VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belagavi – 590018

A Project Report
on
“GEO-POLYMER CONCRETE USING FLY-ASH AND GGBS”
Submitted in partial fulfillment of the requirement for the award
of the degree of
BACHELOR OF ENGINEERING
in
CIVIL ENGINEERING
by

ADARSH JAYAN 4JK17CV007

POURNAMI K 4JK17CV035

ABHIJITH E.S 4JK17CV003

RUKSHA JALAGANDAM 4JK17CV040

Under the Guidance of

Dr. SANGEETHA D.M
Associate Professor
Civil Engineering Department

DEPARTMENT OF CIVIL ENGINEERING

A J INSTITUTE OF ENGINEERING AND TECHNOLOGY
A Unit of Laxmi Memorial Education Trust ®
(Approved by AICTE, New Delhi, Affiliated to VTU, Belagavi, Recognised by Govt. of Karnataka)
Kottara Chowki, Mangaluru-575006, Karnataka
2020-2021

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 A J INSTITUTE OF ENGINEERING AND TECHNOLOGY
A Unit of Laxmi Memorial Education Trust ®
(Approved by AICTE, New Delhi, Affiliated to VTU, Belagavi, Recognised by Govt. of Karnataka)
Kottara Chowki, Mangaluru-575006, Karnataka
2020-2021

DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE
This Certified that the project work entitled “GEO-POLYMER CONCRETE
USING FLY-ASH AND GGBS” carried out by ABHIJITH E.S (4JK17CV003),
ADARSH JAYAN (4JK17CV007), POURNAMI K (4JK17CV035), RUKSHA
JALAGANDAM (4JK17CV040), the bonafide students of A.J. Institute of
Engineering and Technology in partial fulf illment for the award of Bachelor of
Engineering in civil Engineering of the Visvesvaraya Technological University,
Belagavi, during the year 2020-2021. The project report has been approved under our
supervision, as it satisfies the academic requirements in respect of Project Work
prescribed for the said Degree.
Signature of Guide

Dr. SANGEETHA D.M

Department of Civil Engineering,
AJIET Mangalore.

Signature of HOD Signature of Principal

Dr. SUMAN KUNDAPURA Dr. SHANTHARAMA RAI C

Head of the Department Principal
Department of Civil Engineering AJIET Mangalore
AJIET Mangalore

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 DECLARATION
We, the project team hereby declare that the details enclosed in the project proposal are true
and correct to the best of our knowledge and belief and we undertake to inform KSCST of any
changes therein in the project tile, students name will be intimated immediately. In case any of
the above information is found to be false or untrue or misleading, we are aware that we may
be held liable for it. We hereby authorize sharing of the project information with this project
proposal with the Karnataka State Council for Science and Technology, Bangalore.

We are aware that the project team has to exhibit / demonstrate the project in the nodal centre
and interact regarding project with the experts and to exhibit the project in the State Level
Seminar and Exhibition (if selected). If the student team fails to attend the evaluation in nodal
centre or fails to attend the State Level Seminar and Exhibition, the supported project amount
will be returned back to KSCST.

We also hereby, enclose the endorsement form to KSCST, Bengaluru.

Name of the studentsSignature with date

1. ABHIJITH E S

2. ADARSH JAYAN

3. POURNAMI K

4. RUKSHA JALAGANDAM

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 ACKNOWLEDGEMENT
The successful completion of any work would be incomplete without the mention of the people
who made it possible, whose constant guidance and encouragement crowned my efforts with
success.
I am proud to be the part of A J INSTITUTE OF ENGINEERING AND TECHNOLOGY, the
institution which stood my way in all my endeavors.
I like to express my sincere thanks to Dr. SANGEETHA D.M, Associate Prof. Civil
Engineering Department A J INSTITUTE OF ENGINEERING AND TECHNOLOGY, for her
constant support and Guidance.
I am also obliged to Dr. SUMAN KUNDAPURA, Associate Prof. and Head of Civil
Engineering for her motivation and encouragement.
I would like to express my gratitude to Dr. SHANTHARAMA RAI C, principal of A J
INSTITUE OF ENGINEERING AND TECHNOLOGY, Mangalore for providing a very good
working environment.
I would also like to thank and extend my Heart Felt Gratitude to “KARNATAKA STATE
COUNCIL FOR SCIENCE AND TECHNOLOGY” for providing a financial grant to support
my project work.
I am highly obliged in taking the opportunity to sincerely thank to all the lab assistants of civil
engineering department.
I would also like to express my sincere thanks and deep sense of gratitude to my parents for their
everlasting Support.

