European International Journal of Science and Technology

Vol. 2 No. 5

June 2013

Development of Coal Ash GGBS based geopolymer bricks

Bennet Jose Mathew ! S"dhakar M #! Dr$ C %atara&an '

PG student1 / Research Scholar2 / Professor of Civil Engg3 National Institute of Technology Trichy! "2##1$ India E%ail& sudha'ar$$""(g%ail!co%

Abstract Study has een carried out on de!elop"ent of geopoly"er inder ased ric#s using fly ash$ %%&S and otto" ash. ' "i(ture of sodiu" silicate and sodiu" hydro(ide )ere used to prepare the ric#s )hich )ere cured at a" ient te"perature. The effect of percentage of inder y )eight$ percentage of %%&S y )eight in total alu"inosilicate inder "aterials$ sodiu" silicate to sodiu" hydro(ide ratio and al#aline li*uid to alu"inosilicate solid ratio )ere studied using full factorial design. +ercentage of inder and ratio of al#aline li*uid to alu"iosilicate solid ratio had significant i"pact on the strength of ric#. &ric#s )ere casted in industrial site fro" the est "i( o tained fro" factorial design e(peri"ent and "echanical properties li#e co"pressi!e strength and )ater a sorption )ere noted. (eywords) Co%)ressive strength factorial design Geo)oly%er *aste create +ric's *ater a+sor)tion $ *%+,-D.C+*-% The huge de%and fro% housing industry due to )o)ulation e,)losion has entailed the need for sustaina+le +uilding %aterials es)ecially +ric's! Researchers have tried to incor)orate fly ash ground granulated +last furnace slag -GG.S/ li%e stone dust rice hus' ash *elding flu, slag and other *aste )roducts into +ric's so as to i%)rove its sustaina+ility 011"2! 3n interesting area of research *hich has attracted interest of %any scholars is Geo)oly%er +inder *hich utili4es industrial *aste )roducts to for% sustaina+le green +inders! 3s )er TERI -2##1/ re)ort India )roduces %ore than 15## +illion +ric's )er year using 3$# %illion tons of to) soil +y +urning 25 %illion tons of coal there+y e%itting 52 %illion tons of C62 ! In India it is esti%ated that +y end of 2#12 fro% the total ther%al ca)acity of a+out 7# coal / lignite +ased Ther%al Po*er )lants generate ash in the for% of fly ash -8#17#9/ and +otto% ash -1#12#9/ *ould +e of the order of 1:3 ;illion Tons-;t/ )er annu% considering 389 ash content in coal as an average and at 8#9 Plant <oad =actor -CE3 2##711#/! It is further esti%ated that only a+out $19 of the ash generated found gainful utili4ation! Given the fact that econo%ic gro*th of the Nation is generally lin'ed to )o*er availa+ility and given the trend of high )ro)ortions of coal +ased ther%al )o*er stations -TPS/ fly ash generation is li'ely to increase in future! It is esti%ated that coal ash generation *ill li'ely to gro* over 2##;t +y the year 2#1:! >nless *e find %ore *ays to utilise this industrial *aste fully in line *ith its out)ut it *ill greatly endanger the environ%ent! ?ence e,)loring the )ossi+ility of utilising +otto% ash -.3/ along *ith =ly ash is interesting avenue for research!
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The ter% geo)oly%er *as ter%ed +y @avidovits in 1788 0:2 to re)resent %ineral )oly%ers! Geo)oly%ers are che%ically si%ilar to Aeolite +ut has a%or)hous %icrostructure consisting )redo%inantly of Si and 3l ato%s! @uring the synthesi4ed )rocess silicon and alu%iniu% ato%s are co%+ined to for% the +uilding +loc's that are che%ically and structurally co%)ara+le to those +inding the natural roc's 081112! ;ost of the literature in geo)oly%er deals *ith geo)oly%er )astes and geo)oly%er concrete! Geo)oly%er +ased +inder *as )atented in >S3 in 1788 as ?igh Strength ;ineral )oly%er and the +inder *as )re)ared using GG.S *hich re)laced ce%ent %ortar in )recast structural ele%ents! Geo)oly%er has advantages li'e availa+ility of a+undant ra* %aterials Buic' strength gain good dura+ility es)ecially in acidic environ%ent reduced energy consu%)tion and reduced greenhouse gas e%ission 01211$2! Previous study conducted on +loc's %ade of fly ash +otto% ash and al'aline solution confir%s the feasi+ility of +ric' )roduction *here in +ric's *ere )roduced that %eet Israelis Standards for +loc's 01"2! .ric's of strength ranging fro% $1"# ;Pa *as also )re)ared )reviously using Class = fly ash sodiu% silicate and sodiu% hydro,ide solution *ith for%ing )ressure of 3#;Pa and cured at elevated te%)eratures 01:2! Research into geo)oly%er +ric's incor)oration co))er %ine tailings co))er %ine tailing and ce%ent 'iln fly ash %eta'aolin and red %ud red %ud and rice hus' ash fly ash and iron %a'ing slag and %any %ore have )roduced )ro%ising results 0181222! 6+Cective of this study is to )re)are +ric's using +otto% ash fly ash GG.S and al'aline solution consisting of sodiu% hydro,ide and sodiu% silicate! =ly ash and +otto% ash are *aste )roducts of coal +urning )o*er station! The che%ical co%)osition of fly ash and +otto% ash fro% sa%e +atch *ill +e si%ilar! .otto% ash %ay consists of )articles of si4e u) to 1#11$%%! #$ MA+/,*A0S =ly 3sh The fly ash o+tained for the study *as fro% Tuticurin ther%al )o*er station India! Results of DR= analysis of the fly ash is indicated in Ta+le 1! =ly ash falls under Class = as )er 3ST; Standard 0132! The s)ecific gravity of fly ash *as found to +e 2!#$! +able $ Chemical composition of fly ash$ -1ide Si62 3l263 =e263 Ca6 S63

