GEOPOLYMER CONCRETE AN ECO FRIENDLY CONSTRUCTION MATERIAL

A Seminar Report

Submitted by

KRITIKA KAPIL

ROLL NO. 17BTL030103

in partial fulfillment for the award of the degree of

B. Tech. Civil Engineering

RAJIV GANDHI GOVERNMENT ENGINEERING COLLEGE

KANGRA AT NAGROTA BAGWAN (H.P.)

Affiliated to

H.P. TECHNICAL UNIVERSITY, HAMIRPUR (H.P.)

April 2019
 Rajiv Gandhi
Government Engineering College Kangra
at Nagrota Bagwan (H.P.)

CERTIFICATE

I hereby certify that the work which is being presented in the seminar report entitled
<“Geopolymer concrete”> in partial fulfilment of the requirements for the award of the B. Tech. and
submitted to the Department of Civil Engineering of Rajiv Gandhi Govt. Engg. College Kangra at
Nagrota Bagwan is an authentic record of my own work carried out during a period from January 2019
to April 2019 under the supervision of Dr. Deepak Kumar.

The matter presented in this report has not been published earlier and has never been submitted
by us for the award of any other degree elsewhere.

Signature of Student
(KRITIKA KAPIL)
Roll No. 17BTL030103
6th Sem. Civil Engg.
RGGEC, Kangra

This is to certify that the above statement made by the candidates is correct to the best of my
knowledge.

Supervisor:

(Dr. Deepak Kumar)

Prof. & H.O.D. Civil Engg.
RGGEC, Kangra
Date:
Place: Nagrota Bagwan
 INTRODUCTION

1.1 GENERAL

Concrete is the world’s most versatile, durable and reliable construction material.
Large quantities of Portland cement are required for concrete. The consumption of Ordinary
Portland Cement (OPC) causes pollution to the environment due to the emission of CO2.
Geopolymer concrete was introduced to reduce environmental pollution that causes by
production of Portland cement.
In 1978, Professor Joseph Davidovits introduced the development of mineral binders with an
amorphous structure, named geopolymers. Davidovits (1988; 1994) proposed that an alkaline liquid
could be used to react with the silicon (Si) and the aluminium (Al) in a source material of geological
origin or in by-product materials such as fly ash and rice husk ash to produce binders. Because the
chemical reaction that takes place in this case is a polymerization process, he coined the term
‘Geopolymer’ to represent these binders. This was a class of solid materials, produced by the reaction
of an alumino silicate powder and an alkaline liquid. The initial goal for the research done on these
geopolymers was to find a more fire resistant binder material due to the high amount of fires in
Europe at that time. This research led to the material being used as coatings for the fire protection of
cruise ships and thermal protect results in a low flexural strength. Brittleness of both concrete types
is compensated by conventional steel reinforcement.
Geopolymer concrete is an innovative construction material which shall be produced
by the chemical action of inorganic molecules. Otherwise geopolymer is an inorganic
alumino- hydroxide polymer synthesized from predominantly silicon (Si) and aluminium (Al)
materials of geological origin or byproduct materials such as fly ash. The term Geopolymer
was introduced to represent the mineral polymers resulting from geochemistry.Due to its high
mechanical properties combined with substantial chemical resistance (magnesium or
sulphate attack), low shrinkage and creep and environment friendly nature (very less amount
of CO2 production in comparison with OPC), it is a better construction material for future.

1.2 NECESSITIES OF GEOPOLYMER CONCRETE

This type of geopolymer concrete is starting to revolutionize concrete. It is being used

more in highway construction projects and offshore applications. Construction is one of the
world wide growing fields. As per the present world statics, every year million tons of cement
are required. Ordinary Portland cement is commonly used in concrete. While producing one
ton of cement, approximately one ton of carbon dioxide will be emitted to the atmosphere,
which cause major problems in environment. Also huge quantity of energy is also required
for the production of cement. Hence it is most essential to find an alternative binder. The
Thermal Industry produces a waste called fly ash which is simply dumped on the earth,
occupies large areas. The waste water from the Chemical Industries is discharged into the
ground which contaminates ground water. By producing Geopolymer Concrete all the above
mentioned issues shall be solved by rearranging them.

