GEOPOLYMER COCRETE

Akshay Kadam, Dhiraj Kamble, Krishna Jewarikar, Satish Khandare, Pravin Khogare

Guided By : [Link]
Department of Civil Engineering
JSPM NTC, Pune, Maharashtra, India

ABSTRACT
Concrete is the world's most versatile, durable and reliable construction material. Next to
water, concrete is the most used material, which required large quantities of Portland Cement.
Ordinary Portland Cement production is the second only to the automobile as the major
generator of carbon di oxide, which polluted the atmosphere. In addition to that large amount
energy was also consumed for the cement production. Hence, it is inevitable to find an
alternative material to the existing most expensive, most resource consuming Portland
Cement. Geopolymer concrete is an innovative construction material which shall be produced
by the chemical action of inorganic molecules. Fly Ash, a by-product of coal obtained from
the thermal power plant is plenty available worldwide. Fly ash is rich in silica and alumina
reacted with alkaline solution produced alumino silicate gel that acted as the binding material
for the concrete. It is an excellent alternative construction material to the existing plain
cement concrete. Geopolymer concrete shall be produced without using any amount of
ordinary Portland cement. This paper briefly reviews the constituents of geopolymer
concrete, its strength and potential applications..

INTRODUCTION
Concrete is one of the most widely used construction materials. The concrete is used more than any
other man-made material in the world, in fact it is second most consumed substance in the world after
water. The demand for concrete as a construction material is increasing day to day. It has been estimated
that the production of cement had increased to 2.2 billion tons in 2010 which was about 1.5 billion tons
in 1995. The manufacturing of Portland cement is an energy intensive process and releases a large
amount of greenhouse gas to the atmosphere. Climate change due to global warming, one of the greatest
environmental issues has become a major concern during the last decade. Global warming is caused by
the emission of greenhouse gases, such as CO2, to the atmosphere by human activities. CO2 contributes
to about 67% of global warming. The cement industry is responsible for about 6% of all CO2 emissions,
because the production of one ton of Portland cement emits approximately one ton of CO2, into the
atmosphere. In future use of Portland cement is unavoidable. Efforts are being taken to reduce the use of
Portland cement in the production of concrete. The effort includes the utilization of supplementary
cementing material such as fly ash, silica fume, granulated blast furnace slag, rise-husk ash and
metakaolin, and finding alternative binders to Portland cement. A very large amount of fly ash (FA) is
generated in thermal power plants, causing several disposal-related problems despite initiatives taken by
the government, several N.G.O.’s and research and development organizations, the total utilization of
FA is only about 50%. Disposal of FA is a growing trouble as only 15% of FA is presently used for
high-cost addition packages like concrete and constructing blocks, the rest getting used for land filling.
Fly ash utilized around the World is less than 25% of the total annual FA produced. FA has been
successfully used as a mineral admixture component of Portland cement for nearly 60 years. There is
effective utilization of fly ash is used in making cement concretes as it extends technical advantages as
well as controls the environmental pollution. Ground granulated blast furnace slag (GGBS) is a by-
product from the blast furnaces used to make iron. It is a glassy, granular, non-metallic material
consisting essentially of silicates and aluminates of calcium. It has almost the same particle size as
cement. Ground granulated blast furnace slag (GGBS), often blended with Portland cement as low-cost
filler, increases concrete workability, density, durability, and resistance to alkali-silica reaction.
Effective utilization of Fly ash and GGBS in development industry that has risen lately is as
Geopolymer concrete (GPC), Geopolymer concrete (GPC) are inorganic polymer composites, which are
prospective concretes with the potential to form a substantial element of an environmentally sustainable
construction by replacing or supplementing the conventional concretes. GPC have high strength, with
good resistance to chloride penetration, acid attack, etc. Those are typically formed by means of alkali
activation of industrial alumino-silicate waste substances which includes fly ash and GGBS and feature a
totally small Greenhouse footprint whilst as compared to traditional concretes. Therefore, there needs to
find alternatives to make concrete which is less harmful to the environment. Geopolymer is an inorganic
alumino-silicate compound, synthesized from fly ash & Ground Granulated Blast Slag (GGBS). The fly
ash, one of the source materials for geopolymer binders, abundantly available in India, but till date its
utilization is limited. Hence, it is essential to make the efforts to utilize this byproduct in concrete
manufacturing to make the concrete more environmentally friendly
 Aim of Study
To study the properties of geopolymer concrete as a sustainable material for civil construction.
Objective of the Study
To achieve the above aim, the following objectives have been derived for eachof the components of the
study.
i. To determine strength by adding GGBS & Fly Ash in various proportions.
ii. To use FlyAsh in making concrete, to minimize their disposal problem

