INFLUENCE OF CONCENTRATION OF SODIUM

HYDROXIDE ON FLY-ASH BASED GEOPOLYMER

CONCRETE WITH CONCRETE DEMOLITION WASTE.
A PROJECT REPORT

Submitted in partial fulfillment for the award of the degree of

Bachelor of Technology
in

CIVIL ENGINEERING

by

RAVI RAUSHAN
14BCL0147

SHENAL CHOURADIA
14BCL0229

TANAY JAISWAL
14BCL0243

School of Civil and Chemical Engineering

April - 2018

i
 DECLARATION BY THE CANDIDATE

We hereby declare that the project report entitled “Influence of concentration of

sodium hydroxide on fly-ash based geopolymer concrete with concrete
demolition waste” submitted by us to Vellore Institute of Technology, Vellore in
partial fulfillment of the requirement for the award of the degree of Bachelor of
Technology in Civil Engineering is a record of bonafide project work carried out
by us under the guidance of Dr. Rama Mohan Rao P., Associate Professor
(CDMM). We further declare that the work reported in this project has not been
submitted and will not be submitted, either in part or in full, for the award of any
other degree or diploma in this institute or any other institute or university.

Place: Vellore Signature of the Candidates

Date: 26-03-2017

(Ravi Raushan– 14BCL0147)

(Shenal Chouradia – 14BCL0229)

(Tanay Jaiswal – 14BCL0243)

ii
 School of Civil and Chemical Engineering

CERTIFICATE

This is to certify that the project report entitled “INFLUENCE OF

CONCENTRATION OF SODIUM HYDROXIDE ON FLY-ASH BASED
GEOPOLYMER CONCRETE WITH CONCRETE DEMOLITION
WASTE” submitted by Ravi Raushan (14BCL0147), Shenal Chouradia
(14BCL0229), Tanay Jaiswal (14BCL0243) to Vellore Institute of Technology
University, Vellore, in partial fulfillment of the requirement for the award of the
degree of Bachelor of Technology in Civil Engineering is a record of bona fide
work carried out by them under my guidance. The project fulfills the requirements
as per the regulations of this Institute and in my opinion meets the necessary
standards for submission. The contents of this report have not been submitted and
will not be submitted either in part or in full, for the award of any other degree or
diploma and the same is certified.

Dr. Ramamohan Rao P Dr. S. Shantha Kumar

Project Guide HOD-EWRE
SCALE

Internal Examiner External Examiner

iii
 ACKNOWLEDGEMENT

We find immense pleasure in expressing our profound gratitude and thanks to our
guide Dr. Rama Mohan Rao P., Associate Professor (CDMM) for his invaluable
guidance, constant encouragement and keen interest in the progress and completion
of this work. He has always been most willing to spend his valuable time for
discussion. The discussions were always enjoyable as well as his comments have
been extremely valuable. We learned a lot from the discussion. He has associated
with us as a friend, philosopher and advisor. We would like to thank our HODs and
Dean for providing all the infrastructure facilities to carry out our project
successfully.

Ravi Raushan – 14BCL0147

Shenal Chouradia – 14BCL0229
Tanay Jaiswal – 14BCL0243

iv
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

EXECUTIVE SUMMARY vii

LIST OF TABLE viii

LIST OF FIGURES viii

1. INTRODUCTION 1

1.1 Objective 1

1.2 Motivation 2

1.3 Background 2

2. LITERATURE REVIEW 6

3. PROJECT DESCRIPTION 10

3.1 Project Flow 10

3.2 Materials Required 12

4. PRELIMINARY TESTS 18

4.1 Sieve Analysis 18

4.2 Specific Gravity of Aggregates 20

5. MIX DESIGN 21

5.1 Stipulations for Proportioning 21

5.2 Target Strength for Mixed Proportioning 22

5.3 Mix Calculations 22

v
6. LABORATORY TESTS 24

6.1 Workability of Fresh Concrete 24

6.2 Compressive Strength 25

6.3 Split Tensile Strength 27

6.4 Flexural Stress 29

6.5 Water Absorption 30

7. NON-DESTRUCTIVE TESTING 32

7.1 Ultra-Pulse Velocity 32

8. RESULTS AND DISCUSSION 34

9. CONCLUSION 43

10. REFERENCES 44

vi
 EXECUTIVE SUMMARY

The need to reduce the global emission of carbon dioxide has encouraged researchers to look for
sustainable building materials. Cement, contributes nearly 8% of the global carbon dioxide
emission into the environment. Geopolymer concrete (GPC) is manufactured using industrial
waste like fly ash and is considered as a more ecofriendly alternative to Ordinary Portland
Cement (OPC) based concrete. This project includes the use of different molarities (8M, 10M,
12M) of sodium hydroxide solution along with sodium silicate and naphthalene sulphonate based
superplasticizer in the geopolymer concrete. The feasibility of production of geopolymer concrete
using 50% concrete demolition waste in place of coarse aggregate is evaluated in this study. Tests
were done to find out the various mechanical properties of the geopolymer concrete like
compressive strength, split tensile strength and flexural strength. Non-destructive tests were also
done to find the quality and soundness of the samples using Ultra-pulse velocity test (UPV). On
analysis of all the 3 different concentrations of sodium hydroxide solution, we arrived at the
result that geopolymer concrete with 12 M alkalinity, based on 50% CDW, reached an Optimum
strength. Geopolymer Concrete by replacing Concrete Demolition Waste had shown a
remarkable potential as a decent engineering material for the future research, as the Geopolymer
Concrete isn’t just environmental friendly but also it possesses excellent mechanical properties.
The economic benefits and contributions of Geopolymer concrete to sustainable development are
evident.