Name of Students Signature

Ruksha Jalagandam

Abhijith E.S

Adarsh Jayan

Pournami K

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 ABSTRACT
Concrete is one of the most extensively used construction materials in the world. Production
of ordinary Portland cement, the major constituent in the production of concrete, is leading to
large-scale exploitation of the natural reserves of limestones, clays, and coal. It is estimated that
there is a release of 0.8–1.0 tons of carbon dioxide to the atmosphere for the production of
every ton of cement. In view of this, alternative construction materials are being developed, using
industrial by-products such as fly-ash, ground granulated blast furnace slag, and metakaolin,
which are generally rich in alumina and silica. The 21st-century demand's low carbon cement-
free concrete for smart infrastructures.

Geopolymer concrete, a third-generation construction material serves in effectively utilizing

various industrial solid wastes generated by steel and mining industries. Geopolymer concrete
was made up of 100% GGBS, sodium silicate to sodium hydroxide ratio of 2.5, Alkaline to Binder
ratio of 0.5, superplasticizer (2% to 6%) and the concentration of sodium hydroxide of 12M.
Significant increase in workability and slight decrease in strength was observed with increase in
superplasticizer under ambient curing. The combination of 6% superplasticizer and 12M NaOH
concentration of GGBS based Geopolymer concrete was advisable for precast construction
under ambient curing. Geopolymer concrete is useful to utilization of waste materials like
flyash dropped by thermal power plant and GGBS is obtained from industrial by products.

Bond Strength of Geopolymer Concrete Specimens at the ages of 7, 14, 28 days for various
combinations of Flyash and GGBS mixes has investigated. Flyash of 70 % along with GGBS
replaced by 30%. All the mixes has studied at alkaline solution molarity of 12M. The water-to-
solid ratio was found to influence compressive strength and setting time. Increasing GGBS
content in the binder blend resulted in an increase of the compressive strength, but higher GGBS
content caused also early setting which may be undesirable.

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 TABLE OF CONTENTS
DECLARATION ............................................................................................................ iii

ACKNOWLEDGEMENT ............................................................................................... iv

ABSTRACT..................................................................................................................... v

LIST OF FIGURES ....................................................................................................... viii

LIST OF TABLES .......................................................................................................... ix

Chapter 1 : INTRODUCTION .......................................................................................... 1

1.1 General....................................................................................................................... 1

1.2 Need of Geo-Polymer Concrete ................................................................................... 1

1.3 Geo-Polymer .............................................................................................................. 1

1.3.1 Terminology and Chemistry.................................................................................. 2

1.4 Fly-Ash ...................................................................................................................... 3

1.4.1 Production and Classification of Fly-Ash............................................................... 3

1.4.2 Application of Fly-Ash ......................................................................................... 4

1.5 GGBS (Ground Granu lated Blast Fu rnace Slag) ........................................................... 4

1.6 Ob jectiv es of th e Study ................................................................................................. 4

Chapter 2 : LITERATURE REVIEW ................................................................................ 6

2.1 General....................................................................................................................... 6

2.2 Literatu re Rev iew ......................................................................................................... 6

Chapter 3 : MATERIALS AND METHODOLOGY .......................................................... 9

3.1 Materials Used............................................................................................................ 9

3.1.1 GGBS (Ground Granu lated Blast-Fu rn ace Slag) ...................................................... 9

3.1.2 Coarse Aggregate ................................................................................................. 10

3.1.3 Fly-Ash .............................................................................................................. 10

3.1.4 Alk aline So lu tion ................................................................................................. 11

3.1.5 Sup er Plastizers .................................................................................................... 11

vi
3.2 Methodology ............................................................................................................ 12

3.2.1 Mix Design ........................................................................................................ 12

3.2.2 Preparatio n of Alkalin e So lu tion ......................................................................... 13

3.2.3 Manufacturin g and Castin g of Geo -Po ly mer Concrete .............................................. 14

3.2.4 Curing of Geo-Polymer Concrete ........................................................................ 15

3.2.5 Compressive Strength ......................................................................................... 15

Chapter 4 : RESULTS AND DISCUSSIONS .................................................................. 16

4.1 Workability Test ................................................................................................ 16

4.2 Compressive Strength ............................................................................................ 17

4.3 Split Tensile Test................................................................................................... 18

Chapter 5 : CONCLUSION ............................................................................................ 21

Chapter 6 : SCOPE FOR FUTURE WORK..................................................................... 22

