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Composites Part B 97 (2016) 329e335

Contents lists available at ScienceDirect

Composites Part B
journal homepage: www.elsevier.com/locate/compositesb

The effect of curing on the properties of metakaolin and fly ash-based


geopolymer paste
€ rhan*, Rıdvan Aslaner, Osman Şinik
€ khan Go
Go
Afyon Kocatepe University, Engineering Faculty, Civil Engineering Department, 03200, Afyonkarahisar, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: Fly ash was used as the raw material in the preparation of geopolymer paste and metakaolin was used as
Received 8 December 2015 a substitution material in different ratios. Metakaolin material was made of kaolin clay calcined at a
Received in revised form temperature of 1000  C and at a final temperature for 1 h in a laboratory-type electric arc furnace. The fly
28 April 2016
ash in the prepared mixture was substituted by metakaolin ranging from 10% to 40%. In the mixtures,
Accepted 9 May 2016
NaOH was used as the reactive together with a 3-module sodium silicate solution to solve silica and
Available online 11 May 2016
alumina in the fly ash and metakaolin particles. A 9 M NaOH solution was used in the preparation of the
geopolymer pastes and the liquid/solid ratio used in the mixtures was 0.36 ml/gr. The pastes were cast
Keywords:
Physical properties
into a 25 by 50-mm cylinder mold. This process was performed under a 100 bar pressure using a hy-
Strength draulic hand press. Afterwards, the samples were placed in a laboratory-type oven for thermal curing.
Mechanical testing The samples were subjected to curing at 60  C and 80  C (two different curing temperatures) for 2 h, 4 h
Cure and 24 h (three different curing times). Following curing, the samples were maintained under laboratory
Geopolymer conditions at room temperature until the day of the physical and mechanical tests. 7-day geopolymer
paste samples were used for the tests. As a result, the ideal curing temperature and curing time were
decided to be 60  C and 2 h for the production of the geopolymer paste. It was also determined that the
compressive strength values of the samples subjected to curing reached up to 25.1 MPa and that a 40%
metakaolin substitution provided a better geopolymerization and significantly improved compressive
strength values.
© 2016 Elsevier Ltd. All rights reserved.

1. Introduction Geopolymers are thought to harden due to the polycondensation of


the type of hydrolyzed alumina and silicate. A typical composition
Aluminosilicate inorganic polymers called geopolymer were of geopolymerization is generally denoted by nM2O-
first described by Davidovits. Geopolymers are ceramic-like and $Al2O3$xSiO2$yH2O [2,3].
similar to zeolites in terms of their chemical structures, however Geopolymerization occurs in silicates as reagents, aluminosili-
have an amorphous structure. Such materials quickly harden at cate oxides and alkaline solutions. Geopolymerization is a mecha-
ambient temperatures and gain mechanical strength and heat nism which involves the dissolution of various types of silica and
resistance [1]. aluminum from the surfaces of source materials, such as surface
Geopolymerization refers to the hardening of fly ash-based hydration of undissolved particles. Later on, the polymerization of
geopolymers with the dissolution of Al and Si components in fly the soluble types and active surface groups a gel form and reveal a
ash via alkaline activators. This geopolymerization process involves hardened geopolymer structure. In many cases, only a small
a chemical reaction between SieOeAleO polymer chain forms and amount of silica and alumina is found in the particles which need
AleSi oxides. These structures are of three types depending on the dissolution and react in all solidified mixtures [4].
silica/alumina ratio; poly(sialate)(eSieOeAleOe) SiO2/Al2O3 ¼ 2, Numerous aluminosilicate solids are found in nature or pro-
poly(sialate-siloxo) (eSieOeAleOeSieO) SiO2/Al2O3 ¼ 4, and duced industrially. They contain amorphous silica and alumina
poly(sialate-disiloxo) (eSieOeAleOeSieOeSieO) SiO2/Al2O3 ¼ 6. which are partially dissolved in large amounts of alkaline solution
and these aluminosilicate solids are used in the geopolymer syn-
thesis [4e7]. Among the materials used as reagents are feldspars
and albite which can be found in nature; treated minerals such as
* Corresponding author.
€rhan).
E-mail address: ggorhan@aku.edu.tr (G. Go
metakaolin; and waste materials such as furnace slag, fly ash and