Keywords: Geopolymer concrete, Concrete Demolition waste, Alkaline Activator, Naphthalene

sulphonate.

vii
 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1. Timeline for Compressive Strength, Split 14

Tensile and UPV tests

2. Timeline for Flexural Strength test 14

3. Timeline for Water Absorption Capacity test 14

4. Properties of Sodium Silicate solution 16

Quantity of NaOH pellets used for different

5. 17
concentration

6. Sieve Analysis Test results 21

Mix proportion for Geopolymer Concrete per

7. 25
cubic metre

8. Results of Slump test 37

9. Results for Compressive Strength Test 38

10. Results for Split Tensile Strength test 40

11. Results for Flexural Strength test 41

12. Results for Water Absorption Capacity test 42

13. Results for UPV test 43

viii
 LIST OF FIGURES
\
FIGURE NO. TITLE PAGE NO.

1. Materials used in the project 10

2. Casting 11

3. Curing of samples 11

4. Testing of samples 11

5. Fly Ash 13

6. Sodium Hydroxide Pellets 13

7. Sodium Silicate Solution 14

8. Concrete Demolition Waste 15

9. Coarse Aggregate 16

10. Fine Aggregate 16

11. Ceraplast 300 (Superplaticiser) 17

12. Slump Test 25

13. Compression Test 27

14. Split Tensile Test

29

15. Flexural Test 30

16. Water Absorption Test 31

17. Ultra Pulse Velocity Test 33

ix
 Graph for comparison between slump values
18.
34
for all the mixes

Graph for comparison between compressive

19. 36
strength of all the mixes.

Graph for comparison between split tensile

20. 38
for all the mixes

Graph for comparison between flexural

21. 39
strength for all the mixes

Graph for comparison between ultra pulse

22. 42
velocity for all the mixes

x
xi
 CHAPTER 1
INTRODUCTION

A concrete use around the world is second only to water. The production of ordinary Portland
cement contributes 5-7% of total greenhouse gas emission. It also consumes large amount
energy. Hence it is essential to find alternative to cement. The use of recycled materials in
concrete production has been pursued for decades as a means to reduce its environmental impact
as well as for cost optimization. This use of recycled materials is frequently either achieved by
partially replacing natural aggregates with recycled ones, or by partially replacing cement with
industry by-products such as blast furnace slag and ashes. In this research, fly ash is used to
produce a geopolymer concrete with 50% replacement of coarse aggregate with concrete
demolition waste. The effect on the compressive strength of NaOH and Na2SiO3 molar ratios was
evaluated.
Fly ash is a by-product of coal obtained from thermal power plant. It is also rich in silica and
alumina. The aim of this research is to study its utilization in concrete to diversify its
applications. The partial replacement of cement with biomass ashes, apart from implying
economic savings due to the price of cement, also induces a great improvement from the
environmental point of view.
The influence of molarity of NaOH on the evolution of the compressive strength was studied in
mortars and concretes, resulting as a general conclusion that higher the molarity of NaOH, higher
would be its compressive strength, but the soundness of concrete decreases with increase in
molarity of NaOH.

1.1 Objective
The objective of this research is to study the utilization of fly ash and concrete demolition waste
in concrete to diversify its applications. The partial replacement of cement with fly ash, apart
from implying economic savings due to the price of cement, also induces a great improvement
from the environmental point of view.

1
The influence of molarity of NaOH on the evolution of the compressive strength will be studied
in mortars and concretes. The concrete will be subjected to compressive strength test, split tensile
test, flexural strength test (3-point load test), water absorption test and ultra-pulse velocity test
and the optimum molarity of NaOH in the geopolymer concrete will be evaluated.

1.2 Motivation
Concrete is worldwide used construction material after water. Ordinary Portland cement is
conventionally used as primary binder to produce concrete. The production of OPC contributes to
about 5-7% of the total greenhouse gas emission to the earth’s atmosphere. Cement is also among
the most energy intensive construction material after steel and aluminum. Therefore, it is
necessary to find alternative binder to cement. The energy consumption and CO2 emissions
associated with the manufacturing of cement can be reduced when fly ash is used as a partial
replacement of clinker. Fly ash is a byproduct of coal obtained from thermal power plant. It is
rich in silica and alumina. The use of fly ash as a construction material allows the productive use
of an industrial by-product, which would otherwise have ended in landfills. The utilization of fly
ash as cement replacement material in concrete or as an additive has many benefits from
economical, technical and environmental points of view. The cost of fly ash is much lower than
cement, approximately Rs. 5000 per tonne of fly ash compared to Rs. 8000 per ton of cement
except in regions experiencing freeze thaw cycles, which are not common in India, the use of fly
ash has also been associated with the improvement in the long-term performance of concrete. The
use of fly ash is known to result in three main advantages: 1) use of low cost raw materials, 2)
conservation of natural resources and 3) the elimination of wastes. The abundant availability of
fly ash worldwide create opportunity to utilize this by-product of burning coal, as substitute for
OPC to manufacture concrete. Fly ash can be used as a binder by a polymeric reaction of alkaline
liquids with the silicon and aluminum in source material of geological origin.

1.3 Background
1.3.1 Geopolymer concrete
A geopolymer is a synthesized inorganic material that has been used in a wide range of diverse
applications such as heat-resistant ceramics, waste encapsulation and construction products over

2
the past 40 years. It is used to describe a family of mineral binders with chemical composition
similar to zeolites but with an amorphous microstructure. Unlike ordinary Portland/pozzolanic
cements, geopolymers do not form calcium- silicate-hydrates (CSHs) for matrix formation and
strength but utilize the polycondensation of silica and alumina precursors to attain structural
strength. Two main constituents of geopolymers are: source materials and alkaline liquids. The
source materials should be alumina-silicate based and rich in b o t h silicon (Si) and aluminum
(Al). They could be by-product materials such as fly ash, silica fume, slag, rice-husk ash, red
mud, etc. Geopolymers are also unique in comparison to other aluminosilicate materials (e.g.
aluminosilicate gels, glasses, and zeolites). The concentration of solids in geopolymerisation is
higher than in aluminosilicate gel or zeolite synthesis.
In fly ash based geopolymer mix, the fly ash reacts with highly alkaline solution and form
inorganic alumino-silicates polymer, product known as Geopolymer. The reaction between
source material like fly ash and alkaline activator solution is polymerization. For better bonding
in polymer, the elevated temperature is required. In India most of the concrete structures are
constructed on site instead of pre-cast constructions. Practically it is not possible to provide the
temperature curing to structure. The effect of properties of geopolymer concrete with various
concentrations of alkaline solution with temperature curing and ambient curing has been studied.
Without temperature curing, the geopolymer concrete cannot set early and not gain the sufficient
strength. In summer season, the geopolymer concrete can set at sunlight temperature but in winter
season that cannot happen. Surrounding temperature is also affecting the hardening of
geopolymer concrete. Considering these challenges in view, the present research work is carried
out. Investigation has been carried out to achieve the maximum strength of geopolymer at
ambient temperature using some pozzolanic material varying the molarity of NaOH.