REFERENCES............................................................................................................... 23

vii
 LIST OF FIGURES

Figure 1.1 General Polymeric structures from polymerization of

monomers.......................................................................................... 2
Figure 1.2 Chemical Structures of Polysialates .................................... 2
Figure 3.1 Preparation of Alkaline Solution ...................................... 14
Figure 3.2 Sodium Hydroxide in pellets form .................................... 14
Figure 3.3 Filling the mix to mould................................................... 15
Figure 3.4 Adding sodium silicate solution to dry mix ....................... 15
Figure 3.5 Casting of Geo-Polymer concrete cubes ........................... 15
Figure 4.1 Workability test of specimen ............................................ 16
Figure 4.2 7th day compression test. ................................................ 17
Figure 4.3 14th day compression test ................................................ 18
Figure 4.4 28th day compression test ................................................ 18
Figure 4.5 7th day split tensile test.................................................... 19
Figure 4.6 For 14th day split tensile test............................................ 19
Figure 4.7 For 28th day split tensile test............................................ 20

viii
 LIST OF TABLES
Table 3.1 Chemical composition of GGBS.......................................... 9
Table 3.2 Physical Properties of GGBS............................................... 9
Table 3.3 Properties of Coarse Aggregate ......................................... 10
Table 3.4 Chemical Composition of FLY-ASH ................................. 10
Table 3.5 Physical Properties of Fly-ash ........................................... 11
Table 3.6 Percentage of Alkaline Compositions ................................ 11
Table 3.7 Initial Mix Proportion ....................................................... 12
Table 3.8 Alkaline Proportion and Super Plasticizer .......................... 13
Table3.9 Final Mix Design ............................................................... 13
Table 3.10 Molarity of Alkaline Solution .......................................... 14

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Chapter 1 : INTRODUCTION
1.1 General
Geo-polymer concrete is produced by the alkali activation of fly ash or ground granulated slag
combining with aggregates. The progress in the field of geo-polymer concrete up to present
time has been the fruit of an empirical approach, rather than the fundamental and scientific
one. And because of empirical approach, the results from different studies cannot be related to
one another. Geo-polymers are a group of inorganic polymer produced by the result of reaction
between an alkaline solution and an alumina-silicate as a source. The microstructure of
hardened geo-polymer material has an amorphous, three-dimensional structure similar to
that of an alumina-silicate glass. However unlike a glass, these hardened geo-polymer
materials are produced at low temperature and as a result can integrate an aggregate skeleton
and a reinforcing system, if required, during the forming process. The reactants needed to
form a geo-polymer are an alkali hydroxide, alkali silicate solution and an alumino-silicate
fine binder. The binder needs to have a significant proportion of silicon and aluminium ions
held in amorphous phases. Commonly used binders include class -F fly ash, ground
granulated slag and metakaolin, but any fine amorphous alumina-silicate material can be
used. All types of concrete fail under compression when tested. But compression strength
itself is not the property of concrete to explain the performance of concrete. Concrete failure
will always develop in weakest part of one of these three phases namely: aggregate zone,
transition zone and hydrated cement paste. Thus, in order to increase the compressive
strength of concrete, great care must be taken to strengthen all these three phases. It also
depends on the microstructural features of concrete which govern the other properties like
strength, elastic modulus and durability.
1.2 Need of Geo-Polymer Concrete
To produce environmentally 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%. And also the proper usage of industrial.
1.3 Geo-Polymer
Geo-polymers are inorganic, typically ceramic, alumino-silicate forming long-range,
covalently bonded, non-crystalline (amorphous) networks. Commercially produced
geopolymers may be used for fire- and heat-resistant coatings and adhesives, medicinal
applications, high-temperature ceramics, new binders for fire-resistant fiber composites, toxic
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 Geo-Polymer Concrete Using Fly-Ash and GGBS

and radioactive waste encapsulation and new cements for concrete.

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, Davidovits coined 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 on silico-
aluminate. Sialate is an abbreviation for silicon-oxo-aluminate.

Figure 1.1 General Polymeric structures from polymerization of monomers.

Figure 1.2 Chemical Structures of Polysialates

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).