Waste Fly Ash from Thermal Industry + Waste water from Chemical Refineries = Geo
polymer concrete.
 GEOPOLYMER CONCRETE

Geopolymers are members of family of inorganic polymers. The chemical composition

of geopolymer material is similar to natural zeolite materials, bit the microstructure is
amorphous.
The polymerization process involves a substantially fast chemical reaction on Si-Al
minerals, that results in a three-dimensional polymeric chain and ring structure.
There are two main constituents of geopolymers, namely the source materials and
alkaline liquids. The source materials of geopolymers based on alumina-silicate should be
rich in silicon (Si) and aluminium (Al) such as kaolinite, clays, etc.

2.1 CONSTITUENTS OF GEOPOLYMER CONCRETE

2.1.1 Coarse Aggregate

Coarse aggregates used in case of cement concrete can be used in case of
Geopolymer concrete (GPC) also where the coarse aggregate should conform to IS-383-
1970.

2.3.2 Fine Aggregate

In place of sand we can also use bottom ash which can be a replacement of sand. Up
to a level of 20% replacement of sand gives a good compressive strength.

2.3.3 Admixtures
To improve the workability of fresh concrete, a commercially available naphthalene
based superplasticizer was used. Lignin based first generation plasticizer shows better
performance in terms of workability over third generation superplasticizer. High range water
reducing naphthalene based super plasticizer, naphthalene sulphonate based
superplasticizer etc was also use.

2.3.3 Alkaline Activators

According to Prof. J. Davidovits the alkaline liquid should be made prior to one day
before mixing because at the time of mixing of Na 2SiO3 with NaOH solution it generates a
huge amount of heat and the polymerization takes place by reacting with one another, which
will act as a binder in the geopolymer concrete. Common activators include NaOH, Na 2SO4 ,
waterglass, Na2 CO3 , K2 CO3 , KOH, K2SO4 and cement clinker, the most utilized alkaline
activators are a mixture of sodium or potassium hydroxides (NaOH, KOH) and sodium
waterglass (nSiO2 Na2 O) or potassium waterglass (nSiO2 K2 O).

Sodium Hydroxide (NaOH)

NaOH is also commonly used as an alkaline activator in geopolymer production.

Generally NaOH is available in market in the form of pellets or flakes form with 96% to 98%
purity where the cost of the product depends on the purity of the material. The solution of
NaOH was formed by dissolving it in water with different molarity. It is recommended that the
NaOH solution should be made 24 hours before casting and should be used with 36 hours
of mixing the pellets with water as after that it is converted to semi-solid state.
The concentration and molarity of this activating solution determines the resulting
paste properties. While high NaOH additions accelerate chemical dissolution, it depresses
ettringite and CH (carbon-hydrogen) formation during binder formation. Furthermore, higher
concentrations of NaOH promote higher strengths at early stages of reaction, but the strength
of aged materials were compromised due to excessive OH in solution causing undesirable
morphology and non-uniformity of the final products. It is found that geopolymers activated
with sodium hydroxide develop greater crystallinity thus improving stability in aggressive
environments of sulphates and acids.

Potassium Hydroxide (KOH)

KOH has been found to produce high compressive strengths and improved porosity
in geopolymer cements. Since K+ is more basic than other activating ions, it possesses a
greater potential for polymeric ionization in solution resulting in high reactivity of the prime
pozzolan, a denser final product and a matrix formation capable of achieving increased
compressive strength values. NaOH actually possesses a greater capacity to liberate silicate
and aluminate monomer.

Sodium Silicate (Na2SO3) and potassium silicate

Sodium silicate is also known as waterglass which is available in the market in gel
form. The ratio of SiO2 and Na2O in sodium silicate gel highly affects the strength of
geopolymer concrete. Mainly it is seen that a ratio ranging from 2 to 2.5 gives a satisfactory
result.
Sodium or potassium silicates are manufactured by using sand (SiO2) with sodium or
potassium carbonate (Na2 CO3 or K2CO3 ) at temperatures in excess of 1100 °C and
dissolving the product with high pressure steam into a semi-viscous liquid referred to as
waterglass.. It is commonly mixed with NaOH or KOH as a strengthening agent to enhance
alkalinity and increase overall specimen strength. The most common alkaline liquid used in
geopolymerization is a combination of sodium hydroxide or potassium hydroxide and sodium
silicate or potassium silicate.
 MANUFACTURE
3.1 Materials

The materials needed to manufacture the fly ash-based geopolymer concrete are
the same as those for making Portland cement concrete, except for the Portland cement.
Low calcium dry fly ash obtained from a local power station was used as the source
material. For the alkaline activator, a combination of sodium hydroxide solution and sodium
silicate solution was used. The sodium hydroxide solution was prepared by dissolving the
sodium hydroxide solids, either in the form of pellets or flakes, in water. Extra water and
Naphthalene Sulfonate-based superplasticizer were also added to improve the workability
of the fresh fly ash-based geopolymer concrete. The sodium silicate solution used
contained Na2O=14.7%, SiO2=29.4%, and 55.9% of water, by mass. All the liquids were
mixed together before adding to the solids.