1.3.2 Chemical structure and geopolymerisation of Geopolymer cement

The geopolymerisation process involves a substantially fast chemical reaction under alkaline
condition on Si-Al minerals that result in a three-dimensional polymeric chain and ring structure
consisting of Si-O-Al-O bonds, as follows:

3
M n[-(SiO2) z-AlO2] n. wH2O
Where: M = the alkaline element or cation such as potassium, sodium or calcium
n = the degree of polycondensation or polymerization
z = 1,2,3 or higher

n (Si2O5, Al2O2) + 2nSiO2 + 4nH2O +NaOH/KOH

(Si-Al materials)

Na+, K+ + n(OH) 3-Si-O-Al--O-Si-(OH)3 (1)

(OH) 2

(Geopolymer precursor)

n(OH) 3-Si-O-Al--O-Si-(OH)3 + NaOH/KOH

(OH) 2

(Na+, K+) -(-Si-O-Al--O-Si-O-) + 4nH2O (2)

O O O
(Geopolymer Backbone)

4
The schematic formation of geopolymer material can be shown as described by equations (1) and
(2). The exact mechanism of setting and hardening of the geopolymer material is not clear.
However, most proposed mechanism consists the chemical reaction may comprise the following
steps:
(1) Dissolution of Si and Al atoms from the source material through the action of hydroxide ions.
(2) Transportation or orientation or condensation of precursor ions into monomers.
(3) Setting or polycondensation/polymerization of monomers into polymeric structures.

5
 CHAPTER 2
LITERATURE REVIEW

To understand the full potential of fly ash based geopolymer concrete, study of the projects and
papers related to geopolymer concrete was a must. So we extensively reviewed lots of papers and
projects related to geopolymer concrete. Our project is largely based on fly ash and its use with
alkali activators in concrete and thus a thorough knowledge regarding fly ash, alkali activators
and geopolymer concrete was necessary. Out of the papers and projects that we found, a few are
presented below with a brief description. These papers have helped us a lot to grasp more and
more about geopolymer concrete.
Madheshwaran, Gnansundar, Gopalkrishnan investigated the the variation of GGBS in
concrete. It has been studied and longer curing time improved the polymerization process and
results in compressive Strength. Higher the molar ratio (7 M) with higher GGBS (100%) results
in the higher compressive strength and split tensile strength. By this compressive strength in the
range of 45Mpa to 60 Mpa is achieved and highest is for 100% GGBS. Apart from energy
intensiveness, the GPCs utilize the industrial waste for producing the binding system in concrete,
there are both environment and Economical Benefits of Using Fly ash and GGBS. The addition
of Naphthalene based Super Plasticizer content more than 2% slightly reduce the Compressive
Strength.
Olivia et al have investigated on the water penetrability of low calcium fly ash geopolymer
concrete. The conclusion drawn was that fly ash geopolymer concrete exhibits low water
absorption and sorptivity. Low water/cement ratio and a better grading were recommended in
order to reduce the capillary porosity and the overall porosity of geopolymer concrete. Anurag
Mishra et al carried out an experimental study on the effect of concentration of alkaline liquid
and curing time on strength and water absorption of geopolymer concrete. It was reported that
compressive strength increases with increase in concentration of NaOH from 8M to 16M.
Increase in compressive strength was observed with increase in curing time and also tensile
strength increased with increase in concentration of NaOH except for 72 hours curing time.
Palomo, Grutzeck and Blanco investigated the alkali activation of waste materials which has
become an important area of research in many laboratories because it is possible to use these

6
materials to synthesize inexpensive and ecologically sound cement like construction materials.
The mechanism of activation of a fly ash (no other solid material was used) with highly alkaline
solutions was described in the paper. The solutions, made with NaOH, KOH, water glass, etc.,
the product of the reaction was an amorphous aluminosilicate gel. Mechanical strengths with
values about 60 MPa were obtained after curing the concrete at 85 C for 5 hours.
Van Jaarsveld et al have identified the potential use of waste materials such as fly ash,
contaminated soil, mine tailings and building waste to immobilise toxic metals. Swanepoel et al
(2002), Phair et al, Van Jaarsveld and Bakharev have also presented studies on fly ash as the
source material to make geopolymers.
Benjamin Galvin investigated the mechanical properties of geopolymer concrete with
recycled concrete aggregate (RCA) as partial replacement of the natural coarse aggregate. The
observed compressive strength decrease in geopolymer concrete mixtures with the partial
replacement of natural coarse aggregate with recycled concrete aggregate is similar to that
observed in comparable geopolymer cement based concrete with RCA. This demonstrates that
strengths for nominal grade 32 MPa concrete can be developed by geopolymer concrete
containing up to 30 percent RCA with no change to the mix design and higher strengths may be
able to be produced with minor changes to the mix design, analogous to adjusting the water to
cement ratio, by adjusting the water to geopolymer solids ratio. The compressive strength results
of the RCA geopolymer batches presented low standard deviations, which demonstrate that the
RCA may not affect the quality and consistency of the mix in terms of compressive strength and
further research is currently underway at Curtin to assess this impact in both geopolymer and GP
cement base concretes with RCA.
Rajamane (2006), Ambily et.al (2011) and Ambily (2012) carried out experimental studies on
structural behavior of reinforced geopolymer concrete beams and the effect of geopolymeric
binders such as GGBS and fly ash by activating silicon dioxide and aluminium oxide present in
the binders, to form inorganic polymer binder system. It was demonstrated how this binder
system can be used to produce concretes containing river sand as fine aggregate and coarse
aggregate in the form of either sintered fly ash aggregates (SFA) or crushed granite aggregates
(CGA). The lightweight aggregate based geopolymer concrete had one day compressive strength
of about 35 MPa and a 28 days strength greater than 50 MPa. It was concluded that crushed