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

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
polysialatescan be schematized as in Figure 1.1.
Geo-Polymerization 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 as shown in Figure 1.2. 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.
During polycondensation by alkali into poly (sialatesiloxo), 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.
1.4 Fly-Ash
Fly ash is manufactured by the burning of coal in an electrostatic precipitator, a by product

of industrial coal. The cementitious properties of fly ash were discovered in late 19 th century
and it has been widely used in cement manufacture for over 100 years. In UK ,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.
1.4.1 Production and Classification of Fly-Ash
Thermal station is 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 fuel resources generally used to heat the water.
Some prefer to use the term energy center 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 fuel thermal power plants produce a large
part of man -made CO2 emissions to the atmosphere, and efforts to reduce these are varied

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

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 Application 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 Led nock 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 dump
➢ 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 GGBS (Ground Granulated Blast Furnace Slag)
The cement production accounts for 7% of global CO2 emission. Due to this, the fly ash, silica
fume, GGBS were used to produce Geo-polymer Concrete. It has a high compressive strength
rather than ordinary Portland cement. This concrete makes an excellent optio n for quick build.
1.6 Objectives of the Study
➢ Selecting an alternative and suitable material which can replace cement by 100% in total.
➢ The suitability of industrial waste like GGBS (40%) and Fly-ash (60%) as a replacement
for 100% cement in concrete is evaluated.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

➢ To evaluate the effectiveness of adopting sodium hydroxide (NaOH) solution instead of

water cement ratio in concrete.
➢ To design a geo-polymer concrete mix which is subjected to ambient curing (air) instead
of regular water curing.
➢ To develop a mixture proportioning process to manufacture low calcium fly -ash based geo-
polymer concrete with and without OPC.
➢ To study the strength parameters of fresh and hardened low calcium fly ash based geo-
polymer concrete.
➢ To compare the cost, strength, environmental, sustainable and suitability of the proposed
concrete mix.
➢ To produce environment friendly concrete

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Chapter 2 : LITERATURE REVIEW

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.
2.2 Literature Review

➢ Paul O. Awoyera et al (2020) conducted an experiment on estimating strength properties of

geopolymer self- compacting concrete using machine learning techniques. The study adopts
a 12M sodium hydroxide and sodium silicate alkaline solution of ratio tofly ash at 0.33 for
geopolymer reaction. Various properties of the concrete, filler ability and passing ability of
fresh mixtures, and compressive, split- tensile and flexural strength of hardened concrete
were determined.
➢ C. Narasimhan et al (2020) conducted an experiment on Alkali- activated concrete systems.
This chapter discusses the performance of alkali-activated concrete systems with different
binders and alternate aggregates, in terms of their mechanical properties, durability,
performance on exposure to elevated temperatures, performance on inclusion of fibers, and
finally their suitability for use in structural members.
➢ C. Jithendra et al (2019) conducted an experiment on Role of Superplasticizer on GGBS
based Geopolymer Concrete under ambient curing. Increase in the dosage of superplasticizer
can have a significant effect on workability and strength properties of Geopolymer concrete
in ambient curing. In this study, Geopolymer of 2.5, Alkaline to Binder ratio of 0.5,
superplasticizer (2% to 6%) and the concentration of sodium hydroxide of 12M. Significant
increase in workability and slight decrease in strength was observed with increase in
superplasticizer under ambient curing.
➢ S. Saravnam et al (2019) conducted an experiment on Investigation on Compressive Strength
Development of Geopolymer Concrete using manufactured sand. A study reveals, the annual
emission rate of carbonate burns in cement industries contributes

around five to eight percent of the world’s greenhouse gas emissions. In such a case the
manufactured sand (MS) is an economic alternative to river sand in concrete. The ultimate
objective of this thesis paper is to assess the properties of flyash based Geopolymer concrete
by using manufactured sand as fine aggregate.
➢ K. Pandurangan et al (2018) conducted an experiment on Studies on Effect of Sourceof Flyash
on the Bond Strength of Geopolymer Concrete. Geopolymer concrete is a new material used

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

for making the concrete. Geopolymer concrete is useful to utilization of waste materials like
flyash dropped by thermal power plant and GGBS is obtained from industrial by products.
They can be easily available and low cost as compared to the Portland cement. Bond Strength
of Geopolymer Concrete pullout Specimens at the ages of 7, 28 days for various combinations
of Flyash and GGBS mixes has investigated. Flyash of 70 % along with GGBS replaced by
30%. All the mixes has studied at alkaline solution molarity of 12M

➢ T. Venu Madhav et al (2018) conducted an experiment on Compressive strength study of

geopolymer mortar using quarry rock dust. Geopolymer is the term used to represent the
binders produced by polymeric reaction of alkaline liquid with silicon and aluminium as
source materials. Common river sand is expensive due to excessive cost of transportation from
natural sources. River sand is most commonly used fine aggregate in the production of
concrete poses the problem of acute shortage in many areas. Quarry Rock Dust can be defined
as residue, tailing or othernon-voluble waste material after the extraction and processing of
rocks to form fine particles less than 4.75 mm.
➢ Ali Rafeet Raffael et al (2017) conducted an experiment on Guidelines for mix proportioning
of fly ash/GGBS based alkali activated concretes. The effects of paste volume, water content
and precursor blend on consistency, setting time and compressive strength of alkali activated
concrete (AAC) produced with fly ash (FA) and ground granulated blast furnace slag
(GGBS) have been investigated with the aim of developing a suitable mix design procedure.
The water-to-solid ratio was found to influence compressive strength and setting time.

