A Project on

Geopolymer Concrete-An Ecofriendly Concrete

Prepared By:-
Lad Vatsal (100840106046)
Patel Kashyap (110840106004) Guided By:-
Naik Mit (110840106005) Prof. Mohammed A Qureshi
Srivastav Monika (120843106009) (F.E.T.R., Bardoli)
Patel Hiren (120843106011)

DEPARTMENT OF CIVIL ENGINEERING

FACULTY OF ENGINEERING TECHNOLOGY AND RESEARCH
BARDOLI, SURAT

Group ID- 428, CED, FETR, ISROLI, BARDOLI 1

 Project Outline
1) Introduction

2) Aim & Objective

3) Review Of Literature

4) Materials And Methods

5) Test for Concrete Ingredients

6) Mix design of geopolymer concrete

7) Manufacturing Steps For Geopolymer Concrete

8) Test for Concrete

9) Results of Tests

10) Conclusion

11) Future Scope

12) References

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 1. Introduction

 The global consumption of concrete is second after water.

 On the other hand, the global warming is caused by the emission of

greenhouse gases, such as carbon dioxide (CO2), to the atmosphere by
human activities.

 The cement industry is held responsible for some of the CO2

emissions, because the production of one ton of Portland cement
emits approximately one ton of CO2 into the atmosphere.

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 A French Professor Joseph Davidovits (1978) than proposed
that an alkaline liquid could be used to react with fly ash to
produce binders as a replacement of cement.

 Geopolymer concrete is a ‘New’ material that does not need the

presence of Portland cement as a binder.

 The role of Portland cement is replaced by fly ash & Alkaline

solutions

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 This is the world’s first building which is constructed use geopolymer concrete for
structural purposes. The only prior use has been for footpaths by local authorities
as a test case. This building is constructed in Queensland’s University as building
of GCI (Global Change Institute).
 This building has 4 stories and has
3 suspended floors made from
structural geopolymer concrete.
 They are made from slag/fly ash
based geopolymer concrete coined
Earth Friendly Concrete (EFC), a
Wagners brand name for their
commercial form of geopolymer
concrete.

Source : Hassel Architect

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 2. Aim & Objective

 To spread awareness among people to use fly ash and make an eco-friendly
concrete construction so as to stop increasing effects of global warming,
caused by carbon dioxide released during cement manufacturing.

 Also to make people aware about useful properties of GPC, like: Early
strength gaining, use of waste material, low cost, no curing hence saving
useful water, good finishing, high durability , etc.

 As concrete is an unavoidable material for construction hence is noted that

geopolymer concrete has a big importance to play in the near future, in the
construction sector.

 Using fly ash in geo-polymer concrete is particularly important as the disposal

of this waste is a worldwide problem.

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 3. Review Of Literature
Sr. no Author Year Comment
 They studied the effect of age of concrete, curing time, curing
temp, quantity of superplasticiser, etc on geopolymer concrete.
Hardjito
1 2004  They concluded that superplasticiser can be utilized to improve
et al
workability of the fresh G.C.

 They presented that geopolymer concrete doesn’t need portland

cement as a binder. They used Si, Al & high alkaline liquid
Wallah et
2 2005 which fulfils the binder requirement.
al
 They have remarked that curing at elevated temp need extra
care to minimize the loss of water.
 They suggested that geopolymer can be used as a cement paste
which bind the loose C.A., F.A. & other unreacted materials
together to form geopolymer concrete.
Hardjito  They also suggested that G.C. can perform better against sulfate
3 2005 attack or weather affect.
et al
 They concluded that fly ash based geopolymer concrete has
more compressive strength as compare to O.P.C.