7
granite aggregates based geopolymer concretes produced higher compressive strength of about
45 MPa at one day and 65 MPa at 28 days.
Sandeep L. Hake, Mohit K. Adhane, Rupesh V. Gadilkar,Dnyaneshwar R. Gaikwad, Vikas
V. Wagaskar carried out a study on development of strength for various grades of geo-polymer
concrete with varying molarity. Sodium hydroxide (NaoH) and sodium silicate (Na2SiO3) were
used as alkaline liquids in this study for the geo-polymerization. Different molarities of NaOH
solution (1M to 16M) were taken to prepare different mixtures. The test specimens were 150 x
150 x 150 mm cubes. The geo-polymer concrete specimens were tested for their compressive
strength at the age of 7 and 28 days. Geopolymer concrete mixtures with compressive strength
ranging from 15 MPa to 52 MPa were developed. Experimental investigations were carried out
on workability and various mechanical properties of GPCs. The test results indicate that the
combination of fly ash and alkaline solution can be used for development of geo-polymer
concrete.
Salmabanu Luhar, Urvashi Khandelwal carried out a study on water absorption and sorptivity
of geopolymer concrete. The effect of accelerated corrosion on geopolymer concrete was also
studied and the results were compared with control mix. Sorptivity curve was found to be less
linear in geopolymer concrete as compared to control concrete. The rate of absorption, which has
significant effect on durability property of concrete, was found less in geopolymer concrete than
the control concrete. Test results of water absorption test showed that the porosity of geopolymer
concrete is less because fly ash is finer than OPC and results in lesser water absorption than the
control concrete.
Andi Arham Adam conducted study on the effect of concentration of NaOH solution on
compressive strength of fly ash based geopolymer concrete with ambient curing. The
compressive strength of fly ash based geopolymer concrete increases with increase in solution to
fly ash ratio and molarity of NaOH solution. Geopolymer concrete with 12, 14 and 16 molar of
sodium hydroxide solution produce better compressive strength in ambient curing as compared to
8 and 10 molar. At room temperature, the fly ash based geopolymer concrete with 10 percent
OPC can achieve similar strength of geopolymer concrete with temperature curing when the
environmental temperature in range of 17 oC to 32oC.
Ganapati, Adhiseshu investigated the replacement of fly ash for five different GGBS content
(upto 30%) and 8M NAOH solution and NA2SIO3/NAOH ratio was 2.5 taken and the result

8
indicates that with the increase of Slag content , the compressive Strength of 31.85 MPa at 3
days was achieved. From the paper it was also concluded that there is no necessity of subjecting
the geopolymer concrete to higher temperature to attain maximum strength if minimum 9% of
flyash is replaced by GGBS. 90% of compressive Strength was achieved in 14 days and the
average density of geopolymer. Concrete was equal to that of OPC concrete.
Anurag, Deepika investigated the results of their study on the strength and absorption
characteristics of geopolymer concrete. In their study, total nine mixes were prepared with NaOH
concentration as 8M, 12M, 16M and curing time as 24hrs, 48hrs, and 72hrs. Compressive
strength, water absorption and tensile strengths tests were conducted on each of the nine mixes.
Results of the investigation indicated that there was an increase in compressive strength with
increase in NaOH concentration. Also, the strength of the samples increased with increase in
curing time, although the increase in compressive strength after 48hrs curing time was not very
significant. Compressive strength up to 46 MPa was obtained with curing at 600 C. The results of
water absorption test indicated that % water absorption of cubes decreased with increase in
NaOH concentration and curing time.

9
 CHAPTER – 3
PROJECT DESCRIPTION

3.1 Project flow

1. Designing the concrete mix: The first and most important step is to determine the
ingredients that will make up the concrete and their proportions. Mix is designed for
molarities of NaOH as 8M, 10M and 12M considering the fly ash type, aggregate size and
type, and type of superplasticiser.
2. Procurement of materials: Sodium hydroxide, sodium silicate, naphthalene based
superplasticizer and fly ash was procured from Chennai. Concrete demolition waste was
collected from VSPARC project site going on in VIT.

Figure 1: Materials used in the project

3. Casting: Concrete cubes, cylinders and beams were casted for mixes with varying
molarity of NaOH as 8M, 10M and 12M and control mix was also cast.

10
 Figure 2: Casting

4. Demoulding: Samples were demoulded after 24 hours of casting.

5. Curing: The samples were subjected to oven curing for 24 hours at 70°C. After that,
ambient curing was done for 7, 14 and 28 days.

Figure 3: Curing of samples

6. Testing: The samples were tested for their compressive strength, flexural strength, split
tensile strength, water absorption capacity and ultra pulse velocity.

Figure 4: Testing of samples

11
The schedule for performing different tasks is presented below.

Table 1: Timeline for Compressive Strength, Split Tensile and UPV tests.

Table 2: Timeline for Flexural Strength of beams

Table 3: Timeline for Water Absorption Capacity test

3.2 Materials Required

The materials required for the project are listed below:

a. Fly ash
The chemical and physical requirements of fly ash defined by ASTM C5618 distinguish it into
two classes, Class C and Class F. The distinction between Class F and Class C fly ash is based
on the sum of the total silicon, aluminum, and iron (SiO2+Al2O3+Fe2O3) in the ash. When the

12
sum is greater than 70% an ash is classified as Class F. When the sum lies in the range

of 50% to 70% the ash is classified as Class C. Thus fly ash of class C and F of
ASTM classification represent high and low calcium ash respectively.
In this project, Class F fly ash has been used collected from SK Fly ash and bricks
in Gandhinagar, Vellore.

Figure 5: Fly Ash

b. Alkaline activator
 Sodium Hydroxide (NaOH)
The sodium hydroxide (NaOH with 98% purity) flake form, was purchased from
Cera Chemicals, Chennai has been used. The mass of NaOH solids in a solution varied
depending on the concentration of the solution expressed in terms of molar M.