http://dx.doi.org/10.1016/j.compositesb.2016.05.019
1359-8368/© 2016 Elsevier Ltd. All rights reserved.
330 €rhan et al. / Composites Part B 97 (2016) 329e335
G. Go

construction waste [4]. different studies such as flexural behaviour of inorganic polymer
Kaolin which is a natural reactive product is a non-renewable concrete [20], metahalloysite based geopolymer with high strength
resource of clay, however, fly ash is one of the waste materials [21], cotton fabric reinforced geopolymer composites [22], alumi-
obtained from thermal power stations [8]. Fly ash is stored in large nate activated geopolymers [23], fly ash and blast furnace slag
areas and is hazardous to nature [9]. However, fly ash has been based geopolymer mortars [24,25], nanoclay-geopolymer com-
widely used as an original material for the production of geo- posites [26] and strain hardening fiber reinforced engineered
polymer materials in recent years. The factors that affect the geopolymer composite [27].
characteristics of fly ash based geopolymers are the particle size of As stated by the current studies, there is little information in the
the ash, curing temperature, curing time and alkali activator solu- literature on metakaolin and fly ash systems. Fly ash-based geo-
tion [10]. polymer materials were produced in this study. Fly ash was
600 million tons of coal ash is produced as waste material substituted by metakaolin in different ratios for the production of
worldwide every year and although 75%e80% of this waste consists the geopolymers and thermal cure was applied to the samples at
of fly ash (500 million tons), only 20%e30% of it is used as substi- different temperatures and times. This way, the changes in the
tution or fill material in the cement and concrete industry [11]. properties of the fly ash-based geopolymer paste samples by the
Therefore, the use of fly ash in the geopolymer synthesis is curing process, were examined, and the role of metakaolin in these
important for environmental and economic reasons [8]. In recent changes was investigated.
years, the use of fly ash in geopolymers has showed significant
improvements due to its ease of use, handling in production and its 2. Materials and method
capacity to improve durability in the final product [12]. However,
not all fly ash has high reactivity and therefore, low reactive fly ash 2.1. Materials
is used together with other geopolymer precursors in order to
achieve the desired strength [8]. The source of the fly ash used in the preparation of the geo-
Numerous studies have focused on the microstructure of fly ash polymer pastes was Kütahya Seyito € mer Thermal Power Plant. The
geopolymers under different synthesizing conditions [3,13e15]. fly ash was supplied from a private ready-mixed concrete company
However, there is limited information in the literature on the operating in Kütahya, Turkey. The substitution material, the met-
substitution of metakaolin by fly ash in metakaolin-based geo- akaolin used in the mixtures, was obtained from kaolin clay
polymers [8]. brought from Kale Maden and calcined in a laboratory type electric
In the activation of fly ash with NaOH, the reaction starts with arc furnace at 1000  C and at final temperature for 1 h. Metakaolin
the dissolution of Al and Si, which are precursor particles in the was ground and sieved in a laboratory type ball mill until it reached
alkaline solution, and then, followed by polymerization in the a fineness of 250 mm, before it was used as the substitution
aluminum-rich first gel phase, which will be transformed into material.
