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Sumit
Sumit
Introduction: India is the second biggest producer of cement on the planet. No wonder, India's
cement industry is a fundamental piece of its economy, giving work to in excess of a million people,
directly or indirectly. Indian market size of cement production capacity is 502 million tons per year
2018.The expected capacity addition increase of 20 million tons per year in 2019. Nowadays many
attempt have been carried out in construction industry in order to reduce carbon footprint which is
highly generate from construction materials. Many research community try to identify green product
and technology, which supports the concept of sustainable development and green materials. Ordinary
Portland cement is the one of the highly consumed material in worldwide and it also generate the large
amount of carbon di oxide while its production (Maholtra, 2002). Around 7% of carbon di oxide
emission globally generates while production of cement through clinker process which is highly
responsible for global climate change (Shi et.al 2011).
Growing industrialization is also responsible for the release of waste by-products such as fly ash, rice
husk ash, ground granulated blast furnace slags, which are pozzolanic in nature .Environmentally
compatible dumping of these waste materials requires suitable techniques. The world earth summits
also warned cement industry to switch over from Portland cement to a greener alternative binder with
desirable structural as well as durability properties so that the increased emission of greenhouse gases
to the atmosphere can be controlled.
Researchers globally explored the ancient construction materials and found that geopolymer materials
were used in Egyptians pyramids during 2630 BCE–2611 BCE . In this quest, Joseph Davidovits, a
French material scientist proposed a term ‘geopolymer’ to represent a broad range of materials
characterized by chains or networks of inorganic molecules and also pointed out the possibility of its
use as a binder material in concrete. The special features of the geopolymer, such as the development
of high early strength and better resistance to chemical attacks fascinated the scientific community.
Geopolymer materials require raw materials which are rich in silicon (Si) and aluminum (Al) and
alkaline activator solutions. The binding properties of these materials are obtained by the process of
polymerization which primarily differentiates them from the conventional cement based binder
materials. Geopolymeric materials don’t require cement as a binder which emits greenhouse gases, so
it makes it an environmentally friendly material.
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Concrete is a significant material in the field of construction, which consists of components such as
cement, aggregates, water. The demand for the components of concrete can never be satisfied and is
expected to increase in the coming future. However, there is various environmental issue associated
with the components. For instance, the cement industry is acclaimed to be the second-largest
contributor to greenhouse gas emission [1]. Moreover, cement production is expected to reach 4380
million tons by 2050 [2]. One ton of cement production leads to 0.85-1 tons of CO2 [3]. With the
urgency to calm down the global crisis due to the greenhouse gas emission, there is a need for replacing
these environment unfriendly materials and consider some other replacement materials in place of
cement, which is the motive of this research to present a supplementary cementitious material.
Previous research suggests that the industrial by-products can use as the supplementary material, which
can part in saving the earth bit by bit as every individual must contribute with whatever possible in his
hand to save the planet. The industrial by-products in present times are used to prepare an alkali-
activated cement called geopolymer concrete. This geopolymer concrete is sustainable and economical
binder as it produced from the industrial remains, which disposed on the land without proper treatment.
To name a few industrial by-products fly ash, granulated ground blasts, furnaces slag, fumes can
replace the cement in concrete.
Geopolymer concrete is the alkali-activated aluminosilicate material wherein alkaline chemicals used
as binding material. Depending on the material used in curing conditions to prepare the geopolymer
concrete, the geopolymerisation is different for those produced in hydration of OPC [4].
There are various alternatives for cement present and already used. One such is Low-calcium fly ash
(class F), which is a Cementous material suitable for geopolymer concrete. Much research has been
conducted on the heat curing on the mechanical and durability properties, which resulted in similar or
superior to that of OPC concrete. In order to cure at ambient temperature, some admixtures added to
geopolymer concrete.
Moreover, the availability of the excellent quality of aggregate is also declining. To overcome this
shortage many researchers examined to use rubber waste products as the replacement for natural
aggregates. Furthermore, this study solves two problems altogether. The enormous amount of vehicle
industry development leads to large amount of scrap tire and also environmental issues called black
pollution. As it is a non-biodegradable material there is a need to reuse the scrap tire to develop
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sustainable material. That is, it produces an alternative for the natural aggregates and recycles the
disposed rubber, which is home to various diseases and destruction to the land resource. -To
complement this fact, the studies have shown the use of rubber aggregates decreases the compressive
strength due to its elasticity and flexibility. Also, the properties such as ductility, impact resistance and
energy dissipation capacity increases.