Mass 2ercentage $3!3 27!$ 1#!: :!" 1!8

GG.S GG.S is o+tained +y grinding the Buenched +last furnace slag to fine )o*der! It is i%)ortant constituent for geo)oly%er +inders cured at a%+ient te%)erature ! The che%ical co%)osition of GG.S of s)ecific gravity 2!18 o+tained fro% local %ar'et is given in Ta+le 2! +able # Composition of GGBS as determined by 3,4 -1ide Si62 3l263 =e6
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Mass 2ercentage 567 3$!5: 17!3" #!8

European International Journal of Science and Technology

Vol. 2 No. 5

June 2013

Ca6 ;g6 6thers

33!2$ 8!"7 3!2$

.otto% 3sh .otto% ash *as also )rocured fro% Tuticorin Ther%al Po*er Plant Ta%il Nadu! ?o*ever it *as ta'en fro% a different +atch fro% that of fly ash and the che%ical co%)osition is given in Ta+le 3! Sieve 3nalysis of +otto% ash also *as carried out %ainly to deter%ine the Buantity of )articles si4e distri+ution and *as found to +e *ell graded! +able ' Composition of Bottom Ash as determined by 3,4 -1ides Mass 2ercentage 567 Si62 $"!:" 3l263 =e263 Ca6 S63 21!35 $!78 2!88 #!:2

Sodiu% Silicate and Sodiu% ?ydro,ide Sodiu% silicate -Na2Si63/ and sodiu% hydro,ide -Na6?/ *ere +oth )rocured fro% local %ar'et! <a+oratory grade -7:9 )ure/ sodiu% hydro,ide *as in the for% of )ellets -3%% a))ro,i%ately/ *ith s)ecific density of 2!13 g/c%3! The che%ical co%)osition of sodiu% silicate solution *as Na26E1$!239 +y %ass Si62E3$!":9 +y %ass and re%aining *ater! The ;olar Ratio -Si62/Na26/ *as found to +e 2!35! The density of sodiu% silicate solution *as found to +e 1!$3 g/c%3! '$ /32/,*M/%+A0 *%8/S+*GA+*-% A%D ,/S.0+S 3 25 full factorial design *as ado)ted for e,)eri%ental study *ith each )ara%eter having t*o levels! ?igher and lo*er levels of the )ara%eters identified for the full factorial design is ta+ulated in Ta+le 5! The levels *ere identified +ased on )ilot study conducted +y the authors! 3 total of 1" %i,es *ere derived using full factorial design %ethod and the %i,es are listed in Ta+le $! The ;olarity of Na6? solution *as 'e)t constant as " %olar *hile *ater to total geo)oly%er solid -=ly 3sh GG.S .otto% 3sh Na6? Pellets and Na2Si63 solute/ ratio *as 'e)t constant at #!13! +able 9 4actors and their levels considered in 4actorial design$ 2arameter :igher 0evel 5; 7 Percentage .inder +y Feight including 3lu%inosilicate 5# 9 %aterials and <iBuid Percentage of GG.S in 3lu%inosilicate .inder ;aterial Sodiu% Silicate to Sodiu% ?ydro,ide Ratio 3ctivator liBuid to 3lu%inosilicate .inder ;aterial Ratio $# 9 2!$ #!$

