analysis of Sand and Spent Garnet 68
Table 4.3 Trial Mixes 72
Table 4.4 Outcomes and Improvements On Trial Mixes 73
Table 4.5 Mix Design 74
Table 4.6 Flexural Strengths at 28 days 78
Table 4.7 Splitting Tensile Strengths at 28 days 79
Table 4.8 Modulus Of Elasticity of HPCM and HPCMG50 80
Table 4.9 Dry density and UPV of HPCM and HPCMG50 80
Table 5.1 Summary of physical changes after exposure 93
xiv
LIST OF FIGURES
FIGURE NO. TITLE PAGE
Figure 2.1 XRD results on influence of different types of nano-SiO2 on HPC (Khaloo et al., 2016) 16
Figure 2.2 XRD Analysis (Kim et al., 2007) 17
Figure 2.3 (a)Absence of transition zone in HPC (b) Dense cement paste of HPC (Aïtcin, 2003) 18
Figure 2.4 (a) Dense C-S-H gel (b) Dense ettringites in the form of pike and flower (Gao et al., 2002) 19
Figure 2.5 Mechanism of colorimetric method using silver nitrate (Kim et al., 2013) 22
Figure 2.6 Changes in concrete elements by temperature (Khoury, 2000) 24
Figure 2.7 Effect of elevated temperature on compressive strength based on aggregates type (Bilow and Kamara, 2008) 24
Figure 2.8 Colour changes of HPC and conventional concrete based on temperature exposure (Hager, 2014) 26
Figure 2.9 Crack pattern of HPCs after exposure of elevated temperature (Kulkarni and Yaragal in 2011) 27
Figure 2.10 Residual compressive strength after exposure to elevated temperatures (Kulkarni and Yaragal, 2011) 28
Figure 2.11 Types of garnet (Barthelmy, 2014) 29
Figure 2.12 SEM outcomes at 250X by Khiyon (2018) (a) spent garnet (b) sand 32
Figure 2.13 Research Gap 36
Figure 3.1 Research Framework 40
Figure 3.2 Metakaolin 41
Figure 3.3 Spent garnet 42
Figure 3.4 Sieve Machine 44
Figure 3.5 Mastersizer 3000 45
Figure 3.6 Cylindrical metal used for bulk density test 46
Figure 3.7 Pycnometer 47
xv
Figure 3.8 Determination flow of optimum mix 50
Figure 3.9 Preparation of moulds for casting procedure 52
Figure 3.10 Flow Table Test 53
Figure 3.11 Compressive strength test for (a) cube (b) cylindrical 55
Figure 3.12 Flexural Strength Test 56
Figure 3.13 Splitting Tensile Strength Test 57
Figure 3.14 (a) Modulus of elasticity testing. (b) Samples after the test 58
Figure 3.15 (a) UPV Test (b) Schematic Diagram of UPV Test 60
Figure 3.16 Scanning Electron Microscope (SEM) and X-ray Spectroscopy (EDX) 61
Figure 3.17 XRD Test Machine 62
Figure 3.18 (a) The water contains NaCl. (b) pH test. (c) The sample was cut into half. (d) The penetration of chloride was measured. 63
Figure 3.19 Furnace used in elevated temperature test. 64
Figure 4.1 SEM outcomes of (a) spent garnet and (b) sand 67
Figure 4.2 SEM outcomes of metakaolin 67
Figure 4.3 Particle Distribution of Sand and Spent Garnet 69
Figure 4.4 Particle Size Analysis of Metakaolin 70
Figure 4.5 Concrete Flow (mm) 75
Figure 4.6 Compressive Strength 76
Figure 4.7 Relationship of compressive strength and density 77
Figure 5.1 Identification of C-S-H, C-H and ettringite (a) HPCM (b) HPCMG50 86
Figure 5.2 (a) Voids in HPCM (b) Voids in HPCMG (c) Micro-cracks in HPCM (d) Micro-cracks in HPCMG50 (e)ITZ in HPCM (f) ITZ in HPCMG50 87
Figure 5.3 EDX of HPCMG50 and HPCM 88
Figure 5.4 XRD for HPCMG50 and HPC 89
