A PROJECT REPORT

ON

“STRENGTH STUDIES ON GEO-POLYMER CONCRETE BY USING

FLY ASH AND QUARRY DUST”
SUBMITTED TO

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA

IN PARTIAL FULLFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DEGREE

MASTER OF TECHNOLOGY
IN
STRUCTURAL ENGINEERING
BY

SHAIK USMAN
(15KQ1D8714)

Under The Esteemed Guidance Of

M.RAJESH KUMAR, M.TECH

ASST.PROFESSOR, DEPT OF CE.

DEPARTMENT OF CIVIL ENGINEERING

PACE INSTITUTE OF TECHNOLOGY AND SCIENCES, VALLUR

(AFFLIATED TO JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA & ACCRIDATED BY NAAC ‘A’
GRADE & AN ISO 9001-2008 CERTIFIED INSTITUTION)

VALLUR, PRAKASAM(Dt).
2015-2017

PACE INSTITUTE OF TECHNOLOGY AND SCIENCES, VALLUR

 DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE

This is to certify that the project work “STRENGTH STUDIES ON GEO-

POLYMER CONCRETE BY USING FLY ASH AND QUARRY DUST’’
Submitted by SHAIK USMAN, is examined and adjusted as sufficient as a partial
requirement for the MASTER DEGREE IN STRUCTURAL ENGINEERING at
Jawaharlal Nehru Technological university, Kakinada is a bonafide record of the work
done by student under my guidance and supervision.

Project Guide Head of the Department

M.Rajeshkumar ,M.Tech G.GaneshNaidu, M.Tech,(Ph.d)

Asst. Professor Asst. Professor,HOD

DEPARTMENT OF CE DEPARTMENT OF CE

Principal
Dr. C.V.SUBBA RAO, M.Tech ,Phd. PROJECT EXTERNAL EXAMINER
 ACKNOWLEDGEMENT

I would like to take this opportunity to express my heartiest concern of words to all those
people who have helped me in various ways to complete my project.

I express my profound gratitude to my Project guide M.RAJESH KUMAR, M.Tech,

Asst.Professor, Department of CE for his valuable and inspiring guidance, comments, and
encouragements throughout the course of this project.

We are highly indebted to G.GANESH NAIDU, M.Tech,(Ph.d), Assistant

Professor and Head of Civil Engineering Department. He has been a constant source of
encouragement and has inspired me in completing the project and helped us at various stages
of project work.

First and foremost I express my heartfelt gratitude to our principal Dr.C.V.SUBBA

RAO, M.Tech,Ph.d,Department of Mechanical Engineering of our institution for
forecasting an excellent academic environment which made my projectwork possible.

Sincerely thanks to our Secretary and Correspondent Sri.M.SRIDHAR,M.Tech, for

his kind support and encouragement.

I extend my sincere thanks to our faculty members and lab technicians for their help
in completing the project work.

(SHAIK USMAN)
(15KQ1D8714 )
 DECLARATION

I, hereby declare that the work which is being presented in this dissertation entitled
“STRENGTH STUDIES ON GEO-POLYMER CONCRETE BY USING FLY ASH AND
QUARRY DUST”submitted towards the partial fulfillment of requirements for the award
of the degree of Master of Technology in STRUCTURAL ENGINEERING at Pace institute of
technology and sciences, Vallur is an authentic record of my work carried out under the
supervision of your guide name M.RAESH KUMAR, M.Tech Assistant Professor Department
of C.E,. at Pace institute of technology and sciences, Vallur

The matter embodied in this dissertation report has not been submitted by me for the award
of any other degree. Further the technical details furnished in the various chapters in this
report are purely relevant to the above project and there is no deviation from the theoretical
point of view for design, development and implementation.

(SHAIK USMAN)
( 15KQ1D8714 )
 CONTENTS
Pg No
Index i

List of tables & figures iii

Abstract

Chapter 1. Introduction 01

1.1 General 01

1.2 Need of geo polymer concrete 02

1.3 Geo polymer 03

1.3.1 Terminology and chemistry 04

1.4 Fly ash

1.4.1 Production and classification of fly ash 05

1.4.2 Applications of fly ash 06

1.5 Quarry dust 07

1.6 Objective of the study 08

Chapter2. Review of literature 09

2.1 General 09

2.2 Geo polymers 10

2.3 Alkaline liquids 11

2.4 Geo polymer concrete 12

Chapter 3. Properties of materials used for the study 13

3.1 Quarry dust 13

3.2 Coarse aggregate 14

3.3 Fly ash 15

3.4 Alkaline solutions 16

3.5 Super plasticizer 17

 Chapter 4. Experimental work 18

4.1 General 19

4.2 Mix design 20

4.3 Preparation of alkaline solutions 21

4.4 Manfacturing and casting of geo polymer concrete 22

4.5 Curing of geo polymer concrete 23

4.6 Compressive strength 24

Chapter 5. Results and discussions 25

5.1 General 25

5.2 Results of strength tests 26

5.2.1 Compressive strength 27

Chapter 6. Conclusions 28

Chapter 7. Scope for future work 29

Chapter 8. References 30
 LIST OF TABLES
Tables Pg no.
Table 1 Applications of geo polymers 1
Table 2 Physical properties of quarry dust 2
Table 2 Chemical composition of quarry dust 3
Table 4 Properties of coarse aggregate 4
Table 5 Properties of fly ash 5
Table 6 Mixing proportions of geo polymer concrete 6
Table 7 weight of NAOH flakes 7
Table 8 Compressive strength of specimens’ 9

LIST OF FIGURES
Figure Pg no.
Fig.1 Generalpolymeric structures from polymerization of monomers 12
Fig.2 Chemical structures of polysialates 13
Fig.3 Sodium hydroxide in pellets form 14
Fig.4 Sodium hydroxide in flakes form 15
Fig.5 Adding sodium silicate solution to dry mix 16
Fig.6 Fresh geo polymer concrete 17
Fig.7 casting of geo polymer cubes 18
Fig.8 Polymer cubes after compression test 19
Fig.9 compressive strength of sun light curing of cubes at 7 days age 20
 ABSTRACT

The major problem the world is facing today is the environmental pollution. In the construction
industry mainly the production of Portland cement will causes the emission of pollutants results in
environmental pollution. We can reduce the pollution effect on environment, by increasing the usage of
industrial by-products in our construction industry. Geopolymer concrete is such a one and in the present
study, to produce the geo-polymer concrete the Portland cement is fully replaced with fly ash and the fine
aggregate is replaced with quarry dust and alkaline liquids are used for the binding of materials. The alkaline
liquids used in this study for the polymerization are the solutions of Sodium hydroxide (NaOH) and sodium
silicate (Na2Sio3). Different molarities of sodium hydroxide solution i.e. 8M, 10M and 12M are taken to
prepare different mixes. And the compressive strength is calculated for each of the mix. The cube specimens
are taken of size 150mm x 150mm x 150mm.The Geopolymer concrete specimens are tested for their
compressive strength at the age of 7days,mixes of varying sodium hydroxide molarities i.e.8M,10M and
12M are prepared and they are cured by direct sun-light and strengths are calculated for 7 days . The result
shows that the strength of Geopolymer concrete is increasing with the increase of the molarity of sodium
hydroxide.
CHAPTER - 1
 CHAPTER 1
INTRODUCTION

