Geo Polymer 2nd Phase Completed

STUDY ON GEOPOLYMER CONCRETE BY REPLACEMENT OF CEMENT BY FLY ASH AND GGBFS
CHAPTER 1
INTRODUCTION
1.1 GENERAL
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
aluminosilicate 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.
Masonry is the popular and traditional method of construction which is composed of individual
masonry units. Many old age masonry structures are the best examples of durable construction.
The common traditional masonry units are bunks brick masonry and cement blocks masonry. They
are not considered as a sustainable due to many reasons. Burnt bricks consume fossil fuel and top
fertile soil cement block needs traditional cement which produces carbon dioxide during
manufacturing. There is effort to replace these traditional masonry units. Geopolymer is an
inorganic polymer which represents pioneering technology, it creating the large amount of interest
in the construction industry because it is sustainable and environmentally friendly material.
In 1978, Joseph davidovits introduced this technology this can be used as an alternative binder to
ordinary Portland cement (OPC). In this the source material would be rich in silicon (Si) and
aluminum (Al) which reacts with highly alkaline solution through the process of
geopolymerization to produce binding material. This has many benefits including reduction of co2
and effective utilization of industrial wastes such as fly ash ground granulated blast furnace slag
Dept. of Civil Engg. SEACET, B’lore. Page 1

etc. The use of class F fly ash (low calcium) normally produced by burning of bituminous and
anthracite coal it is pozzolonic in nature the lime percentage is less than 5% The class F fly ash is
in combination with Portland cement to produce the structural masonry units. Fly ash when used
as a component of cement has been several benefits like fresh properties ultimate strength and
long-term durability. Moreover, use of fly ash supports the sustainability. This can lead to a
number of environmental, technical and economic benefits.
Geopolymer was the name given davidovits in 1978 to material which are characterized by chains
or networks or inorganic molecules.
Ground granulated blast furnace slag (GGBFS) is a by-product of the manufacturing of iron in a
blast furnace where iron ore, limestone and coke are heated up to 1500oC. When these materials
melt in the blast furnace, two products are produced- molten iron and molten slag.
1.2 ADVANTAGES OF GEOPOLYMER CONCRETE
Geopolymer concrete offers several advantages over ordinary Portland cement concrete the least
of which is as follows:
 For a smaller performance level, geopolymer concrete is cost effective against ordinary
Portland cement.
 Geopolymer concrete has low drying shrinkage as compare to ordinary Portland cement
concrete.
 Geopolymer concrete has low creep as compare to ordinary Portland cement concrete.
 Geopolymer concrete has better resistance to sulphate attack as compare to ordinary
Portland cement concrete.
 Geopolymer concrete has better acid resistance as compare to ordinary Portland cement
concrete.
 Geopolymer concrete has better fire resistance as compare to ordinary Portland cement.
 Geopolymer concrete helps in saving the land filling costs associated with the disposal of
waste material such as fly ash, GGBFS.
 Geopolymer concrete has 55% reduction in the pore diameter as compare to Portland
cement concrete there by leading to reduced permeability.
 The global warming potential of geopolymer concrete is 70% lower than cement concrete.

1.3 DISADAVANTAGES OF GEOPOLYMER CONCRETE

 Curing at elevated temperature is possible at sites and if ambient curing has to be resorted
to than that will also be dependent on the season and geographic location change.
 Preparation of the alkaline activator solution in large quantities requires skilled
supervision.
 Working with alkaline activator solution requires proper safety equipment as its contact
with skim can lead to skin burn also.
 Proper procedure of mixing is to be adopted so as ensure that no case of unreached alkali
remains within the final product which will limit its strength durability to a great extent.

CHAPTER-02
LITERATURE REVIEW
Geopolymer was introduced to the world in late 1970’s. It was developed in 1978 by French
scientist Joseph Davidovis, the use of the material increased during 1980’s for non-structural
application.
Many literature sources have been reviewed to understand the properties of geo polymer concrete
in which cement is fully replaced by fly ash and GGBFS and the fine aggregate by M sand activated
in the presence of alkali activator some of them are found useful to our project work they are
discussed in this chapter are as follows.
1. E.Manimaran1 et.al.(2017) : In this paper he used the low calcium fly ash with high
SiO2(54.40%), Al2O3(25.64%) and low CaO(2.03%) is used. The alkaline activator used is
12Molar Sodium hydroxide solution and Sodium silicate solution with liquid ratio 2.5.The 12
molarity Sodium hydroxide is prepared, one day prior to mixing with fly ash or mortar or
concrete to avoid the heating effect The alkaline solution so prepared is only used for making
geopolymer based paste, mortar and concrete .He conducted various tests such as consistency
and setting time, durability test. The consistency of the fly ash based geopolymer paste is
determined as per Indian standards using Vicat’s apparatus with plunger and accessories.
Geopolymer paste is prepared by mixing with alkaline solution and testing with varying
percentage is done until the standard consistency value is obtained. Saturated water absorption
(SWA) test and Sulphuric acid resistance test are conducted and the results are compared with
conventional cement concrete. Final results were the consistency of Geopolymer paste is
10.3% more when compared to OPC. The initial setting time is 97% more and the final setting
time of Geopolymer paste is 34.2% less compared to OPC paste. This indicates that the rest
period is a must and the cast specimens are to be safely protected for any water loss. The
mortar compressive strength is 3.5% more for Geopolymer mortar. The slump of GPC is
observed to be 9.4% less than OPCC. This indicates that extra water may be required for more
workability.