silicon-rich final geopolymer gel. When we compare fly ash and Laser particle size analyses of the fly ash and the metakaolin
metakaolin, it seems like similar reaction mechanisms are in were carried out in a Malvern Mastersizer 2000 device and d10, d50
progress in both materials, however, under prevailing conditions, and d90 values are presented in Table 1. Table 1 shows that the
the dissolution of fly ash during geopolymerization is much slower metakaolin is a thinner material than the fly ash according to the
than that of metakaolin. Zhang et al. [8] point out that the disso- laser particle size analyses.
lution rate of metakaolin at 40  C is significantly higher than that of According to the XRF analysis results of the fly ash, its total
the fly ash at 50  C and that in the case of alkali activation of fly ash SiO2þAl2O3þFe2O3 value is 81.71% and CaO value is 4.31%. Hence, it
with NaOH at 60  C, the dissolution is about 70 times higher than is classified as class F fly ash according to ASTM C618-08a [28]. The
that of the samples cured at 20  C. In a similar study, Kani and silica/alumina ratio (SiO2/Al2O3) in the fly ash is 2.69 (Table 2).
Allahverdi [16] state that for the geopolymerization reactions to be According to the XRD analysis of the fly ash and the metakaolin, the
completed, temperature ranging from 25 to 90  C should be fly ash contained minerals such as quartz, magnetite, hematite and
implemented for a certain period of time. albite (Fig. 1) while metakaolin contained quartz and mullite
In previous studies, the fly ash samples were activated with minerals (Fig. 2).
NaOH and a solution with a concentration of 8e12 M and they were NaOH and sodium silicate solution (SS) were used as alkali ac-
cured at 85  C for 24 h. It was reported that the compressive tivators in the preparation of the geopolymer pastes and the
strength values obtained were at satisfactory levels and that the properties of these materials are presented in Table 3.
compressive strength values showed a significant increase with the
addition of sodium silicate solution into the mixtures [17]. Swa-
nepoel and Strydom [18] state that curing time and temperature 2.2. Method
have an effect on the compressive strength of the geopolymers
produced using fly ash, kaolinite, sodium silicate solution, NaOH 2.2.1. Mixing procedure
and water, and that the optimum conditions for curing are 60  C NaOH was used together with the sodium silicate solution as the
and 48 h, respectively. reagents to dissolve the silica and alumina in the fly ash and met-
Xu et al. [19] claim that the compressive strength values of akaolin particles [14]. The sodium silicate solution (SS) (water glass)
geopolymers depend on the material used. According to the study, added to the mixtures was a 3-module (SiO2/Na2O ¼ 3) solution.
the compressive strength values of calcined materials such as fly The NaOH solution was prepared in a desired concentration and
ash, slag and metakaolin are much higher than those of natural kept at room temperature for 24 h. Afterwards, the fly ash,
materials such as kaolinite. High compressive strength values are
reached at early stages with the geopolymers produced from Table 1
calcined materials, while compressive strength values increase d10, d50 and d90 values of the materials.
more as a result of long curing times applied on geopolymers
Sample d10 (mm) d50 (mm) d90 (mm)
produced from untreated materials.
Nowadays, geopolymers are used in different areas such as Fly ash 15.96 84.75 231.33
Metakaolin 1.18 11.69 56.34
concrete, mortar and composites. Geopolymers were used in
€rhan et al. / Composites Part B 97 (2016) 329e335
G. Go 331