1.1GENERAL
For the construction of any structure, Concrete is the main material. Concrete usage around the world
is second only to water. The main ingredient to produce concrete is Portland cement. On the other side
global warming and environmental pollution are the biggest menace to the human race on this planet today.
The production of cement means the production of pollution because of the emission of CO2 during its
production. There are two different sources of CO2 emission during cement production. Combustion of fossil
fuels to operate the rotary kiln is the largest source and other one is the chemical process of calcining
limestone into lime in the cement kiln also produces CO2.In India about 2,069,738 thousands of metric tons
of CO2 is emitted in the year of 2010. The cement industry contributes about 5% of total global carbon
dioxide emissions. And also, the cement is manufactured by using the raw materials such as lime stone, clay
and other minerals. Quarrying of these raw materials is also causes environmental degradation. To produce 1
ton of cement, about 1.6 tons of raw materials are required and the time taken to form the lime stone is much
longer than the rate at which humans use it. But the demand of concrete is increasing day by day for its ease
of preparing and fabricating in all sorts of convenient shapes. So to overcome this problem, the concrete to
be used should be environmental friendly.

1.2 NEED OF GEOPOLYMER CONCRETE

To produce environmental friendly concrete, we have to replace the cement with some other binders
which should not create any bad effect on environment. The use of industrial by products as binders can
reduce the problem. In this respect, the new technology geo-polymer concrete is a promising technique. In
terms of reducing the global warming, the geo-polymer technology could reduce the CO2 emission to the
atmosphere caused by cement and aggregates industries by about 80% (Davidovits, 1994c). And also the
proper usage of industrial wastes can reduce the problem of disposing the waste products into the
atmosphere.

1.3 GEOPOLYMER
1.3.1 TERMINOLOGY AND CHEMISTRY
The term geo-polymer was first coined by Davidovits in 1978 to represent a broad range of materials
characterized by chains or networks of inorganic molecules. Geo-polymers are chains or networks of mineral
molecules linked with co-valent bonds. Geopolymer is produced by a polymeric reaction of alkaline liquid
with source material of geological origin or by product material such as fly ash, rice husk ash, GGBS etc.
Because the chemical reaction that takes place in this case is a polymerization process, Davidovitscoined the
term ‘Geopolymer’ to represent these binders.Geo-polymers have the chemical composition similar to
Zeolites but they can be formed an amorphous structure. He also suggested the use of the term ‘poly(sialate)’
for the chemical designation of geopolymers based onsilico-aluminate. Sialate is an abbreviation for silicon-
oxo-aluminate.

Figure-1.1. General Polymeric structures from polymerization of monomers.

Poly(sialates) are chain and ring polymers with Si4+ and AL3+ in IV-fold coordination with oxygen
and range from amorphous to semi-crystalline with the empirical formula:
Mn (-(SiO2) z–AlO2)n. wH2O
Where “z” is 1, 2 or 3 or higher up to 32; M is a monovalent cation such as potassium or sodium, and
“n” is a degree of polycondensation (Davidovits, 1984, 1988b, 1994b, 1999). Davidovits (1988b; 1991;
1994b; 1999) has also distinguished 3 types of polysialates, namely the Poly(sialate) type (-Si-O-Al-O), the
Poly (sialate-siloxo) type (-Si-O-Al-O-Si-O) and the Poly(sialate-disiloxo) type (-Si-O-Al-O-SiO). The
structures of these polysialates can be schematized as in Figure 1.1.

Fig 1.2 Chemical Structures of Polysialates

 Geopolymerization involves the chemical reaction of alumino-silicate oxides (Si2O5, Al2O2) with
alkali polysilicates yielding polymeric Si–O–Al bonds. The most common alkaline polysilicates used in the
geo-polymerization is the combination of Sodium hydroxide/ Potassium hydroxide and Sodium silicate/
Potassium silicate. This combination increases the rate of reaction. Among 15 Alumino-silicate minerals, all
the Al-Si minerals are more soluble in NaOH solution than in KoH solution.

Equation 1.2 shows an example of polycondensation by alkali into poly (sialatesiloxo). The last term
of Equation 1.2 indicates that water is released during the chemical reaction that occurs in the formation of
geo-polymers... This water, expelled from the geopolymer matrix during the curing and further drying
periods, leaves behind discontinuous nano-pores in the matrix, which provide benefits to the performance of
geopolymers. The water in a geopolymer mixture, therefore, plays no role in the chemical reaction that takes
place; it merely provides the workability to the mixture during handling. This is in contrast to the chemical
reaction of water in a Portland cement mixture during the hydration process.
Unlike ordinary Portland/pozzolanic cements, geo-polymers do not form calciumsilicate- hydrates
(C-S-H) for matrix formation and strength, but utilise the polycondensation of silica and alumina precursors
and a high alkali content to attain structural strength. Therefore, geo-polymers are sometimes referred to as
alkali activated alumino silicate binders (Davidovits, 1994a; Palomo et. al., 1999; Roy, 1999; van Jaarsveld
et. al., 2002a). However, Davidovits stated that using the term ‘alkali-activated’ could create significant
confusion and generate false granted ideas about geopolymer concrete

1.4.1 FLY ASH

Fly ash is manufactured by the burning of coal in an electrostatic precipitator, a byproductof
industrial coal. The cementitiousproperties of fly ash were discovered in late 19th century and it has been
widely used in cement manufacture for over 100 years. InUK , fly ash is supplied as a separate component
for concrete and is added at the concrete at the mixer. It generally replaces between 20 and 80 per cent of the
normal Portland cement.
1.4.2 PRODUCTION AND CLASSIFICATION OF FLYASH
A thermal stationis a power plant in which the prime movers steam driven. Water is heated, turns
into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine,
the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle.
The greatest variation in the design of thermal power stations is due to the different fossil fuelresources
generally used to heat the water. Some prefer to use the term energycenter because such facilities convert
forms of heat energy into electrical energy.Certain thermal power plants also are designed to produce heat
energy for industrial purposes of district heating , or desalination of water, in addition to generating electrical
power. Globally, fossil fueled thermal power plants produce a large part of man-made CO2 emissions to the
atmosphere, and efforts to reduce these are varied and widespread.

Two types of fly ash are commonly used in concrete: Class C and Class F. Class C are often high-
calcium fly ashes with carbon content less than 2%; whereas, Class F are generally low-calcium fly ashes
with carbon contents less than 5% but sometimes as high as 10%. In general, Class C ashes are produced
from burning sub-bituminous or lignite coals and Class F ashes bituminous or anthracite coals. Performance
properties between Class C and F ashes vary depending on the chemical and physical properties of the ash
and how the ash interacts with cement in the concrete. Many Class C ashes when exposed to water will react
and become hard just like cement, but not Class F ashes.