Another such possible aggregate is copper slag, which exhibits similar pozzolanic properties because
of low CaO content. It is metallurgical waste-producing during copper extraction. Around 2.2 tons of
copper slag is produced in a year by copper production and 24.6 million tons in the world. Alone in
Asian continent, 7.26 million tons/ annum of copper slag is being generated [5]. The studies mentioned
that the specific gravity of the copper slag lies between 3.4-3.8.
Steel is used as the tension member in concrete as it is weak in tension and high in compression.
However, the material has been costly for repair or rehabilitation due to corrosion of concrete.
Therefore, Glass Fiber Reinforced Polymer (GFRP) bars which are highly tensile and high corrosion
resistance.
he use of a geopolymer can be further accepted if the cost of production is reasonably competitive,
more reliable data is needed, and their establishment for design is a prerequisite for its acceptance [5].
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Problem statement:
Research gap:
Research objectives:
To develop a fly ash based alkali mortar using marble dust as replacement of fine aggregate.
To study the mechanical properties of geopolymer mortar.
To study the durability and micro-structured characteristics of geopolymer mortar.
To study the rheology test of geopolymer mortar.
Reuse the industrial waste in construction sector is substantially raised the sustainable technology.
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Surface
resistivity test
Microstructural
analysis
SEM
EDS
XRD
MAS NMR
NT Build
chloride
migration
ASTM C1556
bulk diffusion
test
Free & bound
chloride
measurements
Chloride
binding
experiments
Apparent
chloride
diffusion
coefficient
Performanc Compressive weight increased
Sulfate e of strength due to the
resistance of geopolymer pH of solution formation of
ferrochrome concrete change in gypsum &
2015
slag based exposed to length ettringite
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different
low calcium
fly ashes
The Evaluates Compressive Need to evaluate
improvement the volcanic strength the geopolymer
of mechanical, tuff-based FT resistance mortar properties
physical, and geopolymer UPV here they just
durability concrete Relative done for concrete
characteristics with the dynamic
of volcanic addition of modulus of
tuff based nano-silica, elasticity
geopolymer micro silica SEM
concrete by and styrene- Water
using nano- Butadiene absorption
silica, micro latex at Density
silica and different
Bulk density &
styrene- rates apparent
butadiene
porosity
latex additives
at different
ratios[8]. 2018
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under drop
weight test
Impact
resistance
under flexural
loading
Comparative Influence of Workability Decrease in
study of inclusion of Absorption workability
geopolymer waste Compressive Strength
and alkali- foundry strength increased
activated slag sand SEM
concrete EDS
comprising Environmental
waste foundry impact
sand[12]. 2019 analysis
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Drying
shrinkage test
SEM
Investigatio Workability Improvement of
Mechanical
n on Setting time mechanical
properties and
geopolymer SEM properties due to
microstructure
concrete EDS the formation of
analysis of
using fly new crystalline
FA-GGBS-
ash, GGBS, phases
HMNS based
high
geopolymer
magnesium
concrete[14]. 2019
nickel slag
The NMR analysis Improvement of
A study on the
durability test strength
characteristics
of Compressive continuous with
and
geopolymer strength test an increase in the
microstructure
concrete RCPT curing period
s of
after nine observed
GGBS/FA
months of
based
the indoor
geopolymer
and outdoor
paste and
curing
concrete[15]. 2019
period
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Load-bearing
capacity
Mid-span
deflection
Ductility and
energy
absorption
Reinforcement
strains
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of the column
capacities
The ambient
cured GPC is
more brittle &
exhibit a higher
strength loss in
the column than
in OPC. More
test needs to
conducted to
determine the
correlation
between
compressive
strength of real
column &
cylinder strength
Novel Shrinkage The future work
Flexural strengthenin performance of should focus on
performance g technique FRGC determining the
of reinforced is proposed Strengthening actual interface
concrete using with extra RC properties and
beams additional layer and the existing
strengthened high- investigation design models to
with fiber- performanc of the effect of taken in to
reinforced e fiber- corrosion account to