0ower 0evel 5< 7 2# 9 1# 9 2 #!3

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Cu+es of :!#: c% side -$#c%2 face area/ *ere casted for each %i,! ?and co%)action in three layers *ith 2$ +lo*s to each layer *as used to co%)act the %i, so as to create the %ini%u% %oulding condition that %ay +e used in site! Cu+es *ere cured in a%+ient te%)erature for 28 days and *ere tested for co%)ressive strength! The results of the test along *ith density are also given in Ta+le $! +able = Average compressive strength and standard deviation of samples Activator 2ercentage %a#Si-' to li?"id to Compressiv Mi1 2ercentage Density Binder by %a-: Al"mino< e Strength %o of GGBS 5(g@m'7 >eight ,atio 5M2a7 silicate ,atio 1 11 1 11 11 #!#" 7:"!2#5 2 11 11 1 11 #!#8 1#2$!7"8 3 11 11 11 1 #!5: 1#:7!"78 5 11 1 1 1 #!78 117$!2"7 $ 11 11 11 11 #!1" 753!7#73 " 11 1 1 11 #!11 1#38!"21 : 11 11 1 1 #!$3 1#$:!127 8 11 1 11 1 #!31 11#1!228 7 1 1 11 11 #!"5 11$#!87: 1# 1 11 1 11 #!7# 113"!2$1 11 1 11 11 1 3!3# 1258!35: 12 1 1 1 1 $!#3 11$:!225 13 1 11 11 11 1!#2 1151!$57 15 1 1 1 11 #!5$ 1#75!335 1$ 1 11 1 1 3!:# 121$!:: 1" 1 1 11 1 5!#: 12:3!3:1

Strength Density #!#" #!#8 #!53 #!82 #!1: #!11 #!$# #!28 #!$" #!:7 2!"5 5!3$ #!7# #!51 3!#5 3!17

The +est %i, in ter%s of strength and strength to density ratio *as found to +e ;i, 12 and it *as used for casting of +ric's of di%ensions 23#%% , 11$%% , :$%%! .ric's *ere %oulded using )neu%atically o)erated electric %achine *ith a )ressure of value 3" ;Pa! .ric's *ere cured at a%+ient te%)erature and *ater a+sor)tion and co%)ressive strength at intervals of : days 15 days 21 days and 28 days *ere noted as )er IS 357" and the results are given in =igure 1 and =igure 2! The average density of +loc' *as found to +e 1$1"!$ 'g/%3!

Compressive Strength
12!## 1#!## 8!## "!## 5!## 2!## #!## # $ Strength M2a

:!23

8!32

7!2"

1#!12

1#

1$ Days

2#

2$

3#

4ig"re $ 8ariation of compressive strength with days

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European International Journal of Science and Technology

Vol. 2 No. 5

June 2013

>ater Absorption
>ater Absorption 567 2$!## 2#!## 1$!## 1#!## $!## #!## # $ 1# 1$ Days 2# 2$ 3# 23!22 21!5$ 2#!#2 18!3"

