Professional Documents
Culture Documents
CHAPTER 1
INTRODUCTION
1.1 GENERAL
Concrete is one of the most widely used construction material, it is usually
associated with Portland cement as the main component for making concrete.
Ordinary Portland cement (OPC) is conventionally used as the primary binder to
produce concrete.
Production of Portland cement is currently exceeding 2.6 billion tons per year
worldwide and growing at 5% annually. Portland cement is a major contributor to
carbon-di-oxide emissions as an estimated 5 to 8 percentage of all human –
generated atmospheric carbon – di – oxide worldwide comes from the concrete
industry. The global warming caused by the emission of greenhouse gases, such as
carbon-di-oxide , to atmosphere by human activities. Among the greenhouse gases,
carbon-di-oxide contributes about 65% of global warming. The amount of the
carbon – di – oxide released during the manufacture of ordinary Portland cement
due to the calcinations of limestone combustion of fossil fuel is approximately in
the order of one ton for every ton of ordinary Portland cement produced. In terms
of reducing the global warming, the Geopolymer technology reduce the carbon-di-
oxide emission to the atmosphere caused by cement about 80%.
1.2 Concrete
Concrete is weak in tension compared to steel. It is the most widely used
building material. This is due to versatility. It has desirable engineering properties.
It can be made on site using easily available materials. Most importantly, it is
produced cost effectively compared to other construction materials.
2
CHAPTER 2
LITERATURE OF REVIEW
2.1. LITERATURE OF GEOPOLYMER CONCRETE
S.J. Foster & T.S.Ng , Future in Mechanics of structure and materials (2009),
‘Development of high performance Geopolymer concrete’.
The paper concludes , the equations developed for elastic modules of
conventional concrete cannot be applied to that of GPC, the density and the
poison’s ratio of Geopolymer concrete are similar to those of OPC concrete.
Compressive strength of Geopolymer concrete of 90 MPa, and more are
achievable. The addition of slag in the fly ash based Geopolymer concrete is found
to be beneficial to its strength development. For a given compressive strength,
Geopolymer concrete has a significantly low elastic modules then a equivalent
OPC concrete. A model for calculation of the elastic based on a two phase material
approach is presented and shown to provide a good correlation.
temperatures for each batch: May 2005 (18-25 °C), July 2005 (8- 18 °C),
September 2005 (12-22 °C). The relative humidity for each batch was within the
range of 40-60 percent. The material with the greatest recorded compressive
strength was molded from the May batch.
Creep and dry shrinkage testing was also performed on 150 x 300 mm
cylinders which were both dry- and steam-cured at 60 °C for 24 hours. Testing
commenced after one week of cure time and the recorded stress was 40 percent of
the compressive strength. Test results illustrated that both cure methods yield
similar results. Little shrinkage was observed in the geopolymer specimens after a
one year time period. The measured value for geopolymer was 100 micro strains,
as compared to 500-800 micro strains for Portland cement concrete. One year
creep coefficients were calculated at 0.6-0.7 for specimens possessing compressive
strength values between 40 MPa and 57 MPa. It was noted that these values are
only 50 percent of the recommended coefficients for Portland cement concrete (per
Australian Standard AS3600).
Testing regimes for chemical resistance to sulfates and sulfuric acids were
also conducted. Geopolymer specimens were immersed in a 5 percent sodium
sulfate bath for up to one year. Factors evaluated were mass and length change and
variances in compressive strength characteristics. Other samples were placed into
sulfuric acid solutions of varying concentrations: 0.5 percent, 1 percent, and 2
percent (by volume). Factors investigated here were based upon mass losses and
changes in overall compressive strength. It was reported that specimens subjected
to the sulfate immersion exemplified excellent resistance to the chemical. Visual
observation at one year of exposure reflected no sign of erosion or cracking of the
specimens. As well, no changes in mass or compressive characteristics were
noticed and the change in overall length was less than 0.015 percent.
9
The sulfuric acid tests revealed slight erosion to the specimen surface and it
was noted that the degradation is increased with increased acid concentrations.