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Sr.
Author Year Comment
No.
 They presented the review of water penetrability of low calcium
fly ash geopolymer concrete.
 They have examined water penetrability, water absorption,
volume of permeable voids etc of low calcium fly ash
4 Olivia et al 2008
geopolymer concrete.
 They remarked that G.C. has low water absorption and
sorptivity. They had also observed that G.C. with lower
agg/binder ratio indicate a high porous matrix.
 They studied on geopolymer concrete mix design structural
Lloyd & behavior and durability.
5 2010
Rangan  They concluded that temp specification of curing help to
increase the compressive strength of concrete.
 They had reviewed on the evaluation of self cure geopolymer
6 Vadiya et al 2011 concrete for mass pour application.
 They achieved compressive strength upto 43MPa.
 They presented the review of strength study of fly ash based
7 Malathi et al 2012 geopolymer concrete under heat curing.
 They replaced cement 100% by fly ash based G.C.
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Sr.no Author Year Comment
 He showed that low calcium fly ash based geopolymer
concrete has the potential to be a promising sustainable
alternative for rigid concrete road furniture.
 He had suggested Slag based LCFG concrete application for
8 D S Cheema 2012
rigid road furniture in non aggressive to mild environments
could be of significant environmental benefits.
 He also achieved average strength up to 40 to 50 Mpa when
cured under ambient conditions.
 They suggested that use of fiber reinforced geopolymer
concrete can be used as greener option of OPC.
 They prepare different mixes and perform different tests on
9 Ruby et al 2013
it.
 They concluded that the fracture energy for GPC is 80%
more than PCC.
They studied that the experimental investigation done on the
variation of alkaline solution on mechanical properties of
Shankar &
geopolymer concrete.
10 Khadiranaik 2013
They concluded that compressive strength and split tensile
ar
strength were in the range of 20.64 N/mm2 to 60 N/mm2 and
3 N/mm2 to 4.9 N/mm2.
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Sr.no Author Year Comment

 They reported that the geopolymer concrete has higher acid

resistance than normal concrete.
11
Gopal &
2013  They prepared geopolymer concrete cube as well as ordinary
kiran concrete cubes, and after curing them, they placed them in 5%
acidic solution to check their resistance against acid attack.

 They conducted different test like Split tensile and Flexure test
and observed that cured at 60 ̊C gives the best result.
Rachel &  They also suggested heat curing which is necessary for
12 Partheeba 2013 achieving strength for geopolymer concrete and concluded that
n geopolymer concrete posses excellent durability as a
construction material.

 They suggested the strength of fly ash geopolymer concrete

was improved to a certain extent by decreasing the water/solids
Olivia & ratio, the aggregate/solids ratio, and the alkaline to fly ash
13 2014 ratio.
Nikraz
 They have concluded that to obtain a low porosity of fly ash
geopolymer

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 4. Materials And Methods
4.1 Source Materials

Alkaline Solution

Flyash Superplasticiser

Geopolymer
Aggregate Water
Concrete

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 4.1.1 Fly Ash
 Fly ash that results from burning sub-bituminous coals is referred as ASTM
Class C fly ash or high-calcium fly ash, as it typically contains more than 10
percent of CaO.

 On the other hand, fly ash from the bituminous and anthracite coals is
referred as ASTM Class F fly ash or low-calcium fly ash and has less than
10 percent of CaO.

 Low-calcium (ASTM Class F) fly ash is preferred as a source than high-

calcium (ASTM Class C) fly ash because the presence of calcium in high
amounts may interfere with the polymerization process.

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 4.1.1.1 Chemical Properties Of Fly Ash
Oxides Obtained Result
CaO (%) 0.50

SiO2 (%) 67.60

Al2O3 (%) 11.30

MgO (%) 0.10

SO3 (%) 0.060

Na2O (%) 0.035

K2O (%) 0.005

Total Chloride (%) 0.008

LOI (%) 2.60

Fe2O3 (%) 1.15

TiO2 (%) Nil

P2O3 (%) 0.0002

Source : Flyash Distributor Group ID- 428, CED, FETR, ISROLI, BARDOLI 13
 4.1.2 About Chemicals (Alkaline liquids)
 The alkaline liquids are from soluble alkali metals that are usually sodium
or potassium based.

 The most common alkaline liquid used in geopolymerisation is a

combination of sodium hydroxide (NaOH) or potassium hydroxide (KOH)
and sodium silicate or potassium silicate.

 For our experimental work we are going to used the mixture of sodium
hydroxide and sodium silicate.