2. K. Sandeep Dutt et.al. (2016): This paper quickly surveys the constituents of geopolymer
solids here Fine aggregate, coarse aggregate and alkaline activators are used Geopolymer
cement is concrete which does not use any Portland bond in its generation. The exploration
yielded non-combustible and nonignitable geo polymer saps and folios. The utilization of fly
ash remains has extra environment favorable circumstances. Soluble Activator Liquid The
geopolymerization is made conceivable by the utilization of soluble fluids. Be that as it may,
the most normally utilized soluble fluids are either the mix of sodium hydroxide (NaOH) or
Potassium hydroxide (KOH) and Sodium Silicate or potassium silicate Geopolymer are
inorganic fasteners, which are distinguished by the taking after fundamental properties,
Compressive strength relies on upon curing time and curing temperature. As the curing time
and temperature builds, the compressive quality increments. Imperviousness to consumption,
since no limestone is utilized as a material, Geopolymer bond has astounding properties inside
both corrosive and salt situations. then concluded that the curing state of a low calcium fly
powder geopolymer concrete additionally impacts the compressive quality.
3. T. Srinivas et.al. (2016): An objective of this paper is to develop and optimization of mix
design for G30 and G50 grades of low calcium fly ash (Class-F) and slag based geopolymer
concrete which is equilent to M30 and M50 respectively. The development of mix design is
based on many factors such as alkaline liquid to fly ash ratio, Na2SiO3 to NaOH ratio,
molarity of NaOH, type of curing methods, temperature and rest period etc. The concrete mix
is designed by using all the above parameters and specimens were casted then tested on 3rd,
7th and 28th day according to codal procedures. The alkaline solution used for the present
study is combination of sodium silicate (Na2Sio3) and sodium hydroxide (NaOH in the range
of 6 to 18 molarity). The ratio of Na2SiO3 to NaOH is 2.5 and SiO2 to Na2O is 2.09 has been
used since the compressive strength is maximum at these ratios. The set of test specimens of
3 cubes of 150mm*150mm*150mm for each composition were cast for testing compressive
strength then after one day rest period, half of the specimens were cured in an oven at 60°C
for 24hours and for the remaining period cured under sun light until the testing is done and
remaining half of the specimens were ambient cured.

4. D. Indu et.al. (2016): This chapter describes the experimental work. First, the materials
mixture proportions, manufacturing and curing of test specimens the sodium hydroxide
(NaOH) solids were dissolved in water to make the solution. The mass of NaOH solids in a
solution varied depending on the concentration of the solution. Similarly, the required amount
of sodium silicate solution was made. The sodium silicate solution and the sodium hydroxide
solution were mixed together with the extra water (if any) to prepare the liquid component of
the mixture. Then fly ash and the fine sand were first mixed together for about 3 minutes. The
liquid component of the mixture was then added to the dry materials and the mixing continued
for further about 4 minutes to manufacture the fresh concrete. The fresh concrete was cast
into the moulds immediately after mixing and well compacted and the top surface is finished
and concluded that Higher concentration of sodium silicate results in higher compressive
strength of fly ash-based geopolymer concrete. The compressive strength of heat cured fly
ash-based geopolymer concrete does not depend upon the age. Water Absorption is less. Since
wet curing is not needed, substitution of water is conserved. Geopolymer concrete is
ecofriendly.
5. Venugopal K et.al. (2015): Block masonry is one of the oldest methods of construction. It
is composed of masonry units and mortar. The most popular masonry units are burnt brick
and concrete blocks. These conventional masonry bricks/blocks are not considered as
sustainable. Burnt bricks consume considerable amount of top fertile soil and fossil fuels.
Conventional cement concrete block need cement which produces carbon dioxide (CO2)
during its manufacturing. Hence there is a need to develop and use alternatives masonry units.
Geopolymer masonry is one of the new materials among many alternatives, in which complete
elimination of cement is achieved without compromising the strength and durability. This
technology makes use of marginal materials like fly ash, blast furnace slag as binders. River
sand can be replaced with M-sand as fine aggregates. The reported literature is silent about
the use of geopolymer masonry blocks in the construction. The present study focuses on this
sustainable technology to save the natural and scarce materials.

6. Chien-chung chen et.al.(2015): The geopolymer concrete was mixed in the following order:
premixing all liquids (Na2SiO3, super plasticizer, and water) in a bucket for two minutes,
mixing coarse and fine aggregates in a concrete mixer for about one minutes, adding slag and
fly ash into the mixer for mixing for one minute, and then adding the previously mixed liquid
into the mixer for mixing for three minutes. After all the materials mixing properly, the
concrete was poured into a pan for testing and making samples. Tests conducted in this study
included air content, unit weight, and slump test. In addition, four 100 mm × 200 mm concrete
cylinders and one 150 mm × 150 mm × 550 mm beam were prepared for obtaining 7-day and
28-day compressive strength and 28-day flexural strength. All specimens were cured under
room temperature Air contents and unit weights from the three geopolymer concrete mixes
studied were comparable to those of OPC concrete, with the air contents being slightly lower
than 2 %, ranging from 1.5 to 1.9, and the unit weights ranging from 2,387 kg/m3 to 2,393
kg/m3. All three mixes showed good workability during the fresh concrete tests and specimen
preparation. The slumps of three mixes ranged from 230 mm to 255 mm. Although the mixes
showed good workability during the fresh concrete tests, initial setting was observed in about
20 minutes after the concrete mixing was stopped. Based on the short initial setting time
observed from this study, the geopolymer concrete studied herein provides an alternative for
applications where fast setting time is desired.
7. A.Maria Rajesh et.al. (2014):The project was carried out by using the following materials
fly ash, Fine aggregate ,Coarse aggregate, Alkaline liquid, Gypsum and super plasticizers and
later concluded that Compressive strength ,split tensile strength, flexural strength of GPC
specimens with 12M is 1.25,1.18,1.058 times more than that of GPC with other molarities
after 28 days of hot curing. Geopolymer technology does not only contribute to the reduction
of greenhouse gas emissions but also reduces disposal costs of industrial waste. Geopolymer
technology encourages recycling of waste and finally it will be an important step towards
sustainable concrete industry.