4ig"re #$ 8ariation of compressive strength with days 9$ D*SC.SS*-% A%D C-%C0.S*-% ;ost of the %i,es under study gave relatively lo*er strength *hen co%)acted +y hand co%)action %ethod! The )ara%eter *hich had the highest influence on strength of the %i, *as +inder )ercentage! Fhen +inder )ercentage +y *eight level *as changed fro% lo*er -2#9/ to higher level -5#9/ an average change of G2!#$1 ;Pa *as noted! Changing the 3ctivator liBuid to 3lu%inosilicate .inder ;aterial Ratio fro% #!$ to #!3 also increased the strength considera+ly -G1!8:1 ;Pa/! 3%ong the )ara%eter interaction effects +inder )ercentage +y *eight 1 3ctivator liBuid to 3lu%inosilicate .inder ;aterial Ratio had an effect of 1!5#1 ;Pa! The average individual effects and average interaction effects of t*o and %ore )ara%eters on strength are given in Ta+le "! +able A S"mmary of effects and *nteraction effects 2arameter @ *nteraction Average /ffect on Strength 5M2a7

Percentage .inder +y Feight including 3lu%inosilicate %aterials 2!#$1 and <iBuid -3/ Percentage of GG.S in 3lu%inosilicate .inder ;aterial -./ Na2Si63 to Na6? Ratio -C/ 3ctivator liBuid to 3lu%inosilicate .inder ;aterial Ratio -@/ 31 . Interaction . H C Interaction C H @ Interaction 3 H C Interaction 3 H @ Interaction . H @ Interaction 3 H . H C Interaction 3 H C H @ Interaction . H C H @ Interaction 3 H .1 @ Interaction #!18" #!217 1!8:1 #!131 #!1$$ #!3#" #!#55 1!5#1 #!535 1#!#31 #!115 #!137 #!321

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3%ong the )ara%eters )ercentage GG.S had the least effect and a%ong interactions )ercentage +inder +y *eight including alu%inosilicate %aterials and liBuid 1 )ercentage of GG.S in alu%inosilicate +inder %aterial 1 Na2Si63 to Na6? ratio had the least effect on strength! Study conducted on the +ric's %anufactured using ;i, 12 indicates that there is increase in co%)ressive strength of the +ric's as curing ti%e goes on! 3n increase of 1$9 strength *as noted *hen the curing ti%e *as increased fro% days to 15 days! Reduction in *ater a+sor)tion for the sa%e )eriod *as :!"9! 3s the strength increases the *ater a+sor)tion reduced! This could +e due to filling of )ores *ith +inder gel as a result of geo)oly%eri4ation! 3dditionally there *as an increase of density of the +ric' -319/ *hen )neu%atically o)erated %achine *as used! This has tre%endously increased the co%)ressive strength of the +loc'! .ut still the density of the +loc' is lo*er than conventional +ric's %ade using clay! ,/4/,/%C/S 012 <ingling Du et al! IStudy on fired +ric's *ith re)lacing clay +y fly ash in high volu%e ratio!I 2onstruction and &uilding 3aterials 17!3 -2##$/& 253125:! 022 ;alhotra S! J! and S! P! Tehri! I@evelo)%ent of +ric's fro% granulated +last furnace slag!I 2onstruction and &uilding 3aterials 1#!3 -177"/& 1711173! 032 Turgut Pa'i and ?alil ;urat 3lgin! I<i%estone dust and *ood sa*dust as +ric' %aterial!I &uilding and En!iron"ent 52!7 -2##:/& 3377135#3! 052 Rah%an ;! 3! IPro)erties of clay1sand1rice hus' ash %i,ed +ric's!I International Journal of 2e"ent 2o"posites and 4ight)eight 2oncrete 7!2 -178:/& 1#$11#8! 0$2 Caroline EK @yl%ar P@ Lose N Ronaldon P! MThe use of su+%erged1arc *elding flu, slag as ra* %aterial for the fa+rication of %ulti)le1use %ortars and +ric's!N Soldage" Insp 2##7O15-3/&2$:H"2! 0"2 Raut S! P! R! K! Ralegaon'ar and S! 3! ;andavgane! I@evelo)%ent of sustaina+le construction %aterial using industrial and agricultural solid *aste& 3 revie* of *aste1create +ric's!I 2onstruction and &uilding 3aterials 2$!1# -2#11/& 5#3:15#52! 0:2 @avidovits L! MSoft ;ineralurgy and Geo)oly%ers!N In proceeding of %eopoly"er 55 International 2onference$ the 6ni!ersit7 de Technologie 1778 Co%)iPgne =rance! 082 @avidovits L! MChe%istry of geo)oly%er syste%s ter%inology!N In +roceedings of %eopoly"er 8// International 2onferences 1777 =rance! 072 @u,son P =ernande41Li%ene4 3 Provis L< <u'ey GC Palo%o 3 Kan @eventer LSL! MGeo)oly%er technology& the current state of the art!N Journal of 3aterial Science 2##:O52&271:H33! 01#2 @i%as @! I! Gianno)oulou and @! Panias! IPoly%eri4ation in sodiu% silicate solutions& a funda%ental )rocess in geo)oly%eri4ation technology!I Journal of "aterials science 55!15 -2##7/& 3:1713:3#! 0112 ;aCidi .eh4ad! IGeo)oly%er technology fro% funda%entals to advanced a))lications& a revie*!I 3aterials Technology, 'd!anced +erfor"ance 3aterials 25!2 -2##7/& :718:! 0122 Lose)h @avidovits La%es <! Sa*yer MEarly high1strength %ineral )oly%erN >S Patent Pu+lication No! >S 5$#778$ 3! 0132 <yon Richard E! et al! I=ire1resistant alu%inosilicate co%)osites!I 9ire and 3aterials 21!2 -177:/& ":1:3! 0152 Palo%o 3! ;! F! Grut4ec' and ;! T! .lanco! I3l'ali1activated fly ashes& a ce%ent for the future!I 2e"ent and 2oncrete :esearch 27!8 -1777/& 132311327!