Figure 6: Sodium Hydroxide pellets

13
  Sodium Silicate (Na2SiO3)
Many types of sodium silicate solution depending upon applications are available in market. In
this project, we collected the solution from Cera Chemicals, Chennai. The addition of sodium
silicate solution to the sodium hydroxide solution as the alkaline activator enhanced the reaction
between the source material and the solution. Properties of the sodium silicate solution used are
given in the following table.
Table 4: Properties of Sodium Silicate solution

Figure 7: Sodium Silicate solution

Preparation of Alkaline solution.

In this project, the compressive strength of geopolymer concrete is examined for the mixes of
varying molarities of Sodium hydroxide (8M, 10M and 12M). The molecular weight of sodium
hydroxide is 40. To prepare 8M i.e. 8 molar sodium hydroxide solution, 320g of sodium
hydroxide flakes are weighed and they can be dissolved in distilled water to form 1 litre solution.
For this, volumetric flask of 1 litre capacity is taken, sodium hydroxide flakes are added slowly to
distilled water to prepare 1liter solution. After cooling, sodium silicate solution was added to the
sodium hydroxide solution in the ratio of 2.5: 1 by weight.
The activator solution was prepared at least one day prior to its use in specimen casting.

14
Table 5: Quantity of NaOH pellets used for different concentration

c. Concrete Demolition Waste (CDW)

Concrete Demolition Waste was collected from VIT Vellore, VSPARC project site. The concrete
test cubes were broken to required aggregate size and sieved for 20 mm and 10 mm. 50% by
weight of aggregate was replaced by CDW.

Figure 8: Concrete Demolition Waste

d. Coarse Aggregate
The coarse aggregate particles passing through 20mm and retained on 10 mm I.S Sieve used as
the natural aggregate which met the grading requirement of IS 383-1970

15
 Figure 9: Coarse Aggregate

e. Fine Aggregate
Locally available river sand passing through 2.36 mm sieve was used as fine aggregate in the
mixes. Sieve analysis was performed to find out the fineness modulus of the sand.

Figure 10: Fine Aggregate

f. Super Plasticiser
CERAPLAST 300 was collected from Cera Chemicals, Chennai. It is a Naphthalene Sulphonate
based superplasticiser. Workability is greatly improved and decreases the amount of vibration
required.

16
Dosage: 0.3 % - 1.2 % by weight of cement. Naphthalene Sulphonate condensates sodium salts
are advisable to carry out trial mixes to establish the exact dosage rate required. Naphthalene
Sulphonate condensates sodium salts is compatible with types of Portland cement, but
recommended to have a trial before use it and decide a dosage. Naphthalene Sulphonate
condensates sodium salts can be added directly to the freshly mixed concrete.

Figure 11: Ceraplast 300 ( Napthalene Sulphonate Superplasticiser )

17
 CHAPTER – 4
PRELIMINARY TESTS

4.1 Sieve Analysis

This is the name given to the operation of dividing a sample of aggregate into various fractions
each consisting of particles of the same size. The sieve analysis is conducted to determine the
particle size distribution in a sample of aggregate, which we call gradation.
The aggregates used for making concrete are normally of the maximum size 80 mm, 40 mm, 20
mm, 10 mm, 4.75 mm, 2.36 mm, 600 micron, 300 micron and 150 micron. The aggregate
fraction from 80 mm to 4.75 mm is termed as coarse aggregate and those fractions from 4.75 mm
to 150 micron are termed as fine aggregate. The size 4.75 mm is a common fraction appearing
both in coarse aggregate and fine aggregate (C.A. and F.A.).
From the sieve analysis the particle size distribution in a sample of aggregate is found out. In this
connection a term known as “Fineness Modulus” (F.M.) is being used. F.M. is a ready index of
coarseness or fineness of the material. Fineness modulus is an empirical factor obtained by
adding the cumulative percentages of aggregate retained on each of the standard sieves ranging
from 80 mm to 150 micron and dividing this sum by an arbitrary number 100.

Procedure:
Grading pattern of a sample of C.A. or F.A. is assessed by sieving a sample successively through
all the sieves mounted one over the other in order of size, with larger sieve on the top. The
material retained on each sieve after shaking, represents the fraction of aggregate coarser than the
sieve in question and finer than the sieve above. Sieving can be done either manually or
mechanically.

18
Table 6: Sieve Analysis Test results

i) Fineness modulus of a given sample of fine aggregate = 2.738. That indicates medium sand.
ii) The given sample of fine aggregate belongs to Grading Zones I.
The following limits may be taken as guidance:
 Fine sand : Fineness Modulus : 2.2 - 2.6
 Medium sand : F.M. : 2.6 - 2.9
 Coarse sand : F.M. : 2.9 - 3.2

Sand having a fineness modulus more than 3.2 will be unsuitable for making satisfactory
concrete.

19
4.2 Specific Gravity of Coarse Aggregate

Procedure:
According to Indian Standard Specification IS: 2386 (Part III) of 1963, sample of aggregate not
less than 2 kg is taken. It is thoroughly washed to remove the finer particles and dust adhering to
the aggregate. It is then placed in a wire basket and immersed in distilled water at a temperature
between 22° to 32°C. Immediately after immersion, the entrapped air is removed from the sample
by lifting the basket containing it 25 mm above the base of the tank and allowing it to drop 25
times at the rate of about one drop per sec. During the operation, care is taken that the basket and
aggregate remain completely immersed in water. They are kept in water for a period of 24 ± 1/2
hours afterwards. The basket and aggregate are then jolted and weighed (weight A1) in water at a
temperature 22° to 32° C. The basket and the aggregate are then removed from water and allowed
to drain for a few minutes and then the aggregate is taken out from the basket and placed on dry
cloth and the surface is gently dried with the cloth. The aggregate is transferred to the second dry
cloth and further dried. The empty basket is again immersed in water, jolted 25 times and
weighed in water (weight A2). The aggregate is exposed to atmosphere away from direct sunlight
for not less than 10 minutes until it appears completely surface dry. Then the aggregate is
weighed in air (weight B). Then the aggregate is kept in the oven at a temperature of 100 to
110°C and maintained at this temperature for 24 ± 1/2 hours. It is then cooled in the air-tight
container, and weighed (weight C).