8. M. I. Abdul Aleem1 et.al. (2012): The following are the constituents of Geopolymer
concrete Such as Fly Ash- rich in Silica and Aluminum, Sodium Hydroxide or Potassium
Hydroxide, Sodium Silicate or Potassium Silicate and results was Fly ash reacted with alkaline
solution and formed a binding material. The higher concentration of sodium hydroxide
(molar) resulted higher compressive strength and higher the ratio of sodium silicate-to-sodium
hydroxide liquid ratio by mass, showed higher compressive strength of geopolymer concrete.
They also found that the increased in curing temperature in the range of 30 to 90 °C increased
the compressive strength of geopolymer concrete and longer curing time also increased the
compressive strength. They handled the geopolymer concrete up to120 minutes without any
sign of setting and without any degradation in the compressive strength, resulted very little
drying shrinkage and low creep. The Geopolymer mortar specimens manufactured from fly
ash with alkaline activators were structurally intact and did not show any recognizable change
in colour after 18 weeks exposure in 10% sulfuric acid solution and the Geopolymer Concrete
was high resistance against sulfuric acid. The strength of geopolymer concrete decreased as
the ratio of water to geopolymer solids by mass increased. The concentration (in term of
molarity) of NaOH influenced the strength characteristic of geopolymer concrete. Uniform
temperature was developed throughout the mass and Elastic Modulus and Poisson’s ratio were
within the acceptable limits. The Compressive strength of GPC increased over controlled
concrete by 1.5 times (M-25 achieves M-45), Split Tensile Strength of GPC increased over
controlled concrete by1.45 times and Flexural Strength of GPC increased over controlled
concrete by 1.6 times.
9. B. Vijaya Rangan et.al. (1987): This paper presents test data on fly ash-based geopolymer
concrete. The paper covers the material and the mixture proportions, the manufacturing
process, the fresh and hardened state characteristics, the influence of various parameters on
the fresh and hardened state concrete, the utilization of the material in structural members,
and the long-term behavior. The fly ash-based geopolymer concrete also shows excellent
resistance to sulfate attack, undergoes low creep, and suffers very little drying shrinkage.

CHAPTER-03
OBJECTIVES
The main objective of the study is to develop, manufacture and study the engineering properties
of alkali activated geopolymer concrete produced by using industrial wastes. In order to achieve
the same, the following objectives have been set.
 To study the proportion of alkali activated concrete.

 To characterize the materials required to make geo polymer concrete like Fly ash and
GGBFS and study their suitability for use.
 To investigate the properties of the concrete like compressive strength, split tensile
strength, characteristics etc.
 To find optimum percentage replacement of fly ash and GGBFS.
 To study the tensile strength of optimum mix of alkali activated concrete.
 To analyze future scope of application of alkali activated concrete.
This research is expected to provide a strong base for the potential utilization of marginal materials
like Fly ash, GGBFS and M-Sand for manufacturing and reveals a wide range of possible
applications of geo polymer concrete in the construction industries.

CHAPTER – 04
METHODOLOGY
4.1 MATERIALS USED
The following materials were used to prepare geopolymer concrete.

 Class F fly ash and GGBFS
 Fine aggregate (natural sand)
 Coarse aggregate
 Sodium hydroxide and sodium silicate
 Water
Fig 4.1 Material used
In this experiment, class F fly ash and GGFBS were used as binders; natural sand is used as fine
aggregate.
4.2 DESCRIPTION OF MATERIALS

In order to study the interaction of the Geopolymer concrete under compression, flexure and
split tension.
1 Materials used: Fly ash, GGBFS, Coarse aggregate, fine aggregate (M sand), Alkaline
solution.

2 Tests on materials: Fly ash and GGBFS-Physical and chemical properties, specific gravity
test Fine Aggregate-Specific gravity and water absorption test, sieve analysis test coarse
aggregate-specific gravity and water absorption test, sieve analysis test.
3 Mix design: M20 grade.
4 Mixing and Batching: All the material is added and mixed thoroughly for two minutes
and alkaline solution is added mixed thoroughly until we get uniform colour.
Fig.4.2 Mixing and batching
5 Curing: Curing is the process of maintaining satisfactory moisture content and temperature
in freshly cast concrete for a definite period of time
6 Test on hardened concrete:
 Compression test
 Split tensile test
 Water absorption test
 Density test

Collection of material
Characterization of material
Preliminary test for collected

material
Specific gravity test Water absorption test Sieve analysis
Mix design
Mixing of material
Casting
Curing
Test for specimen
Result
Fig.4.2.1 FLOW CHART FOR HARDENED CONCRETE

4.3 PRELIMINARY TEST:

Some of the tests are carried on the materials which are used in the preparation of geo polymer
concrete
4.3.1 FLY ASH:
Fly ash may be defined as an alumina silicate source which represents the majority component of
geopolymer concrete quality wise and has the least unit cost of all the cement in materials used in
the mix. Fly ash plays the important role of reducing brittleness in geopolymer concrete to a
considerable extent so that it can withstand more tensile stress without addition of reinforcing
Steel. The fly ash particles are dominantly spherical in shape and range in diameter from 1 to 200
µm. some of the fly ash particles are even hollow Shaped. It contains both crystalline phases like
quartz, mullite, hematite etc. and also amorphous phases.
Fly ash, as the solid by-product of the combustion of coal, is generally extracted from the
combustion fuel gases emanating from coal-fired power plant through the process of electrostatic
precipitation. The fly ash used in the dissertation work was procured from a coal based Thermal
Power Plant located in Shakti Nagar Raichur district village near Raichur town in Karnataka.
Some of the physical characteristics of Fly ash are Fineness, specific Gravity and particle size.
FIG.4.3. FLY ASH

Table 4.1: - Physical properties of Fly ash. (Provided by supplier)
Characteristics Value
Blaine fineness 290-350 m2/kg
Specific gravity 2.50
Particle size 8 to 14 µm
4.3.2 GROUND GRANULATED BLAST-FURNACE SLAG (GGBFS):
GGBFS may be defined as calcium silicate source which provides the necessary cations to be acted
upon by alkaline activator. The use of GGBFS in geopolymer concrete provides an additional
source of Alumina which on reaction with alkaline activator leads to creation of additional
cementing by products. The role of GGBFS is mainly concerned with early strength gain as
majority of the GGBFS present reacts within first 7 days.
The physical characteristics of GGBFS are Fineness, Specific Gravity and Particle size of
GGBFS.
FIG.4.4. GGBFS