 We are making 8 molar and 10 molar solution of sodium hydroxide and

sodium silicate for making GPC.
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4.1.2 About Chemicals (Alkaline liquids) (Cont…)

Sodium Hydroxide Flakes Sodium Silicate Solution

Source: P.globalsources.com Source:imimg.com

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 4.1.3 Aggregates , Superplasticiser and Water
 The coarse aggregates are of two types. One is of 20mm and the other is
10mm. The fine aggregate to be used is of sand confirming zone II. Both
coarse and fine aggregates are in surface-saturated-dry (SSD) condition.

 To improve the workability of the fresh geopolymer concrete, a naphthalene

sulphonate superplasticizer, supplied by BASF, Ahmedabad, under the brand
name of Rheobuild 1126, is to be used in all the mixtures.

 In practice, very often great control on properties of cement and aggregate is

exercised, but the control on the quality of water is often neglected. Since
quality of water affects the strength, it is necessary for us to go into the
purity and quality of water.

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 5. Mix design of geopolymer concrete
GEOPOLYMER CONCRETE DESIGN
FLY ASH 400.00 Kg/m3
FINE AGGREGATE 620.60 Kg/m3

COARSE AGGREGATE
755.40 Kg/m3
20 mm
504.00 Kg/m3
10 mm

NaOH 40.00 Kg/m3

Na2SiO3 80.00 Kg/m3
ADMIXTURE 6.00 Kg/m3
WATER 45.00 Kg/m3
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 6. Test Conducted on Ingredients

Test On
Ingredients

Sand Coarse
Fly Ash Admixture
Aggregate

Specific Specific Specific Marsh Cone

Gravity Gravity Gravity Test

Chemical
Sieve Analysis Sieve Analysis
Composition

Water Water
Absorption Absorption

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 7. Manufacturing Steps For Geopolymer Concrete

i. Dry mixing of Aggregates & Fly ash.

ii. Adding of Alkaline solution to the mixture.

iii. Compaction of Cubes on Vibrating Table.

iv. Curing of cubes at 60 ºC temp. in oven.

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The fly ash and the aggregates are first mixed together dry in pan mixer.

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Final mixture of sodium hydroxide and sodium silicate

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The liquid component of the mixture is then added to the dry materials and the mixing
continued usually for another four minutes
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Curing of cubes at 60ºC temp at oven. (The specimens are wrapped by plastic sheet to
prevent loss of moisture and placed in an oven.)
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 8. Test for concrete
Tests For Concrete
Test For
Concrete

Fresh Hardened
Concrete Concrete

Compressiv Flexural Split Tensile

Workability
e Strength Strength Strength

Destructive Non
Slump
Test Destructive
Test
Compaction
Factor Rebound
Hammer

Flow Test

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 9. Reports of Test
Compressive Strength Results for Ambient Cured Samples of OPC Concrete
Average Compressive strength
Compressive strength

Sr. No Mix type N/mm2 N/mm2

7 days 14days 28 days 7 days 14 days 28 days

25.84 29.28 32.68

1 OPC 26.31 28.62 33.87 26.01 29.22 34.10

25.88 29.75 35.75

Split Tensile Strength Results for Ambient Cured Samples of OPC Concrete
Average Split Tensile
Split Tensile strength
strength
Sr. No Mix type
N/mm2 N/mm2
28days 28 days
3.53
1 OPC 3.26 3.17
2.71

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 Compressive Strength Result for Oven Exposure Sample of GPC
Compressive strength
Sr. No Mix type Oven curing 70° 90°
7 days 28days 7 days 28days
25.20 34.62 27.90 39.45
24.78 33.22 26.87 40.81
1 8M 24 hours
24.22 35.66 28.03 39.26
24.73 34.50 27.60 39.84
28.42 38.66 30.95 45.71
27.18 37.55 32.41 43.57
2 10M 24 hours
26.84 39.59 32.04 42.24
27.48 38.60 31.80 43.84
Split Tensile Strength Result for oven Exposure Sample of GPC
Split Tensile Average Split
Sr. Oven strength Tensile strength
Mix type
No curing N/mm2 N/mm2
28 days 28 days
5.35
1 8M 24 hours 6.04 5.63
5.51
6.92
2 10M 24 hours 6.78 6.94
7.13

