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The Effect of Curing On The Properties of Metakaolin and Fly Ash-Based Geopolymer Paste
The Effect of Curing On The Properties of Metakaolin and Fly Ash-Based Geopolymer Paste
Composites Part B
journal homepage: www.elsevier.com/locate/compositesb
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.
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
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 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%
a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
50 50
10% 20% 30% 40% 10% 20% 30% 40%
45 45
Water absorption (%)
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)
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)
a) 9M NaOH - 60 oC b) 9M NaOH - 80 oC
2500 2500
10% 20% 30% 40% 10% 20% 30% 40%
1500 1500
1000 1000
500 500
0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)
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)
25 25
20 20
15 15
10 10
5 5
0 0
2 4 24 2 4 24
Curing time (h) Curing time (h)
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The authors would like to thank the Scientific and Technological
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