METHODOLOGY

Collection of Information

Collection and Preparation of raw materials

Characterization of raw materials (Chemical and physical)

Trial mix with different material and different ratio

Activation process with different

ratio

Mixing and casting of concrete

Testing

Result and discussion

3.1 Theory of Geopolymer Concrete and Other Ingredients

The physical and chemical properties of materials, mixture proportions, the

mixing process, and the curing conditions of geopolymer concrete were discussed in this
chapter.

3.1.1 Fly ash

Pulverized fuel fly ash conforming to IS 3812 (part 1). Fly is the finely divided
residue that results from the combustion of pulverized coal. Fly ash is a heterogeneous
by-product material produced in the combustion process of coal used in power stations.
It is a fine grey coloured powder having spherical glassy particles that rise with the flue
gases. As fly ash contains pozzolanic materials components which reach with lime to
form cementitious materials. Figure No 3.1 show the fly ash.

Figure No 3.1 show the fly ash.

[Link] Following are the Chemical Composition of Fly Ash

The chemical composition of fly ash depends upon the type of coal used and the
methods used for combustion of coal. Table No. 3.1 shown the physical properties
of fly ash different coals.
[Link] Following are the Physical Properties of Fly Ash

Table No. 3.1 Physical properties of fly ash.

Test Particular Test Result Unit

Standard Consistency (P) 30 %

Fineness (Residue on 45-micron sieve) 21 %

Initial Setting Time 153 Minutes

Final Setting Time 259 Minutes

Fineness by Blains Air permeability 432 Sqm/kg

7 days Compressive Strength 30 N/[Link]

28 Days Compressive Strength 37 N/[Link]

 i. As per ASTM, the fineness of the fly ash is to be checked in dry and wet [Link] fly ash
sample is sieved in 45-micron sieve and the percentage of retained on the 45-micron s
Fineness of Fly Ash
ieve is calculated. Further fineness is also measured by Le-Chateliermethod and
Blaine Specific Surface method.
ii Specific Gravity of Fly Ash:

The specific gravity of fly ash ranges from a low value of 1.90 for a sub-
bituminous ash to a high value of 2.96 for an iron-rich bituminous ash.
iii Size and Shape of Fly Ash:

As the fly ash is a very fine material, the particle size ranges in between 10 to
100 microns. The shape of the fly ash is usually spherical glassy shaped.

iv Colour:
The colour of the fly ash depends upon the chemical and mineral constituents.
Lime content in the fly ash gives tan and light colours whereas brownish colour
is imparted by the presence of iron content. A dark grey to black colour is
typically attributed to an elevated un-burned content.

3.1.2 Ground-granulated blast-furnace slag (GGBS)

Ground granulated blast-furnace slag confirming IS 16714. Ground granulated

blast-furnace slag is a by-product of iron in blast furnace. Ground-granulated blast-
furnace slag (GGBS or GGBFS) is obtained by quenching molten iron slag (a by-
product of iron and steel making) from a blast furnace in water or steam, to produce a
glassy, granular product that is then dried and ground into a fine powder. Figure No. 3.2
shows the ground granulated blast furnace slag. Ground-granulated blast furnace slag is
a latent hydraulic binder forming calcium silicate hydrates (C-S-H) after contact with
water. It is a strength-enhancing compound improving the durability of concrete. Its
main advantage is its slow release of hydration heat allowing to limit the temperature
increase in massive concrete components and structures during cement setting and
concrete curing, or to cast concrete during hot summer.
 Fig. No. 3.1.2: - Ground Granulated Blast Furnace Slag

[Link] Following are the Chemical composition of GGBS.