Maximum mass loss was reported to be 3 percent after one year, which was stated
to be far less than that of similar Portland cement specimens. Compressive strength
values were also compromised by the acid bath. As with the degradation, the
compressive limits were affected by increases in acid solution concentration.
Finally, the geopolymer material was tested for practical applications by
creating and loading column and beam specimens. The test parameters investigated
were longitudinal reinforcement ratios, load eccentricity values, and compressive
strength. Additional information regarding these tests is defined in detail within the
publication body.
the existing pozzolans. It was noted that while the bonds of polymerization are not
as strong as those created through dehydration, they boast increased water
resistance once formed.Precipitation of formed metal silicates occurs as available
multivalent cations (Ca+, Mg+2,Zn+2, Cu+2, Fe+3) react with the added silicates
to form solids and drop out of solution as a chemical binder. Pozzolans such as
commercial fly ash, blast furnace slag and cement kiln dust contain many of these
required elements needed for precipitation and offer an economic and
environmentally safe alternative to the energy intensive manufacture of Portland
cement. It was found that unlike other available materials, pozzolans require the
introduction of heat and/or chemicals to activate the binder solution and allow for
crucial crystalline formations. As well, they tend to set slower (allowing for
increased reaction degrees) and they are less susceptible to foreign substances in
the matrix. For pozzolan activation, a silicate ratio of 2.0 is recommended.
Sofi, M., van Deventer, J.S.J., Mendis, P.A., Lukey, G.C., “Engineering
Properties of Inorganic Polymer Concretes (IPC’s)”, Cement and Concrete
Research 37, pp. 251-257, 2007.
Structural comparisons between inorganic polymer concretes (IPC’s) and
PCC-based concrete were studied. Few published studies on the engineering
properties of IPC’s exist; therefore, the following IPC tests were conducted:
compressive strength, splitting tensile strength, flexural strength, static chord
modulus of elasticity and Poisson’s Ratio. For IPC densities similar to Portland
cement concretes, the average compressive strengths of the IPC mixes were close
to the design strength of 52.4-MPa. The splitting tensile and flexural strength IPC
models compared to those of PCC. The static chord modulus and Poison’s Ratio
evaluations yielded results similar to high-strength PCC.
observation revealed that the bonding within the AAFA materials caused the 8 mm
bars to break prior to bond sheer. Conversely, the bars embedded in the PCC
material slipped prior to bar damage. It is noted that the Solution 'W' reached an
ultimate stress of 12.5 MPa, while Solution 'N' achieved 17 MPa; each higher than
the 9.7 N/mm beam test requirement per the Spanish concrete code (EHE).
Finally, shrinkage analysis for the AAFA materials (both N and W) showed
less than 0.025 percent reduction after 90 days, versus 0.09 percent for the PCC
samples. It was noted that these results illustrate the dimensional stability of alkali-
activated fly ash concretes.
The mortar used in testing was prepared in accordance with the Spanish
standard UNE-80-101-88 with Spanish blast furnace slag from local industry.
Specimen prisms were constructed using a 2:1 aggregate/slag ratio and an
alkaline/slag ratio of 0.51 for the 450 m2/kg slag material and 0.61 for the 900
m2/kg batch. Curing time was 20 hours at two differing temperatures: 25 °C and
15
45 °C. Compressive and flexural testing regimes were conducted at three, seven,
28, 90 and 180 days.
A combination of test data and statistical analysis revealed that the
slag specific surface used in the batch mix is least relevant to the resultant
mechanical properties of the geopolymer. The second most relevant factor was
found to be the curing temperature, followed immediately by the activator
concentration. Thus, the factor determined to hold the greatest significance as
related to mechanical strength was the nature of the alkaline activator. The highest
mechanical strengths recorded during this research (6-8 MPa for flexural and 40-60
MPa for compressive) resulted from an activator mix of Na2SO3, NAOH and
H2O.
were realized through this research: a calcium hydrate rich in aluminum and an
alkaline aluminosilicate hydrate with threedimensional structure.