Table 2
Chemical (XRF) composition of the fly ash and metakaolin.

Oxide (%) SiO2 Al2O3 Fe2O3 MgO Na2O K2O SO3 CaO L.O.I. Total

Metakaolin 61.61 35.02 0.89 0.06 0.03 0.50 0.08 0.15 0.27 98.61
Fly ash 49.81 18.50 13.40 4.56 0.55 1.84 1.45 4.31 3.52 97.94

Fig. 1. XRD diffractogram of the fly ash.

Fig. 2. XRD diffractogram of the metakaolin.

metakaolin and alkali solution were mixed for 10 min. The fly ash in 2.2.2. Preparation of the geopolymer pastes
the prepared mixture was substituted by metakaolin ranging from Solution with a 9 M NaOH concentration was used in the geo-
10% to 40%. polymer pastes. The liquid/solid ratio used in the preparation of the
pastes was 0.36 ml/gr. The NaOH, which was in pellet form dis-
solved in pure water and turned into concentration. The SS/NaOH
332 €rhan et al. / Composites Part B 97 (2016) 329e335
G. Go

Table 3 completely dissolves in the alkaline solution and forms tetrahedral


The alkali activators and their properties. aluminosilicate units. During the geopolymerization process, which
Sodium silicate solution (SS) Sodium hidroxide (NaOH) is initiated by the reaction between silicate and aluminate oligo-
Na2O: 26.98 (%) M: 40 g/mol
mers, silicate dissolves in the alkaline solution and accelerates the
SiO2: 8.77 (%) NaOH  99.0 (%) polymerization process. Hence, an increase in the silicate content
H2O: 64.25 (%) enhances the progress of the geopolymerization and results in an
increase in the amorphous phase content [36]. Hence, an increase
in the compressive strength values of the samples is expected due
ratio used in the preparation of the pastes was 2. to the increase in the metakaolin rate in the bodies of the mixtures,
The pastes were cast into a 25 by 50-mm cylinder mold and it and in addition, materials with better properties are expected.
was performed under 100 bar pressure using a hydraulic hand It was observed that the curing temperature applied to the
press. Then the samples were placed in a laboratory-type oven to be geopolymer pastes had a significant effect on the apparent porosity
subjected to thermal curing. The samples were subjected to curing and water absorption rates. They increased with an increase in the
at 60  C and 80  C (two different curing temperatures) for 2 h, 4 h curing temperature applied to the samples. The water contained in
and 24 h (three different curing times). Table 4 shows the prepared the liquids had the tendency to leave the sample bodies during the
samples and the applied curing process. curing. It moved towards the surfaces and as a result of this
movement, micro cracks formed. The water absorption rates of the
2.2.3. The tests samples were thought to increase due to the increase in the for-
After curing, the samples were maintained under laboratory mation of the micro cracks. Therefore, it can be stated that an in-
conditions at room temperature until the day of the physical and crease in the curing temperature increased the rates of open pores.
mechanical tests. 7-day geopolymer paste samples were used for The apparent porosity and water absorption values of the geo-
the tests. The mean values of three samples from each sample polymer pastes cured at 60  C increased with an increase in the
group were calculated in the physical tests and in the compressive curing time (Figs. 3a and 4a). Among the sample groups, the highest
strength test. values were obtained from the samples cured for 24 h. It appears
The samples were placed in a water tank for 24 h in order to that the curing time, as well as the curing temperature, had a sig-
determine their physical properties. The physical properties of the nificant effect on the data. It was also observed that the apparent
samples such as water absorption, apparent porosity, bulk density porosity and water absorption rates of the samples decreased
and apparent density were determined based on the Archimedes depending on the increase in the metakaolin substitution rate used
principle. During the determination of the physical properties, the in the preparation of the samples. The structure of the metakaolin is
samples were removed from the water tank and their submerged more cohesive than that of the fly ash. This was initially thought to
weights and saturated surface dry weights were calculated. Then give rise to the results obtained. However, what yielded these re-
they were dried in the oven until a constant weight was reached. sults was actually the metakaolin having more reactivity than the
With the help of these values, the apparent porosity, bulk density fly ash during the polymerization process. The apparent porosity
and apparent density values of the samples were determined based and the water absorption rates of the samples cured at 60  C ranged
on TS EN 772-4 [29] and the water absorption values were deter- from 24.4% to 36.8% and from 17.1% to 29.9%, respectively.
mined based on TS EN 771-1 [30]. The mechanical properties of the The apparent porosity and water absorption rates of the samples
samples were determined based on the TS EN 196-1 [31] standard. cured at 80  C significantly increased depending on the increase in
the temperature. However, the effect of the applied cure time on
the values varied. The apparent porosity values of the samples with
3. Results and discussion
a 10% and 30% metakaolin substitution increased with an increase
in the curing time (Fig. 3b) while only the water absorption rate of
Clay and metakaolin are the most widely used raw materials in
the pastes with a 30% substitution increased with an increase in the
the production of geopolymers [32e34]. However, fly ash material
curing time (Fig. 4b). Therefore, no linear relationship was observed
is also used in the production of geopolymers. During the geo-
regarding the data in the case of the increase in the curing tem-
polymerization process, fly ash reacts with alkali solution and
perature applied to the geopolymer pastes. Different trends were
causes the formation of cementitious material containing alumino-
observed depending on the curing time and metakaolin substitu-
silicate-hydrate. The low reactivity and slow setting of the fly ash
tion rates. The apparent porosity and the water absorption rates of
hinders the development of resistance. In many cases, fly ash
the samples cured at 80  C ranged from 38.6% to 46.5% and from
cannot complete dissolution before the final hardening [35]. During
29.4% to 40.2%, respectively.
the geopolymerization process, metakaolin powder partially or

