METHODOLOGY

Data gathering

The data needed in this study were generated from the following:

1. Engineering books for general information about aggregates, cement, sand, related topics;

2. Compilation of student thesis for information in proportioning, mixing and testing of

concrete; and

3. Internet for most recent findings that were related to the study, particularly about the

properties of coal fly ash.

Materials and apparatus

The following materials that will be used in making concrete sample are fly ash, sodium

hydroxide flakes and sodium silicate granules, water, gravel, and sand.

The following materials that will be used for determining the unit weight of coconut shell

ash are metal volumetric measure, tamping rod, steel, 5/8 inches in diameter, 24 inches long and

balance and weights

The following materials that will be used for slump test are mixing board, slump mold,

metal ruler or meter stick, tamping rod, pointing trowel and container

The following material and equipment that will be used to determine the compressive

strength of the concrete sample are compression cylindrical mold, 6 inches in diameter, 12 inches

in height, capping materials and facilities, curing materials and facilities, pointing trowel, shovel

container for mixing sample and universal testing machine

Making geopolymer cement

For the development of fly ash based geopolymer concrete mix design method, detailed

investigations will be carried out and following parameters were selected on the basis of

workability and compressive strength. In the investigation, sodium based alkaline activators will

be used. The combination of sodium hydroxide flakes and sodium silicate granule will be used

for the activation of fly ash based geopolymer concrete.

Dry mixing method will be used in mixing the fly ash and the activators. A mixture with

80% fly ash and 20% activators. Activators is composed of 25% Sodium Hydroxide and 75%

Sodium Silicate will be combined. All proportions will be based on mass.

Mixing concrete

Correct proportioning of the ingredients to produce concrete also provides a balance

between the requirements of economy, workability, strength, durability and appearance.

The right proportioning of all the ingredients for concrete is the most difficult

manufacturing step to control, although it is one of the most important aspects in producing high

quality economical concrete.

In this study, the researchers will be conducting 3 sample specimens of geopolymer-

based concrete with the same proportion and will be placed in three cylindrical molds.

Procedure for Mixing Concrete

1. The working surface will be cleaned off. The materials will be also assured to be clean.

2. Materials such as fly ash, sand and gravel will be carefully weighed according to their

respective amount.

3. The alkaline activators will be mixed according to its specified proportion.

 4. Fly ash and alkaline activators will be mixed according to its specified proportion to

produce geopolymer cement.

5. Sand will be placed on the mixing surface together with geopolymer, mixing them to

achieve evenly distributed particles of each material.

6. With a shovel, a crater was made in the center of the heap.

7. Gravel was poured around the heap during the mixture by mixing to be evenly and

properly mixed together.

8. With a shovel, another crater was formed in the top of the heap.

9. As water was then added, a shovel was moved from the sides of the heap into the central

crater and turn part of the heap to distribute the water throughout the mixture.

10. Mixing the mixture within a minimum of almost fifteen minutes or even for much longer

period was done to assure that all ingredients were mixed uniformly.

Unit Weight Test

Compact Weight Determination Procedure

1. Fill 1/3 of the measure, level and tamp 25 times evenly distributed over the surface.

2. Fill 2/3 of the measure, then to over – flowing. Each time the same procedure as in step

one is repeated. In tamping the rod should penetrate only the layer being tamped and

should not be forced into the bottom of the measure or last layer placed.

3. Strike off the excess aggregate with the tamping rod.

4. Get net weight of aggregate in measure. Compute unit weight by dividing the net weight

by the volume of measure.

 Loose Weight Determination

5. Fill volumetric measure of measure of over flowing by means of a shovel or scoop.

Discharge the aggregation from a height of about 2 inches from the top of the measure.

Exercise care to prevent aggregation of particular sizes.

6. Level – off carefully surface of aggregate

7. Get net weight of aggregate and compute unit weight by dividing net weight by volume

of measure.

Slump Test

Slump of concrete was conducted pursuant to ASTM C143 or the standard test method

for slump of hydraulic-cement concrete. The slump test includes the following procedures:

1. Place the freshly mixed concrete inside the mold in 3 layers. Each layer is rodded

separately by a 6 mm rod 25 times.

