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International Journal of Sustainable Built Environment (2016) xxx, xxx–xxx

H O S T E D BY
Gulf Organisation for Research and Development

International Journal of Sustainable Built Environment

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Original Article/Research

Setting time and standard consistency of quaternary binders:

The influence of cementitious material addition and mixing
Niragi Dave a, Anil Kumar Misra b,⇑, Amit Srivastava b, S.K. Kaushik b
a
Department of Civil Engineering, Petroleum University, Gandhinagar, Gujarat, India
b
Department of Civil and Environmental Engineering, The NorthCap University, Sector 23A, Palam Vihar, Gurgaon 122017, Haryana, India

Received 24 August 2016; accepted 25 October 2016

Abstract

This paper presents three pozzolanic materials that were used to make quaternary binders, Granulated blast furnace slag, fly ash
(PFA), metakaolin, and silica fume as partial replacement in quaternary binders with Ordinary Portland Cement (OPC) to investigate
the effect of standard consistency, initial and final setting times of quaternary paste. Experiments demonstrate that SF has greater influ-
ence on the standard consistency of the OPC–FA–SF–GGBS paste, as compare to FA and GGBs. Water requirement in the paste esca-
lates, with increase in SF percentage level within the paste, owing to the high surface area. In case of GGBS, around 3–5% of reduction in
water/binder ratio was recorded, whereas for SF, it was 10–12%. In quaternary OPC–FA–SF–GGBS pastes, increases in initial and final
setting times at 5%, 7.5%, 10%, and 15% replacement of SF and GGBS were observed, whereas OPC–FA–SF–MK paste setting time
shows an increase at 5% replacement of SF and MK with 20% and 70% replacement of FA and OPC, however, it starts decreasing
between 7.5% and 15% replacement of SF and MK. The consistency of the quaternary binders increases with an increase in percentage
of SF and MK. In general the effect of FA, SF, GGBS and MK reflects in the behavior of quaternary binders even though the perfor-
mance of all three pozzolans behaves completely independent of each other.
Ó 2016 The Gulf Organisation for Research and Development. Production and hosting by Elsevier B.V. All rights reserved.

Keywords: Ordinary Portland Cement; Pozzolans; Fly ash; Metakaolin; Silica fume; Ggbs; Consistency; Initial and final setting times

1. Introduction finishing of concrete. Placement of concrete in formwork

depends on the setting time of concrete, which makes the
Setting properties of concrete is the most important part concrete rigid (Clear and Harrison, 1985). Nowadays pro-
in the field of concrete construction (Brooks et al., 2000). It duction of new generation concrete like geopolymer con-
helps in the development of different kinds of concreting crete, self-compacting concrete, high strength concrete,
operations such as transporting, placing, compacting and and high performance concrete has been increasing
throughout the world. For their better performance and
to achieve better engineering properties, mineral admix-
⇑ Corresponding author.
tures such as fly ash (FA), silica fume (SF), ground granu-
E-mail addresses: [email protected] (N. Dave), anilgeology@gmail.
com (A.K. Misra).
lated blast furnace slag (GGBS), metakaolin (MK) and rice
Peer review under responsibility of The Gulf Organisation for Research husk ash (RHA) are normally added as partial replacement
and Development. of cement for the better performance of advanced concrete.

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2212-6090/Ó 2016 The Gulf Organisation for Research and Development. Production and hosting by Elsevier B.V. All rights reserved.

Please cite this article in press as: Dave, N. et al. Setting time and standard consistency of quaternary binders: The influence of cementitious material
addition and mixing. International Journal of Sustainable Built Environment (2016), http://dx.doi.org/10.1016/j.ijsbe.2016.10.004
2 N. Dave et al. / International Journal of Sustainable Built Environment xxx (2016) xxx–xxx