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Compressive Strength Results for Ambient Cured Samples of GPC
Average Compressive
Compressive strength
strength
Sr No Mix type
N/mm2 N/mm2
7 days 28days 7 days 28 days
5.20 8.42
1 8M 4.11 8.17 4.05 8.00
2.86 7.42
2.33 7.68
2 10M 3.13 8.51 2.80 8.44
2.94 9.13

Split Tensile Strength Results for Ambient Cured Samples of GPC

Average Split Tensile
Split Tensile strength
strength
Sr No Mix type
N/mm2 N/mm2
28days 28 days
4.65
1 8M 4.11 4.13
3.64
4.64
2 10M 4.36 4.61
4.82

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 10. Conclusion
 Geopolymer concrete has better compressive and tensile strength then the
ordinary portland cement concrete.
 In geopolymer concrete, we use flyash instead of cement. So, geopolymer
concrete has greater corrosion resistance, higher fire resistance (2400° F),
low shrinkage etc. compared to OPC concrete.
 Geopolymer concrete can resist against acid and salts in better way than
OPC concrete.
 Geopolymer technology does not only contribute in 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.

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 Geopolymer Concrete is cheaper than the ordinary portland cement.
GPC GPC
OPC
Material 8M 10M
(Rs/m³)
(Rs/m³) (Rs/m³)
Cement --- --- 2451.20

Fly ash 1300.00 1300.00 ---

F.A 517.16 517.16 522.90

C.A
10mm 125.90 125.90
1099.80
20mm 453.60 453.60

NaOH 407.40 480.06 ---

Na2CO3 291.00 342.90 ---

Admixture 1200.00 1200.00 ---

Total 4299.64 4424.20 4596.80

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 The average compressive strength of heat cured specimens was higher than
that of ambient air curing.

 Geopolymer concrete has excellent durability as construction material.

 The oven curing is more effective then ambient curing regarding gaining
physical strength of concrete.

 Geopolymer technology does not only contribute in 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.

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 11. Field Application Of GPC

Water Tank

Precast
Bridge Decks Buildings

Precast
Beams

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 12. References

 James Aldred and John Day, 2000, “Review of alternative to traditional

concrete regarding geopolymer concrete”, 37th Conference on Our World in
Concrete & Structures, 29-31 August 2012, Singapore.

 D. Hardjito and S. E. Wallah, 2004, “Review of compressive strength of fly

ash regarding geopolymer concrete”, Faculty of Engineering and Computing,
Curtin University of Technology, Perth, Australia.

 B. Vijaya Rangan, Djwantoro Hardjito, Steenie E. Wallah, and Dody M.J.

Sumajouw, 2005, “The review of fly ash based geopolymer concrete”,
Faculty of Engineering and Computing, Curtin University of Technology
Perth, Western Australia.

 Djwantoro Hardjito , Steenie E. Wallah, B. Vijaya Rangan, and Dody M.J.

Sumajouw, 2006, “Properties and application of fly ash based concrete”,
Faculty of Engineering and Computing, Curtin University of Technology

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 S Vaidya, E I Diaz and E N Allouche, 2011, “Experimental Evaluation of
Self-Cure Geopolymer Concrete for Mass Pour Applications”, World of Coal
Ash (WOCA) Conference, Denver, USA.

 Monita Olivi and Hamid R. Nikraz, 2011, “Strength and Water Penetrability
of Fly ash Geopolymer Concrete”. ARPN (Asian Research Publishing
Network) Journal of Engineering and Applied Sciences.

 Anuar K.A, Ridzuan A.R.M. and Ismail S, 2011, “Strength Characteristics of

Geopolymer Concrete Containing recycled Concrete Aggregate”, Institute of
Infrastructure Engineering and Sustainable Management (IIESM), Faculty of
Civil Engineering, Selangor, Malaysia.

 M. Fareed Ahemd, M. Fadhil Nuruddin, and Nasir Shafiq, 2011,

“Compressive Strength and Workability Characteristics of Low-Calcium Fly
ash-based Self-Compacting Geopolymer Concrete”, World Academy of
Science, Engineering and Technology.