3.2 Mixing and Compacting

The aggregates in saturated surface dry condition and the dry fly ash were mixed in a
pan mixer for 3-4 minutes. At the end of this mixing, the liquid component of the geopolymer
concrete mixture, i.e. the combination of the alkaline solution, the superplasticizer and the
extra water, was added to the solids, and the mixing continued for a specified period of time.
In this study, the wet mixing period was designated as the ‘mixing time’. The fresh concrete
had a stiff consistency and was glossy in appearance. The fresh concrete was then cast in
moulds. Compaction was performed using the usual practice, either by applying strokes or
using vibration or a combination of both. After casting, the concrete samples were cured at
an elevated temperature for a specified period of time.

3.3 Curing

In this study, curing was carried out at a specified elevated temperature, either in an
oven (dry curing) or in a steam chamber. At the end of the curing period, the test specimens
were left in the mold for about six hours. The samples were then removed from the molds,
and left to air dry in the room temperature before testing at a specified age.
 STUDY OF PROPERTIES OF GEOPOLYMER CONCRETE

4.1 STUDY OF FLY ASH BASED GEOPOLYMER CONCRETE

4.1.1Creep Test

Test Specimens
Test specimens for the creep test were 150x300 mm cylinders and eight cylinders
were prepared for each test. Three cylinders were used for measuring the creep, two
companion cylinders measured the drying shrinkage and the other three cylinders were used
for the compressive strength test.

Test Procedure
The three specimens for creep test were placed in a specially-built creep testing frame
with a hydraulic loading system. Before the creep specimens were loaded, the 7th day
compressive strength of geopolymer concrete was determined by testing the three cylinders
reserved for the compressive strength test. The creep specimens were applied with a load
corresponding to 40 percent of the measured mean compressive strength of concrete. This
load was maintained as the sustained load throughout the duration of the test. The strain
values were measured and recorded immediately before and after the loading. Strains
experienced by the control shrinkage specimens were measured at the same time as the
strain measurements on creep specimens. The strain values were measured and recorded
at 2 hours, 6 hours, and then every day for the first week, after loading. The measurements
then continued once a week until the fourth week. After that, the measurements were done
once in 2 weeks until the twelfth week and the once every four weeks until one year. The
creep tests were conducted in a laboratory room where the temperature was maintained at
about 23ºC, but the relative humidity could not be controlled. The relative humidity varied
between 40% and 60% during the test.

Fig.4.1 creep test

In OPC concrete creep is higher than that of geopolymer concrete and thus the
geopolymer concrete specimens undergo low creep.
4.1.2 Drying Shrinkage Test

Test specimen
75x75x285 mm prisms with gauge studs were used for drying shrinkage test.

Test Procedure
The shrinkage strain measurements started on the third day after casting the concrete.
On the third day after casting, the specimens were demoulded and the first measurement
was taken. Horizontal length comparator was used for length measurements. The next
measurement was on the fourth day of casting, considered as Day 1 for the drying shrinkage
measurements. The measurements then continued every day in the first week, once a week
until the fourth week, once in two weeks until the twelfth week, and then once in four weeks
until one year. During the drying shrinkage tests, the specimens were kept in a laboratory
room where the temperature was maintained at approximately at 23ºC. The relative humidity
of the room varied between 40% and 60%.