Since the different mineral admixtures possess different mated the time limit to handle the concrete and final setting
chemical and mineralogical compositions as well as differ- time designates the onset improvement of strength. It was
ent particle characteristics, they could have different effects also, examined that setting time of concrete depends on
on the properties of concrete inclusive of the setting char- water/binder ratio, initial and curing temperature, dosage,
acteristics. Knowledge of the setting characteristics is type of mineral admixtures and composition of cement
important in the field of concrete construction. This will (Kruml, 1990; Eren et al., 1995; Naik and Singh, 1997;
help in scheduling the various stages involved in concrete Naik and Ramme, 1990; Hogan and Meusel, 1981;
construction operation such as transporting, placing, com- Sivasundaram et al., 1989; Tazawa et al., 1989; Khedr
pacting and finishing of concrete. Such information is nec- and Abou-Zeid, 1994; Alshamsi et al., 1997, 1993; Pistilli
essary when deciding whether or not to use a retarding et al., 1984; De Almeida and Goncalves, 1990; Malhotra
admixture or accelerator. and Mehta, 1996; Ramachandran and Malhotra, 1995).
The hydration product formation starts immediately Some researchers have found that with the increasing per-
once the water is mixed within the cement. The initial centage level of FA and GGBS, the setting time of concrete
and final setting time of concrete can be determined by decreases (Eren et al., 1995; Naik and Singh, 1997; Naik
the rigid behavior of the matrix. The initial setting time and Ramme, 1990; Hogan and Meusel, 1981;
of the concrete refers to the beginning of hardening of Sivasundaram et al., 1989; Tazawa et al., 1989; Verma
the mixture and the final setting time refers to the sufficient and Misra, 2015; Dave et al., 2016). Reverse effect has been
hardness of the concrete mixture (Naik et al., 2001). Stud- investigated in case of silica fume. It was investigated that
ies have reported that with increase in fly ash content SF increases the setting time with the replacement level
within the binder, setting time also increases (Brooks (Alshamsi et al., 1997; Alshamsi et al., 1993; Pistilli et al.,
et al., 2000; Carette and Malhotra, 1984). A study shows 1984). The objective of this study is to investigate the com-
(Mailvaganam et al., 1983) that setting time of ternary bined effects of mineral admixtures in quaternary binders,
blended concrete made of FA and GGBs shows delayed to our knowledge no other author has identify the setting
initial setting time in the range of 60–120 min. time effects in quaternary binders with the utilization of
Silica fume is the byproduct of silicon industry and it is a mineral admixtures.
pozzolanic material, which is used to improve the fresh and
hardened properties of concrete (Federation internationale
2. Experimental studies
de la Precontrainte, 1988; Yazici, 2007). Utilization of silica
fume with fly ash gives an interesting substitute. Much
2.1. Materials
research has been conducted on ternary binder using a
combination with FA and SF (Demirboga, 2007; Yazici
Ordinary Portland Cement, fly ash, GGBs, silica fume
et al., 2008). A study also (Snelson, 2011) investigated the
and metakaolin are used in the production of quaternary
utilization of fly ash/or ground granulated blast furnace
binders. The physical and chemical properties OPC, FA,
slag (GGBs) with silica fume. Using the Ground granu-
SF, GGBS and MK are represented in Table 1. The com-
lated blast furnace slag in binder, the setting time can be
binations of the binder series has been divided into three
slightly extended. The effect of GGBS is more pronounced
groups: Group 1 (100% OPC), Group 2 (OPC + SF
at high level replacement in binders. An extended setting
+ FA + GGBS), Group 3 (OPC + SF + FA + MK). The
time is an advantage, as it makes concrete remain workable
details of three groups are represented in table 2.
for a longer period of time, therefore resulting in fewer
joints and it is extremely useful in warm weather.
MK and SF have a very high surface area, due to very 2.2. Preparation of specimens
high fineness of MK and SF, the effects on setting time is
different as compared to FA and GGBS. Although there Vicat apparatus was used to determine standard consis-
is an increase in both initial and final setting times at low tency, initial and final setting time of the quaternary bin-
replacement levels of SF and MK, binary effects of other ders and placed in a mold as per IS 4031 part 4 and 5 (IS
mineral admixtures investigated with silica fume (SF), fly 4031 (4), 1988; IS 4031 (5), 1988). The mix proportion
ash (FA) and ground granulated blast furnace slag for consistency and setting times of the quaternary binders
(GGBS), show an increase in setting times with an increase with and without supplementary cementitious materials (at
in replacement level. 30% and 50% replacement by weight of OPC) are given in
The present study findings revealed that the combined table 2. The standard consistency of the paste is determined
quaternary effect of FA, SF and MK/GGBS with the by adding water at different percentage levels till the paste
replacement of OPC was unusual. With an increase in per- has a given resistance to penetration.
centage levels of SF, and GGBS the initial and final setting Vicat apparatus mold has been used to determine the
time also increases, whereas, with an increase in percentage standard consistency of different pastes. Consistency was
level of MK in quaternary binders, there is a decrease in recorded when the plunger of the Vicat apparatus pene-
initial and final setting time. A study (Mehta and trated into the paste 5 mm to 7 mm above the bottom of
Monteiro, 1993) reported that initial setting time that esti- the mold. Consistency was determined by taking an aver-