1.4.2 APPLICATIONS OF FLY ASH

Fly ash highly recommended for mass concrete applications. i.e. large mat foundations, dams etc. the
hungry horse dam, conyan ferry dam and the Wilson dam, hart well dam and sultan dam in USA, the
Lednock dam in UK and sudagin dam in Japan are few examples abroad, LUI center in Vancouver
successfully used 50% fly ash for all structural elements in India, some portions of Rihand dam and some
part of barrages in Bihar are some examples.

Fly ash can be used for the following

∑ Filling of mines,
∑ Replacement of low lying waste land and refuse dumps,
∑ Replacement of cement mortar,
∑ Air pollution control,
∑ Production of ready mix fly ash concrete,
∑ Laying of roads and construction of embankments,
∑ Stabilizing soil for road construction using lime- fly ash mixture,
∑ Construction of rigid pavements using cement-fly ash concrete,
 ∑ Production of lime-fly ash cellular concrete,
∑ Production of precast fly ash building units,
∑ Making of lean-cement fly ash concrete

1.5 QUARRY DUST

Now-a-days the natural river sand has become scarce and very costly. Hence we are forced to think of
alternative materials. The Quarry dust may be used in the place of river sand fully. The world
wideconsumption of fine aggregate inconcrete production is very high, and several developing countries
have encountered difficulties in meeting the supply of natural fine aggregate in order to satisfy the
increasingneeds of infrastructural development in recent years.To overcome the stress and demand for river
fineaggregate, researchers and practitioners in the constructionindustries have identified some alternative
materials such asfly ash, slag, limestone powder and siliceous stone powder.In India attempts have been
made to replace river sand withquarry dust.The successful utilization of quarry dust as fine aggregate would
turn this waste material that causes disposalproblem into a valuable resource. The utilisation will alsoreduce
the strain on supply of natural fine aggregate, whichwill also reduce the cost of concrete

A comparatively good strength is expected when sand is replaced fully with or without concrete admixtures.
It is proposed to study the possibility of replacing sand with locally available crusher waste without
sacrificing the strength and workability of concrete.
Coarse aggregate of 20mm maximum size is used in Reinforced cement concrete work of all types of
structures. This is obtained by crushing the stone boulders of size 100 to 150mm in the stone crushers. Then
it is sieved and the particles passing through 20 mm and retained on 10mm sieve known as course aggregate.
The particles passing through 4.75mm sieve are called as quarry dust. The quarry dust is used to sprinkle
over the newly laid bituminous road as filler between the bitumen and coarse aggregate and manufacturing
of hollow blocks.Based on this experimental investigations, it is found thatquarry dust can be used as an
alternative material to thenatural river sand. The physical and chemical properties ofquarry dust satisfy the
requirements of fine aggregate. It isfound that quarry dust improves its mechanical property ofconcrete if
used along with super plasticizer. Usage of quarrydust it will also reduce the cost of concrete.

1.6OBJECTIVE OF THE STUDY

Our aim is to have an alternative binder instead of Cement in Concrete. The reason is during the
production of cement, higher amounts of Carbon dioxide is released into atmosphere and causes global
warming. In this respect Geopolymer concrete is produced by replacing cement with Geopolymer
binderwhich consists of Flyash and alkaline liquidsand also fine aggregate is replaced with quarry
dustbecause it is most economical than fine aggregate.
CHAPTER-2
 CHAPTER 2
REVIEW OF LITERATURE
2.1 GENERAL

There is a wide range of research undergoing for the use of Geo-polymer Concrete. For our
investigation, some important publications were reviewed to have a broad idea about Geo-polymer Concrete
and they have been listed in the references at the end of the report.
2.4 LITERATURE REVIEW
DjwantoroHardjito, Steenie E Wallah, Dody M.J. Sumajouw, and B.V. Rangan (1992) describes
the effects of several factors on the properties of fly ash based Geopolymer concrete, especially the
compressive strength. The test variables included were the age of concrete, curing time, curing temperature,
quantity geo-polymer of super-plasticizer, the rest period prior to curing, and the water content of the mix.
They concluded that compressive strength of concrete does not vary with age, and curing the concrete
specimens at higher temperature and longer curing period will result in higher compressive strength. They
also concluded Naphthalene-based super-plasticizer improves the workability of fresh geo-polymer concrete.

[14]. D. M. J. Sumajouw D. Hardjito S. E. Wallah B. V. Rangan (2007) presents the results of

experimental study and analysis on the behaviour and the strength of reinforced Geopolymer concrete
slender columns. They concluded that heat-cured low-calcium fly ash-based geopolymer concrete has
excellent potential for applications in the precast industry. The products currently produced by this industry
can be manufactured using geopolymer concrete. The design provisions contained in the current standards
and codes can be used in the case of geopolymer concrete products.

[5]. Shuguang Hu, Hongxi Wang, GaozhanZhang ,Qingjun Ding(2007) they prepared three repair
materials by using cement-based, geo-polymeric, or geo-polymeric containing steel slag binders. They
concluded that the geo-polymeric materials had better repair characteristics than cement-based repair
materials, and the addition of steel slag could improve significantly the abrasion resistance of geopolymeric
repair. By means of scanning electron microscopy (SEM) it can also be concluded that the steel slag was
almost fully absorbed to take part in the alkali-activated reaction and be immobilized into the amorphous
aluminosilicategeopolymermatrix.

[6]. Christina K. Yip, Grant C. Lukey, John L. Provis, Jannie S.J. van Deventer(2008) in this paper at
low alkalinity, the compressive strength of matrices prepared with predominantly amorphous calcium
silicates (blast furnace slag) or containing crystalline phases specifically manufactured for reactivity
(cement) is much higher than when the calcium is supplied as crystalline silicate minerals. They concluded
that the compressive strength of matrices containing natural (crystalline) calcium silicates improves with
increasing alkalinity, however the opposite trend is observed in matrices synthesised with processed calcium
silicate sources. At high alkalinity, calcium plays a lesser role in affecting the nature of the final binder, as it
forms precipitates rather than hydrated gels. Thus, the different calcium silicate sources will not have a
major impact on the mechanical properties of these matrices. The effects of different calcium silicates on
geo-polymerisation are therefore seen to depend most significantly on two factors: the crystallinity of the
calcium silicate source and the alkalinity of the activating solution used.

[1]. Zhu Pan, Jay G. Sanjayan , B. V. Rangan(2009) they concluded that the ductility of the mortars has
a major correlation to this strength gain/loss behaviour. They prepared the specimens with two different fly
ashes, with strengths ranging from 5 to 60 MPa, were investigated. They concluded that the strength losses
decrease with increasing ductility, with even strength gains at high levels of ductility. This correlation is
attributed to the fact that mortars with high ductility have high capacity
to accommodate thermal incompatibilities. It is believed that the two opposing processes occur in mortars:
(1) further geo-polymerisation and/or sintering at elevated temperatures leading to strength gain; (2) the
damage to the mortar because of thermal incompatibility arising from non-uniform temperature distribution.
The strength gain or loss occurs depending on the dominant process.