Table 4.2: - Physical properties of GGBFS (provided by manufacture)
Characteristics Value
Blaine fineness 4490 cm2/gm
Specific gravity 2.9
Particle size < 2.5 µm-10%
< 6 µm- 50%
< 12 µm- 90%
Table 4.3: - Chemical Properties of GGBFS (provided by manufacturer)
SL.NO Composition Values in (%)
1 SiO2 29.96
2 Al2O3 12.25
3 CaO 45.45
4 SO3 3.62
5 Na2O 0.31
6 LOI 2.39

4.3.3 MANUFACTURED SAND (M-sand):
In construction industry usually river sand is used as an important building material. The world
consumption of sand in concrete generation alone is around 1000 million tons per year, making
it scarce and limited.
Hence in our present investigation, M-sand is used as fine aggregate in the place of river sand.
M-sand is a kind of waste material that is generated from the stone crushing industry which is
abundantly available to the extent of 200 million tons per annum which has landfill disposal
problems and health and environmental hazards (ref). specific gravity test for M-sand was
conducted and found to be 2.56. the test results are given in the following table.
Fig 4.5: - Manufactured Sand (M-Sand)

SPECIFIC GRAVITY TEST FOR M-SAND BY PYCNOMETER:
Apparatus used:
1. Pycnometer of about 1liter capacity.

2. Balance accurate to 1gm, glass rod, desired distilled water.
Fig 4.6: - Pycnometer
Procedure:
1) Weight of empty pycnometer (w1)

2) Weight of pycnometer + M-sand (w2)
3) Weight of pycnometer + M-sand + water (w3)
4) Weight of pycnometer + water (w4)
Formula: G= (W2-W1) / ((W2-W1-(W3-W4))

Table 4.4: - Specific gravity of M-sand
SL.NO PARTICULARS WEIGHT (g)
Trail 1 Trail 2 Trail 3
1 Wt. of empty pycnometer, W1 644.5 645 645
2 Wt. of pycnometer + M-sand, W2 1129 1130 1128
3 Wt. of pycnometer + M-sand + water, W3 1846 1847 1848.5
4 Wt. of pycnometer + water, W4 1552 1552 1552
5 Specific gravity = (W2-W1)/(W4-W1) - (W3-W2) 2.54 2.55 2.58
Average 2.56
Result: Specific gravity of M-Sand = 2.56

WATER ABSORBTION TEST FOR M-SAND:
Procedure:
1) Weight of surface dry sample, W1 (gm)

2) Weight of oven dried sample, W2(gm)
3) Water absorption=((W1-W2)/W2) *100
Table 4.5: - Water absorption test for M-sand
SL.NO DESCRIPTION %Water Absorption
Trail 1 Trail 2
1 Weight of surface dry sample, W1 (gm) 1.5 1.5
2 Weight of oven dried sample, W2(gm) 1.49 1.486
3 Water absorption=((W1-W2)/W2) *100 0.67 0.94
Average 0.80 %
Result: Water absorption=0.80 %

SIEVE ANALYSIS TEST FOR M-SAND: -
Apparatus:
1. Sieve of size: 4.75 mm, 6.3 mm, 10 mm, 12.5 mm, 16 mm and 20 mm
2. Thermostatically controlled oven
3. Trays, sieve brushes, mortar with a rubber covered pestle
4. Mechanical sieve shaker
Fig 4.7: - IS SIEVES
Procedure:
1) Take 1 kg of sand from a lab sample of 10 kg and break the clay lumps if any in a clean
dry rice plate.
2) Arrange the sieves in order of Indian standard sieve numbers 4.75 mm, 2.36 mm, 1.18 mm,
600 µ, 300 µ, 150 µ, with 4.75 mm at the top and 150 µ at the bottom fix them in a sieve
shaking machine with the pan at the bottom and cover at the top.
3) Keep the sand in the top sieve, carry out the sieving in the set of sieves for not less than 10
minutes and find the mass retained in each sieve.

Table 4.6: - Sieve analysis for M-sand
SL. NO IS Sieve Weight %weight Cumulative Cumulative

retained Retained % Retained % passing
Size
(gram) (%Finer)
1 4.75mm 21.17 4.23 4.23 95.77
2 2.36mm 45.36 9.07 13.30 86.70
3 1.18mm 73.58 14.72 28.02 71.98
4 600µ 38.30 7.66 35.68 64.32
5 300µ 134.06 26.81 62.49 37.51
6 150µ 89.71 17.94 80.43 19.57
7 75µ 71.57 14.31 94.74 5.26
8 PAN 26.21 5.24 99.98 0.02
Total 500
Result:
Fineness modulus of m-sand =2.56

4.3.4 COARSE AGGREGATE
Coarse aggregates are stones that are retained on 4.75 mm sieve. Uncrushed gravel or stones which
are the result of natural disintegration and Crushed gravel or stones are usually called as “coarse
aggregates”. Nearly all-natural aggregates originate from bedrocks. There are three kinds of rocks.
They are igneous, sedimentary and metamorphic. Thus, many properties of aggregate depend on
the properties of parent rock.
SPECIFIC GRAVITY AND WATER ABSORPTION OF COARSE

AGGREGATE
Apparatus:
Balance machine, wire basket of not more than 6.3 mm mesh, container, Shallow tray and
absorbent cloth.
FIG.4.8. TESTING APPARATUS
Procedure:
1. Weight of saturated surface dry sample (W1)

2. Weight of basket suspended in water (W2)
3. Weight of material + basket suspended in water (W3)
4. Weight of oven dried aggregate sample in air (W4)