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01$2 Kan @eventer Lannie SL et al! ITechnological environ%ental and co%%ercial drivers for the use of geo)oly%ers in a sustaina+le %aterials industry!I Sohn International Sy"posiu" 'd!anced +rocessing of 3etals and 3aterials! Kol! 3! L6; Lournal of the ;inerals ;etals and ;aterials Society 2##"! 01"2 =reidin C! ICe%entless )ressed +loc's fro% *aste )roducts of coal1firing )o*er station!I 2onstruction and &uilding 3aterials 21!1 -2##:/& 12118! 01:2 3rQR4 S%er et al! IPhysical ;echanical and ;icro1Structural Pro)erties of = Ty)e =ly13sh .ased Geo)oly%eric .ric's Produced +y Pressure =or%ing Process!I 'd!ances in Science and Technology "7 -2#11/& "71:5! 0182 3h%ari Saeed and <ianyang Ahang! IProduction of eco1friendly +ric's fro% co))er %ine tailings through geo)oly%eri4ation!I 2onstruction and &uilding 3aterials 27 -2#12/& 3231331! 0172 SiddiBue Rafat! I>tili4ation of ce%ent 'iln dust -CJ@/ in ce%ent %ortar and concreteTan overvie*!I :esources$ conser!ation and recycling 58!5 -2##"/& 31$1338! 02#2 Ju%ar 3nuC and SanCay Ju%ar! I@evelo)%ent of )aving +loc's fro% synergistic use of red %ud and fly ash using geo)oly%eri4ation!I 2onstruction and &uilding 3aterials 38 -2#13/& 8"$18:1! 0212 ?e Lian et al! IThe strength and %icrostructure of t*o geo)oly%ers derived fro% %eta'aolin and red %ud1fly ash ad%i,ture& 3 co%)arative study!I 2onstruction and &uilding 3aterials 3# -2#12/& 8#171! 0222 Nath S! J! and SanCay Ju%ar! IInfluence of iron %a'ing slags on strength and %icrostructure of fly ash geo)oly%er!I 2onstruction and &uilding 3aterials 38 -2#13/& 725173#! 0232 .ureau of Indian Standards& IS& 37$2&1788! S)ecification for +urnt clay hollo* +ric's for *alls and )artitions Ne* @elhi& 1788! B#9C 3ST; C "181##& Standard s)ecification for coal fly ash and ra* or calcined natural )o44olan for use as a %ineral ad%i,ture in concrete 3nnual .oo' of 3ST; Standards Philadel)hia >S3!

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