Please cite this article in press as: Dave, N. et al. Setting time and standard consistency of quaternary binders: The influence of cementitious material
addition and mixing. International Journal of Sustainable Built Environment (2016), http://dx.doi.org/10.1016/j.ijsbe.2016.10.004
 N. Dave et al. / International Journal of Sustainable Built Environment xxx (2016) xxx–xxx 3

Table 1
Physical and Chemical properties of the OPC, FA, GGBS and SF.
OPC Fly Ash GGBS SF MK Water
Physical properties
Specific gravity 3.15 2.34 3.10 2.25 2.72 1.00
Blaine’s fineness, cm2/gm 2287 3728 3350 16028 8738
Chemical properties
Calcium oxide, Cao % 66.71 1.32 35.91 1.45 1.47
Aluminum oxide, Al2O3% 9.83 25.98 17.1 0.8 46.89
Silicon dioxide, SiO2% 17.53 62.21 40.69 87.29 50.67
Manganese oxide, MnO % 0.02 0.03 0.035 0.00 0.00
Ferric oxide, Fe2O3% 2.18 3.29 0.69 1.51 0.39
Magnesium oxide, MgO % 1.25 2.62 3.77 0.14 0.10
Sodium oxide, Na2O % 0.21 0.052 0.20 0.38 0.081
Potassium oxide, K2O % 0.49 0.998 0.561 2.02 0.19
Loss of ignition % 0.8 3.36 1.09 2.1 0.57

Table 2
Percentage of ingredients for consistency and setting times.
Series Cement mixes (gm) Standard IS/FS (min)
OPC FA SF GGBS MK Consistency

Control OPC100% 400 0 0 0 0 32 150/220

G1
1 OPC70% SF 5% FA20% GGBS5% 280 80 20 20 0 29.5 160/215

2 OPC70% SF 7.5% FA15% GGBS7.5% 280 60 30 30 0 31 170/245

3 OPC50% SF 10% FA30% GGBS10% 200 120 40 40 0 33 185/245
4 OPC50% SF 15% FA20% GGBS15% 200 80 60 60 0 33 180/225
5 OPC50% SF20% FA15% GGBS15% 200 60 80 60 0 32.5 190/305
G2
1 OPC70% SF 5% FA20% MK5% 280 80 20 0 20 32.5 165/280
2 OPC70% SF 7.5% FA15% MK7.5% 280 60 30 0 30 33 155/235
3 OPC50% SF 10% FA30% MK10% 200 120 40 0 40 35 160/220
4 OPC50% SF 15% FA20% MK15% 200 80 60 0 60 38 158/215
5 OPC50% SF 20% FA15% MK15% 200 60 80 0 60 38.5 170/295

age of three tests. Once the standard consistency had been levels are shown in Fig. 1. A study (Nochaiya et al.,
established the setting time was determined. 2010) reported that in ternary binder, with OPC–FA–SF
Two periods of times are used to assess the setting at 20FA10SF and 30FA10SF, with the replacement of
behavior. These are called ‘‘initial setting time” and ‘‘final OPC, the requirement of water increases with the increas-
setting time”. The initial setting time was recorded as per ing percentage levels of SF due to its very high fineness.
IS: 4031 part-5. A needle of 1 mm square is used to pene- It is also reported that in binary binder with the increasing
trate into the paste at every 10 min intervals till the index percentage level of FA, the water demand is decreasing. It
scale shows 5 + 0.5 mm from the bottom of the mold. was found that while adding GGBS with FA and SF in
For determining the final setting time, the needle has been replacement of OPC to make quaternary binder, the water
replaced of the Vicat’s apparatus by the needle with an demand is again decreasing in quaternary binder. GGBS
annular attachment. Released needle at every 30 min inter- exhibit some properties that are similar to OPC, like the
vals till the needle makes an impression on the test block. surface area of GGBS, which is almost equivalent to
Initial and final set value was recorded at an average of OPC. Reduction in water demand from 3% to 5% is
three tests. recorded with the use of GGBS. The overall standard con-
sistency for quaternary binder OPC–FA–SF–GGBS was
3. Results and discussions found almost similar to OPC for all replacement levels.