Formula:
𝐖𝟏
1. Bulk specific gravity = 𝐖𝟏−(𝐖𝟑−𝐖𝟐)
𝐖𝟒
2. Apparent specific gravity = 𝐖𝟒−(𝐖𝟑−𝐖𝟐)
(𝑾𝟏−𝑾𝟒)
3. Percentage of water absorption = ∗ 𝟏𝟎𝟎
𝑾𝟒
Table 4.7: - specific gravity and water absorption
SL. NO Description Water absorption
Trail 1 Trail 2
1. Weight of surface dry sample, W1 (gm) 3000 3000
2. Weight of oven dried sample, W2 (gm) 2985 2985
3. water absorption = ((W1-W2)/W2) *100 0.5 0.5
Average 0.5 %
Result:
1. The mean value of bulk specific gravity = 2.67

2. The mean value of apparent specific gravity = 2.68
3. The mean value of water absorption = 0.5 %
SIEVE ANALYSIS OF COARSE AGGREGATE:
Apparatus:
1) Sieve of size: 40 mm, 20 mm, 10 mm, and 4.75 mm

2) Trays, sieve brushes, mortar with a rubber covered pestle
3) Mechanical sieve shaker

4.9 SIEVE ANALYSIS APPARATUS
Procedure:
1. Take 5 Kg of coarse aggregate of nominal size of 20 mm

2. Carry out by sieving by mechanical sieve shaker, shake each size in the order 40 mm, 20
mm, 10 mm, 4.75 mm for a period of not less than 10 minutes.
3. Find the mass of aggregates retained on each sieve taken in order.
Result:
Fineness modulus of coarse aggregate = 7.75

4.3.5 SODIUM HYDROXIDE AND SODIUM SILICATES:
These are dissolved in water to make alkaline solution. This alkaline solution activates silica and
alumina. In reaction with high pH alkali solution, alumina silicates release free SiO4 and AlO4
tetrahedral structures which further condensates to form a rigid network. Potassium hydroxide can
also be used instead of sodium hydroxide. But studies showed that reactions take place rapidly in
the presence of NaOH when compared to KOH. In present work molarity is kept as constant to 8
M. molecular mass of NaOH is 40 grams. To prepare 8 M sodium hydroxide solution, 480 grams
of NaOH flakes are dissolved in one liter of water. Dissolution of NaOH flakes in water is an
exothermic reaction and large amount of heat releases.
Alkaline liquid used in the present study is a combination of sodium hydroxide and sodium silicate
solutions in a definite proportion. Sodium-based solutions were preferred because of their local
availability and lower cost as compared to potassium-based solution. Sodium silicate facilitates
faster dissolution of the binder components. The exact proportions used for different
experimentations are illustrated in the appropriate section of the thesis.
Both the alkalis were of commercial grade and procured from local suppliers. Sodium hydroxide
pellets were with 96 % purity, having a specific gravity of 2.13. The aqueous solution of sodium
silicate with SiO2 / Na2O is in the ratio of 3.37 with a pH value of 10.4.
FIG 4.10: - SODIUM HYDROXIDE FIG 4.11: - SODIUM SILICATE

4.3.6 WATER:
Almost any natural water that is drink17able and has no pronounced taste or odour can be used as
mixing water for making concrete. Excessive impurities in mixing water not only may affect
setting time and strength, but also may cause efflorescence, staining, corrosion of reinforcement,
volume instability, and reduced durability. Therefore, certain optional limits may be set on
chlorides, sulphates, alkalis, and solids in the mixing water or appropriate tests can be performed
to determine the effect the impurity has on various properties. Some impurities may have little
effect on strength and setting time, yet they can adversely affect durability and other properties.
Water containing less than 2000 parts per million (ppm) of total dissolved solids can generally be
used satisfactorily for making concrete. Water containing more than 2000 ppm of dissolved solids
should be tested for its effect on strength and time of set. pH of water to even 9 is allowed in
coastal areas, where local water us saline and have no alternate sources, the chloride concentration
up to 1000 ppm is even allowed for drinking. But this excessive amount of alkali carbonates and
bicarbonates, in some natural mineral water, may cause alkali-silica reaction. For the present work,
potable water according to IS: 456-2000 has been used.
Fig:4.12 portable water

CHAPTER-05
WORK DONE
5.1 MIX DESIGN
Since there is no standard method of designing geopolymer concrete. The mix design method
proposed by IS was first employed to design the conventional concrete mixes. The purpose of mix
proportioning is to produce the required properties of Fly ash, water binders by working out a
combination of available materials with various economic and practical standards.
Design of M20 grade of normal concrete mix
 Design stipulation:
 The design procedure is followed by IS 10262-2009
 Desired characteristics strength of concrete fck = 20N/mm2
 Maximum size of aggregates = 20 mm
 Degree of workability = 100 mm slump
 Type of exposure = severe
 Data:
 Specific gravity of: -
i. Coarse aggregate = 2.68
ii. Fine aggregate = 2.56
iii. Fly ash = 2.50
iv. GGBFS = 2.9
 Water absorption of: -
i. Coarse aggregate = 0.5
ii. Fine aggregate = 0.80
 Target strength for mix proportioning
Fck1 = Fck+1.65s
S=standard deviation
Fck=characteristics compressive strength at 28 days

Fck1=target average compressive strength at 28 days
From table1, standard deviation, s=4.0 N/mm2
Therefore, target strength = 20+(1.65*4.0) =26.6 N/mm2
 Selection of water-binder ratio

From table 5 of IS 456, max water-binder ratio =0.45
Based on experience, adopt water-binder ratio as 0.40
0.40<0.45
Hence, O.k.
 Selection of water content

From table2 of IS 10262, max water content for 20 mm aggregate= 186 liters
Estimated water content for 100 mm slump= 186+((6/100) *186) = 197 liters
 Calculation of fly ash and GGBFS content

