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DOI 10.1007/s13369-015-1757-z
Abstract Geopolymer binders are attracting the attention Keywords Geopolymer paste · Final setting time ·
of researchers as substitution to cement binder in conven- Compressive strength · Normal consistency · Alkaline
tional concrete. In manufacturing 1 ton of cement, 1 ton of solution
CO2 is released into the atmosphere. Thus, replacement
of cement by geopolymer material in construction industry
reduces pollution by two ways: reduction in carbon diox- 1 Introduction
ide emission into atmosphere by reducing the consumption
of cement and utilization of fly ash, which is another waste Concrete usage is second to water in this present-day world.
product piling in huge quantities in thermal power plants. To Ordinary Portland cement (OPC) is conventionally used as
examine the use of geopolymer as a replacement to cement, the primary binder to produce concrete due to its availabil-
it is essential to investigate normal consistency, final setting ity of the raw materials over the world and ease of mold
time and compressive strength of geopolymer which are rou- ability. The application of concrete in the realms of infrastruc-
tine tests generally conducted for cement. The procedure ture, habitation and transportation has greatly promoted the
adopted for determining the normal consistency, final set- development of civilization, economic progress, stability
ting time and compressive strength of geopolymer is same and quality of life. Nowadays with the advent of high-
as the procedure adopted for cement. In these tests, cement performance concrete (HPC), the durability and strength
is replaced by geopolymer material and water is replaced of concrete have been improved largely. The environmen-
by alkaline activator solution. The parameters considered in tal issues associated with the production of OPC are well
this investigation are geopolymer source material (fly ash known. The amount of the carbon dioxide released during the
and GGBS) and alkaline activator consisting of sodium meta manufacture of OPC due to the calcination of limestone and
silicate and sodium hydroxide of different molarities (8, 12, combustion of fossil fuel is in the order of 1 ton for every ton
16 M). The ratio of sodium meta silicate to sodium hydrox- of OPC produced. In addition, the extent of energy required
ide considered in this study is 2.5. The test results indicated to produce OPC is only next to steel and aluminum. On the
that combination of fly ash and GGBS results in decreased other hand, the abundant availability of fly ash worldwide cre-
final setting time and increased compressive strength. It was ates opportunity to utilize this by-product of burning coal, as
also observed that increase in sodium hydroxide increases a partial substitute for OPC to manufacture cement concrete
compressive strength of geopolymer mortar. products.
Geopolymer has the potential to replace OPC in the
construction sector. Geopolymer is used as the binder to
completely replace OPC in producing geopolymer con-
crete. In order to produce geopolymer, low-calcium fly ash,
B G. Mallikarjuna Rao a source material, needs to be activated by an alkaline
gmyadav25@gmail.com
solution to produce polymeric Si–O–Al bonds. The alka-
1 Department of Civil Engineering, National Institute line solution is the combination of sodium hydroxide and
of Technology, Warangal, Warangal 506004, India sodium meta silicate. Geopolymer concrete has the potential
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to reduce greenhouse emissions from the concrete indus- Table 1 Chemical composition of fly ash and GGBS (% by mass)
try by 80 % [1,2]. Geopolymer concrete is also known as Chemical composition Fly ash GGBS
alkali-activated concrete or inorganic polymer concrete. It is
reported that fly ash-based geopolymer concrete possesses SiO2 60.11 34.06
excellent physical properties such as high early strength, low Al2 O3 26.53 20
shrinkage, high resistance to freezing and thawing, sulfate Fe2 O3 4.25 0.8
attack and corrosion [3]. A study which was carried out SO3 0.35 0.9
to investigate the effect of composition of source materials CaO 4.00 32.6
and curing process on the chemical and physical proper- MgO 1.25 7.89
ties of geopolymer revealed that curing at high temperatures Na2 O 0.22 NIL
resulted in cracking and can impose negative effects on LOI 0.88 NIL
the physical properties of geopolymer [4]. Another study
using alkali-activated ground-granulated blast-furnace slag
concrete incorporated with sodium silicate as an activator Fine aggregate used is clean dry river sand. It is sieved using
gave compressive strength up to 50 MPa [5]. Fly ash-based 2.36 mm sieve to remove all the pebbles. Saturated surface
geopolymer mortar cured at ambient temperature with addi- dry specific gravity of sand is 2.67 which confirms to zone
tion of Cao and Ca(OH)2 as calcium compounds had shown II as per IS: 383 [12].