Table 4
Prepared samples and the applied curing process.
 
Serial no Metakaolin substitution (%) Curing time (h) Curing temperature ( C) Serial no Metakaolin substitution (%) Curing time (h) Curing temperature ( C)

1 10 2 60 13 10 2 80
2 10 4 60 14 10 4 80
3 10 24 60 15 10 24 80
4 20 2 60 16 20 2 80
5 20 4 60 17 20 4 80
6 20 24 60 18 20 24 80
7 30 2 60 19 30 2 80
8 30 4 60 20 30 4 80
9 30 24 60 21 30 24 80
10 40 2 60 22 40 2 80
11 40 4 60 23 40 4 80
12 40 24 60 24 40 24 80
€rhan et al. / Composites Part B 97 (2016) 329e335
G. Go 333

a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
55 55
50
10% 20% 30% 40% 50
10% 20% 30% 40%

Apparent porosity (%)


Apparent porosity (%)
45 45
40 40
35 35
30 30
25 25
20 20
15 15
10 10
5 5
0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)

Fig. 3. Apparent porosity rates of the geopolymer pastes.

a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
50 50
10% 20% 30% 40% 10% 20% 30% 40%
45 45
Water absorption (%)

Water absorption (%)


40 40
35 35
30 30
25 25
20 20
15 15
10 10
5 5
0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)

Fig. 4. Water absorption rates of the geopolymer pastes.

The bulk density values of the samples increased in parallel with The apparent density values of the geopolymer paste samples
the increase in the rates of the metakaolin substitution used in the cured at 60  C increased depending on the increase in the curing
preparation of the geopolymer pastes. The specific weight of the time and the metakaolin substitution rate, and the highest
metakaolin material is higher than that of the fly ash, therefore, the apparent density values were obtained from the samples cured for
bulk density values of the samples increased with an increase in the 24 h. The apparent density values of the samples cured at 80  C
substitution rates, while the bulk density values of the samples increased relatively more. However, the density values of the
cured at 60  C slightly decreased with an increase in the curing samples cured for 2 h and 4 h increased with an increase in the
temperature. The highest bulk density values were obtained from metakaolin substitution rate in the mixtures while the highest
the samples with a 40% metakaolin substitution cured for 2 h apparent density values of the samples cured for 24 h were ob-
(Fig. 5a). As observed in the porosity and the water absorption tained from the pastes with a 10% metakaolin substitution (Fig. 6a
values of the samples cured at 80  C, the bulk density values varied and Fig. 6b).
depending on the applied curing time. An increase in the bulk The compressive strength of geopolymer pastes is also a result of
density values with an increase in the curing time was observed physico-chemical interactions that take place between the
only in the samples with a 20% metakaolin substitution (Fig. 5b). unreacted particles and the geopolymeric gel, and a result of

a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
1800 1800
10% 20% 30% 40% 10% 20% 30% 40%
1600 1600
Bulk density (kg/m3)

Bulk density (kg/m3)

1400 1400
1200 1200
1000 1000
800 800
600 600
400 400
200 200
0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)

Fig. 5. Bulk density values of the geopolymer pastes.