Water binder ratio = 0.4
Fly ash and GGBFS = 197/0.4 = 492.5
Therefore, Fly ash and GGBFS = 492.5 kg/m3
 Proportion of volume of coarse and fine aggregate
From table 3, volume of coarse aggregate corresponding to 20 mm size aggregate and fine
aggregate (zone 1) for water-binder ratio 0.5 = 0.60.
But, in present case water-binder ratio is 0.40
According to IS10262-2009, volume of coarse aggregate = 0.62*0.9=0.56
For pumpable concrete value should be reduced by10 %
Therefore, volume of coarse aggregate = 0.62*0.9 = 0.56
Volume of the fine aggregate = 10.56 = 0.44
 Mix calculations
The mix calculations per unit volume of concrete shall be as follows:
a) Volume of concrete = 1m3

b) Volume of Fly ash and GGBFS = (mass of Fly ash/specific gravity of Fly ash) *(1/1000) =
(492.5/2.5) *(1/1000) =0.197 m3.
c) Volume of water = (mass of water / specific gravity of water) *(1/1000) = (197/1) *(1/1000)
=0.197m3
d) Volume of all in aggregate = [a-(b+c)] = [1-(0.197+0.197)] = 0.606 m3.
e) Mass of coarse aggregate = d*mass of coarse aggregate*specific gravity of coarse
aggregate*1000 = 0.606*0.56*2.74*1000 = 929.84 Kg.
f) Mass of fine aggregate = d*mass of fine aggregate*specific gravity of fine aggregate *1000
= 0.606*0.44*2.63*1000 = 701.26 Kg.
 Proportion by ratio
Fly ash and GGBFS Fine aggregate Coarse aggregate Water-binder ratio
1 1.5 3 0.45
5.2 MIX PROPORTIONS
 Grade designation : M20

 Type of binder : Fly ash and GGBFS
 Maximum nominal size of coarse aggregates : 20mm
 Type of fine aggregate : M-Sand
 Method of concrete placing : Rod tamping
 Type of curing : Ambient curing

5.3 MIXING PROCEDURE
All materials are added and mixed thoroughly for two to three minutes. Then Alkali Solution is
added and is mixed thoroughly until we get a homogeneous mix is obtained.
Fig 5.1: Photo of mixing process

5.4 CASTING PROCEDURE

Minimum 3 numbers of specimen moulds of 150 mm x 150 mm were casted for each proportion
of mixing. Before placing the concrete into moulds, the moulds have to be lubricated properly so
that there won’t be any bonding between the concrete into moulds Casting done as per moulds of
IS specification.
Fig 5.2: Photo of casting process

5.5 CURING PROCEDURE:
Curing is the process of maintaining satisfactory moisture content and temperature in freshly cast
concrete for a definite period of time. It prevents the loss of moisture from the concrete. It
maintains temperature for hydration to occur for definite period. We cure concrete to maximize its
strength and reduce cracks.
Fig 5.3: Photo of curing process

5.6 TESTS ON HARDENED CONCRETE

Some of the test are carried on the hardened concrete
5.6.1 COMPRESSIVE STRENGTH TEST:
Fig 5.4: -Compression test apparatus
Compressive strength is one of the important properties of the concrete. Compressive strength of
the concrete is measured in N/mm2. The compressive strength depends on various factors like
material/water ratio, degree of compaction, type and quality of binding material, type and texture
of aggregate, curing, temperature.
The specimens after 28 days’ air curing are tested for compressive strength as per IS:516-1959.
The specimens are placed in the compression testing machine in such a way that the load was
applied on the opposite side of the cubes. Then the load was gradually being applied without shock.
The maximum load applied is noted and the compressive strength of the cube specimen is
calculated using the following formula,
Compressive strength,
fc = P/A (N/mm2)
Where, P = Applied Load in
A = Surface area of cube

5.6.2 SPLIT TENSILE STRENGTH TEST
Fig 5.5: - Split tensile testing machine
Split Cylinder test is the standard test, to determine the tensile strength of concrete in an indirect
way. A standard test cylinder of concrete specimen (300 mm length and 150 mm diameter) is
placed horizontally between the loading surface of compression testing machine as per IS: 5816-
1970.
The compression load is applied diametrically and uniformly along the cylinder until the failure of
the cylinder along the vertical diameter strips of plywood or plate are placed between the specimen
and loading platens of the testing machine to allow uniform distribution of this applied load and
to reduce the magnitude of the high compressive stresses near the points of application of this load.
Concrete cylinders split into two halves along this vertical plane.
The split tensile strength of the specimen is calculated using following formula:
Split tensile strength = 2P/πDL (N/mm2)
Where, P= load at failure in N
D = diameter of the specimen in mm
L = length of the specimen in mm

5.6.3 WATER ABSORPTION TEST
Fig 5.6: - Water curing tank
Water absorption test is determined to know the percentage of water content. Three full size blocks
shall be completely immersed in clean water at room temperature for 24 hours. The blocks shall
then be removed from the water and allowed to drain for one minute by placing them on a 10 mm
or coarser wire mesh, visible surface water being removed with a damp cloth, the saturated and
surface dry blocks immediately weighed.
The water absorption calculates as given below:
Water absorption, percent = (A-B)/B*100
Where,
A= wet mass of unit in kg
B= dry mass of unit in kg.