The slag obtained for use was found via XRD to consist mainly of a glassy
phase, absent of crystalline phase. The fly ash was analyzed similarly and found to
consist of a glass phase, quartz and mullite. Further testing of the slag material
confirmed a composition near that of Akermanite and Gehlenite.
Mechanical testing was conducted on 1 x 1 x 6 cm prisms with a fly ash/slag
ratio of 1.0. The proprietary activator used was NaOH at a concentration of 10M.
Curing was conducted for five hours at two separate temperatures for comparison:
22 °C and 60 °C. Each specimen then remained at ambient temperature with 98
percent relative humidity for seven and 28 days prior to testing. Compressive
testing results at seven days cure time were recorded at 30 MPa for each mix
design. It was surprisingly revealed that the specimens cured at ambient developed
over 60 MPa of compressive strength within a 28 day cure period; higher than the
samples cured at 65 °C.
It was discovered that the degree of silicate polymerization varies directly
with reaction time; thus, longer cure times allow for greater polymerization and
greater overall concrete strength.
the load carrying capacity of most of the GPC beams was in most cases marginally
more than that of the corresponding conventional OPCC beams. The deflections at
different stages including service load and peak load stage were higher or GPC
beams. However , the ductility factor was comparable to that of OPCC beams. The
studies showed that the conventional RC theory could be used for reinforced
GPCC flexural beams for the computation of moment capacity, deflection, and
crack width within reasonable limits the GPC mixes developed compressive
strength of 17 to 63 MPa compared to 35 to 52 MPa of OPCC. The flextural
strength o GPC mixes is found to be close to that predicted from IS : 456 formula
and compares well with the strength of OPCC specimens. The elastic modules is
significantly lower for GPCs and ACI 318 prediction seems to be closer to
measured elastic modulus compared to IS : 456. This is attributed to the lower
aggregate volume fraction on the GPC mixes used.
material ratio of 0.485 and a fine aggregate/cement material ratio of 2.45. The
fresh paste and mortar mixes were formed into 10 cm3 steel molds and allowed to
remain for 24 hours before being demolded, and water bath cured for up to 28 days
at 20 °C. Compressive testing regimes were conducted at 1, 3, 7 and 28 days and
the tested samples were then crushed and immersed in acetone to prevent further
hydration and freeze-dried prior to micro-analysis.
Compression analysis at one day of cure revealed greater strengths in the
activated pastes than those receiving no alkaline activation. Of all activator
solutions evaluated, the potassium-based alkaline (K2SO4) was found to be most
effective in promoting early strength development and reducing porosity, while
those containing triethanolamine maintained the lowest results of compressive
strengths. N2SO4 was found to efficiently decrease the levels of Ca(OH)2 in the
paste mixes and promoted growth of ettringite within seven days of cure, aiding
the high strength development.
It was concluded that while the activators employed for this experiment
promoted early strength development, the measured strength values at 28 days
were comparable to the fly ash/Portland mixes absent of alkaline activators. It was
stated that further testing would be required to fully understand the affects related
to activation in both early and late stage development.
24
CHAPTER 3
METHODOLOGY
The methodology explains about the step by step procedure that is going to be
done in the project. The methodology is explained in the following figure.
Literature Collection
Collection of Material
Experimental Analysis
Testing of Specimen
Conclusion
25
CHAPTER 4
MATERIAL AND PROPERTIES
4.1 INTRODUCTION
The utilization of waste in the construction industry has two glaring
dividends, one ,environmental impact is addressed by disposal of the waste and
second , the economic impact and this waste has the edge of being available large
quantity, everywhere and at low value. The materials used for this investigation
were fly ash, M Sand, Metakaloin, and sisal fibre. In this project is replacement by
fly ash in clay soil and its strength is studied. In this chapter the material
characteristics, properties used in brick in brick are discussed.
4.3 Metakaolin
Metakaloin is a de hydroxide form of the clay mineral kaolinite. Stone that
are rich in Kaolinite are known as china clay or kaolin, traditionally used in the
manufacture of porcelain. The particile size of metakaolin is smaller than cement
particles, but not as fine as a silica fume. Kaolinite chemical composition is Al 2O3.