geopolymer reinforced Accelerated improve
concrete geopolymer corrosion characteristics of
2019
under concrete testing by FRGC-to-
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Fracture
properties
Shrinkage
Chemical
resistance
The resistance
of seawater
attack and
sulfate attack
Acid attack
Thermal
resistance and
high
temperature
Microstructure
analysis of
geopolymer
concrete
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Nano silica
properties on
geopolymer
concrete
Effect of nano
clay on the
durability of
flax fabric
reinforced
geopolymer
nanocomposite
s
Anti-microbial
efficiency of
nano-silver
silica modified
geopolymer
mortar
Structural Mechanical Better
performanc strength mechanical,
e in terms Bond-behavior flexural strength
of bond between and bond
strength, concrete and strength observed
Structural
flexural reinforcement in nano-silica
performance
strength, bars modified fly ash
of nano-silica
microstruct Flexural geopolymer
modified fly
ural strength concrete under
ash-based
behavior analysis of ambient
geopolymer
has reinforced temperature
concrete[26]. 2016
evaluated
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Flexural compressive
elasticity compared to
natural
Recycling of
aggregates
geopolymer
whereas it is 25-
concrete[27]. 2015
30% for OPC
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pattern of improvement at
repaired RC levels
The load
capacity of
fixed RC
specimen
Interface slip
measurements
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fuel ash
when
exposed to
2% sulfuric
acid for 18
months
Influence of Workability Inclusion of OPC
one-part Setting time reduces
hybrid OPC Compressive workability but
geopolymer strength tests increase in
concrete Microstructura compressive
where solid l analysis strength at an
potassium early age due to
carbonate its quick reaction
as the of OPC with
primary alkali activators
activator
and OPC as
a source of
silicate and
polysilicate
Mechanical
blended
properties of
with
ambient cured
geopolymer
one-part
raw
hybrid OPC
materials in
geopolymer
different
concrete[34]. 2018
proportion
Effect of Effect of SEM There is a
2018
source and particle size Absorption decrease in
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Electrochemic
al
measurements
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Material :
Low-calcium processed fly ash from thermal power plant was used as source material in the proposed
mix proportioning method. The laboratory grade sodium hydroxide in flake form (97.8 percent purity)
and sodium silicate (50.72 percent solids) solutions are used as alkaline activators.
Geopolymer:
The term 'geopolymer' was designed in the 1970's by Prof. Joseph Davidovits and the French analysts
and applied to a class of source materials combined by the response of a soluble arrangement with an
alumino-silicate powder (Davidovits, 1991a).
Geo-polymerization is a geo-synthesis response that artificially incorporates minerals that relys upon
the capacity of the aluminium particle 6-overlap or 4-crease coordination to instigate crystallo-
graphical and compound changes in a silica spine.
where M is an alkaline element such as sodium (Na+) or potassium (K+), z is Si/Al ratio which varies
from 1, 2, 3 or higher, n is the degree of polymerization and “–” indicates the presence of bonding
(Davidovits, 1991). The ratio of Si/Al results in different properties of geopolymer, however, the low
ratio of Si/Al ≤ 3 has been widely used to obtain 3-dimensional cross-link networks as cement and
ceramics [21].
Fly ash
Fly ash is the secondary product of coal production power plant where pulverized coal is consumed
for electricity generation. It consists of aluminous and siliceous material, and termed as pozzolana due
to its tendency to undergo chemical reaction with calcium hydroxide to obtain cementitious
compounds. Fly ash that contains high amounts of Al2O3 and SiO2 but less than 10% CaO obtained
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from anthracite and bituminous coals which comes under Class F fly ash whereas class C fly ash have
self-hardening traits due to the presence of calcium oxide (CaO) content more than 10%(Headwaters,
2005).
The similar were gathered from the Ready Mix Concrete plant at Phagwara. The collected fly ash is
of category of low calcium and examined against specific gravity according to IS 1727-1697. The
elemental composition based on energy dispersive X-ray analysis (EDAX) is performed and
recorded. Fly ash shows glassy, spherical sphere of sleek and smooth surface based on scanning
electron microscopy (SEM) analysis.