Figure 5.5 Physical changes (a) HPCM at 200°C (b) HPCMG50 at 200°C (c) HPCM at 400°C (d) HPCMG50 at 400°C (e) HPCM at 600°C (f) HPCMG50 at 600°C (g) HPCM at 800°C (h) HPCMG50 at 800°C 92
xvi
Figure 5.6 Residual compressive strengths of HPCM and HPCMG50 after exposed to elevated temperature 94
Figure 5.7 Percentage of mass loss for HPCM and HPCMG50 after exposed to elevated temperature 96
Figure 5.8 UPV Percentage of HPCM and HPCMG50 After Elevated Temperature Test 97
Figure 5.9 Chloride penetration by colorimetric test of HPCM and HPCMG50 98
Figure 5.10 Penetration depth of HPCMG50 and HPCM 99
Figure 5.11 Reduction of compressive strength towards NaCl exposure 100
xvii
LIST OF ABBREVIATIONS
ACI - American Concrete Institute
ASTM - American Society for Testing and Materials
BS - British Standard
CBR - California Bearing Ratio
CMT - Chloride Mitigation Test
CRM - Cement Replacement Material
DMDA - Densifies Mixture Design Algorithm
EDX - X-ray Spectroscopy
ECC - Engineered Cementitious Composite
GGBS - Ground Granulated Blast Furnace Slag
HPC - High Performance Concrete
HPCM - High Performance Concrete Utilizing Metakaolin
HPCMG - High Performance Concrete Utilizing Metakaolin and Spent
Garnet
HPCMG50 - High Performance Concrete Utilizing Metakaolin and 50%
Spent Garnet Replacement
HSC - High Strength Concrete
ITZ - Interfacial Transition Zone
LOI - Loss Of Ignition
MIP - Mercury Intrusion Porosimetry
MS - Malaysian Standard
OPC - Ordinary Portland Cement
PSA - Particle Size Analysis
RCPT - Rapid Chloride Penetration Test
SEM - Scanning Electron Microscopic
SG - Specific Gravity
SHRP - Strategic Highway Research Program
SSD - Saturated Surface Dry
TG - Thermogravimetry
TLCP - Toxicity Characteristic Leaching Procedure
xviii
UPV - Ultra Sonic Pulse Velocity
U.S EPA - United States Environmental Protection Agency
XRD - X-ray Diffraction
XRF - X-ray Fluorescence
xix
LIST OF SYMBOLS
℃ - Celsius
AgNO3 - Silver Nitrate
K2CrO4 - Pottasium Chromate
AgCl - Silver Chloride
AgOH - Silver Hydroxide
AgNO3 - Silver Nitrate
K2CrO4 - Pottasium Chromate
AgCl - Silver Chloride
AgOH - Silver Hydroxide
AgNO3 - Silver Nitrate
Al2O3 - Aluminum Oxide
Ca(OH)2 - Calsium Hydroxide
C3S - Alite
C2S - Belite
C-S-H - Calcium Silicate Hydrate
Ca(OH)2 - Calsium Hydroxide
C3S - Alite
C2S - Belite
Fe - Iron
Fe2O3 - Iron (III) Oxide
H2 - Hydrogen
H2O - Water
K2O - Pottasium Oxide
MgO - Magnesium Oxide
MnO - Manganese
Na2O - Sodium Oxide
O2 - Oxygen
OH - Hydroxide
P2O5 - Phosphorus Pentoxide
SiO2 - Silicon Oxide
xx
TiO2 - Titanium Dioxide
ZnO - Zinc Oxide
xxi
LIST OF APPENDICES
APPENDIX TITLE PAGE
Appendix A Sand Mining Issue 115
1
CHAPTER 1
INTRODUCTION
1.1 Introduction
Rapid changes in the construction world have created an urge for exploration
of various type of concrete to suit the need of the structures to be built. Nowadays, the
demand of concrete does not only concern on high strength but the needs of concrete
that will provide a longer lifespan of the structure. In order to achieve this, high-
performance concrete which hold the ability to perform well compared to conventional
concrete offers a better opportunity to fulfill the requirement.