Table No. 3.2 Chemical composition of GGBS

Sr. No Characteristics Requirement as per Test

IS16714:2018 Result

1 Fineness 320(min) 380

2 Specific Gravity 2.90

3 Residue by wet basis on 45(%) 4.60

4 Manganese Oxide (Mno)% 5.50(Max0 0.26

5 Magnesium Oxide (Mgo) 17.009(Max) 7.96

6 Sulphide Sulphur (s) % 2.00(Max) 0.66

7 Sulphate (S)% 3.00(Max) 0.16

8 Insoluble Residue% 3.00(Max) 0.18

9 Chloride Content% 0.10(Max) 0.004

 10 Loss on ignition% 3.00(Max) 0.26

11 Moisture content% 1.00(Max) 0.26

12 Glass content% 85 (min) 0.020

13 Slag Activity Index% 95.70

A 7 days Not less than 60% of 70.05

control OPC43 Grade
cement mortar cube

B 28 days Not less than 75% of 89.80

control OPC43 Grade
cement mortar cube

15 Chemical moduli -- --

A (Cao+Mgo+1/3 AL2O3) 1.00(min) 1.09

B CaO+MgO+ AL2O3 SiO2) 1.00(min) 1.82

3.1.1 Coarse aggregates

Locally available crushed granite stone aggregate of 20mm & 10mm size was
used as coarse aggregate. The properties of coarse aggregates were determined as per
IS: 2386- 1963. Figure No. 3.3 shows the coarse aggregate.
 3.1.3 Fine aggregates
The locally available river sand, passing through 4.75 mm was used in this
experimental work. The properties of fine aggregates were determined as per IS: 2386-
1963. Figure No. 3.4 shows the fine aggregate.

[Link].3.1.4: - Fine aggregates

3.1.4 Alkaline solution

A combination of sodium silicate solution and sodium hydroxide solution was

used as alkaline solution.

1. Sodium Hydroxide (NaOH) confirming to IS 252

The most common alkaline activator used in geo-polymerisation is a combination

of sodium hydroxide (NaOH) or potassium hydroxide (KOH) and sodium silicate
(Na2Sio3) or potassium silicate (K₂ SiO₃). The type and concentration of alkali solution
affect the dissolution of Pozzolanic material. It is a white solid and highly caustic
metallic base and alkali salt, which is available in pellets, flakes, granules, and as
prepared solutions at several different concentrations. Sodium hydroxide forms an
approximately 50% (by weight) saturated solution with water. Sodium hydroxide is
soluble in water, ethanol, and methanol. This alkali is deliquescent and readily absorbs
moisture and carbon dioxide in air. Pure sodium hydroxide is a whitish solid, sold in
pellets, flakes, and granular form, as well as in solution. Figure no. 3.5 shows sodium
hydroxide.

It is highly soluble in water, with a lower solubility in ethanol and methanol, but
is insoluble in ether and other non-polar solvents. Like the hydration of sulfuric acid,
dissolution of solid sodium hydroxide in water is a highly exothermic reaction in which
a large amount of heat is liberated, posing a threat to safety through the possibility of
splashing. The resulting solution is usually colourless and odourless.

[Link].3.1.5: - Sodium Hydroxide (NaOH)

As with other alkaline solutions, it feels slippery when it meets skin. Sodium
hydroxide is industrially produced as a 50% solution by variations of the electrolytic
chloralkaline process. Chlorine gas is also produced in this process. Solid sodium
hydroxide is obtained from this solution by the evaporation of water. Solid sodium
hydroxide is most sold as flakes, pills, and cast blocks. When NaOH reacts with water
gives disassociation of the sodium and hydroxide ions and the hydration of those ions
releases a LOT of heat, trough to boil water in some circumstances. Great care is needed.
Hence it is an exothermic reaction. The concentrations of sodium hydroxide solution as
20 Molar.