Specific Gravity = C / (B-A)

Where, A = the weight in gm of the saturated aggregate in water (A1 – A2)
B = the weight in gm of the saturated surface-dry aggregate in air
C = the weight in gm of oven-dried aggregate in air.

20
 CHAPTER – 5
MIX DESIGN

5.1 Stipulations for proportioning:

a) Grade designation : M30
b) Type of Fly ash : Class F
c) Type of Superplasticiser : Ceraplast 300 (Napthalene
Sulphonate)
d) Maximum nominal size of aggregate : 20 mm
e) Minimum nominal size of aggregate : 10 mm
f) Maximum nominal size of Concrete
Demolition waste : 20 mm
g) Minimum nominal size of Concrete
Demolition waste : 10 mm
h) Replacement of Coarse Aggregate by
Concrete demolition waste : 50%
i) Nominal size of Fine aggregate : 2.36 mm
j) Fine Aggregate to Coarse aggregate ratio : 1: 1.5
k) Alkaline solution to Fly ash ratio : 0.39
l) NaOH to Na2SiO3 ratio : 1: 2.5
m) Molarity of NaOH Solution used : 8M, 10M, 12M
n) Superplasticiser : 1.5% by wt of Fly ash
o) Specific gravity of Concrete demolition waste : 2.41

p) Specific gravity of Coarse aggregate : 2.61

q) Specific gravity of Fine aggregate : 2.65
r) Sieve analysis: Fine aggregate : Conforming to grading Zone 1

21
5.2 Target strength for mix proportioning:
where
fm =fck+ 1.65s
fm = target average compressive strength at 28 days,
fck = characteristics compressive strength at 28 days, and
s = standard deviation.
From IS 456:2000, Standard Deviation,
s = 5 N/mm (for M30)
Therefore, target strength =30 + 1.65 x 5 = 38.25 N/mm2

5.3 MIX CALCULATION:

The mix calculations per unit volume of concrete shall be as follows:
a) Volume of concrete = 1 m3
b) Density of concrete = 2400 kg/m3
c) Mass of concrete for 1 m^3 = 2400 kg
d) Mass of combined aggregate = 77% of total mass
= 0.77x2400
= 1848 kg
1. Mass of Fine aggregate = 739.2 kg

2. Mass of Coarse aggregate (10mm) = 158.4 kg

3. Mass of Coarse aggregate (20mm) = 396 kg

4. Mass of Concrete demolition waste (10mm) = 158.4 kg

5. Mass of Concrete demolition waste (20mm) = 396 kg

e) Mass of Fly ash + Alkaline sol. = 2400-1848

= 552 kg
f) Mass of Fly ash = 552/1.39
= 397 kg
g) Mass of Alkaline solution = 552-397
= 155 kg

22
h) Mass of NaOH solution = 155/3.5
= 44.2 kg
i) Mass of Na2SiO3 = 155-44.2
= 110.8 kg
j) Mass of Superplasticiser = 6 kg

 Fly ash = 397 kg/m3

 Alkaline Solution = 155 kg/m3
 Fine aggregate = 739.2 kg/m3
 Coarse aggregate = 1108.8 kg/m3

MIX RATIO = 1: 1.86: 2.79

Table 7: Mix proportion for Geopolymer Concrete per cubic metre

23
 CHAPTER 6
LABARATORY TESTS

6.1 WORKABILITY OF FRESH CONCRETE

The word “workability” or workable concrete signifies much wider and deeper meaning.
Workability is a parameter, a mix designer is required to specify in the mix design process, with
full understanding of the type of work, distance of transport, loss of slump, method of placing,
and many other parameters involved. Assumption of right workability with proper understanding
backed by experience will make the concreting operation economical and durable.
To find the workability of the fresh concrete Slump Test has been used in this project.

6.1.1 SLUMP TEST

Slump test is the most commonly used method of measuring consistency of concrete which can
be employed either in laboratory or at site of work. It is used conveniently as a control test and
gives an indication of the uniformity of concrete from batch to batch.

Apparatus Used
The apparatus for conducting the slump test essentially consists of a metallic mould in the form
of a frustum of a cone having the internal dimensions as under:
Bottom diameter: 20 cm
Top diameter: 10 cm
Height: 30 cm

24
 Figure 12: Slump Test

Procedure
The mould is placed on a smooth, horizontal, rigid and non-absorbent surface, the mould is then
filled in four layers, each approximately 1/4 of the height of the mould. Each layer is tamped 25
times by the tamping rod taking care to distribute the strokes evenly over the cross section. After
the top layer has been rodded, the concrete is struck off level with a trowel and tamping rod. The
mould is removed from the concrete immediately by raising it slowly and carefully in a vertical
direction. This allows the concrete to subside. This subsidence is referred as SLUMP of concrete.
The difference in level between the height of the mould and that of the highest point of the
subsided concrete is measured. This difference in height in mm. is taken as Slump of Concrete.

6.2 COMPRESSIVE STRENGTH

Compression test is the most common test conducted on hardened concrete, partly
because it is an easy test to perform, and partly because most of the desirable characteristic
properties of concrete are qualitatively related to its compressive strength. The compression test
is carried out on specimens cubical or cylindrical in shape. Prism is also sometimes used, but it is

25
not common in our country. Sometimes, the compression strength of concrete is determined
using parts of a beam tested in flexure.

6.2.1 Mould
Metal mould, preferably steel or cast iron, thick enough to prevent distortion are required. They
are made in such a manner as to facilitate the removal of the moulded specimen without damage
and are so machined that, when it is assembled ready for use, the dimensions and internal faces
are required to be accurate within the following limits. The dimension of mould used in this
project is 100 x 100 x 100 mm.