High performance concrete (HPC) has been defined by American Concrete
Institute (ACI) as concrete meeting special combinations of performance and
uniformity requirements that cannot always be achieved routinely using conventional
constituents and normal mixing, placing and curing practice. HPC does not only bear
high stresses but also beneficial in high durability which is one of the important key
elements in a safe structure. Previously, the design of the concrete mixes used in
concrete focus on the strength and workability while less attention was given to the
durability. This leads to deterioration, corrosion, bleeding, efflorescence or cracks that
appear commonly within few years of construction (P.K Chang et al, 2001). Due to
this, various studies have been conducted all around the world aiming to achieve a
better quality of concrete that not only focus on its strength but also its resistance
toward the harsh environment. To achieve this, the design of the HPC mixes does not
only rely on additions of appropriate amount of chemical admixture and pozzolanic
materials but also the substitution of microaggregate that contributes to filling effect
thus will improve compactness of the concrete and slows down the diffusion of ions
(Y.N Chan et al, 2000). Alongside this, silica fume has also been widely used in
producing HPC (Rana et al.,2016). However, in this study usage of silica fume is not
significance as metakaolin as supplementary cementitious material. Many researches
2
have stated that the usage of metakaolin as supplementary cementitious material have
increases compressive strengths, resistance towards chemical attack and enhance
workability (Antoni M. et al, 2012), (V. P.Dinkar et al, 2013) and (Sabale V.D et
al,2014). Hence, in this study, metakaolin as part of cementitious material while
garnet as part substitution of fine aggregates were used in producing HPC.
Other than supplementary cementitious material (SCM), replacement of fine
aggregates is also an effective approach in producing HPC. Garnet, a material that had
been utilized in many industrial areas especially as abrasive blasting, abrasive
powders, waterjet cutting and water filtration. Its angular fractures, relatively high
hardness and specific gravity, chemical inertness and its ability to be recycled making
it ideal for these industry applications (Olson, 2016). Upon achieving the recycle
period, garnets will be treated as waste material and to be treated in the landfill. These
garnets are now addressed as spent garnet. As spent garnet is no longer beneficial, it
will be dumped in the landfill and with time the waste will affect the environment.
Spent garnet can threatened ground water quality when this material entered the
waterways through surge runoffs (Aletba et.al, 2018). Taking this as a factor has
initiated the utilization of spent garnet as fine aggregates replacement materials in
concrete Iqbal (2018) and (Muttashar et al., 2018). Both studies have shown positive
results with replacement of spent garnet as fine aggregates at 25% and 40%. Hence
the utilization of spent garnet as part of material replacement for fine aggregates in
producing HPC is a good prospect to be explored.
The development of HPC has opened an exploration path towards utilizing
various materials to produce HPC. This development has led to the extensive usage
of materials to their full potential in order to produce new material that will sustain a
longer life cycle making it more ecological (Aïtcin, 2003). Despite many researches
had been conducted in utilizing various materials in producing HPC, the utilization of
garnet as fine aggregates in HPC and metakaolin as supplementary cementitious
material has not been highlighted. Thus, a study on this is reasonable in identifying
the suitability of these materials to be utilized in HPC. The study will focus on the
properties of the materials used, mechanical and chemical properties, morphology and
durability of the HPC.
3
1.2 Problem statement
High performance concrete has been applied all over the world in many
structures. Due to its ability to resists high compression stresses along with its
excellence in performance, high performance concrete seems to provide great solution
towards construction in producing better quality of structure. As most concrete
structures are designed for 50 years of age traditionally, applying high performance
concrete in some structures has expanded the life span of the structures in design and
built a service life of 100 years (P. Kumar Mehta, 2004). Consequently, many studies
have been conducted implementing various materials to enhance the understanding of
high-performance concrete behavior. One of the well-known and common materials
used is metakaolin that had been applied as supplementary cementitious material for
high performance concrete and other different types of concrete. Likewise, studies on
utilizing garnet in producing geopolymer concrete and high strength concrete had been
conducted and these studies had indicated the positive results. However, the utilizing
of both materials metakaolin and garnet had not yet been highlighted thus it is
relevance to combine these materials in producing high performance concrete.