2 SiO2. 2H2O.
It is white in color and acts as a pozzolanic material. Kaolin is a flaky, white
clay rock, essentially composed of Kaolinite. Kaolin is formed by hydrothermal or
meteoric degradation of minerals, and other silicates. This kaolin clay is ground
and then calculated at 750oC, which causes disorganization of the crystalline
structure.
27
4.3.1 Sources
High purity Kaolin Deposits
Kaolinite deposits or tropical soils of lower purity
Paper sludge waste
Oil sand tailings
4.3.2 Advantages
Increased compressive and flexural strengths
Reduce permeability
Increased resistance to chemical attack
Increased durability
2 Hemicelluloses 12%
3 Lignin 9.9%
4 Waxes 2%
4.5 Aggregates
The aggregate are the main components of the concrete which greatly varies
the strength , density and other properties of the concrete. Different types of
aggregates used are discussed.
4.5.1 Fine Aggregate
Sand is used as a fine aggregate in mortars and concrete. Due to the scarcity
of river sand, the manufactured sand is used as fine aggregates in concrete. M Sand
is an eco-friendly and economical which has become widely popular for use in all
constructional purposes. The fine aggregate used in the project was locally
supplied and conformed to grading zone II as per IS 383:1970. It was first sieved
through 4.75 mm sieve to remove any particles greater than 4.75 mm. Properties of
the fine aggregate are tabulated below in Table 4.4.
4 Maximum Size 20 mm
CHAPTER – 5
34
5.1 GENERAL
This method is recommended for designing mixed for general types of
construction. Using the ingredients of concrete normally available. The design is
carried out for specified compressive strength and workability of concrete using
continuously graded aggregate. The method can be for both reinforced and pre-
stressed concrete.
From Table 5 of IS 456, minimum cement content for ‘very sever’ exposure
condition = 240 kg/m3.
36
a. Volume of Concrete - 1 m3
mass of cement / specific gravity of cement
b. Volume of cement - ---------------------------------------------------- x 1/1000
Specific gravity of cement
- 394 x 1
----- ----
3.15 1000
- 0.125 m3
37
mass of water
c. Volume of water - ---------------------------------------------------- x 1/1000
Specific gravity of cement
- 197 x 1
----- ---- = 0.197
1 1000
= 2.61 kg
Weight of CA = 2.78 / 5.58 x 8.1
= 4.03 kg
5.5.2 Cylinder
Size of mould = 300 x 150 mm
PCC Unit Weight = 2400 kg/m3
Volume of cylinder = 3.14 / 4 x 0.152 x 2400
= 12.24
Weight of Cement = 1.5.58 x 12.72
= 2.27 kg
Weight of FA = 1.8 / 5.58 x 12.72
= 4.1 kg
Weight of CA = 2.78 / 5.58 x 12.72
= 6.33 kg
5.5.3 Prism
Size of mould = 500 x 100 x 100 mm
PCC Unit Weight = 2400 kg/m3
Volume of cylinder = 0.5 x 0.1 x 0.1 x 2400
= 12
Weight of Cement = 1/5.58 x 12 = 2.15 kg
Weight of FA = 1.8 / 5.58 x 12
= 3.87 kg
Weight of CA = 2.78 / 5.58 x 12
= 5.97 kg
CHAPTER – 6
CONCLUSION
40
6.1 GENERAL
The main objective and the background of this research project are
outlined in the initial chapters of this thesis.
The experimental program and the analytical study performed during the
research project to achieve the objective are explained and discussed in
Chapters 1 to 5 in general.
Due to time and resource constraints, it was not possible to address all of
the issues associated with the current topic and therefore a number of
possible scenarios are listed at the next chapter for researchers who are
interested in this area.
CHAPTER 7
PHASE I & II SCHEDULE
REFERENCE
1] E.Sreenivasulu & A. Ramakrishnaiah “Experimental Investigation On
Durability Properties Of Geopolymer Concrete By Partial Replacement
Of Fly Ash And MK”