[2]. XiaoluGuo ,Huisheng Shi , Warren A. Dick(2009) they studied the compressive strength and micro
structural characteristics of a class C fly ash geopolymer (CFAG) were studied. They concluded that a high
compressive strength was obtained when the class C fly ash (CFA) was activated by the mixed alkali
activator (sodium hydroxide and sodium silicate solution) with the optimum modulus viz., molar ratio of
SiO2/Na2O of 1.5. When CFA is alkali activated the sphere seems to be attacked and broken due to the
dissolution of alumino-silicate in the high pH alkali solution. Utilization of this fly ash in geo-polymer
materials is a resource and energy saving process and it also indirectly reduces the emission of green house
gas CO2 released from cement manufacturing. This is beneficial for resource conservation and
environmental protection.
[4]. SmithSongpiriyakij,TeinsakKubprasit,ChaiJaturapitakkul, PrinyaChindaprasirt(2010) they
usedRice husk and bark ash as a source to partially replace fly ash in making geopolymer. They concluded
that the optimum SiO2/Al2O3 ratio to obtain the highest compressive strength was 15.9. Fly ash was more
reactive than RHBA.
[19]. N A Lloyd and B V Rangan (2010) concluded based on the tests conducted on various short-term
and long-term properties of the geo-polymer concrete and the results of the tests conducted on large-scale
reinforced geo-polymer concrete members show that geo-polymer concrete is well-suited to manufacture
precast concrete products that can be used in infrastructure developments. In this paper a simple method to
design geo-polymer concrete mixtures has also described and illustrated by an example. The paper also
includes brief details of some recent applications of geopolymerconcrete
CHAPTER -3
 CHAPTER 3
PROPERTIES OF MATERIALS USED FOR THE STUDY
3.1 QUARRY DUST:
To produce geo-polymer concrete mix, the quarry dust is used as a fine aggregate and it was taken
from local quarries. It has following properties.
Table 3.1.1physical Properties of quarry dust
Property Quarry rock dust Test method

Specific gravity IS 2386 (PartIII) 1963

2.60
Bulk
relative IS 2386 (PartIII) 1963
density 1700
(kg/m3)
Absorption (%) 1.30 IS 2386 (PartIII) 1963
Moisture
Content(%) Nil IS 2386 (PartIII) 1963
Fineparticles
less than IS 2386 (PartI) 1963
0.075mm 14
(%)
Sieve
Analysis Zone III IS 383-1970

Table3.1.2 chemical composition of quarry dust

constituent Quarry Test method
Rockdust(%)
SiO2 62.48

Al2O3 18.72
Fe2O3 06.54
Cao 04.83 IS: 4032-
1968
Mgo 02.56
Na2O Nil
K2O 03.18
3.2 COARSE AGGREGATE:
Coarse aggregates of sizes 12mm and 20mm having following properties taken from a local supplier are
used in the present study.
Table3.2 Properties of Coarse Aggregate

Coarse Aggregate
Property

20mm 12mm

Fineness Modulus 8.14 8.14

Specific gravity 2.87 2.83

Bulk Density 1533.33 kg/m3 1517 kg/m3

Percentage of voids 45.24% 47.14%

3.3 FLYASH:

Flyash is taken from VIJYAWADA THERMAL POWER STATION,VIJYAWADA in Andhra

Pradesh .
Properties of FLYASH
Oxide composisition (%by mass) flyash
Sio2 59.2
Al2O3 38.02
CaO 0.94
MgO 0.28
Na2O3 0.47
K2O 0.22
Loss of ignistion 1.05
3.4 ALKALINE SOLUTIONS
The solutions of Sodium hydroxide and Sodium Silicate are used as alkaline solutions in the present
study.
Sodium hydroxide is available in market in various forms as flakes, pellets and in powder forms. In
the study, Commercial grade Sodium Hydroxide in flakes form (97%-100% purity) is used.
Sodium silicate is available in powder form. By using sodium silicate we may prepare solution of
required molarity. In this study, sodium silicate used in solution form having the following chemical
proportion is used.
Na2O - 7.5%-8.5%
Sio2 - 25% -28%
Water - 67.5%-63.5%.

3.5 SUPER PLASTICIZER

In order to improve the workability of fresh concrete, Super plasticizer Cornplast
SP 430, of colour brown based on sulphonated naphthalene polymers, complies with IS 9103-1999, BS:
5075 part 3 and ASTM C-494, Type F was used.

Advantages
ß Reduction in water-cement ratio of the order of 20-25%
ß Flowing, pumpable concrete
ß Excellent workability and retention even in extreme temperatures
CHAPTER - 4
 CHAPTER 4
EXPERIMENTAL WORK

4.1 GENERAL

This Chapter describes the experimental work. First, Mix design of geo-polymer concrete,
manufacturing and curing of the test specimens are explained. This is then followed by description of types
of specimens used, test parameters, and test procedures.

4.2 MIX DESIGN

The mix design in the case of geo-polymer concrete is based on conventional concrete with some
modification. In the case of conventional concrete the material proportion can be found out for the required
strength using the code, but in the case of geo-polymer concrete there is no design method or codal
provisions. Here by means of trial and error method optimized mixes is being produced.

The mix proportions given byN A Lloyd and B V Rangan(2010) is taken as a reference one,
several trial mixes are prepared with flyash and constant molarity of NaOH as 2M. The mix which gives
high workability is taken as final one and the project continues with the final one. The trial mixes are as
follows.
The trial mixture proportion is as follow: combined aggregates = 1848 kg/m3, GGBS = 408 kg/m3,
sodium silicate solution = 103 kg /m3, and sodium hydroxide solution = 41 kg/m3(2M solution). 20 mm
aggregates = 910 kg/m3, 12 mm aggregates = 390 kg/m3, fine sand = 554 kg/m3 .The geo-polymer concrete
is wet-mixed for four minutes and cured at 60oC for 24 hours in hot air oven after casting. Commercially
available super plasticizer of about 0.75% of mass of GGBS, i.e. 5 kg/m3 is added to the mixture to facilitate
ease of placement of fresh concrete. In this manner, by changing the quantities of aggregates and by
increasing the fines in the mixture the final mix is as follows. The total volume occupied by the aggregates
(Coarse and fine aggregates) is assumed to be 65%. The alkaline liquid to GGBS ratio is taken as 0.30. The
quantities of all ingredients are kept constant as given in table-4.1 except the molarity of NaOH is changed
in the each mix.
 Assume the density of geo-polymer concrete as 2500 kg/m3. Assume the volume of combined
aggregates occupied 70% of the mass of concrete, i.e. 0.70x2500= 1750 kg/m3.

In this,
The mass of fine aggregates + coarse aggregates = 1750kg/m3.