➢ R. S. Krishna J et al (2020) conducted an experiment on Industrial solid waste management

through sustainable green technology. The generation of industrial solid waste is increasing
at an alarming rate worldwide and landfilling is no longer a feasible method for managing
various industrial solid wastes. However, recent developments in environmental policies
have led to many sustainable approaches towards integrated solid waste management.
➢ I.R. Mithanthaya et al (2017) conducted an experiment on Influence of superplasticizer on
the properties of geopolymer concrete using industrial wastes. Normally Geo-Polymer
concrete (GPC) is developed using source materials like Fly Ash, and alkaline activator sodium
hydroxide and sodium silicate solution, cured at elevated temperature.
➢ A. Joshua Daniel et al (2017) conducted an experiment on Comparative study on the
behaviour of Geopolymer Concrete with Hybrid Fibers under Static Cyclic Loading. Geo-
polymer is a latest advancement in which the cement is substituted by an eco-friendly
Pozzolanic material. It is activated by a highly alkaline solution to produce aluminosilicate
gel which acts as a binder in concrete. In this study cement is fully replaced by Ground

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Granulated Blast Furnace Slag (GGBS).

➢ N A Lloyd and B V Rangan et al (2010) conducted an experiment 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 geo-polymer concrete. From the literature it is observed that, the use of fly-
ash and GGBS are used in preparing a Geo-Polymer concrete. Most of the studies, includes
alkalinity, creep and shrinkage, effect of plasticizers, etc. are studied . In the present work,
the combination of both Fly-ash and GGBS as 100% replacement to cement is adopted.
Also, the effect of change in alkalinity on strength are experimentally studied.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Chapter 3 : MATERIALS AND METHODOLOGY

In this Chapter, the materials used and the experimental work adopted for the present investigation
are discussed. 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.
3.1 Materials Used
The properties of various materials like GGBS, Fly-ash, Coarse Aggregates, and Super-plasticizers
listed in detail. Method adopted for preparing the alkaline solution is also discussed.

3.1.1 GGBS (Ground Granulated Blast-Furnace Slag)

Blast furnace slag is a by-product of iron manufacturing industry. Iron ore, coke and limestone are
fed into the furnace and the resulting molten slag floats above the molten iron at a temperature
of about 1500 C to 1600 C. The chemical and physical properties of GGBS are listed in Table
3.1 and 3.2 respectively. The molten slag has a composition of 10% to 20% silicon dioxide
(SiO2) and approximately 40% CaO, which is close to the chemical composition of Portland
cement.
Table 3.1 Chemical composition of GGBS

Oxides GGBS
SiO2 29.2
Al2O3 13.8
CaO 44.9
MgO 6.2
Fe2O3 5.5
Na2O 0.3
K2O 1.0
Ti02 2.1
Loss of Ignition -
CaO/SiO2 1.54

Table 3.2 Physical Properties of GGBS

Properties GGBS
Specific Gravity 2.85
Bulk Density 1200 Kg/m3
Absorption % 1.3
Moisture Content % Nil

Sieve Analysis Zone III

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

3.1.2 Coarse Aggregate

The properties of the coarse aggregate used in a concrete mixture are listed in Table 3.3.
Aggregates were purchased from D.C. Ananda exports Mangalore. The modulus of elasticity of
the coarse aggregate has a greater strength on concrete properties. A higher aggregate modulus
will result in a concrete having a higher modulus.

Aggregates make up 60-80% of the volume of concrete and 70-85% of the mass of concrete.
Aggregate is also very important for strength, thermal and elastic properties of concrete,
dimensional stability and volume stability. Including aggregate in the mix can control the
shrinkage level and prevent cracking.

Table 3.3 Properties of Coarse Aggregate

Property Coarse Aggregate

20mm 12mm

Fineness Modulus 8.14 8.14

Specific Gravity 2.87 2.83

Bulk Density 1533.33 Kg/m3 1517 Kg/m3

Percentag e of Voids 45.24 % 47.14%

Coarse aggregates of sizes 12mm and 20mm having following properties taken from a local
supplier are used in the present study.