6.2.2 Compacting
The test cube specimens are made as soon as practicable after mixing and in such a way as to
produce full compaction of the concrete with neither segregation nor excessive laitance. The
concrete is filled into the mould in layers approximately 5 cm deep. In placing each scoopful of
concrete, the scoop is required to be moved around the top edge of the mould as the concrete
slides from it, in order to ensure a symmetrical distribution of the concrete within the mould.
Each layer is compacted either by hand or by vibration. After the top layer has been compacted
the surface of the concrete is brought to the finished level with the top of the mould, using a
trowel.

6.2.3 Curing
The test specimens are stored in place free from vibration, in moist air of at least 90% relative
humidity and at a temperature of 27° ± 2°C for 24 hours ± 1/2 hour from the time of addition of
water to the dry ingredients. After this period, the specimens are marked and removed from the
mould and unless required for test within 24 hours, immediately submerged in clean fresh water.

6.2.4 Compression Testing Machine

The cube specimen after curing period (7, 14, 28 days) respectively is tested in Compression
testing machine and the load at which the specimen fails is noted down for further calculation.

26
 Figure 13: Compression Test

6.3 SPLIT TENSILE STRENGTH

This is also sometimes referred as, “Brazilian Test”. This test was developed in Brazil in 1943.
At about the same time this was also independently developed in Japan. The test is carried out by
placing a cylindrical specimen horizontally between the loading surfaces of a compression testing
machine and the load is applied until failure of the cylinder, along the vertical diameter.

6.3.1 Procedure
i. Take the wet specimen from water after 7, 14 & 28 days of curing respectively.
ii. Wipe out water from the surface of specimen
iii. Draw diametrical lines on the two ends of the specimen to ensure that they are on the
same axial place.
iv. Note the weight and dimension of the specimen.

27
 v. Set the compression testing machine for the required range.
vi. Keep are plywood strip on the lower plate and place the specimen.
vii. Align the specimen so that the lines marked on the ends are vertical and centered over the
bottom plate.
viii. Place the other plywood strip above the specimen.
ix. Bring down the upper plate to touch the plywood strip.
x. Apply the load continuously without shock at a rate of approximately 14-
21kg/cm2/minute (Which corresponds to a total load of 9900kg/minute to
14850kg/minute)
xi. Note down the breaking load(P)

6.3.2 Calculations

Range Calculation
As per IS456, split tensile strength of concrete = 0.7 x √ (fck)

The splitting tensile strength is calculated using the formula

T = 2P/ π x DL

Where P = applied load

D = diameter of the specimen

L = length of the specimen

Therefore P = (T x π x DL)/2

Expected load = P x fs

Range to be selected is

Split tensile strength

T = 2P/ π x DL

28
 Figure 14: Split Tensile Test

6.4 FLEXURAL STRESS

The value of the modulus of rupture (extreme fiber stress in bending) depends on the dimension
of the beam and manner of loading. The systems of loading used in finding out the flexural
tension are central point loading and third point loading. In the central point loading, maximum
fiber stress will come below the point of loading where the bending moment is maximum. In this
project third point loading test has been done.

6.4.1 Third Point Loading Method

The bearing surfaces of the supporting and loading rollers are wiped clean, and any loose sand or
other material removed from the surfaces of the specimen where they are to make contact with
the rollers. The specimen is then placed in the machine in such a manner that the load is applied
to the uppermost surface.

29
 Figure 15: Flexural Test

The flexural strength of the specimen is expressed as the modulus of rupture fb which if ‘a’
equals the distance between the line of fracture and the nearer support, measured on the center
line of the tensile side of the specimen, in cm, is calculated to the nearest 0.05 MPa as follows:

fb = (3 x P x a)/ b x d2

Where,
d = Depth or thickness of tested beam, (mm),
l = length in cm of the span on which the specimen was supported, and
p = maximum load in kg applied to the specimen.

6.5 WATER ABSORPTION TEST

Water absorption characteristic of concrete plays an important role in finding the durability. This
test was performed to evaluate the water absorption characteristics of geopolymer concrete and
control mix.

30
6.5.1 Test Specimens
The size of Test specimens used for this test were 100×100×100 mm cubes of control concrete
and geopolymer concrete each. 3 specimens for each test were prepared change in mass to take
average result of the specimen.

6.5.2 Test Procedure

Test specimens were oven dried at 105 C for 24 hours duration using hot air oven. After oven dry
the specimens were immersed in water for 24 hours duration. Absorption characteristic of
concrete were evaluated by difference in weight of specimen after complete drying in oven at 105
C and weight after immersion in water.

Figure 16: Water Absorption test

31
 CHAPTER 7
NON-DESTRUCTIVE TESTING

Non-destructive methods have been in use for about four decades. In this period, the development
has taken place to such an extent that it is now considered as a powerful method for evaluating
existing concrete structures with regard to their strength and durability apart from assessment and
control of quality of hardened concrete. In certain cases, the investigation of crack depth,
microcracks, and progressive deterioration are also studied by this method.
In this project Ultra pulse velocity test has been used to find the quality of the Geopolymer
concrete.

7.1 Ultra Pulse Velocity Test

Ultrasonic Pulse Velocity Method, which involves measurement of the time of travel of
electronically generated mechanical pulses through the concrete. When mechanical impulses are
applied to a solid mass, three different kinds of waves are generated. These are generally known
as longitudinal waves, shear waves and surface waves. These three waves travel at different
speeds. The longitudinal or compressional waves travel about twice as fast as the other two types.
The shear or transverse waves are not so fast, the surface waves are the slowest. The pulses can
be generated either by hammer blows or by the use of an electroacoustic transducer.
Electroacoustic transducers are preferred as they provide better control on the type
and frequency of pulses generated. The instrument used is called “Sonoscope”. Ultrasonic pulse
velocity method consists of measuring the time of travel of an ultrasonic pulse, passing through
the concrete to be tested. The pulse generator circuit consists of electronic circuit for generating
pulses and a transducer for transforming these electronic pulses into mechanical energy having
vibration frequencies in the range of 15 to 50 kHz. The time of travel between initial onset and
the reception of the pulse is measured electronically. The path length between transducer divided
by the time of travel gives the average velocity of wave propagation.