3.1. Standard consistency 3.1.2. Standard consistency of OPC–FA–SF–MK

The quaternary binder that consists of OPC-FA-SF-
3.1.1. Standard consistency of OPC–FA–SF–GGBS MK requires more water with the increasing percentage
The result of standard consistency tests for the quater- level of SF and MK. Studies (Snelson, 2011; Bai and
nary binder OPC–FA–SF–GGBs at different percentage Gailius, 2009) have revealed that replacement of OPC with

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addition and mixing. International Journal of Sustainable Built Environment (2016), http://dx.doi.org/10.1016/j.ijsbe.2016.10.004
4 N. Dave et al. / International Journal of Sustainable Built Environment xxx (2016) xxx–xxx

Figure 1. Standard consistency of quaternary (OPC-FA-SF-GGBS/MK) binder paste.

MK increases the water demand with the increasing level of that the setting time of OPC–FA reduces with the addition
MK in binary binder. Studies also indicate that OPC–FA of SF and the addition of GGBS along with OPC, FA and
acted same as OPC. That means FA does not demand SF retard the setting time. Rao (Rao, 2003) studied the
much water due to its spherical size. Immediately adding effect of silica fume on the setting time of cement paste.
MK with this binary binder and converting into ternary It was observed that initial setting time decreased with
binder, the consistency started increasing. This indicates the increase in silica fume content. At smaller contents,
that quaternary binder with MK shows almost same result the setting time of cement paste did not affect much. How-
as in binary and ternary binder with MK. But results of ever, at higher SF contents, the initial setting time was sig-
consistency in quaternary binder along with SF and MK nificantly decreased. The final setting time seem to be not
is slightly more due to the high surface area of SF and influenced by silica fume. The pozzolanic action of silica
MK, they demand more water but addition of FA, recom- fume seems to be very active at early hours of hydration.
pense the water demand and consistency can be deal within Due to the addition of GGBS the hydration process
limit. The quaternary mix combinations 50%OPC + 20% takes longer time and retards the setting time. However,
FA + 15%SF + 15%MK and 50%OPC + 15%FA + 20% it does not impact on final setting time so much. As per
SF + 15%MK demand more water and their consistency IS: 4031 part-5, the final setting time should be within
is higher than other combinations. These combinations 600 min.
cannot be fruitful for the construction materials which
can decrease the mechanical and durability properties of 3.2.2. Initial and final setting time of OPC–FA–SF–MK
mortar and concrete. The addition of MK along with OPC, FA and SF accel-
erate the setting time of quaternary binder. However, A
3.2. Setting time study (Snelson, 2011), shows that the addition of MK,
replaced with OPC, accelerate the initial and final setting
3.2.1. Initial and final setting time of OPC–FA–SF–GGBS time of binary binder, while in ternary binder (Mehta
The setting times of the quaternary binders containing and Monteiro, 1993) along with OPC, FA and SF the set-
mineral admixtures are given in Figs. 2 and 3. It was ting time decreases. In quaternary binders formed using
observed that the common effect of the FA, SF, GGBS OPC, FA, SF and MK the setting time escalates due to
and MK has lengthened the setting times of quaternary excessive fineness of SF and MK, which results in dense
binders. The observed retardation in setting times can be microstructure, thereby resulting in accelerated setting
mainly due to the combined effect of lower cement content. time. However at 5%, 7.5%, 10% and 15% replacement
Berg and Kukko (Berg and Kukko, 1991) reported that set- level of SF and MK smooth reduction in setting time is
ting time retards in binary binder with the addition of fly recorded. At 20% SF and 15% MK replacement with
ash, if high carbon content is available. It is also reported OPC and FA, the setting time shows disorder.

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addition and mixing. International Journal of Sustainable Built Environment (2016), http://dx.doi.org/10.1016/j.ijsbe.2016.10.004
 N. Dave et al. / International Journal of Sustainable Built Environment xxx (2016) xxx–xxx 5

Figure 2. Initial setting times of quaternary (OPC-FA-SF-GGBS/MK) binder paste.