Coarse Aggregate = 60% of 1750

3
= 1050 kg/m
Quarry dust = 40% of 1750
3
= 700 kg/m
Mass of Alkaline liquid and Fly ash = 2500-1750
3
= 750 kg/m

Assume,
Mass of fly ash = 60% of 750
3
= 450 kg/m

3
Mass of alkaline liquid = 40% of 750 kg/m
3
=300 kg/m
Take the ratio of sodium silicate solution-to-sodium hydroxide solution by mass as 2;
The mass of sodium hydroxide solution = 100kg/m3;
The mass of sodium silicate solution = 200 kg/m3;

The mass of super-plasticizer = 0.75X450

=3.375 kg/m3;
 The final mix proportion is shown in table 4.1

Table-4.1 Mixing proportions of the geo-polymer concrete

Coarse
Sodium Sodium
Name Quarry Aggregate Super-
Fly ash silicate hydroxide
of the dust (kg/m3) Plasticizer
(kg/m3) solution solution
Mixture (kg/m3) 20 12 (kg/m3)
(kg/m3) (kg/m3)
mm mm

GP1 450 700 400 650 200 100(8M) 3.375

GP2 450 700 400 650 200 100(10M) 3.375

GP3 450 700 400 650 200 100(12M) 3.375

4.3 PREPERATION OF ALKALINE LIQUIDS

NOTE: Molarity = moles of solute/litre of solution

In this project the compressive strength of geo-polymer concrete is examined for the mixes of
varying molarities of Sodium hydroxide ( 8M, 10M, and 12M). The molecular weight of sodium hydroxide
is 40. To prepare 8M i.e. 8 molar sodium hydroxide solution, 320g of sodium hydroxide flakes are weighed
and they can be dissolved in distilled water to form 1 liter solution. For this, volumetric flask of 1 liter
capacity is taken, sodium hydroxide flakes are added slowly to distilled water to prepare 1liter solution. The
weights to be added to get required molarity are given in Table.4.2
 Table.4.2 Weights of NaOH flakes

Required Molarity Weight in g. of Sodium

hydroxide flakes

320
8M

10M 400

12M 480

The sodium silicate solution and the sodium hydroxide solution were mixed together
at least one day prior to use to prepare the alkaline liquid. On the day of casting of the specimens, the
alkaline liquid was mixed together with the super plasticizer and the extra water (if any) to prepare the liquid
component of the mixture.

Fig 4.1 sodium hydroxide in pellets form

 Fig 4.2 sodium hydroxide in flakes form

4.4 MANUFACTURING AND CASTING OF GEO-POLYMER CONCRETE

The conventional method used in the making of normal concrete is adopted to prepare geo-polymer
concrete. First, the quarry dust, coarse aggregate and Flyashare mixed in dry condition for 3-4 minutes and
then the alkaline solution which is a combination of Sodium hydroxide solution and Sodium silicate solution
with super-plasticizer is added to the dry mix. The mixing is done about 6-8 minutes for proper bonding of
all the materials. After the mixing, the cubes are casted with the mixes GP1 toGP3 by giving proper
compaction. The sizes of the cubes used are of size 150mmX150mmX150mm.
 Fig 4.3 Adding sodium silicate solution to dry mix

Fig 4.4 Fresh geo-polymer concrete

Fig 4.5 Casting of geo-polymer concrete cubes

4.5 CURING OF GEO-POLYMER CONCRETE
For the curing of geo-polymer concrete cubes, the cubes are placed in direct sun-light. For the sun
light curing, the cubes are demoulded after 1 day of casting and they are placed in the direct sun light for 7
days.
4.6 COMPRESSIVE STRENGTH

Compressive strength is the capacity of a material or structure to withstand axially

directed pushing forces. Cubes of 150mm×150mm×150mm were casted and compressive strength
test was conducted on specimens at 7 days. To conduct the test the specimens are placed in a
compression testing machine and the load is applied to the cube and the load at failure is noted as
failure load. The compressive strength is calculated by using the formula given in 4.1. The results
in tables 5.1.1.

Fck=Pc/A
Where, Pc=load at failure in N
A=loaded area of cube in mm2

Fig 4.6-polymer concrete cubes after compression test

CHAPTER - 5
 CHAPTER 5
RESULTS AND DISCUSSIONS
5.1 GENERAL
The results of the tests which are specified in chapter 4 are given in the following tables with their
corresponding graphs.

5.2 RESULTS OF STRENGTH TESTS

5.2 .1COMPRESSIVE STRENGTH
TABLE 5.1.1 Compressive strength

Name of the mix Compressive strength in N/mm2 of specimens Cured

by
7days 14days 28days

CC
18.6 23.4 27

GP1 19.23 23.6 27.5

GP2 20.26 24.2 28.2

GP3 21 25.2 29.4

35

30

25

20
cc
15 mix

10

0
Gp1 Gp2 Gp3

Figure 1 Compressive strength of specimens at the age of 7

 40

35

30

25

20 cc
mix ratio
15

10

0
Gp1 Gp2 Gp3

Figure 2 Compressive strength of specimens at the age of 14 days

30

29.5

29

28.5

28 cc
mix ratio
27.5

27

26.5

26
Gp1 Gp2 Gp3

Figure 3 Compressive strength of specimens at the age of 28 days

By showing the above graph the compressive strength increase the strength by 40% in 7days.The
other one shows the increase of the strength by 60% it reflects that by increase the days limit the
strength of the mixture can be increased .The last one shows the increase of the strength by 75%.
5.3 Split Tensile Test

Name of the mix Split Tensile Test in N/mm2 of specimens Cured by

7days 14days 28days

CC 1.7 2.25 2.87

GP1 1.9 2.34 2.74

GP2 2.2 2.47 2.85

GP3 2.3 2.52 2.96

2.5

1.5
cc
mix ratio
1

0.5

0
Gp1 Gp2 Gp3

Figure 4 Split Tensile Test of specimens at the age of 7 days

 3

2.5

1.5 cc
mix ratio
1

0.5

0
Gp1 GP2 Gp3

Figure 5 Split Tensile Test of specimens at the age of 14 days

3.5

2.5

2
cc
1.5 mix ratio

0.5

0
Gp1 Gp2 Gp3

Figure 6 Split Tensile Test of specimens at the age of 28 days

In case of considering the split tensile test the strength can be varies as it compare with the compressive
strength. The only difference can we observe is mixing ratio of the quantity .The graphs shows that increase
of composition by 40% to 80 %
5.4 Workbility Test
S.NO Name of the Mix Workbility in mm
1 cc 65
2 Gp1 75
3 Gp1 82
4 Gp1 92

90
80
70
60
50
40 cc

30 mix ratio

20
10
0
Gp1 Gp2 Gp3

Figure 7 Workbility Test of specimen

CHAPTER - 6
 CHAPTER 6
CONCLUSIONS

Based on the experimental work reported in this study, the following conclusions are drawn.
ÿ Higher concentration (in terms of molar) of sodium hydroxide solution results in higher compressive
strength of fly ash & quarry dust based geo-polymer concrete.

ÿ Longer curing time, in the range of 4 to 96 hours (4 days), produces higher compressive strength
offly ash &quarry dust based geo-polymer concrete. However, the increase in strength beyond 24
hours is not significant.

ÿ The fresh flyash-based geo-polymer concrete is easily handled up to 120 minutes without any sign of
setting and without any degradation in the compressive strength.

ÿ The mix GP3 gives higher compressive strength, as it has high molarity of NaOH

ÿ we Observe that the compressive strength is increased with the increase in the molarity of the sodium
hydroxide

ÿ After three days of curing the increase the compressive strength is not sufficient

ÿ The geo-polyemer concrete shall be effeviely used for the beam coloumn junction of the reinforced
concrete structure

ÿ Geo-polymer concrete shall also be used in the Infrastructure works.