improved mechanical properties [6]. The term ‘geopolymer’
was coined in 1970s by the French scientist and engineer
Prof. Joseph [7], and it was applied to a class of solid materi- 2.1 Alkaline Solution
als synthesized by the reaction of an aluminosilicate powder
with an alkaline solution. A demonstration was given on the The alkaline activator is a combination of sodium hydrox-
synthesis of construction materials by alkaline activation of ide and sodium meta silicate solutions. Sodium hydroxide
solid, non-Portland cement precursors (usually high-calcium solution is used as alkaline activator because it is widely
metallurgical slags) [8]. In particular, coal fly ash with low available and is less expensive than potassium hydroxide
calcium content (<5 wt% CaO) is an abundant industrial by- solution. Sodium hydroxide of 98 % purity is in flakes and
product which is currently underutilized worldwide [9]. It pellets form. These pellets are dissolved in distilled water to
is also well known that the reactions of slag are dominated obtain sodium hydroxide solution of required molarity. The
by small particles. Particles above 20 microns in size react mass ratio of SiO2 to Na2 O of the sodium silicate solution
only slowly, while particles below 2 microns react com- is 2.61 (SiO2 = 30.0 %, Na2 O = 11.5 % and water = 58.5 %).
pletely within approximately 24 h in blended cements and Sodium hydroxide solution of required molarity and sodium
in alkali-activated systems [10]. Clearly, when using slag meta silicate in liquid form are mixed and stored at room
in geopolymerization, careful control of particle size distri- temperature of 25 ± 2 ◦ C and relative humidity of 65 % for
bution can be utilized to control the strength development 24 h before its use.
profile, as is done in OPC blends [11].
This paper presents the results of research that deal with 2.2 Paste
study of normal consistency, final setting time and com-
pressive strength of geopolymer mortar. The calcined source The source materials, i.e., fly ash and GGBS, with differ-
material class F fly ash (commonly used) is partially replaced ent proportions by weight are mixed in dry condition in a
with ground-granulated blast-furnace slag, and the mix is pan mixer. The mixture is activated by adding alkaline solu-
activated with alkaline solution of sodium hydroxide and tion and mixed for 3 min to ensure homogeneity by uniform
sodium meta silicate. Molarity (concentration) of sodium color. A series of geopolymer pastes are prepared by vary-
hydroxide is varied as 8, 12 and 16. The ratio of sodium ing the proportions of calcined source material (fly ash and
meta silicate to sodium hydroxide is maintained as 2.5. GGBS) as well as different concentrations of alkaline acti-
vator (molarities of sodium hydroxide).
Materials used in this research are GGBS obtained from Scanning electron microscopy is performed to ascertain the
Andhra Cements, Vishakhapatnam, India, and fly ash from microstructure properties of the binder material fly ash and
Ramagundam Thermal Power Plant, India, with a specific GGBS. The scanned images of fly ash and GGBS are pre-
gravity of 2.90 and 2.17, respectively. The chemical com- sented in Figs. 1 and 3. Scanning electron microscopy image
positions of fly ash and GGBS are presented in Table 1. gives an approximate idea about the shape, angularity, size
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Fly ash (%) GGBS (%) Alkaline activator solution Alkaline activator solution Alkaline activator solution
with sodium hydroxide 8 M with sodium hydroxide 12 M with sodium hydroxide 16 M
1 100 0 28 28 27
2 90 10 27 27 28
3 80 20 31 30 31
4 70 30 33 31 32
5 60 40 33 33 32
6 50 50 33 33 33
7 40 60 33 33 35
8 30 70 33 35 38
9 20 80 37 37 39
10 10 90 37 37 39
11 0 100 37 37 39
Table 4 Final setting time of geopolymer paste for various molarities of NaOH
S.no. Calcined source Final setting time (minutes)
material combination
Fly ash (%) GGBS (%) Alkaline activator solution Alkaline activator solution Alkaline activator solution
with sodium hydroxide 8 M with sodium hydroxide 12 M with sodium hydroxide 16 M
final setting time of geopolymer with the variation in concen- behavior clearly indicates that the GGBS readily reacts with
tration of sodium hydroxide in alkaline activator for different the alkaline activator compared to fly ash. The setting aspects
mixes of fly ash and GGBS is presented in Table 4. The of GGBS with the alkaline activator are faster than fly ash.