Fig. 4.2 Horizontal Length Comparator with Drying Shrinkage Test Specimen

Geopolymer concrete specimens undergo low drying shrinkage. The drying shrinkage
of geopolymer concrete, cured at ambient temperatures, shows shrinkage significantly higher
than that of heat cured geopolymer concrete. The excess water in the geopolymer concrete
evaporates during the heat curing process, eliminating almost any chance of drying
shrinkage. The drying shrinkage for geopolymer concrete cured at ambient temperatures is
similar compared to that of OPC concrete. Figure 4.3 shows the drying shrinkage of heat
cured and ambient curing specimens.
 Fig.4.3 Drying shrinkage of heat cured and ambient cured specimens

4.1.3 Sulphate Resistance Test

Test Procedure
The test specimens were immersed in sulphate solution on the 7th day after casting.
Sodium sulphate (Na2 SO4) solution with 5% concentration was used as the standard
exposure solution for all tests. The specimens were immersed in the sulphate solution in a
container, the volume proportion of sulphate solution to specimens was four to one. In order
to maintain the concentration, the solution was replaced every month.

Fig.4.4 Specimens Soaked in Sodium Sulphate Solution

4.1.4 Acid Resistance Test

Sulphuric acid is one type of acid solution that is frequently used to simulate the acid
attack in sewer pipe systems. In such systems, sulphuric acid attack is a particular problem
as it is generated bacterially from hydrogen sulphide. To test the acid resistance of
geopolymer concrete, the specimens be exposed to sulphuric acid solution with a
concentration of pH = 1. To evaluate the acid resistance of fly ash based geopolymer
concrete, the specimens were soaked in sulphuric acid solution with selected concentrations
ranging from 0.25% to 2% with the measured pH ranges from about 0.9 to 2.1, up to one
year of exposure. The test specimens were immersed in sulphuric acid solution in a
container; the ratio of the volume of the acid solution to the volume of the specimens was 4.
The solution was stirred every week and replaced every month.
4.1.5 Compressive Strength
It has been confirmed that geopolymer concrete can reach significantly high
compressive strengths when cured either by heat activation or at ambient temperatures. Heat
activation is necessary to accelerate the geopolymerisation process and therefore higher
compressive strengths will be achieved when heat activated, compared to ambient curing.
The addition of slag in the matrix improves the compressive strength of the geopolymer
concrete significantly when cured at ambient temperatures.
The test results plotted in Figure 4.6 show that the 7th day compressive strength of
ambient-cured geopolymer concrete and the subsequent strength gain with respect to age
depend on the ambient temperature at the time of casting. The 7th day compressive strength
of fly ash-based geopolymer concrete increased as the average ambient temperature at
casting increased. Also, the compressive strength of ambient tcured geopolymer concrete
significantly increased with the age.

Fig. 4.5 Compressive Strength of Geopolymer Concrete Cured in Ambient

Condition
 ADVANTAGES OF GEOPOLYMER CONCRETE

5.1 High Strength

It has a high compressive strength that showed higher compressive strength than that
of ordinary concrete.it also has rapid strength gain and cures very quickly. Making it an
sexcellent for quick builds. Geopolymer concrete has high tensile strength.it is less brittle
than Portland concrete and can withstand more movement. it is not completely earth quake
proof, but does withstand the earth moving better than traditional concrete.

5.2 Very Low Creep And Shrinkage

Shrinkage can cause severe and even dangerous cracks in the concrete from the
drying and heating of the concrete or even the evaporation of water from the concrete.
Geopolymer concrete does not hydrate; it is not as permeable and will not experience
significant shrinkage. The creep of geopolymer concrete is very low. The tendency of the
concrete become permanently deformed due to the constant forces being applied against it
is known as creep in concrete.

5.3 Resistant To Heat And Cold

It has the ability to stay stable even at temperature of more than 2200 degrees
Fahrenheit. Excessive heat can reduce the stability of concrete causing it to spall or have
layers break off. Geopolymer concrete does not experience spalling unless it reaches over
2200 degrees Fahrenheit.As for old temperatures, it is resistant to freezing. The pores are
very small but water can still enter cured concrete. When temperature dip to below freezing
that water freezes and then expands this will cause cracks to form. Geopolymer concrete will
not freeze.

5.4 Chemical Resistance

It has a very strong chemical resistance. Acids, toxic waste and salt water will not
have an effect on geopolymer concrete. Corrosion is not likely to occur with this concrete as
it is with traditional Portland concrete.

5.5 Environmental Benefits

The use of geopolymer concrete reduces the need of OPC, that’s why we have to reduce the
environmental pollution that caused by the emission of CO 2 during the production of OPC.
 DISADVANTAGE OF GEOPOLYMER CONCRETE

6.1 Difficult To Create

Geopolymer concrete requires special handling needs and is extremely difficult to
create. It requires the use of chemicals, such as sodium hydroxide, that can be harmful to
humans.