ÿ In addition to that fly ash shall be effectively used and hence no land fills are required to dump the
fly ash
CHAPTER - 7
 CHAPTER 7

SCOPE FOR FUTURE WORK

7.1 SCOPE FOR FUTURE WORK

As geo-polymer concrete technology is a new one, there is lot of scope to work in this topic. In the
present study we used fly ash as a binder instead of cement. We recommended to extend this topic by using
byproducts like rice husk ash, GGBS, pulverized fuel ash etc .And also, investigation of Long term
properties like durability, creep, drying shrinkage may also gives the suitability of geo-polymer concrete in
the field.To implementing such a method the durability can be increased and strength of the material can also
be increased .The most impartent thing is that cement can be made to increase the stricking property of the
materials can be increased in proper quantity .

To Provide a most Economical Concrete

ÿ It should be easily adopted in field.
ÿ To reduce the cost of construction.
ÿ To promote low cost housing for the people.
ÿ To find the optimum strength of the partial replacement of concrete.
ÿ To make the maximum usage of locally available materials.
CHAPTER - 8
 CHAPTER 8
REFERENCES

[1].Zhu Pan , Jay G. Sanjayan , B. V. Rangan,(2007) “An investigation of the mechanisms for strength gain
or loss of geopolymer mortar after exposure to elevated temperature” , published in J Matera Science (2009)
44:1873–1880.

[2].Davidovits, J. (1988b). Geopolymer Chemistry and Properties. Paper presented at the Geopolymer ’88,
First European Conference on Soft Mineralurgy, Compiegne, France.

[3].XiaoluGuo, HuishengShi , Warren A. Dick (2009) “Compressive strength and microstructural

characteristics of class C fly ash Geopolymer” published in Elsevier .Ltd, Cement & Concrete Composites
32 (2010) 142–147 www.elsevier.com/locate/cemconcomp.

[4].Smith Songpiriyakij, TeinsakKubprasit , Chai Jaturapitakkul , PrinyaChindaprasirt(2010) “Compressive

strength and degree of reaction of biomass- and fly ash-based Geopolymer” published in Elsevier .Ltd,
Construction and Building Materials 24 (2010) 236–240.

[5].Shuguang Hu, Hongxi Wang, GaozhanZhang ,Qingjun Ding(2007) “Bonding and abrasion resistance of
geopolymeric repair material made with steel slag” published in Elsevier .Ltd ,Cement & Concrete
Composites 30 (2007) 239–244.

[6].Christina K. Yip, Grant C. Lukey, John L. Provis, Jannie S.J. van Deventer (2008), “Effect of calcium
silicate sources on geopolymerisation” published in Elsevier .Ltd, Cement and Concrete Research 38 (2008)
554–564.

[7].C.A. Hendriks1, “Emission Reduction of Greenhouse Gases from the Cement Industry” Greenhouse gas
control technologies conference paper.

[8].Ernst Worerell. Lynn Price, et al. “CO2 emission from the global cement industry”, Annual review of
energy and the environment. Vol 26: p-303-329.

[9].M.F.Nuruddin, SobiaQuzi, N. Shafiq, A. Kusbiantoro, “Compressive strength P& Micro structure of

polymeric concrete incorporating fly ash and silica fume”, Canadian journal on civil engineering Vol.1,
No.1, feb-2010.
[10].Warner, R. F., Rangan, B. V., Hall, A. S., &Faulkes, K. A. (1998).ConcreteStructures. Melbourne:
Longman.

[11].Wee, T. H., Suryavanshi, A. K., Wong, S. F., &Rahman, A. K. M. A. (2000) Sulfate Resistance of
Concrete Containing Mineral Admixtures.ACIMaterials Journal, 97(5), 536-549.

[12].Xu, H., & Deventer, J. S. J. V. (1999). The Geopolymerisation of Natural Alumino-Silicates.Paper

presented at the Geopolymere ’99 International Conference,Saint-Quentin, France.

[14].Xu, H., & Deventer, J. S. J. V. (2000). The geopolymerisation of alumino-silicateminerals.International

Journal of Mineral Processing, 59(3), 247-266.

[15].D.M.J. Sumajouw, D. Hardjito, S. Wallah, and B.V. Rangan, “.Behavior of Geopolymer Concrete
Columns under Equal Load Eccentricities”.

[16].vanJaarsveld, J. G. S., van Deventer, J. S. J., & Schwartzman, A. (1999). Thepotential use of
geopolymeric materials to immobilise toxic metals: Part II.Material and leaching characteristics. Minerals
Engineering, 12(1), 75-91.

[17].vanJaarsveld, J. G. S., van Deventer, J. S. J., &Lukey, G. C. (2002a). The effect ofcomposition and
temperature on the properties of fly ash- and kaolinite-basedgeopolymers.Chemical Engineering Journal,
89(1-3), 63-73.

[18].HuaXu, J S J Van Deventer, “The geopolymerisation of alumino-silicate minerals”, International

Journal of Mineral Processing (2000) Volume: 59, Issue: 3, Publisher: Elsevier, Pages: 247-266

[19].D. M. J. Sumajouw D. Hardjito S. E. Wallah B. V. Rangan, “Fly ash-based geopolymer concrete: study
of slender reinforced columns”, Springer Science+Business Media, LLC 2006

[20].N A Lloyd and B V Rangan Curtin University of Technology, “Geopolymer Concrete with Fly Ash”

[21].E.N. Allouche1, C. Montes1 ,E.I. Diaz1 and G. Vernon2, “APPLICATIONS OF GEOPOLYMER

CONCRETE IN THEREHABILITATION OF WASTEWATER CONCRETE STRUCTURES”, North
American Society for Trenchless Technology 2008 No-Dig Conference & Exhibition, Paper C-1-02
[22].Monita Olivia- PhD Student; Hamid Nikraz- Professor; PrabirSarker- Lecturer, “IMPROVEMENTS IN
THE STRENGTH AND WATER PENETRABILITY OF LOW CALCIUM FLY ASH BASED
GEOPOLYMER CONCRETE”, The 3rd ACF International Conference- ACF/VCA 2008

[23].B. VijayaRangan, DjwantoroHardjito, Steenie E. Wallah, and Dody M.J. Sumajouw , “Studies on fly
ash-based geopolymer concrete”, Geopolymer: green chemistry and sustainable development solutions.

[24].Rangan, B.V., Hardiito, D., Wallah, S.E., &Sumajouw, D.M.J. (2005b). Studies of fly ash-based
geopolymer concrete. Paper presented at the World Congress Geopolymer 2005, Sain t-Quentin, France

[25].Teixeira-Pinto, A., P. Fernandes, S. Jalali (2002).Geopolymer Manufacture and Application - Main

problems When Using Concrete Technology.Geopolymers 2002 International Conference, Melbourne,
Australia, Siloxo Pty. Ltd.

[26].Hardjito, D. and Rangan, B. V. (2005) Development and Properties of Low-Calcium Fly Ash-based
Geopolymer Concrete, Research Report GC1, Faculty of Engineering, Curtin University of Technology,
Perth.

[27].Malhotra, V. M. (1999). Making Concrete "Greener" With Fly Ash.ACI Concrete International, 21(5),
61-66.