River and mining sand have been known as one of the main materials in
producing concrete worldwide. Its properties provide a suitable condition to be
utilized as fine aggregates in the concrete. As construction field grow rapidly, the
demand of natural minerals including sand have increase intensely. In order to produce
more sand to meet the demand of the industry, the process of sand mining from the
water bodies had been conducted excessively. The phenomenon does not only harm
the stabilization of the riverbank, but the ecology system and environment were also
impacted. As one of the rapid developing country, Malaysia too has been impacted
with sand mining issue (Appendix A). In 2010, 1.17 billion metric tons of sand and
gravel out of 2.76 billion metrics of natural mineral in total has been used in Malaysia
(Umara et al., 2016)
As the sand mining issue had been a continuous concern with time, many
studies had been conducted all over the world focusing on producing a better quality
of concrete while minimizing the usage of this natural resource by replacing it with
4
other materials. These materials included waste product from industrial and
construction. Among these waste materials is spent garnet that is used for
sandblasting, water jet cutting and water filtration granules. In 2013, assessment on
Malaysia shipyard industry disclose that 2000 million tons of garnet had been imported
to the country and massive amount of the quantity was dumped as waste (Muttashar et
al., 2018). These spent garnets will end up in landfill and needed to be managed
properly to ensure the safety of environment. Therefore, the utilization of spent garnet
as fine aggregates had been identified as a positive contribution to decrease amount of
spent garnet in landfill and producing better quality of concrete at the same time.
1.3 Aims and Objectives
This study aims for developing high performance concrete utilizing metakaolin
as supplementary cementitious material and garnet as partial replacement of fine
aggregates and to identify its performance. Three objectives had been outlined to
accomplish the aim as listed:
1. To design on optimum concrete mix of HPC utilizing metakaolin and spent garnet.
2. To investigate physical, mechanical and morphology properties of HPC utilizing
metakaolin and spent garnet.
3. To study the durability on chloride penetration and elevated temperature exposure
of HPC utilizing metakaolin and spent garnet
1.4 Significance of Study
Evolution of construction field has necessitated production of better type of
concrete that can resist harsh environment thus sustain structure’s long-life span. The
utilization of garnet as fine aggregates in the study will reduce a great amount of sand
5
required in the concrete mix. This will be a positive contribution in fighting the
struggling issue faced from sand mining operations that jeopardize the environment.
The high bearable of compression stresses and more durable of the high-performance
concrete utilizing garnet and metakaolin will benefits in applying the concrete to
produce a better structure that will sustain high compression stresses while resisting
harsh environment that can prolong the structure’s life span. The morphology study
of the concrete will produce better understanding of high-performance concrete
utilizing garnet and metakaolin. In this study, the high-performance concrete produced
was also tested for chloride penetration and its changes when exposed to elevated
temperature up to 800°C. This will be beneficial in providing data to understand its
performance thus provide a reference in design works.
1.5 Scope of Study
Scope of study for the research consists of producing high performance
concrete utilizing metakaolin and spent garnet as supplementary cementitious material
and fine aggregates replacement. All testing procedures were conducted in accordance
of several guidelines which are Malaysian Standard (MS), British Standard (BS),
American Society for Testing and Materials (ASTM) and suggested practices by
previous studies. Sand, spent garnet and metakaolin used in the studies were tested
for their physical properties including specific gravity, density, water absorption and
sieve analysis. The investigation on metakaolin and spent garnet were then proceeded
with SEM testing in order to understand the shape of their particles. Study on
mechanical properties testing of compressive strength test was conducted for 3 cube
samples each of HPC with metakaolin (HPCM) and HPC with metakaolin and spent
garnet replacement by percentage (HPCMG). Flexural strength test with 3 prism
specimens for each type, splitting tensile strength and modulus of elasticity test with 3
cylindrical specimens were conducted for selected optimum mix HPC with metakaolin
and HPC with metakaolin and spent garnet replacement were then conducted.
Scanning Electron Microscopic (SEM), X-ray Diffraction (X-RD) and X-ray
Spectroscopy (EDX) were also conducted to understand the morphology of these
samples. Study on durability for elevated temperature test limited till 800°C were
6
executed for total of 24 cubic specimens for both HPCM and HPCMG. Changes on
physical, colour, appearance of cracks and spalling were observed and recorded.
Residual compressive strength and mass loss of specimens after exposed to elevated
temperature were also conducted. Colorimetric test was then executed in order to
understand chloride penetration towards HPCM and HPCMG. Total of 12 cubic
specimens were used to observe the penetration before the specimens were then tested
for reduction of compressive strengths after exposure of chloride. Durability towards
chloride resistance in this study was limited to 120 days of chloride exposure.
107
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