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The Effect of Partial Replacement of Cement With Kaolin Powder in The Production of C-25 Concrete

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Journal of Xidian University https://doi.org/10.37896/jxu15.

5/063 ISSN No:1001-2400

The Effect of Partial Replacement of Cement with Kaolin


Powder in the Production of C-25 Concrete
Hunda Hailu#1, Yerosan Abera*#2, Jifara Chimdi#3, Dumesa Gudissa*4 Firaol Tadesse*5
#
Construction Technology and Management Department, Ambo Institute of Technology, Ambo University, Ambo, Ethiopia
*
Civil Engineering Department, Ambo Institute of Technology, Ambo University, Ambo, Ethiopia.
*#
corresponding Author
Abstract: The construction industry is growing quickly demanding a huge amount of concrete. The demand for concrete leads to an
increased usage of binding material (cement). The need for a huge quantity of cement leads to the depletion of natural sources of which in
turn affects the environment. There is a quest to find a suitable material to substitute cement in concrete production. Kaolin powder is
material abundant in Ethiopia, which naturally portrays the properties of cementitious material. Thus, this study aimed at exploring the
characteristics of this material and its effects on the property of concrete when used as a partial replacement of cement in C-25 concrete
production. The kaolin powder was oven-dried and sieved by 150 μm to remove the coarser particle. The percentage of replacement of
cement with kaolin powder was varied from 0% to 20% with respect to the cement in incremental steps of 5%. The experimental program
was designed to investigate the effect of kaolin powder on the setting time of cement, workability, density, and compressive strength of
concrete. The workability of each mix was measured before the specimens cast and cured in water at room temperature and tested at the
ages of 7 and 28 days respectively. A total of thirty (30) 150 x 150 x 150mm concrete test cubes were cast using a mix proportion of 1:2:3,
with a constant water/cement ratio of 0.6. The result showed that the addition of kaolin powder in cement paste as partial replacement of
cement increase both initial and final setting time of cement. However, the workability and density of concrete decrease with the increase
of kaolin powder content in the mix. Regarding the compressive strength, increasing the kaolin powder content (up to 10%) the
improvement in compressive strength of concrete mixes was continuous. At the curing age of 7 days, the concrete containing 5% and 10%
kaolin powder as cement, gained 6.3% and 1.09% of strength while at 15% and 20% replacement level concrete loosed 10.18% and
18.91% of strength respectively. Nevertheless, the replacement of 10% of kaolin powder still improves the compressive strength of
concrete as compared to the control concrete, but for much better results, the 5% of kaolin powder was taken as the optimum
replacement level Finally, the results encourage the use of kaolin powder as pozzolanic material for partial cement replacement in
producing conventional concrete and to compensate for environmental, technical and economic issues caused by cement production.

Keywords— Bellessa kaolin, Cementitious Material, Compressive strength, Kaolin powder, Workability

I. INTRODUCTION
Concrete is one of the most extensively used construction materials in the world, with two billion tons produced worldwide each
year [1, 17]. It is produced from locally available materials can be cast into a wide variety of structural configurations. However,
environmental concerns, stemming from the high energy expense and CO2 emission associated with cement manufacture, have
brought about pressures to reduce cement consumption through the use of supplementary materials[1]. Production of cement among
all other constituents of concrete is harmful to the atmosphere because during the manufacturing of cement there is large emission of
CO2 i.e. 3%-5% [3]. Portland cement manufacture is a high carbon- and energy-intensive. The manufacture of one ton of Portland
cement generates 730~990 kg of CO2 emission [4]. Given the huge amount of Portland cement produced globally, it is estimated
that about 5% of anthropogenic CO2 emissions per annum are produced from the cement manufacturing industry [4, 5].
Supplementary cementitious materials (SCMs) are finely ground solid materials that accustomed to replace a part of the cement
during a concrete mixture. In addition to their positive environmental impact, SCMs improve concrete workability, mechanical
properties, and durability [6]. These may be naturally occurring materials, industrial wastes, or by-products, or those requiring less
energy to manufacture. The commonly used supplementary cementing materials are ash, silica fume, granulated furnace slag, rice
husk ash, and Metakaolin, etc. It’s getting used very commonly as pozzolanic material in concrete and has exhibited considerable
influence in enhancing the mechanical and sturdiness properties of concrete [7].
Kaolin is a white and soft, plastic clay composed dominantly of fine rained platy mineral aggregate kaolinite (A4Si4Ol0 (OH)
8). The kaolin deposits are generally classified as either primary or sedimentary. The first deposits are formed as a result of in-place
weathering products of feldspar-bearing rocks, such as granites, pegmatites, gneisses, or sandstones. It’s is also the result of
hydrothermal alteration and weathering products of acidic to intermediate volcanic rocks [8]. It’s widely utilized in making
ceramics, refractory and paper manufacturing industries, Pigment, filler, coater, extender, catalyst-base, electrical insulator, and
pharmaceutical [8, 9].
Geological works in the past indicated the presence of kaolin in many localities within Ethiopia, some of which namely,
Kombolcha, near Harar, and many occurrences in Tigray are worth mentioning. Of these the best studied and presently extraction
are Bambo Wuha and Bellessa kaolin deposit. Both kaolin mining sites are supplying the main ceramic raw material to the ceramic
factory of Ethiopia known as Tabor ceramic factory, located in Hawasa, south Ethiopia [8]. Exploration for kaolin in Ethiopia was
carried out mainly at the granites and pegmatites [9].