3.1.3 Fly-Ash
Fly ash consists of silt-sized particles which are generally spherical, typically ranging in size
between 10 and 100micron. These small glass spheres improve the fluidity and workability of
fresh concrete.
Table 3.4 Chemical Composition of FLY-ASH

Properties FLY-ASH

Specific Gravity 2.85

Bulk Density 1200 Kg/m3

Absorption % 1.3

Moisture Content % Nil

Seive Analysis Zone III

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Fineness is one of the important properties contributing to the pozzolanic reactivity of fly ash.
Some of the physical and chemical properties of the Fly-ash are listed in Table 3.4 and 3.5
respectively. Fly- ash and GGBS were purchased online from India mart.

Table 3.5 Physical Properties of Fly-ash

Oxides FLY-ASH
SiO2 59.2
Al2O3 38.02
CaO 0.94
MgO 0.28
Na2O 0.47
K2O 0.22
Ti02 2.1
Loss of Ignition 1.05

3.1.4 Alkaline Solutio n

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 chemical
proportion are given in Table 3.6.
Table 3.6 Percentage of Alkaline Compositions

Na 2O - 7.5-8.5 %
SiO2 - 25-28 %
Water - 67.5-63.5%

3.1.5 Super Plastizers

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

Advantages
• Reduction in water-cement ratio of the order of 20-25%
• Flowing, pumpable concrete
• Excellent workability and retention even in extreme temperature.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

3.2 Methodology
In this project a comparative study between Conventional Concrete (CC) of M25 grade and Geo-
Polymer mix GP 1, GP 2, GP 3 is carried out. For M25 grade, the mix ratio is 1:1:2.

3.2.1 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 IS code method, 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 by N A Lloyd and B V Rangan (2010) is taken as a reference one,
several trial mixes are prepared with fly-ash and constant molarity of NaOH as 12M. 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 initial mix proportion and the alkaline proportions are listed in Table 3.7 and 3.8 respectively.
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/m 3 is added to the mixture to facilitate ease of placement of fresh concrete.
Table 3.7 Initial Mix Proportion

The mass of fine aggregates +coarse aggregate 1750 Kg/m3

Coarse aggregate 60% of 1750
= 1050 Kg/m3
GGBS 40% of 1750
=700 Kg/m3
Mass of alkaline liquid and fly-ash 2500-1750
=750 Kg/m3
Mass of fly-ash 60% of 750
=450 Kg/m3
Mass of alkaline liquid 40% of 750
=300 Kgm3

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

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/m 3 Take the ratio
of sodium silicate solution-to-sodium hydroxide solution by mass as 2; 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-3.9 except the molarity of NaOH is changed in
the each mix.
Table 3.8 Alkaline Proportion and Super Plasticizer

The mass of sodium hydroxide solution 100 Kg/m3

The mass of sodium silicate solution 200 Kg/m3

The mass of super- plasticizer 0.75 x 450

=3.375 Kg/m3

Table3.9 Final Mix Design

Name of Fly-ash GGBS Coarse Aggregate Sodium Sodium Super

the (Kg/m3 ) (Kg/m3 ) (Kg/m3 ) Silicate Hydroxide Plasticizer
Mixture solution solution (Kg/m3 )
20 mm 12 mm (Kg/m3 ) (Kg/m3 )

GP 1 450 700 400 650 200 100(8M) 3.375

GP 2 450 700 400 650 200 100(10M) 3.375
GP 3 450 700 400 650 200 100(12M) 3.375

3.2.2 Preparatio n of Alkaline Solution

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 weight of flakes required, to prepare the required
molarity of NaOH solution is shown in Table 3.10 and Figure 3.1.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Table 3.10 Molarity of Alkaline Solution

Required Molarity Weight in gms of Sodium Hydroxide flake

8M 320
10 M 400
12 M 480

Figure 3.1 Preparation of Alkaline Solution

The pellet form of Sodium Hydroxide is shown in Figure 3.2. 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.

Figure 3.2 Sodium Hydroxide in pellets form

3.2.3 Manufacturing and Casting of Geo-Poly mer Concrete

The conventional method used in the making of normal concrete is adopted to prepare geo-
polymer concrete. First the GGBS, coarse aggregate and Fly-ash are 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

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

6-8 minutes for proper bonding of all the materials. After the mixing, the cubes are casted with the
mixes GP1 - GP3 by giving proper compaction. The sizes of the cubes used are of size
150mmX150mmX150mm. The process of missing is shown in Figure 3.3-3.5.