[28].Malhotra, V. M., & Mehta, P. K. (2002).High-Performance, High-Volume Fly Ash Concrete: Materials,
Mixture Proportioning, Properties, Construction Practice, and Case Histories. Ottawa: Supplementary
Cementing Materials for Sustainable Development Inc.

[29].Neville, A. M. (2000). Properties of Concrete (Fourth and Final ed.). Essex, England: Pearson
Education, Longman Group.

[30].Palomo, A., M.W.Grutzeck, &M.T.Blanco.(1999). Alkali-activated fly ashes A cement for the
future.Cement And Concrete Research, 29(8), 1323-1329.
 AIJREAS VOLUME 2, ISSUE 5 (2017, MAY) (ISSN-2455-6300) ONLINE

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STRENGTH STUDIES ON GEO-POLYMER CONCRETE BY USING

FLY ASH AND QUARRY DUST

SHAIK USMAN M.RAJESH KUMAR, M.TECH

Structural Engineering M Tech Asst. Professor, Dept of CE.
Pace Institute Of Technology And Sciences, Pace Institute Of Technology And Sciences,
Vallur Vallur

ABSTRACT
The major problem the world is facing today is the INTRODUCTION
environmental pollution. In the construction industry
1.3 GEOPOLYMER
mainly the production of Portland cement will causes
1.3.1 TERMINOLOGY AND
the emission of pollutants results in environmental
pollution. We can reduce the pollution effect on CHEMISTRY
environment, by increasing the usage of industrial The term geo-polymer was first coined by
by-products in our construction industry. Davidovits in 1978 to represent a broad
Geopolymer concrete is such a one and in the present
range of materials characterized by chains or
study, to produce the geo-polymer concrete the
networks of inorganic molecules. Geo-
Portland cement is fully replaced with fly ash and the
fine aggregate is replaced with quarry dust and polymers are chains or networks of mineral
alkaline liquids are used for the binding of materials. molecules linked with co-valent bonds.
The alkaline liquids used in this study for the Geopolymer is produced by a polymeric
polymerization are the solutions of Sodium hydroxide
reaction of alkaline liquid with source
(NaOH) and sodium silicate (Na2Sio3). Different
material of geological origin or by product
molarities of sodium hydroxide solution i.e. 8M, 10M
and 12M are taken to prepare different mixes. And
material such as fly ash, rice husk ash,
the compressive strength is calculated for each of the GGBS etc. Because the chemical reaction
mix. The cube specimens are taken of size 150mm x that takes place in this case is a
150mm x 150mm.The Geopolymer concrete
polymerization process, Davidovitscoined
specimens are tested for their compressive strength at
the term ‘Geopolymer’ to represent these
the age of 7days,mixes of varying sodium hydroxide
molarities i.e.8M,10M and 12M are prepared and binders.Geo-polymers have the chemical
they are cured by direct sun-light and strengths are composition similar to Zeolites but they can
calculated for 7 days . The result shows that the be formed an amorphous structure. He also
strength of Geopolymer concrete is increasing with
suggested the use of the term ‘poly(sialate)’
the increase of the molarity of sodium hydroxide.
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 AIJREAS VOLUME 2, ISSUE 5 (2017, MAY)
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for the chemical designation of geopolymers
based onsilico-aluminate. Sialate is an
abbreviation for silicon-oxo-aluminate.
Figure-1.1. General Polymeric structures
from polymerization of monomers.
Poly(sialates) are chain and ring polymers
with Si4+ and AL3+ in IV-fold coordination
with oxygen and range from amorphous to
semi-crystalline with the empirical formula:
Mn (-(SiO2) z–AlO2)n. wH2O
Where “z” is 1, 2 or 3 or higher up to
32; M is a monovalent cation such as
potassium or sodium, and “n” is a degree of
polycondensation (Davidovits, 1984, 1988b,
1994b, 1999). Davidovits (1988b; 1991;
1994b; 1999) has also distinguished 3 types
of polysialates, namely the Poly(sialate) type
(-Si-O-Al-O), the Poly (sialate-siloxo) type
(-Si-O-Al-O-Si-O) and the Poly(sialate-
disiloxo) type (-Si-O-Al-O-SiO). The
structures of these polysialates can be
schematized as in Figure 1.1.
Fig 1.2 Chemical Structures of Polysialates
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2.4 LITERATUREREVIEW
DjwantoroHardjito, Steenie E Wallah,
Dody M.J. Sumajouw, and B.V. Rangan
(1992) describes the effects of several
factors on the properties of fly ash based
Geopolymer concrete, especially the
compressive strength. The test variables
included were the age of concrete, curing
time, curing temperature, quantity geo-
polymer of super-plasticizer, the rest period
prior to curing, and the water content of the
mix. They concluded that compressive
strength of concrete does not vary with age,
and curing the concrete specimens at higher
temperature and longer curing period will
result in higher compressive strength. They
also concluded Naphthalene-based super-
plasticizer improves the workability of fresh
geo-polymer concrete.
[14]. D. M. J. Sumajouw D. Hardjito S. E.
Wallah B. V. Rangan (2007) presents the
results of experimental study and analysis on
the behaviour and the strength of reinforced
Geopolymer concrete slender columns. They
concluded that heat-cured low-calcium fly
ash-based geopolymer concrete has
excellent potential for applications in the
precast industry. The products currently
produced by this industry can be
manufactured using geopolymer concrete.
The design provisions contained in the
current standards and codes can be used in
the case of geopolymer concrete products.
[5]. Shuguang Hu, Hongxi Wang,
GaozhanZhang ,Qingjun Ding(2007) they
prepared three repair materials by using
cement-based, geo-polymeric, or geo-
polymeric containing steel slag binders.
They concluded that the geo-polymeric
materials had better repair characteristics
than cement-based repair materials, and the
addition of steel slag could improve
significantly the abrasion resistance of
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geopolymeric repair. By means of scanning Al2O3 18.72

electron microscopy (SEM) it can also be
concluded that the steel slag was almost Fe2O3 06.54 IS: 4032-
fully absorbed to take part in the alkali- Cao 04.83 1968
activated reaction and be immobilized into Mgo 02.56
the amorphous aluminosilicate geopolymer Na2O Nil
matrix. K2O 03.18

PROPERTIES OF MATERIALS USED

Property Coarse
FOR THE STUDY
Aggregate
3.1 QUARRY DUST: 20mm 12mm
To produce geo-polymer concrete Fineness
mix, the quarry dust is used as a fine 8.14 8.14
aggregate and it was taken from local Modulus
quarries. It has following properties. Specific gravity 2.87 2.83
Table 3.1.1physical Properties of quarry Bulk Density 1533.33 kg/m3 1517 kg/m3
dust
Percentage of
Property Quarry Test method 45.24% 47.14%
rock voids
dust
Specific IS 2386 (PartIII) 1963
gravity 2.60 Properties of FLYASH
Bulk Oxide composisition flyash
relative IS 2386 (PartIII) 1963 (%by mass)
density 1700 Sio2 59.2
(kg/m3) Al2O3 38.02
Absorption 1.30 IS 2386 (PartIII) 1963 CaO 0.94
(%) MgO 0.28
Moisture Na2O3 0.47
Content(%) Nil IS 2386 (PartIII) 1963 K2O 0.22
Fineparticles Loss of ignistion 1.05
less than IS 2386 (PartI) 1963
0.075mm 14
(%) 3.4 ALKALINE SOLUTIONS
Sieve
Analysis Zone IS 383-1970
Na2O - 7.5%-8.5%
III
Sio2 - 25% -28%
Water - 67.5%-63.5%.
Table3.1.2 chemical composition of
quarry dust
constituent Quarry Test EXPERIMENTAL WORK
Rockdust(%) method 4.2 MIX DESIGN
In this,
SiO2 62.48 The mass of fine aggregates + coarse
aggregates= 1750kg/m3.
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Coarse Aggregate = 60% of 1750 The mass of sodium silicate solution