Alkaline Activator
Sodium based alkaline activators are used in the current investigation. Single activator either of sodium
hydroxide or of sodium silicate alone is not as clearly seen as being successful. So, the combination of
sodium hydroxide and sodium silicate solutions is used to activate geopolymer concrete based on fly
ash. The compressive strength of geopolymer concrete is observed to increase with increased
concentration of sodium hydroxide solution and or sodium silicate solution with increased fresh mix
viscosity. As the concentration of sodium hydroxide solution in terms of molarity (M) increases, the
concrete becomes more brittle with an increased compressive strength. Second, the sodium hydroxide
solid costs are high, and preparation is very caustic. Similarly, extra water is required to achieve the
desired degree of workability which ultimately reduces the concentration of sodium hydroxide
solution. So the sodium hydroxide concentration was maintained at 13 M while the sodium silicate
solution concentration contains 16.37% Na2O, 34.35% SiO2 and 49.72% H2O as alkaline solutions.
Similarly, the mass-to-mass ratio of sodium silicate to sodium hydroxide was maintained at to which
set cubes within 24 h after casting and yields fairly good compressive strength results[40].
We purchased sodium silicate from chemical shop near Jalandhar in liquid form and we also purchased
sodium hydroxide in flaky form around 100 kg. And we mix together according to our mix design to
make alkaline solution.
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Copper slag
The recent study explore the likelihood of introducing cooper slag in geopolymer concrete as partial
replacing the fine aggregate at standard and oven air curing constraints has been analyzed. The
various proportion of cooper slag with fine aggregate mix is studied for its strength upgradation and
properties enhancement (K.Mahendran and N. Arunachelam, 2016).
Cooper slag for the experiment is collected from the cooper extraction plant by smelting process in
Jodhpur. These are the impurities termed as slag remains on the top of the molten metal snuff out
with the help of water in the form of angular granules(Al-Jabriet al., 2011).
Examine geopolymer binder created from copper mine tailings (MT) and low-calcium slag (SG) for
potential applications in street development. The examination deliberately researched the impacts of
water-to-strong proportion (w/s), SG content (0%, 25%, and half), sodium hydroxide (NaOH) focus
(5, 10 and 15 M), and the proportion of sodium silicate (SS) to sodium hydroxide (0.0, 0.5, 1.0, and
1.5) on the unconfined compressive quality (UCS) of incorporated geopolymer fastener examples.
Examining electron microscopy (SEM), vitality dispersive X-beam spectroscopy (EDS) and X-beam
diffraction (XRD) investigations were likewise performed to portray the microstructure and stage
piece of the geopolymer examples. The outcomes show that the consideration of SG improves UCS
and diminishes the underlying water content required for accomplishing a specific usefulness of the
geopolymer glue. Temperature significantly affects the mechanical properties of geopolymer. The Fe
from SG likewise takes an interest in the eopolymerization procedure. It is imperative to consider the
impact of Fe in the geopolymer response when SG is incorporated (Manjarrez et al., 2019).
To manage the contamination made and better use copper slag, another controlled low strength
filling material (CLSFM) was suggested for the copper slag from a mine in Africa .The filling cost of
utilizing CLSFM is proportional to that of cement, just as the strategy is increasingly biological and
complies with the nearby government condition arrangement. So as to contemplate the impacting
elements of this material, symmetrical test strategy and information representation were utilized in
the method, which make it conceivable to watch the impact of multifaceted composite activity on
copper slag and the ideal proportion. The slag powder must be completely hydrated when it arrives at
certain fineness, and the particles bigger than 60 μm are inactive particles, which have no beneficial
outcome on the quality. The copper slag slurry tests were set up as indicated by the enhanced
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proportion, and afterward the UCS of 7 d and 28 d were resolved. The objective of proportion
advancement is a mine in Zambia, Africa, which requires 0.5MPa of inlay strength.The CLSFM was
set up by blending the enacted copper slag with the crude copper slag (the mass division of complete
solids in each test was 70 %). The trial results show that mechanical actuation and soluble base
excitation can adequately enact the copper slag. Minute investigation shows that the primary
hydration result of CLSFM, C-S-H, makes the copper slag cementitious, and improves its auxiliary
quality (Wentao et al., 2019).
Aggregate : The size of aggregate we used in this experiment ,which is having size of 10mm.