Figure 3.4 Adding sodium silicate solution to dry mix Figure 3.3 Filling the mix to mould

Figure 3.5 Casting of Geo-Polymer concrete cubes

3.2.4 Curing of Geo-Polymer Concrete

For the curing of geo-polymer concrete cubes, the cubes are placed in direct sun-light
(ambient curing). For the sun light curing, the cubes are de-moulded after 1 day of casting and
they are placed in the direct sun light for 7, 14 and 28 days.

3.2.5 Compressive Strength

Compressive strength is the capacity of a material or structure to withstand axially
directed pushing forces. Cubes were casted and compressive strength test was conducted on
specimens at 7, 14 and 28 days. 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.
.......
fck =Pc/A Equation 1

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

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Chapter 4 : RESULTS AND DISCUSSIONS

Based on the methodology and mix proportions discussed in the previous chapter, the cubes are
casted. It is demoulded after 24 hours and kept for air curing for 7, 14 and a 28 days. Workability
of the fresh concrete mix is found. The compressive and split tensile strength of cubes are carried
out, results are discussed in this section.

4.1 Workability Test

Workability means the ease of placement and workable concrete means the concrete which can be
placed and can be compacted easily without any segregation. Workability is a vital property of
concrete and related with compaction as well as strength. The concrete slump test or slump cone test
is the most common test for workability. For all the mixes, the test is carried out and the results are
represented in Table 4.1 and Figure 4.1. It is observed that, the higher values are observed in the mix
GP-3, as it has high molarity of alkaline solution. Higher concentration (in terms of molar) of alkaline
solution results in higher workability of Fly-Ash & GGBS based geo-polymer concrete.

Table 4.1 Workability Test

S/L Name of the mix Workability in

No. mm
1 CC 65

2 GP 1 75

3 GP 2 82

4 GP 3 92

Figure 4.1 Workability test of specimen

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Also, it is observed that, the initial setting time of CC is found to be 65-75 mins, whereas for GP-
1, GP-2 and GP-3 are found to be 120, 135, 148 minutes respectively. Thus, Geo -polymer concrete
provides each in workability with high initially setting time. On an average, it can be noted that
initial setting time of GPC is found to be double the time of CC.

4.2 Compressive Strength

Compressive strength or compression strength is the capacity of a material or structure to withstand
loads tending to reduce size, as opposed to Tensile strength which withstands loads tending to
elongate. Compressive strength increases with the number of days after curing. Conventional concrete
cube is kept for normal water curing, whereas the Geo-Polymer cubes are allowed for ambient curing.
The cubes are tested after 28 days and the results are tabulated in Table 4.2, it is noticed that around
30% more strength is achieved from that of 7 days. The difference in the strength achieved by 7, 14,
28 days cubes as compared with CC is shown in Figure 4.2 -4.4. Among the mixes GP1, GP2 and
GP3, the mix GP3 gives higher compressive strength because of its high molarity of alkaline solution.
Table 4.2. Compressive strength

Name of the Mix Compressive Strength in N/mm 2 of Specimen Cured by

7 Days 14 Days 28 Days

CC 18.6 23.4 27

GP 1 19.23 23.6 27.5

GP 2 20.26 24.2 28.2
GP 3 21 25.2 29.4

Figure 4.2 7th day compression test.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Figure 4.3 14th day compression test

Figure 4.4 28th day compression test

4.3 Split Tensile Test

One of the important properties of concrete is “tensile strength” as structural loads make concrete
vulnerable to tensile cracking. Tensile strength of concrete is much lower than its compressive
strength. The cubes are tested after 7,14 and 28 days of curing and the results are shown in Table 4.3.
It is observed that, the strength gained is around 20% higher than the conventional concrete. Upon 28
days of curing, the strength achieved is almost same. But relatively GP3 gives higher compressive
strength, as it has high molarity of alkaline solution. Higher concentration (in terms of molar) of
alkaline solution results in higher split tensile strength of Fly -Ash & GGBS based geo-polymer
concrete.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Table 4.3 Split Tensile Test

Split Tensile Test in N/mm 2 of Specimen Cured by

Name of the Mix 7 Days 14 Days 28 Days

CC 1.7 2.25 2.87

GP 1 1.9 2.34 2.74

GP 2 2.2 2.47 2.85

GP 3 2.3 2.52 2.96

Figure 4.5 7th day split tensile test

Figure 4.6 For 14th day split tensile test

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Figure 4.7 For 28th day split tensile test