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 K. Madhan Gopal and B. Naga Kiran, 2013, “Investigation on Behavior of
Fly Ash Based Geopolymer Concrete in Acidic Environment”, International
Journal of Modern Engineering Research (IJMER).

 Shankar H. Sanni and R. B. Khadiranaikar, 2013, “Performance of alkaline

solution on grades of geopolymer concrete”, International Journal of
Research in Engineering and Technology.

 A Motorwala, v Shah and R Kammula, 2013, “Alkali activated geo-

polymer”, International Journal of Emerging Technology and Advanced
Engineering Volume 3, Issue 1, January 2013.

 P P Rachel and P Partheeban, 2013, “Durability Study of Low Calcium Fly

ash Based Geopolymer Concrete”, St. Peter’s University, Chennai - 600 054,
Tamil Nadu, India.

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 Sourav Kr. Das, Amarendra Kr. Mohapatra and A.K. Rath, 2014, presented
paper on “Geopolymer Concrete Green Concrete for the Future”,
International Journal of Civil Engineering Research. ISSN 2278-3652
Volume 5, Number 1.

 M Olivia and H R Nikraz, 2014, “Strength and Water Penetrability of Fly

Ash Based Geopolymer Concrete”, ARPN (Asian Research Publishing
Network) Journal of Engineering and Applied Sciences.

 A M Rajesh, A Joe and R Mammen, 2014, “Study of the Strength

Geopolymer Concrete with Alkaline Solution of Varying Morality”, IOSR
Journal of Engineering (IOSRJEN) ISSN (e): 2250-3021, ISSN (p): 2278-
8719 Vol. 04, Issue 06 (June. 2014), ||V1|| PP 19-24.

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 Steenie E. Wallah, B. Vijaya Rangan, Djwantoro Hardjito and Dody M.J.
Sumajouw, 2006, “Reinforced low-calcium fly ash based geopolymer
concrete beam and columns”, Faculty of Engineering and Computing, Curtin
University of Technology.

 M. Olivia, H. Nikar and P. Sarker, 2008, “Water Penetrability of Low

Calcium Fly Ash Geopolymer Concrete”, Curtin University of Technology,
Perth, Western Australia, Australia.

 N A Lloyd and B V Rangan, 2010, “Geopolymer Concrete with Fly Ash”,

Curtin University of Technology, Perth, Western Australia, Australia.

 N A Lloyd and B V Rangan, 2010, “Geopolymer concrete: A review of

development and opportunities”. Curtin University of Technology, Perth,
Western Australia, Australia

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 Nataraja MC and Dattatreya J K, 2011, “Flexural behavior of reinforced
Geopolymer concrete beams”, International Journal of Civil and Structural
Engineering Volume 2, No 1.

 N Dave and V Sahu, 2012, “Experimental Evaluation Of Low Calcium Fly

Ash Based Geopolymer Concrete”, International Journal of Engineering
Science and Technology (IJEST).

 D S Cheema, 2012, “Low Calcium Fly Ash Geopolymer Concrete – A

Promising Sustainable alternative For Rigid Concrete Road Furniture”, 25th
ARRB Conference – Shaping the future: Linking policy, research and
outcomes, Perth, Australia 2012.

 Deepa Raj S., Ruby Abraham, N. Ganesan and Divya Sasi, 2013, “Fracture
Properties of Fiber Reinforced Geopolymer Concrete”, International Journal
of Scientific & Engineering Research

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 Sonal P. Thakkar, Darpan J. Bhorwani and Rajesh Ambaliya, 2014,
“Geopolymer Concrete using different Source of Materials”, Post-Graduate
Student, Institute of Technology, Nirma University, Ahmadabad.

 Darpan J. Bhorwani, 2014, “Evaluation of Strength of Geo-Polymer

Concrete Using Combination of Fly Ash and GGBFS as Source Material”,
Post-Graduate Student, Institute of Technology, Nirma University,
Ahmadabad.

 A Maria Rajesh and Dr. T. R. Sethuraman, 2014, “Behavior of low calcium

fly ash based geopolymer concrete structural elements with GGBS & steel
fiber”, International Journal of Scientific Research Engineering &
Technology (IJSRET) Volume 2 Issue 11 pp 782-789 February 2014

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