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Fig. 1. Kombolcha, Ansho and Bellessa kaolin from left to right respectively [9, 10]

The main sources of kaolin for the ceramic industry in Ethiopia are the weathering products of granites and pegmatites. Acidic
volcanic rocks (such as rhyolite or trachyte) in central and northern Ethiopia, and the coal-related clay sediments of northwest
Ethiopia, near Chilga are sources of kaolin in Ethiopia.

Fig. 2. General Geology and Kaolin Occurrences of Ethiopia [7]

For this study, the Belessa kaolin powder was used as partial replacement of cement for C-25 concrete production. The
occurrence of Belesa kaolin is located in the central part of Ethiopia near Belessa town and it is known as Belessa Kaolin. The
specific location of this deposit is 384352 E and 837967 N.

A. Previous Work
According to [2], the cement replacement materials are Ceramic waste powder, Hypo sludge, GGBS, Glass ash, paper pulp,
Waste glass powder, Waste paper sludge ash, Industrial waste, Flexible polymer, Marble dust powder, Fly ash, Waste paper sludge,
Recyclable material, and metakaolin. Almost all the above cement replacement materials are pozzolanic materials and used to
improve concrete properties. In addition, [11] investigated the usage of additional cementing materials are the essentials in the
production of high/ultrahigh strength concrete (HSC/UHSC) and high/ultrahigh-performance concrete (HPC/UHPC).
The supplementary cementing materials can be used individually with Portland or blended types of cement or in different
combinations. Suitability of Fly Ash in Replacement of Cement in Pervious Concrete was conducted by [12, 19]. According to [12],
the effects of fly ash replacement on the important engineering properties of pervious concrete were investigated. These include,
compressive strength, flexural strength, split tensile strength, and permeability of pervious concrete. The cement was replaced by a
proportion of 0, 10, 20, and 30 percentages of fly ash. The result reveals it is observed that 20% replacement of cement with fly ash
showed better performance compared to previous concrete without fly ash.
Strengthening of concrete by partial replacement of cement with fly ash and Metakaolin mix was studied by [13, 16] which deals
with the effect of mineral admixtures incorporated with cement replacement and keeping the water-cement ratio same for the
ordinary concrete and modified concrete. 0, 5, 10, 15, 20, 30 percentages of fly ash and Metakaolin were partially replaced with
cement and the best proportion that gives the maximum strength was obtained. The experiment result revealed that the most
appropriate strength was obtained for a replacement rate of metakaolin to binder ranging between 10% and 15% [21].

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In addition, [14, 22] studied the replacement of cement by Metakaolin at the proportion of 0, 4, 6, 8%, and 10%, and a suitable
increase in compressive strength, resistance to rapid chloride permeability was found. Compressive strength of high-grade concrete
was increased by10.13%, 14.24%, and 22.90% due to the addition of Metakaolin content of 4%, 6%, and 8% respectively, and
found that rapid chloride permeability decreases with an increase in Metakaolin content [14, 22].
Aiswarya et.al [14] and Erhan G. et.al [21], made an investigation to determine the effectiveness of Metakaolin (MK) and silica
fume (SF) on the mechanical properties, shrinkage, and permeability-related durability of high-performance concrete. The
compressive and tensile strength were evaluated. Permeability and water absorption tests were carried out to find out the saturation
characteristics of the concrete with Metakaolin and Silica fume. The experimental results revealed an increase in the compressive
strength of the concrete when blended with MK and SF than the control mix for different water-cement ratios.
The effects of Metakaolin and calcined kaolin on the concrete were investigated by Error! Reference source not found..
Calcined kaolin and Metakaolin were assigned at the replacement levels of (5%, 10%, 15%, and 20%) for concrete production.
According to the researcher, the compressive strength of the concretes was carried out at 3, 7, 28, and 90 days. The result showed
that the kaolin replacement level has an effect on the strength development of the concretes.