final setting time of different mixes considered in this inves- Thus for developing high early strength geopolymer mate-
tigation varied from 40 to 330 min. It is found that increase rial, GGBS is a better source material than fly ash. Partial
in the concentration of sodium hydroxide solution resulted replacement of fly ash by GGBS by 20 % decreased the final
in increased final setting time. When fly ash content in the setting time from 200 to 120 min when the molarity of the
mix is 100 %, the final setting time increased from 200 min sodium hydroxide is 8 M. From the test data, it is clear that
(with alkaline solution having sodium hydroxide of 8 M) to final setting time has drastically reduced from 200 to 40 min
330 min (with alkaline solution having sodium hydroxide of when the total fly ash is replaced by GGBS for 8 M mix. Such
16 M). When the fly ash content is totally replaced by GGBS, fast setting behavior is not convenient for geopolymer mortar
the final setting time increased from 40 min (with alkaline in conventional construction. Thus, it can be concluded that
solution having sodium hydroxide of 8 M) to 60 min (with to have a desired value of final setting time suitable combi-
alkaline solution having sodium hydroxide of 16 M). This nation of GGBS and fly ash can be advocated.
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1 100 0 41 52
2 90 10 44 54
3 80 20 46 55
4 70 30 49 56
5 60 40 50 58
6 50 50 50 59
7 40 60 52 62
8 30 70 57 65
9 20 80 63 72
10 10 90 69 77
11 0 100 75 82
1 100 0 44 53
2 90 10 45 55
3 80 20 47 57
4 70 30 50 59
5 60 40 52 61
6 50 50 53 65
7 40 60 55 68
8 30 70 62 74
9 20 80 65 77
10 10 90 72 82
11 0 100 78 85
The normal consistency of 100 % fly ash-based geopoly- are presented in Tables 5, 6 and 7. The compressive strength
mer paste is 28 %, and the alkaline activator used for estimat- of geopolymer mortar ranges from 41 to 87 MPa. The
ing the final setting time is 0.85 P (0.85 × 28 = 23.8 %) [15]. outdoor-cured samples have shown variation in compressive
Whereas for 100 % GGBS-based geopolymer paste, the nor- strength with variation in molarity of sodium hydroxide in
mal consistency is 37 % and the alkaline activator used for the alkaline activator from 41 to 69 MPa. Increase in molarity
estimating final setting time is 0.85 P (0.85 × 37 = 31.45 %). of sodium hydroxide in alkaline activator increased the com-
The chemical composition difference between fly ash and pressive strength of the mortar, and similar trend is reported
GGBS and difference in the quantity of alkaline activa- by Hardjito et al. [16]. In case of outdoor-cured samples,
tor perhaps decreased setting time for 100 % GGBS-based increase in percentage of replacement of fly ash by GGBS
geopolymer paste. increased the compressive strength of geopolymer mortar.
Total replacement of fly ash by GGBS has shown a compres-
4.3 Compressive Strength sive strength of 79 MPa. This indicates that geopolymer can
attain strength even under outdoor curing if GGBS and fly ash
The compressive strengths of geopolymer mortars having together are used as source material. The reason for increase
different proportions of fly ash and GGBS along with differ- in compressive strength due to GGBS can be attributed to
ent concentrations of sodium hydroxide in alkaline activator higher calcium content present in GGBS [17]. Oven curing
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1 100 0 45 54
2 90 10 47 58
3 80 20 52 62
4 70 30 56 63
5 60 40 59 65
6 50 50 63 66
7 40 60 65 69
8 30 70 67 73
9 20 80 69 78
10 10 90 75 83
11 0 100 79 87
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14. IS: 4031–1988 (PART 5). Method of Physical Test for Hydraulic 16. Hardjito, D.; Wallah, S.E.; Sumajouw, D.M.J.; Rangan, B.V.: On
Cement: Determination of Initial and Final Setting Time. Bureau the development of fly ash-based geopolymer concrete. ACI Mater.
of Indian Standards, New Delhi (1988) J. 101(M52), 467–472 (2004)
15. Hardjito, H.; Cheak, C.C.; Lee Ing, C.H.: Strength and setting 17. Yip, C.K.; Van Deventer, J.S.J.: Effect of granulated blast furnace
times of low calcium fly ash-based geopolymer mortar. Mod. Appl. slag on geopolymerisation. In: Proceedings of 6th World Congress
Sci. 2, 3–11 (2008) of Chemical Engineering Melbourne, Australia, pp. 23–27 (2001)
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