And the aggregate, we obtain from near RMC plant Phagwaga. The specific gravity of aggregate is
obtained from lab test is 2..64. Geopolymer concrete workability is also affected by gradations Of a
fine aggregate. So, on the basis of fine gradation,In the proposed mix proportioning, aggregate, fine
to total aggregate ratio is selected.
Methodology :
The fresh Geopolymer concrete based on fly ash was found to be viscous, dark on color and
cohesive. Having made the homogeneous mix, the workability fresh geopolymer concrete was
measured by flow table apparatus as per IS 5512-1983 and IS 1727-1967. Concrete cubes of side 150
mm are casted in three layers. Each layer is well compacted by tamping rod of diameter 16 mm.
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2.36 97 97.4
1.18 95 72.5
The alkaline activator used in this study is a combination of the ratio 1:2.5 of sodium hydroxide and
sodium silicate. 14 M solution of sodium hydroxide is prepared by dissolving the sodium hydroxide
flakes in distilled water Single day before use. For this function, the sodium silicate is supplied by
the local supplier having the ratio of Na2 to SiO2 of 2:1.
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Mix Proportion
The mix proportion for the sample is achieved by keeping as constant the volume of fly ash and
coarse aggregate. The sodium hydroxide to sodium silicate ratio is taken as 1:2.5 and the alkaline
liquid to fly ash ratio is kept as 0.4. A 4% dosage of the super plasticiser Conplast SP430 (sulphoned
naphthalene formaldehyde condensate) in compliance with IS: 9103-1999 and ASTM C-494 was
applied to the mix to boost the concrete 's workability. The sand is replaced by its weight with a 10
% increase in each mixture and the mixing ratio.
Mix proportion
Mix ID M1 M2 M3 M4 M5 M6 M7 M8 M9
Fine agg. 615.2 553.8 489.4 427.4 368.2 307.5 250.4 180.4 125.6
NaOH 52 52 52 52 52 52 52 52 52
Na2SiO3 130.6 130.6 130.6 130.6 130.6 130.6 130.6 130.6 130.6
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Specimen Preparation:
The prepared sodium silicate and the sodium hydroxide are premixed. The dry aggregate and fly ash
are mixed in a pan mixture for about 3 minutes .The Premixed Alkaline Activator and Super
Plasticizer are added The dry mixed materials are then mixed for about five minutes and then
transferred to the mold in 3 layers, each layer is compacted for Ten seconds by a table vibrator to
eliminate air voids and the surface is levelled. The specimens are then sealed off with a polyvinyl
sheet to prevent water loss due to evaporation. The specimens shall be left as a rest time in the room
temperature for a day. After the rest time is complete, the specimens are demolished and cured for 24
hours at 60 ° C and the remaining cube specimens are left to cure under ambient conditions.
The copper slag appearance looks like black and glassy with a specific gravity of 3.80 . That is higher
than the specific gravity of sand 2.52 .Water absorption of copper slag is 20% as compared to sand
which is having water absorption of 95% . In the table above, an elementary analysis preformed for
copper slag, sand and fly ash reveals that Si is higher in copper slag relative to sand. The presence of
Al in copper slag is also noted to be higher compared with both fly ash and sand. In copper slag the
presence of Si and Al slag may lead to enhancement of the concrete strength as the percentage of
copper slag replacement increases. During the testing of slump, it was found that the workability is
high if we add super plasticizer. Without adding of plasticizer the workability is low due to less water
content. The compressive strength of cubes checks in after 3 rd day, 7th day, 14th day and 28th day. And
in many researcher observe that increasing the percentage of copper slag also increasing the
compressive strength. And it was observed that after 28 th days the higher percentage water absorption
reduce due to copper slag.
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Conclusion:
The amounts of copper slag significantly affect the performance of geopolymer concrete. The strength
of geopolymer concrete with copper slag as a fine aggregate is compared to control concrete found to
be 1.35 and 1.51 times higher strength when healed in ambient and oven healing. t is found that in the
geopolymer concrete the percentage of copper slag has been increased, and the compressive strength
has also been increased. The highest compressive strength geopolymer concrete found that 59.83.
When cured in oven and ambient condition, there is a small variance found in the concrete density.
Compared with the ambient healing state, water absorption of the oven cured geopolymer concrete is
found to be low. The geopolymer concrete microstructure reveals the homogeneity of the geopolymer
concrete, and fly ash dissolution is also observed on the surfaces of the specimen.
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