5.6.4 DENSITY TEST FOR HARDENED CONCRETE:
Fig 5.7: Weighing balance with standard size moulds
This test was conducted as per IS 2185-2008 (part 4) [124]. The densities of various moulds with
different proportion of Fly ash and GGBFS are shown in the results. The density varies from 1800-
2501 kg/m3. It can be observed that the density of the moulds with 100 % replacement of Fly ash
are less as compared to the moulds with 60 % replacement of Fly ash. This is due to usage of the
Fly ash which has low specific gravity.
The density is calculated from the mass (weight) and volume, which are obtained from a hardened
concrete test specimen.
D= m/V
Where,
D = density in kg/m3
m = mass of specimen at time of test in kg
V = volume determined by the relevant method in m3

CHAPTER-06
RESULTS AND DISSCUSSIONS
The results obtained in the project are represented in the form of tables and graphs. Based on the
knowledge of literature review interpretation of the results is carried out at each phase of the
project.
6.1 RESULTS
6.1.1 COMPRESSIVE STRENGTH
1) 3 days compressive strength of concrete with different percentages of Fly ash and
GGBFS.
Table 6.1: 3 days compressive strength
Cube No. % Replacement of by Fly ash and GGBFS
100 % 80-20 % 60-40 %
Compressive 1 5.56 7.28 8.96

Strength (MPa)
2 5.45 8.26 9.42
3 5.68 7.98 9.56
Average (MPa) 5.56 7.84 9.31

Compressive Strength
10
Strength in N/mm2
8
0
100% 80-20% 60-40%
% replacement of Fly ash & GGBFS
Shows the 3 days compressive strength
GGBFS.
100 % 80-20 % 60-40 %
Compressive 1 12.35 13.28 14.29

Strength (MPa)
2 11.28 14.37 15.86
3 12.26 14.56 15.38
Average (MPa) 11.96 14.07 15.17

16
14
Strength in N/mm2 12
10
8
6
4
2
0
100% 80-20% 60-40%

GGBFS.
100 % 80-20 % 60-40 %
Compressive 1 13.16 16.86 17.98

Strength (MPa)
2 14.28 17.2 18.28
3 14.58 17.86 19.35
Average (MPa) 14.06 17.48 18.53
20
18
16
Strength in N/mm2
14
12
10
8
6
4
2
0
100% 80-20% 60-40%

4) 28 days compressive strength of concrete with different percentages of fly ash and
GGBFS.
100 % 80-20 % 60-40 %
Compressive 1 16.46 19.81 22.89

Strength (MPa)
2 17.28 20.29 23.45
3 17.32 19.96 23.92
Average (MPa) 17.02 20.02 23.42
25
20
Strength in N/mm2
15
10
0
100% 80-20% 60-40%
% replacement of Flyash & GGBFS

Compressive strength
25
20
Strength in N/mm2
15
3 days
7 days
10
14 days
28 days
0
100% 80-20% 60-40%
COMPRESSIVE STRENGTH OF GEO POLYMER CONCRETE

6.1.2 SPLIT TENSILE STRENGTH
1) 7 days split tensile strength of Fly ash and GGBFS.

Table 6.5: 7 days split tensile strength
100 % 80-20 % 60-40 %
Split Tensile 1 0.68 0.83 1.28

Strength (MPa)
2 0.71 0.92 1.38
3 0.65 0.94 1.31
Average (MPa) 0.68 0.89 1.32
Split Tensile Strength

1.4
1.2
Strength in N/mm2
1
0.8
0.6
0.4
0.2
0
100% 80-20% 60-40%
Shows the 7 days split tensile strength


100 % 80-20 % 60-40 %

Strength (MPa)
2 0.78 1.18 1.51
3 0.81 0.94 1.56
Average (MPa) 0.80 1.02 1.51

1.6
1.4
strength in N/mm2
1.2
1
0.8
0.6
0.4
0.2
0
100% 80-20% 60-40%


100 % 80-20 % 60-40 %

Strength (MPa)
2 1.22 1.53 2.18
3 1.16 1.59 2.02
Average (MPa) 1.18 1.53 2.05
Split Tensile strength

2.5
2
Strength in N/mm2
1.5
0.5
0
100% 80-20% 60-40%
Shows the 28 days split tensile strength


2.5
2
Strength in N/mm2
1.5
7 days
14 days
1
28 days
0.5
0
100% 80-20% 60-40%
SPLIT TENSILE STRENGTH OF GEO POLYMER CONCRETE

6.1.3 WATER ABSORPTION TEST

Water absorption, percent = (A-B)/B*100
Where,
A= wet mass of unit in kg
B= dry mass of unit in kg.
1.Dry weight of concrete cube (B) = 7.330 Kg

2.Wet weight of concrete cube (A) = 7.580 Kg
= (A-B)/B*100
= (7.580 – 7.330)/7.330 *100
Water absorption = 3.41%
Fig 6.1: Water curing tank

6.1.4 DENSITY TEST FOR HARDENED CONCRETE
Formula,
D= m/V
Where,
D = density in kg/m3
m = mass of specimen at time of test in kg
V = volume determined by the relevant method in m3
Table 6.8: Density test
Replacement of Fly ash and GGBFS

Density (kg/m3)
in (%)
100:0 2148.40
80:20 2156.32
60:40 2162.50

6.2 DISCUSSIONS
COMPRESSIVE STRENGTH:
The above table and graph represent compressive strength for different concrete mixes at age of
3,7,14 & 28 days. It is observed that there is increase in compressive strength by increasing the
GGBFS due to high molarities, and maximum compressive strength obtained at 60 % of fly ash
and 40 % of GGBFS.
SPLIT TENSILE STRENGTH:
The above table and graph represent split tensile strength for different concrete mixes at age of
7,14 & 28 days. It is observed that there is increase in split tensile strength by increasing the
GGBFS due to high molarities, and maximum split tensile strength obtained at 60 % of Fly ash
and 40 % of GGBFS.
WATER ABSORPTION TEST:
In the above result represents the initial water absorption test for the replacement of 60 % of Fly
ash and 40 % of GGBFS at age of 28 days. We get the water absorption is about 3.41 %.
DENSITY TEST:
In the above table represents the density test for hardened concrete of different percentages like
100:0 %, 80:20 %, 60:40%. And the results are shown in above table.