From the above results, it is to be noted that the workability of Geo-polymer concrete is much higher than
conventional concrete. It is having an initial setting time almost double as that of conventional concrete. Also,
the results have shown that the compressive and split tensile behavior of Geo-Polymer concrete is excellent.
Hence, it can be effectively used as an alternate for conventional concrete.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Chapter 5 : CONCLUSION
From the above results and discussion, some of the basic conclusions are drawn and are listed
below:

➢ Higher concentration (in terms of molar) of sodium hydroxide solution results in higher
compressive strength of fly ash & GGBS based geo-polymer concrete.
➢ The fresh Fly-ash based geo-polymer concrete can be easily handled up to 120 minutes
without any sign of setting and without any degradation in the compressive strength. Also,
Initial setting time is more for Geopolymer concrete compared to Conventional concrete.
➢ Compressive strength and split tensile strength is found to increase with the increase in the
molarity of the NaOH solution and with increase in number of days of ambient curing. Maximum strength
is achieved in GP-3 model with 12M solution and 28days of curing.
➢ Geo-polymer concrete shall also be used in the Infrastructure works. In addition to that
fly ash shall be effectively used and hence no landfills are required to dumpthe fly-ash.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

Chapter 6 : SCOPE FOR FUTURE WORK

➢ Geo-polymer concrete is made using Fly-Ash, GGBS, Alkaline Solution and Coarse
Aggregate. Various tests were performed on geopolymer blocks as a part of study like
compression test, split tensile strength etc. The work can be extended in several directions and
are listed below:
➢ Some of the properties like drying-shrinkage test, creep test, chemical test, acid attack test etc.
can be carried out.
➢ For preparing Alkaline solution, researches can be done by replacing sodium hydroxide and
sodium silicate by potassium hydroxide and potassium silicate. Also, Alkaline solution with
different molarities can be tried.
➢ Materials like Metakoline, silica fumes, Rice husk ash, quarry dust etc. can be used instead of
Fly-Ash and GGBS. Also, tests can be conducted on slag-based, rock-based geopolymers.
➢ It is found in literatures that, through heat curing concrete can attain more strength in short
span of time. Further research can be continued for varying temperature and exposure
conditions.
➢ Microscopic studies like SEM can be carried out.

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 Geo-Polymer Concrete Using Fly-Ash and GGBS

REFERENCES

1) Paul O. Awoyera Mehmet, S. Kirgiz A, Viloria D & Ovallos - Gazabon, Estimating

strength properties of geopolymer self - compacting concrete using machine learning
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9, Issue 4, Pages 9016- 9028.
2) R. Manjunath Mattur & C. Narasimhan, Alkali- activated concrete systems. New
Materials in Civil Engineering, 2020, Pages 459-491.
3) C. Jithendra & S.Elavenil, Role of Superplasticizer on GGBS based Geopolymer
Concrete under ambient curing. Materials today proceeding, volume 18, part 1, 2019,
pages 148-154.
4) S. Saravnam, S. Nagajothi & S. Elavenil, Investigation On Compressive Strength
Development Of Geopolymer Concrete Using Manufactured Sand. Materials today
proceeding, volume 18, part 1, 2019, pages 114-124.
5) K. Pandurangan, M.Thennavan & A. Muthadhi, Studies on Effect of Source of Flyash on
the Bond Strength of Geopolymer Concrete.Materials today proceeding, volume 5,
Issue 5, part 2, 2018, pages 12725-12733.
6) T. Venu Madhav, I.V Rama Reddy, Vaishali G Ghorpade & Jyothirmai, Compressive
strength study of geopolymer mortar using quarry rock dust. Materials Letters, volume
231, 2018, pages 105-108.
7) Ali Rafeet Raffael, Construction and Building, Guidelines for mix proportioning of fly
ash/GGBS based alkali activated concretes. Materials Volume 147, 30 August 2017,
Pages 130-142.
8) R. S. Krishna J. Mishra Saurabh K. Singh, Industrial solid waste management through
sustainable green technology. Materials Today: Proceedings In press, corrected proof
Available online 27 March 2020.
9) R. Mithanthaya Shriram, Influence of superplasticizer on the properties of geopolymer
concrete using industrial wastes. Materials Today: Proceedings Volume 4, Issue 9,
2017, Pages 9803-9806.
10) Joshua Daniel, Comparative Study on the Behaviour of Geopolymer Concrete with
Hybrid Fibers under Static Cyclic Loading. Procedia Engineering Volume 173, 2017,
Pages 417-423.

11) N A Lloyd and B V Rangan Curtin University of Technology, tests conducted on

various short-term and long-term properties of the geo-polymer concrete “Geopolymer
Concrete with Fly Ash”

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