2. Sodium Silicate (Alkaline grade) Confirming to IS 381

Sodium silicate is the common name for compounds with the formula Na2(SiO2).
Concrete treated with a sodium silicate solution helps to significantly reduce porosity in
most masonry products such as concrete. A chemical reaction occurs with the excess Ca
(OH)2 (portlandite) present in the concrete that permanently binds the silicates with the
surface, making them far more durable and water repellent. This treatment generally is
applied only after the initial cure has taken place (7 days or so depending on conditions).
The sodium silicate solution A53 with SiO2 to Na2O ratio by mass approximately 2,
(Na2O = 14.7%, SiO2=29.4% and water 55.9% by mass) was used. The sodium with
97-98% purity, in flake or pellet form was used. The solids must be dissolved in water
to make a solution with the required concentration. The ratio of sodium silicate solution
to sodium hydroxide solution by mass was fixed as 2:2.5 and 3. The reason being the
 sodium silicate solution was cheaper than the sodium hydroxide solution. Figure No.
3.6 show the sodium silicate solution.

TEST RESULTS
GPC TEST RESULT

MIXES WEIGHT DENSITY LOAD AREA COMPRESIVE

(KN) (cm2) STRENGTH
3
(Kg/m )
(N/mm2)

75:25 8.85 2622.22 565.20 22.5 25.12

65:35 8.85 2622.22 880.65 22.5 39.14

55:45 8.83 2617.78 940.95 22.5 41.82

Table No 4.1.1 Compressive Strength of GPC at 7 Days

MIXES WEIGHT DENSITY LOAD AREA COMPRESIVE

(KN) (cm2) STRENGTH
(Kg/m3)
(N/mm2)

75:25 8.58 2542.22 650.77 22.5 34.79

65:35 8.76 2595.55 900.25 22.5 44.90

55:45 8.38 2482.96 962.37 22.5 45.35

Table No. 4.1.2 Compressive Strength of GPC at 28 Days

OPC TEST RESULT

MIXES WEIGHT DENSITY LOAD AREA COMPRESIVE AVERAGE

(KN) (cm2) STRENGTH STRENGT
(Kg/m3) H
2
(N/mm )
(N/mm2)

M30 8.32 2465.18 789.30 22.5 35.08

8.65 2562.96 883.35 22.5 39.26

37.40
8.41 2491.85 852.30 22.5 37.88

Table no.4.1.3 Compressive

strength of opc at 7 days

MIXES WEIGHT DENSITY LOAD AREA COMPRESIVE AVERAGE

(KN) (cm2) STRENGTH STRENGT
3
(Kg/m ) H
(N/mm2)
(N/mm2)

M30 8.32 2465.18 789.30 22.5 35.08

8.65 2562.96 883.35 22.5 39.26

37.40
8.41 2491.85 852.30 22.5 37.88

Table No 4.1.4 Compressive

strength of opc at 28 days
 CONCLUSION

Based on the Experimental investigation the following Conclusions arelisted

below:

1. From the test results, it was observed that the maximum strength was obtained for mix
55% Fly ash and 45% GGBS.
2. The compressive strength of GPC of proportion 75% - 25% is increased by 6.8% as
compared with compressive strength of OPC at 28 days.
3. User-friendly geopolymer concrete can be used under conditions like those suitable for
ordinary Portland cement concrete.
4. Due to the high early strength Geopolymer Concrete shall be effectively used in the
precast industries, so that huge production is possible in short duration and the
breakage during transportation shall also be minimized.
5. In addition to that the Fly ash shall be effectively used and hence no landfills are
required to dump the fly ash.
6. By replacing cement in concrete with waste products, it minimizes CO2 emissions.

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