6.2 Pre Mix Only

Geopolymer concrete is sold only as a pre-cast or pre mix material due to the dangers
associated with creating it.

6.3 Geopolymerization Process Is Sensitive

This field of study has been proven inconclusive and extremely volatile. Uniformity is
lacking.
 APPLICATIONS OF GEOPOLYMER CONCRETE

Geopolymer mortars and concretes possess a high potential for use in commercial
applications due to their enhanced durability, thermal and chemical
22 resistance properties, rapid development of mechanical strength, adherence to
reinforcements aggregates and economic benefit as an industrial by-product material.

7.1 Concrete Pipes The use of geopolymer concretes for commercial sewer piping is a good
option from the basis of their resistance to sulphates and acidic products. Sulphuric acid is
generated in conventional sewer systems through the breakdown of hydrogen sulphide by
aerobic bacteria in the system and is the main factor in corrosion and structural deterioration
of the piping networks over time. Approximately 40 percent of the damage to PCC pipes can
be attributed to corrosion by biogenous sulphuric acid attack as a result of long flow periods
and insufficient ventilation of wastewater.

Fig. 7.1 Precast Geopolymer Concrete Pipes

7.2 Structural Elements

Geopolymer concrete is used for the casting of both columns and beams. The load
capacity of geopolymer columns is influenced by load eccentricity, concrete compressive
strength values and longitudinal reinforcement ratios. Decreased eccentricity loading and
reinforcement ratio increases favour an increase in overall column load capacity.

Fig.7.2 Geopolymer Columns After Demoulding.

 Fig.7.3 Geopolymer beam(10.8m ) craned into position.

7.3 Pavements Geopolymer concrete is used for the construction of heat resistant pavement
due to its thermal capacity. Pozzolan-based geopolymer cements do not readily decompose
when exposed to high temperatures and appear to be more structurally stable under such
conditions than PCC. Geopolymer cements utilize more and store less water from solution
during particle reaction, and therefore, prevent aged dry shrinkage and strength degradation
due to rapid water loss under extreme heat.

Fig.7.4 Placing Of Pavement Using Geopolymer Concrete.

7.4 Retaining Wall

A total of over fifty 40 MPa geopolymer precast panels were used a retaining wall for
a private residence. The panels were up to 6 metres long by 2.4 metres wide and were
designed to retain earth pressure of 3 metres.
 Fig.7.5 Precast Geopolymer Retaining Walls For A Private Residence.

7.5 Other Applications

According to Davidovits (1988), geopolymeric materials have a wide range of
applications in the field of industries such as in the automobile and aerospace, nonferrous
foundries and metallurgy, civil engineering and plastic industries. The type of application of
geopolymeric materials is determined by the chemical structure in terms of the atomic ratio
Si:Al in the polysialate. Davidovits (1999) classified the type of application according to the
Si:Al ratio as presented in Table 9.6 . A low ratio of Si:Al of 1, 2, or 3 initiates a 3DNetwork
that is very rigid, while Si:Al ratio higher than 15 provides a polymeric character to the
geopolymeric material.
Table 7.1 Application of geopolymeric materials based on Si:Al atomic ratio Si:Al
ratio
 CONCLUSION

Geopolymer concrete is well known for its promising mechanical properties, acid
resistance and fire resistance and therefore is a potential alternative construction material
with comparable properties to OPC concrete. The constituents of Geopolymer Concrete shall
be capable of being mixed with a relatively low alkali activating solution and must be curable
in a reasonable time under ambient conditions. Geopolymers emit approximately 80% less
CO2 than OPC during production, making it a more environmental friendly building material.
Like OPC concrete, geopolymer concrete has a brittle failure. Alternatively, fibres can be
added to improve the ductility of concrete. The properties of geopolymer include high early
strength, low shrinkage, freeze-thaw resistance, sulphate resistance and corrosion
resistance. These high-alkali binders do not generate any alkali-aggregate reaction. The
geopolymer binder is a low CO2 cementious material. It does not depend on the Calcination
of limestone that generates CO2. This technology can save up to 80% of CO2 emissions
caused by the cement and aggregate industries. Due to the high early strength, Geopolymer
Concrete shall be effectively used in the precast industries, so that huge production is
possible in short duration of time.
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