= 1050 kg/m
3
= 200 kg/m3;
Quarry dust = 40% of 1750
3 The mass of super-plasticizer = 0.75X450
= 700 kg/m
Mass of Alkaline =3.375 kg/m3;
liquid and Fly ash = 2500-1750
3
= 750 kg/m
Assume,
Mass of fly ash = 60% of 750
3
= 450 kg/m
3
Mass of alkaline liquid = 40% of 750 kg/m
3
=300 kg/m
Take the ratio of sodium silicate solution-to-
sodium hydroxide solution by mass as 2;
The mass of sodium hydroxide solution
= 100kg/m3;

Table-4.1 Mixing proportions of the geo-polymer concrete

Coarse
Sodium Sodium
Name of Quarry Aggregate Super-
Fly ash silicate hydroxide
the dust (kg/m3) Plasticizer
(kg/m3) solution solution
Mixture (kg/m3) 20 12 (kg/m3)
(kg/m3) (kg/m3)
mm mm
GP1 450 700 400 650 200 100(8M) 3.375
GP2 450 700 400 650 200 100(10M) 3.375
GP3 450 700 400 650 200 100(12M) 3.375

Table

Required Molarity Weight in g. of

Sodium hydroxide
flakes
8M 320

10M 400

12M 480

Figure 4.2 Weights of NAOH flakes

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RESULTS AND DISCUSSIONS

5.2 RESULTS OF STRENGTHS TESTS
5.2.1 COMPRESSIVE STRENGTH

Name of Compressive strength in N/mm2 of specimens Cured by

the mix
7days 14days 28days

CC
18.6 23.4 27

GP1 19.23 23.6 27.5

GP2 20.26 24.2 28.2

GP3 21 25.2 29.4

35 Figure 2Compressive strength of

specimens at the age of 14 days
30
25 30
20 29.5
cc
15 29
mix
28.5
10
28 cc
5
27.5 mix ratio
0 27
Gp1 Gp2 Gp3
26.5
26
Figure 1Compressive strength of Gp1 Gp2 Gp3
specimens at the age of 7

Figure 3 Compressive strength of

40 specimens at the age of 28 days
5.3 Split Tensile Test
30
20 cc

10 mix ratio

0
Gp1 Gp2 Gp3

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Name of the mix Split Tensile Test in N/mm2 of specimens Cured by

7days 14days 28days

CC 1.7 2.25 2.87

GP1 1.9 2.34 2.74

GP2 2.2 2.47 2.85

GP3 2.3 2.52 2.96

2.5 5.4 Workbility Test

2
S.NO Name of Workbility in
1.5
cc the Mix mm
1 1 cc 65
mix ratio
0.5 2 Gp1 75
0 3 Gp1 82
Gp1 Gp2 Gp3 4 Gp1 92

Figure 3 Split Tensile Testof specimens at 100

the age of 14 days
80
4 60
cc
3 40
mix ratio
20
2 cc
mix ratio 0
1 Gp1 Gp2 Gp3

0 Figure 5 Workbility Testof specimen

Gp1 Gp2 Gp3

Figure 4 Split Tensile Testof specimens at CONCLUSIONS

the age of 28 days

Based on the experimental work reported in

this study, the following conclusions are
drawn.

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ÿ Higher concentration (in terms of
molar) of sodium hydroxide solution
results in higher compressive
strength of fly ash & quarry dust
based geo-polymer concrete.
ÿ Longer curing time, in the range of 4
to 96 hours (4 days), produces higher
compressive strength offly ash
&quarry dust based geo-polymer
concrete. However, the increase in
strength beyond 24 hours is not
significant.
ÿ The fresh flyash-based geo-polymer
concrete is easily handled up to 120
minutes without any sign of setting
and without any degradation in the
compressive strength.
ÿ The mix GP3 gives higher
compressive strength, as it has high
molarity of NaOH
ÿ we Observe that the compressive
strength is increased with the
increase in the molarity of the
sodium hydroxide
ÿ After three days of curing the
increase the compressive strength is
not sufficient
ÿ The geo-polyemer concrete shall be
effeviely used for the beam coloumn
junction of the reinforced concrete
structure
ÿ Geo-polymer concrete shall also be
used in the Infrastructure works.
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ÿ In addition to that fly ash shall be
effectively used and hence no land
fills are required to dump the fly ash
REFERENCES
[1].Zhu Pan , Jay G. Sanjayan , B. V.
Rangan,(2007) “An investigation of the
mechanisms for strength gain or loss of
geopolymer mortar after exposure to elevated
temperature” , published in J Matera Science
(2009) 44:1873–1880.
[2].Davidovits, J. (1988b). Geopolymer
Chemistry and Properties. Paper presented at the
Geopolymer ’88, First European Conference on
Soft Mineralurgy, Compiegne, France.
[3].XiaoluGuo, HuishengShi , Warren A. Dick
(2009) “Compressive strength and
microstructural characteristics of class C fly ash
Geopolymer” published in Elsevier .Ltd, Cement
& Concrete Composites 32 (2010) 142–147
www.elsevier.com/locate/cemconcomp.
[4].Smith Songpiriyakij, TeinsakKubprasit , Chai
Jaturapitakkul , PrinyaChindaprasirt(2010)
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biomass- and fly ash-based Geopolymer”
published in Elsevier .Ltd, Construction and
Building Materials 24 (2010) 236–240.
[5].Shuguang Hu, Hongxi Wang, GaozhanZhang
,Qingjun Ding(2007) “Bonding and abrasion
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with steel slag” published in Elsevier .Ltd
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244.
[6].Christina K. Yip, Grant C. Lukey, John L.
Provis, Jannie S.J. van Deventer (2008), “Effect
of calcium silicate sources on geopolymerisation”
published in Elsevier .Ltd, Cement and Concrete
Research 38 (2008) 554–564.
[7].C.A. Hendriks1, “Emission Reduction of
Greenhouse Gases from the Cement Industry”
Greenhouse gas control technologies conference
paper.
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[8].Ernst Worerell. Lynn Price, et al. “CO2 emission

from the global cement industry”, Annual review of
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[9].M.F.Nuruddin, SobiaQuzi, N. Shafiq, A.

Kusbiantoro, “Compressive strength P& Micro
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[10].Warner, R. F., Rangan, B. V., Hall, A. S.,

&Faulkes, K. A. (1998).ConcreteStructures.
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