B. Objective of the Study


To determine the effect of using kaolin powder as a partial replacement of cement on the properties of concrete.
 To investigate the effect of using kaolin powder as a partial replacement of cement on the workability of fresh concrete
 To determine the compressive strength of concrete produced using kaolin powder as a partial replacement of cement.
 To determine the density of concrete produced using kaolin powder as a partial replacement of cement.
 To determine the optimal mix of kaolin powder as partial replacement of cement in concrete production.

II. MATERIALS & EXPERIMENTAL METHODS

A. Materials
The materials used for this research include Ordinary Portland Cement (OPC), kaolin powder, river sand, crushed stone coarse
aggregate, and water which were all obtained from various places in the Southern Nation Nationality and Peoples (SNNP) region of
Ethiopia.
1) Cement: Ordinary Portland cement of grade 42.5R manufactured by Dangote, a local cement manufacturer in Ethiopia was used
for the preparation of the cube specimens
2) Kaolin Powder: The kaolin used in this research was waste material obtained from the Belessa kaolin mining site. The kaolin
was in the form of rock bolder which were broken into smaller sizes and subsequently milled into powder form. The powder was
sieved through a Standard sieve 150micron to have a fined powder for the research as shown in the following Fig. 3 below.

Fig. 3. Production Process of Kaolin Powder

The Property of Belesa kaolin was as shown in table below.


TABLE I: PHYSICAL PROPERTIES OF CEMENT AND BELESA KAOLIN POWDER
Material Specific gravity Fineness (𝝁𝒎) Specific surface (m2/kg)
OPC 3.15 85 20
Kaolin Powder 2.59 65 17
TABLE II: CHEMICAL PROPERTIES OF CEMENT AND BELESA KAOLIN POWDER
Material SiO2 Al2O3 Fe2O3 CaO MgO Na2O SO3 K2O LOI
OPC 18.68 1.25 9.26 52 1.45 - 1.4 - 3.27
Kaolin Powder 64.5 24.2 0.4 0.02 0.01 0.04 - 0.03 9.29
3) Fine Aggregate: Ordinary river sand obtained from Wabe River in Gurage Zone, was used for the concrete mixes. The
sand was dried in the sun to reduce the moisture content as follows. The sand sieved through the standard sieves as defined
in ASTMC (33) to achieve a standardized grain size distribution, was used in this study. The specific gravity of the sand
was found to be 2.7 and fineness modulus of 2.8. Using the quartering sampling method, the sand for testing and concrete
mix were selected.
4) Coarse Aggregate: The Coarse aggregate used for this research was graded crushed granite stone obtained around the
Wabe River. The coarse aggregate was sieved to determine the particle size distribution of the coarse aggregate.

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5) Water: The water used for the concrete mixes was drinkable water. The water-cement ratio used for the mixes was 0.6

B. Mix Design
The concrete mix proportion of 1:2:3 was used throughout for the mixes. The materials were measured by weight using an
electronic weighing machine. The percentage of kaolin powder in the mixes was varied from 0%, 5%, 10%, 15%and 20% [13].
The samples produced were six every mix which made a total of 30 cubes including the control mixture. The concrete cubes
produced were of size 150mmx150mmx150mm. The percentage replacement of kaolin powder is shown in the following
TABLE III. From the concrete mix design, a cement content of 9.74 kg was required to produce concrete with compressive strength of
25N/mm2. Based on this value, the content of kaolin powder for the other specimen was calculated accordingly.
TABLE III: MIX DESIGN
Replacement Weight of cement Weight of Weight of sand Weight of Weight of water
level (%) (Kg) kaolin(Kg) (Kg) C/aggregate (kg) (Kg)
0% 9.22 0 22.3 26.9 5.54
5% 8.76 0.461 22.3 26.9 5.54
10% 8.30 0.922 22.3 26.9 5.54
15% 7.84 1.383 22.3 26.9 5.54
20% 7.376 1.844 22.3 26.9 5.54