32
Figure 17: Ultra Pulse Velocity Test

33
 CHAPTER 8
RESULTS AND DISCUSSION

8.1 Slump Test

The fresh concrete of Control mix as well as of Geopolymer concrete of varying molarity (8M,
10M, 12M) were tested for workability.

Table 8: Results of Slump test.

Figure 18: Graph for comparison between Slump values for all the mixes.

34
8.2 Compressive Strength Test
The cubes were tested in compressive testing machine to determine their compressive strength at
the age of 7 days, 14 days and 28 days of curing. The figures below show the compressive
strength of Control mix and the Geopolymer concrete with increment in molarity of NaOH. (8M,
10M and 12M) for the specimens which were cured by hot air oven and by direct sun light at the
age of 7, 14 and 28 days.

Table 9: Results for Compressive Strength Test.

35
 Figure 19: Graph for comparison between Compressive Strength of all the mixes.

8.3 Split Tensile Strength Test

The Cylinders were tested in compressive testing machine to determine their compressive
strength at the age of 7 days, 14 days and 28 days of curing. The figures below show the Tensile
strength of Control mix and the Geopolymer concrete with increment in molarity of NaOH. (8M,
10M and 12M) for the specimens which were cured by hot air oven and by direct sun light at the
age of 7, 14 and 28 days

36
Table 10: Results for Split Tensile Strength test.

37
 Figure 20: Graph for comparison between Split Tensile Strength of all the mixes.

8.4 Flexural Stress

The Beam specimen of size 500 x 100 x 100 mm were tested by Third point loading test to
determine their Flexural stress at the age of 28 day of curing. The figures below show the
Flexural stress of Control mix and the Geopolymer concrete with increment in molarity of
NaOH. (8M, 10M and 12M) for the specimens which were cured by hot air oven.

Table 11: Results for Flexural Strength test.

38
 Figure 21: Graph for comparison between the Flexural Strength of all the mixes.

8.5 Water Absorption Test

The size of Test specimens used for this test were 100×100×100 mm cubes of control concrete
and geopolymer concrete with varying molarity of 8M, 10M and 12M each. Test specimens were
oven dried at 105 C for 24 hours duration using hot air oven. After oven dry the specimens were
immersed in water for 24 hours duration. Absorption characteristic of concrete were evaluated by
difference in weight of specimen after complete drying in oven at 105 C and weight after
immersion in water. The figure below shows the percentage gain in weight after water
absorption.

39
 Table 12: Results for Water Absorption Capacity test.

8.6 Ultra Pulse Velocity Test

The size of Test specimens used for this test were 100×100×100 mm cubes of control concrete
and geopolymer concrete with varying molarity of 8M, 10M and 12M each. The figure below
shows the pulse velocity for concrete.

40
 Table 13: Results for UPV test.

*NOTE: The following values are the mean of 3 faces of each cube.

41
Figure 22: Graph for comparison between the UPV of all the mixes.

42
 CHAPTER 9
CONCLUSION

 Results show that an optimum strength is achieved by 12 M concentration of NaOH. The

graph depicts that compressive strength, split tensile strength and flexural strength of
geopolymer concrete increase when increasing the concentration of NaOH solution.
 Geopolymer Concrete by replacing Concrete Demolition Waste had shown a significant
potential as a good engineering material for the future research as compared to the control
mix. The economic benefits and contributions of Geopolymer concrete to sustainable
development are evident.
 Geopolymer concrete had very less curing time and achieves early strength. Hence, it can
be used in structures as pre-fabricated units.
 The water absorption capacity of the geopolymer concrete decreases with increase in
concentration of NaOH. It achieves its optimum value at 8M concentration. Test results
show that the porosity of geopolymer concrete is less as fly ash is fine than OPC which
results in to less water absorption than the control concrete.
 Results of Ultra Pulse Velocity test show that the soundness of the geopolymer decreases
with increase in NaOH concentration as the concrete becomes brittle in nature.

43
 CHAPTER 10
REFERENCES

[1] Fareed ahmed memon, Muhd fadhil Nuruddin, Sadaqatullah khan, Nasir shafiq, Tehmina
ayub (2013) , “Effect of sodium hydroxide concentration on fresh properties and compressive
strength of self-compacting geopolymer concrete” Journal of Engineering Science and
Technology Vol. 8, 44 – 56.

[2] Madheswaran C. K, Gnanasundar G, Gopalakrishnan. N (2013) ,“Effect of molarity in

geopolymer concrete” International journal of civil and structural engineering, Vol. 4, ISSN
0976 – 4399 , 106-116.

[3] Shankar H. Sanni, R. B. Khadiranaikar (2013), “Performance of alkaline solutions on grades

of geopolymer concrete”. IJRET: International Journal of Research in Engineering and
Technology EISSN: 2319-1163. ISSN: 2321-7308.

[4] M. Poojidha, K. Nirmalkumar Review Paper on Reaction of Alkaline Solution in Geo-

Polymer Concrete, IJRIPCC, ISSN: 2321-8169, 223-227.

[5] Allahverdi A and Najafi Kani E,”:Construction Wastes as Raw Materials for Geopolymer
Binders”, International Journal of Civil Engineerng, Vol. 7, No. 3, September 2009, pp: 154 –
160.

[6] IS 456:2000 Indian standard plain and reinforced concrete - code of practice (Fourth revision)

[7] IS 10262:2009 Indian standard concrete mix proportioning- guidelines (First revision)

[8] IS: 383(1970) – Specifications for fine & coarse aggregate from natural sources for concrete.

[9] IS: 2386(1963) – Methods of tests for aggregate for concrete.

[10] IS: 516(1959) – Methods of test for strength of concrete.

44
[11] A.Prabhakaran [1], G.Rajagopal [1], S. Ashok Manikandan [2] Non Destructive Testing on
Geopolymer Concrete using Concrete Demolition Waste.

[12] Salmabanu Luhar, Urvashi Khandelwal A Study on Water Absorption and Sorptivity of
Geopolymer Concrete.

45