Figure 3. Final setting times of quaternary (OPC-FA-SF-GGBS/MK) binder paste.

Table 3
Estimated cost of each binder constituents. within the binder. The estimated cost of each constituent
OPC 50 KG 4.51$ (in US dollar) is based on the existing market cost and it is illustrated in
GGBS 50 KG 2.26 $ (in US dollar) Table 3 and 4.
FA 50 KG Industrial by product freely available
MK 50 KG Industrial by product freely available
SF 25 KG 7.51 $ (in US dollar) 4. Conclusions

The results show that all the supplementary cementi-

3.2.3. Estimated binder cost tious materials have their own different effects on both
The cost of each binder composition is estimated on the standard consistency and setting times of quaternary bin-
basis of different binder constituents and their percentage ders.Following conclusions can be drawn from the study:

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addition and mixing. International Journal of Sustainable Built Environment (2016), http://dx.doi.org/10.1016/j.ijsbe.2016.10.004
6 N. Dave et al. / International Journal of Sustainable Built Environment xxx (2016) xxx–xxx

Table 4
Cost of developed binder composites.
Series Cement mixes (gm) Cost of materials Cost per tonne in
per tonne in US dollars
OPC FA SF GGBS MK
Indian rupees
Control OPC100% 400 0 0 0 0 7000 Rs. 105.32 $
G1
1 OPC70% SF 5% FA20% GGBS5% 280 80 20 20 0 6047.86 Rs. 91$
2 OPC70% SF 7.5% FA15% GGBS7.5% 280 60 30 30 0 6624.73 Rs. 99.68 $
3 OPC50% SF 10% FA30% GGBS10% 200 120 40 40 0 5774.7 Rs. 86.89 $
4 OPC50% SF 15% FA20% GGBS15% 200 80 60 60 0 6949.72 Rs. 104.57 $
5 OPC50% SF20% FA15% GGBS15% 200 60 80 60 0 7949.94 Rs. 119.62 $
G2
1 OPC70% SF 5% FA20% MK5% 280 80 20 0 20 5049.63 Rs. 75.98 $
2 OPC70% SF 7.5% FA15% MK7.5% 280 60 30 0 30 5124.73 Rs. 77.11 $
3 OPC50% SF 10% FA30% MK10% 200 120 40 0 40 3800 Rs. 57.18 $
4 OPC50% SF 15% FA20% MK15% 200 80 60 0 60 3950 Rs. 59.43 $
5 OPC50% SF 20% FA15% MK15% 200 60 80 0 60 3950 Rs. 59.43 $

1. Replacement of OPC by 30% with FA, SF and GGBS higher amount of MK in quaternary binder. The silica
has very limited influence on the consistency, but fume and metakaolin are highly reactive, and small size
replacement impact on consistency increases as it of particles speeds up the reaction with calcium
reaches 50%, however an increase in consistency was hydroxide.
recorded within standard limit and almost similar to 5. Overall effect of FA, SF, MK and GGBS on standard
the OPC. These findings suggest that supplementary consistency, an initial and final setting time in quater-
cementitious materials have almost negligible impact nary binder is to retard the setting time. The influence
on consistency. of increasing the levels of GGBS is to provide greater
2. Standard consistency in quaternary binder (OPC–FA– retardation in the setting time, due to less content of
SF–MK) increases with increasing percentage levels of C3A.
MK, owing to the high surface area of MK and high 6. These types of binders are useful for the manufacturing
levels of water demand. These findings revealed that of RMC concrete where longer time is needed for plac-
by controlling the percentage level of MK in binder, ing the concrete.
both water and standard consistency requirements can 7. Based on the cost analysis these binders are very eco-
be addressed. nomic. If these types of combinations are used in RMC
3. 30% replacement of OPC by FA, SF and GGBS has lit- plant then construction cost can be reduced manifold.
tle control on consistency. Partial replacement of OPC
(50%) by FA, SF and GGBS increased consistency.
But that is also in limit and almost similar to OPC. This References
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Please cite this article in press as: Dave, N. et al. Setting time and standard consistency of quaternary binders: The influence of cementitious material
addition and mixing. International Journal of Sustainable Built Environment (2016), http://dx.doi.org/10.1016/j.ijsbe.2016.10.004