III. RESULT AND DISCUSSION

A. Setting Time:
The determination of the time of setting for mortar was done according to ASTM C191 -99, Standard Test Method for Time of
Setting of Hydraulic Cement by Vicat Needle. The results of the penetration tests were recorded at the regular time interval of 30
minutes and by linear regression, the time when penetration of 25mm was achieved was recorded. According to ASTM C150-02a
cited in [15], the minimum and maximum setting times of cement are 45min and 375min respectively.
TABLE IV: SETTING TIME OF KAOLIN POWDER REPLACED CEMENT
Sample Regression formula Consistency (%) Initial setting time Final setting time R2
Pure OPC f(t)= -1162t+41.048 31 138 225 0.9694
5%K+95%OPC f(t)= -0.0758t+40.33 33 202 332 0.9967
10%K+90%OPC f(t)= -0.0722t+40.89 35 220 354 0.9933
15%K+85%OPC f(t)= -0.0734t+40.083 37 205 336 0.9895
20%K+80OPC f(t)= -0.07857t+41.25 38 207 339 0.9723

Effect of Kaolin Powder on Setting Time of Cement


400
332 336 339
300 354
225 202 220 205 207
200
138
100

0
Pure OPC 5%K+95%OPC 10%K+90%OPC 15%K+85%OPC 20%K+80OPC

Initial setting time Final setting time

Fig. 4. Setting time of kaolin powder replaced cement

It is clear from Fig. 4 that the initial, as well as final setting times, are higher in cement blended with kaolin powder than the
control. The increase in kaolin powder content has no impact on setting times. The increase in setting times could be attributed to
the pozzolanic property of kaolin powder. The pozzolanic reaction is much slower than normal hydration hence, the setting time is
delayed.

B. Workability
The study also sought to find out the influence of kaolin powder on the workability of concrete. The results are shown in Fig. 5. The
results revealed that the kaolin powder reduces the workability of concrete as it’s (i.e. the kaolin powder) percentage in the mix
increases. The curve slopes down from the left to the right. The following relationship has proposed the workability of concrete in

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Journal of Xidian University https://doi.org/10.37896/jxu15.5/063 ISSN No:1001-2400

terms of the percentage of kaolin powder used in a given mix. y = -1.44x+47.8, Where x = the percentage of kaolin powder used in
a given mix. The relationship shows the presence of kaolin powder has a retrogressive effect on the workability of concrete. The
above effect can be attributed to the fact that kaolin powder has high water absorption capacity and specific surface area than any
other ingredients within the mix. Thus, as more of the kaolin powder is used, the content of water in the mix is reduced hence less
workable concrete is exhibited.

Fig. 5. Workability behaviour of the concrete

C. Compressive Strength
The 150mm concrete cube specimen that was cast was used to determine the compressive strength for each of the mixes with 0%,
5%, 10%, 15%, and 20% replacement of kaolin powder. After curing, the specimens were tested. The results for compressive
strength for kaolin powder replacement of cement at 7 days and 28 days were as shown in the following TABLE V and Fig. 6.

TABLE V: COMPRESSIVE STRENGTH FOR KAOLIN POWDER REPLACEMENT OF CEMENT

Binder Composition 7 Day Compressive 28 Day Compressive Percentage increment or loose


Strength (N/mm2) Strength (N/mm2) at 7days at 28 days
100% OPC 27.5 35.1 - -
95% OPC+5% kaolin 29.23 38.87 6.3% 10.77%
90% OPC+10% kaolin 27.8 35.2 1.09% 0.3%
85% OPC+15% kaolin 24.7 33.4 -10.18% -4.8%
80% OPC+20% kaolin 22.3 32.2 -18.91% -8.3%

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Journal of Xidian University https://doi.org/10.37896/jxu15.5/063 ISSN No:1001-2400

Fig. 6. Compressive Strength at 7 and 28 days against percentage kaolin powder replacement