2. Level the mold and lift at once.

3. Measure the slump action immediately by getting the difference in height between the

height of the mold and the top of the slumped concrete.

4. If the slump measures 5 cm, it is called 5 cm slump.

The degree of consistency of concrete could be ascertained by referring to Table 1.

Table 1. Recommended slumps for various construction structures
Types of construction Maximum Minimum
cm. cm.
Reinforced foundation wall and footing 13 5

Plain footing, caissons and sub – structure walls 10 2.5

Slab, beam and reinforced walls 15 7.5

Building columns 15 7.5

Pavements 7 5

Heavy mass construction 7 2.5

Source: Building Construction by Max Fajardo

Casting Cylinders

This test was carried out following the procedure of ASTM C31 or the standard practice for

making and curing concrete test specimens in the field. Test cylinders were casted to verify the

specified compressive strength of the mix has been achieved. The procedures for casting

cylinders are:

1. After slump test, mix the concrete thoroughly and place the casting molds on the concrete

floor.

2. Fill the mold to 1/3 full by volume (4-inch depth) and rod the bottom layer with 25

strokes evenly spaced

3. Fill the mold to 2/3 full (8-inch depth) and rod the second layer with 25 strokes

penetrating the top of the second layer.

4. Heap the concrete on the top of the mold and rod the top layer with 25 strokes penetrating

the top of the second layer.

5. Tap the sides of the mold lightly to close the voids left by the rod.
 6. Strike off the top surface of the concrete using a sawing action with the rod. Smooth the

surface and be sure to mark the cylinders with your mix number, cylinder number, batch

number and date.

7. Carefully move the cylinder to temporary storage.

8. Cover the cylinders with a plastic bag.

9. After 20 to 24 hours remove the mold. Place the concrete in container filled with water

for curing.

Curing of Concrete

Following the standard procedure of ASTM C31 or the standard practice for making and

curing concrete test specimens in the field, concrete cylinders were cured at 7 days, 14 days and

28 days period. The procedure involves the following:

1. After removing the concrete from the mold, place the concrete inside the container filled

with water.

2. Cover the surface of the container to avoid evaporation of water.

3. Let the concrete absorb water until the specified days.

4. Be sure that the concrete does not undergo any disturbance.

Compression Test

Cylinders tested for acceptance and quality control are made and cured in accordance with

procedures described for standard-cured specimens in ASTM C 31 standard practice for making

and curing concrete test specimens in the field. An average of 3 consecutive tests shall be done

for each mix design. Compression test involves the following procedures:
1. For a coarse aggregate not more than 5 cm diameter, prepare a cylindrical specimen 15

cm diameter and 30 cm long.

2. For a coarse aggregate more than 5 cm diameter, prepare a cylindrical specimen with a

diameter 3 times the maximum size of the aggregate and a height double its diameter.

3. The mold should be made of metal placed on a plane surface preferably 6 to 12 mm plate.

4. Place the fresh concrete inside the mold in 3 separate equal layers rodded separately with

16 mm rod 25 strokes.

5. Level the surface with trowel and cover with a glass or plane steel.

6. After 4 hours, cover the specimen with a thin layer of cement paste and cover again with

plane metal or glass.

7. After 24 hours, start curing in a moist atmosphere at 21 °centigrade.

8. Test should be done at 7 and 28 days period.

9. Be sure that both ends of the specimen are perfectly leveled.

10. Specimen is placed under a testing machine and a compressive load is applied until the

specimen fails. The load that causes the specimen to fail is recorded.

11. The recorded load divided by the cross sectional area of the cylinder gives the ultimate

compressive unit stress of the sample

Statistical Analysis

The experiment will be conducted using the Least Significant Difference method (LSD)

in Statistical Package for Social Sciences (SPSS). SPSS is a widely used program for statistical

analysis in social science. It is also used by market researchers, health researchers, survey

companies, government, education researchers, marketing organizations, data miners, and others.

Analysis of Variance (ANOVA) will be used to analyze the data collected. The results

will be tabulated and interpreted.