334 €rhan et al. / Composites Part B 97 (2016) 329e335
G. Go

a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
2500 2500
10% 20% 30% 40% 10% 20% 30% 40%

Apparent density (kg/m3)


Apparent density (kg/m3)
2000 2000

1500 1500

1000 1000

500 500

0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)

Fig. 6. Apparent density values of the geopolymer pastes.

chemical bonds comprising aluminosilicate gel form. The activation information, it was concluded that the curing times applied to the
of metakaolin in the presence of moderate to high concentrations of geopolymer pastes were sufficient and that there were no signifi-
calcium can result in the generation of CeSeH and CeAeSeH gels cant differences between them.
as well as geopolymer-type gel. In such structures, the Ca2þ ions In the pastes with a 40% metakaolin substitution, the highest
may also be linked to the SieOeAl structure of the geopolymeric compressive strength values (26.1 MPa) were obtained from the
gel, assisting in the equalization of the negative charge linked with samples cured at 60  C for 24 h (Fig. 7a). Joe et al. [39] cured the
tetrahedral Al(III), rather than the alkali metal cations that gener- geopolymer pastes at 50  C for 24 h and obtained a compressive
ally perform this duty [37]. strength of 33.9 MPa. Manjunatha et al. [40] report that the
The metakaolin substitution rate made a significant contribu- compressive strength values of the geopolymer binder increased
tion to the compressive strength values of the samples. Fig. 7 shows with an increase in both the curing temperature and the curing
the data. In a general sense, it was observed that the samples cured time. This study indicates that the compressive strength values of
at 60  C resulted in better geopolymerization and that the the samples had an upward trend with an increase in the curing
compressive strength values were higher for this reason (Fig. 7). times applied to the samples while lower compressive strength
The effect of the metakaolin substitution rates and the curing times values were obtained when the curing temperature increased.
used in the production of the samples on the compressive strength In the geopolymer pastes, the samples cured at 60  C for 2 h and
values varied. It was determined that the compressive strength 24 h revealed similar compressive strength values. Short curing
values increased with an increase in the metakaolin substitution time was preferred over long curing time considering the electric
and the curing time; however, the compressive strength values of power spent on the curing of the samples. Therefore, it was
the samples decreased when the curing temperature was raised to concluded that the ideal curing temperature and time in the pro-
80  C (Fig. 7). It was noted that although different optimal curing duction of geopolymer pastes were 60  C and 2 h, respectively.
temperatures for different alkali - activated raw materials result in However, it was noted that the 40% metakaolin substitution used in
high compressive strength values, a curing process applied for the preparation of the samples resulted in better geo-
more than a day does not result in high compressive strength [38]. polymerization and led to a significant increase in the compressive
It has been proven that longer curing times at high temperatures strength values. The compressive strength values of the geo-
weaken the structure and that a small amount of water should be polymer pastes varied between 11.8 MPa and 26.1 MPa.
present in the body to prevent the formation of cracks and to
provide structural integrity. However, it is noted that the first
curing at higher temperatures (over 50e80  C) does not increase
4. Results
the compressive strength. In general, suitable curing time should be
implemented to ensure the durability and the mechanical devel-
Based on the data obtained from this study which examined fly
opment of the geopolymer materials [16]. Based on this
ash e metakaolin based geopolymer paste production;

a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
30 30
Compressive strength (MPa)

10% 20% 30% 40% 10% 20% 30% 40%


Compressive strength (MPa)

25 25

20 20

15 15

10 10

5 5

0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)

Fig. 7. Compressive strength values of the geopolymer pastes.


€rhan et al. / Composites Part B 97 (2016) 329e335
G. Go 335

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