The compressive strength of all concrete mixes was measured at the age of 7 and 28. The results of average compressive strength
and the percentage loss or gain in compressive strength are given in TABLE V above. The effect of kaolin powder on compressive
strength at curing ages of 7 and 28 is illustrated by Fig. 6 above. It is evident from Table values that with increasing the kaolin
powder content (up to 10%) the improvement in compressive strength of concrete mixes is continuous. At the curing age of 7 days,
the concrete containing 5% and 10% kaolin powder as cement, gained 6.3% and 1.09% of strength while at 15% and 20%
replacement level concrete loosed 10.18% and 18.91% of strength respectively. Nevertheless, the replacement of 10% of kaolin
powder still improves the compressive strength of concrete as compared to the control concrete but for much better results, the 5%
of kaolin powder seems to be the optimum. This improvement in strength can be attributed to the fact that kaolin powder contains a
high amount of silicate (the primary chemical responsible for strength development) and a high pozzolanic reaction between
calcium hydroxide and reactive silica in kaolin powder. Thus, as the optimum of the kaolin powder is used, the content of silicate in
the mix is increased hence a strong concrete is produced.

D. Density
The density of produced concrete for 6 cubes over all ages (7 and 28 days) was measured and average values were as shown in
TABLE VI. Theoretical densities, which were calculated from concrete mix proportions, are also presented in the table.
TABLE VI: MEASURED AND THEORETICAL DENSITIES OF CONCRETES
Concrete mixes Measured Density (Kg/m3) Theoretical Density (Kg/m3) Difference (%)
100% OPC 2447.06 2428.3 0.81
95% OPC+5% kaolin 2446.43 2428.3 0.70
90% OPC+10% kaolin 2446.25 2428.3 0.73
85% OPC+15% kaolin 2445.91 2428.3 0.77
80% OPC+20% kaolin 2445.45 2428.3 0.71
Fig. 7 shows the variation of hardened density of concrete with different replacement levels of cement with kaolin powder. The
figure indicates the retrogressive density loose of mixes with the percentage of cement replacement with kaolin powder, the lines of
best fit were done according to a linear regression function.

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Journal of Xidian University https://doi.org/10.37896/jxu15.5/063 ISSN No:1001-2400

Fig. 7. Average Density of Hardened Concrete

The above Fig. 7 shows the average hardened density of concrete irrespective of its age. The results revealed that the kaolin powder
reduces the hardened density of concrete as its ‘percentage in the mix increases. The curve slopes down from the left to the right.
Using and an average of six cubes for each mix at age 7 days and 28 days, the following relationship is proposed the hardened
density of concrete in terms of the percentage of kaolin powder used in a given mix.
y= -0.0748x+2446.968
Where x = the percentage of kaolin powder used in a given mix. The relationship above shows that the presence of kaolin powder
has a retrogressive effect on the hardened density of concrete. The above effect can be attributed to the fact that the specific gravity
of kaolin powder is less than the cement used in this mix. Thus, as more of the kaolin powder is used, the density of the mix is
reduced hence lighter concrete is produced.

IV. CONCLUSION
The study revealed that the consistency of kaolin powder blended cement is higher than control. Also, it was increased with an
increase in the replacement of cement by kaolin powder. The initial and final setting times of cement blended with kaolin powder
are higher than the control. However, the increase in kaolin powder content has no impact on setting times. It has been observed that
the addition of kaolin powder has an inverse relationship to the workability of concrete. As the content of kaolin powder in the mix
increases, the workability of the concrete decrease. Therefore, the optimum replacement of cement with kaolin powder is limited to
5% for better results.
From the above results, it can be concluded that the strength increases with an increase in kaolin powder percentage up to 10%
replacement of Cement with kaolin powder, and with further increase in kaolin powder percentage the strength decreases. In this
study the maximum compressive strength is attained at a replacement level of 5%, hence for a better result, this replacement level is
taken as an optimum replacement. The study result shows the inclusion of kaolin powder has also a retrogressive effect on the
hardened density of concrete. As the amount of kaolin powder in the mix increases, the density of hardened concrete decreases.
The results encourage the use of kaolin powder as pozzolanic material for partial cement replacement in producing conventional
concrete. The utilization of supplementary cementitious material like kaolin powder in concrete can compensate for environmental,
technical, and economic issues caused by cement production.
It is recommended that further studies be done on the effect of kaolin powder on concrete properties such as durability permeability,
shrinkage, water absorption, flexural and tensile strength.

ACKNOWLEDGMENT
Sincere gratitude goes to Ethiopian Mineral Biogas and Fuel Corporation for their support by giving us kaolin samples and data
related to its property. We would like to acknowledge the people who most directly and indirectly contributed their effort for this
study to become a reality we also would like to express our deepest gratitude to Ambo University Institute Technology laboratory
technicians for their patience, cooperation, and effort throughout the work.

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