REFERENCES
1. A.Maria Rajesh, M.Adams Joe, Roy Mammen:” “Study of the Strength Geopolymer
Concrete with Alkaline Solution of Varying Molarity” (IOSR journal of engineering)
Vol.04 issuse.06 (2014)
2. B. Vijaya Rangan, Djwantoro Hardjito, Steenie E. Wallah, and Dody M.J. Sumajouw:
“Studies on fly ash-based geopolymer concrete” (Green chemistry and sustainable
development) (1987)
3. Chien-chung chen, Ivan diaz, Kathleen menozzi, Luis murillo “AN EXPERIMENTAL
STUDY ON SLAG/FLY ASH-BASED GEOPOLYMER CONCRETE” (international
journal of mechanical and production engineering) Vol.03 Issuse. 08, (2015)
4. D0. Indu, R.Elangovan: “Study and Manufacture of Geopolymer Concrete using Class C
type Fly Ash” ( International Journal of Engineering Trends and Technology (IJETT) )–
Vol 37 No. 6 - (2016)
5. E. Manimaran1 and G. Mohan Kumar” Study on the Properties of Alkaline Activated Fly
Ash Based Geopolymer Composites” (International Journal of Chemtech Research) Vol.10
No.7, pp:254-259 (2017)
6. K. Sandeep Dutt, K. Vinay Kumar, I. Siva Kishore, Ch. Mallika Chowdary: “A Case Study
on Fly Ash Based Geo-Polymer Concrete” (international journal of engineering trends and
technology) Vol.34 issuse 02 (2016)
7. M. I. Abdul Aleem1, P. D. Arumairaj “GEOPOLYMER CONCRETE- A REVIEW”

(International journal of engineering science and emerging technologies) Vol.01 issue 2,
pp:118-122 (2012).

8. T Srinivas and N V Ramana Rao” Development and Optimization of Mix Design Of Low
Calcium Fly Ash and Slag Based Geopolymer Concrete for Standard Grade” (ISOR journal
of mechanical and Civil engineering) Vol.13 issue 4 pp:39-47 (2017)
9. Venugopal K, Radhakrishna J. Raju, M. A. Dar” Properties and Application of

Geopolymer Masonry Units” (SSRG International Journal of Civil Engineering (SSRG-
IJCE) – EFES) (2015)

IS CODE OF REFERENCES
1) IS 383:1970; Specification for coarse and fine aggregate from natural sources.
2) IS 516:1959; Methods of tests for strength of concrete.
3) IS 10262:2009; Mix design of concrete.
4) IS 456:2000; Plain and reinforced concrete code of practice.

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STUDY ON GEOPOLYMER CONCRETE BY REPLACEMENT OF CEMENT BY FLY ASH AND GGBFS

Dept. of Civil Engg. SEACET, B’lore. Page 1

1.2 ADVANTAGES OF GEOPOLYMER CONCRETE

Dept. of Civil Engg. SEACET, B’lore. Page 2

1.3 DISADAVANTAGES OF GEOPOLYMER CONCRETE

Dept. of Civil Engg. SEACET, B’lore. Page 3

Dept. of Civil Engg. SEACET, B’lore. Page 4

Dept. of Civil Engg. SEACET, B’lore. Page 5

Dept. of Civil Engg. SEACET, B’lore. Page 6

Dept. of Civil Engg. SEACET, B’lore. Page 7

Dept. of Civil Engg. SEACET, B’lore. Page 8

 To study the proportion of alkali activated concrete.

Dept. of Civil Engg. SEACET, B’lore. Page 9

4.1 MATERIALS USED

The following materials were used to prepare geopolymer concrete.

Fig 4.1 Material used

4.2 DESCRIPTION OF MATERIALS

Dept. of Civil Engg. SEACET, B’lore. Page 10

Fig.4.2 Mixing and batching

6 Test on hardened concrete:

Dept. of Civil Engg. SEACET, B’lore. Page 11

Preliminary test for collected

Specific gravity test Water absorption test Sieve analysis

Test for specimen

Fig.4.2.1 FLOW CHART FOR HARDENED CONCRETE

Dept. of Civil Engg. SEACET, B’lore. Page 12

4.3 PRELIMINARY TEST:

4.3.1 FLY ASH:

FIG.4.3. FLY ASH

Dept. of Civil Engg. SEACET, B’lore. Page 13

Table 4.1: - Physical properties of Fly ash. (Provided by supplier)

Blaine fineness 290-350 m2/kg

Specific gravity 2.50

4.3.2 GROUND GRANULATED BLAST-FURNACE SLAG (GGBFS):

Dept. of Civil Engg. SEACET, B’lore. Page 14

Table 4.2: - Physical properties of GGBFS (provided by manufacture)

Blaine fineness 4490 cm2/gm

Specific gravity 2.9

Particle size < 2.5 µm-10%

< 6 µm- 50%

< 12 µm- 90%

Table 4.3: - Chemical Properties of GGBFS (provided by manufacturer)

SL.NO Composition Values in (%)

Dept. of Civil Engg. SEACET, B’lore. Page 15

4.3.3 MANUFACTURED SAND (M-sand):

Fig 4.5: - Manufactured Sand (M-Sand)

Dept. of Civil Engg. SEACET, B’lore. Page 16

SPECIFIC GRAVITY TEST FOR M-SAND BY PYCNOMETER:

1. Pycnometer of about 1liter capacity.

Fig 4.6: - Pycnometer

1) Weight of empty pycnometer (w1)

Formula: G= (W2-W1) / ((W2-W1-(W3-W4))

Dept. of Civil Engg. SEACET, B’lore. Page 17

Table 4.4: - Specific gravity of M-sand

SL.NO PARTICULARS WEIGHT (g)

Trail 1 Trail 2 Trail 3

1 Wt. of empty pycnometer, W1 644.5 645 645

2 Wt. of pycnometer + M-sand, W2 1129 1130 1128

3 Wt. of pycnometer + M-sand + water, W3 1846 1847 1848.5

4 Wt. of pycnometer + water, W4 1552 1552 1552

5 Specific gravity = (W2-W1)/(W4-W1) - (W3-W2) 2.54 2.55 2.58

Result: Specific gravity of M-Sand = 2.56

Dept. of Civil Engg. SEACET, B’lore. Page 18