EFFECT OF METAKAOLIN ON STRENGTH

PROPERTIES OF FLY ASH-GGBS BASED

GEOPOLYMER CONCRETE
These is submitted to JNTUA, Ananthapuramu in partial fulfillment of the
requirements for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
STRUCTURAL ENGINEERING
BY
J.SAI RAGHAVA
(Regd.No.219X5A01D3)

Under the esteemed guidance of

Dr. K.V.S. Gopala Krishna Sastry
Professor & HOD of H&BS

DEPARTMENT OF CIVIL ENGINEERING

G. PULLA REDDY ENGINEERING COLLEGE
(AUTONOMOUS)
(Affiliated to JNTUA, ANANTAPURAMU)
KURNOOL - 518 007(A.P)
2021-2024
 G. PULLA REDDY ENGINEERING COLLEGE
(AUTONOMOUS)
KURNOOL – 518007 (A.P)
(Affiliated to JNTUA, ANANTAPURAMU)
DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE
This is to certify that this project work entitled

“EFFECT OF METAKAOLIN ON STRENGTH

PROPERTIES OF FLY ASH-GGBS BASED
GEOPOLYMER CONCRETE”
is a bonafide record work carried out by

J.SAI RAGHAVA
(Regd.No.219X5A01D3)
Under the guidance and supervision

In partial fulfilment of the requirements for the award of Degree of

BACHELOR OF TECHNOLOGY
IN
STRUCTURAL ENGINEERING

Head of the Department Project Guide

Dr. K. Chinnapa Reddy,
Professor and Head of the Department,
Civil Engineering Department
G. Pulla Reddy Engineering College,
Kurnool-518007. (A.P)
Dr. K.V.S Gopala Krishna Sastry,
Professor and Head of the Department,
Humanities and Basic Sciences Department
G. Pulla Reddy Engineering College,
Kurnool-518007. (A.P)
 ACKNOWLEDGEMENT

I Convey my thanks to DR.K.V.S. Gopala Krishna Sastry, Professor of Civil Engineering

and Head of department of H&BS, G. Pulla Reddy Engineering College, Kurnool, for his valuable
insight and guidance regarding the project and my academic path. His consistent motivation and
encouragement allowed me to perform the best and unleashed my capabilities in many areas,
especially in the field of study.

My sincere thanks to Dr.K. Chinnapa Reddy, Professor and Head of the Department of Civil
Engineering for the encouragement.

My sincere thanks to Dr.B. Sreenivasa Reddy, Principal, for facilities provided me during
the course study.

I humble express my heartful thanks to all faculty members of Department of Civil

Engineering for their encouragement and generous treatment throughout the period of project work.

I am thankful to the Concrete Technology Laboratory staff and my classmates for their
cooperation in experimental work.

I am thankful to my beloved parents, family members and friends for their moral support
extended till to the end of B. Tech course

iii
 DECLARATION

I hereby declare that the dissertation wok titled “EFFECT OF METAKAOLIN ON

STRENGTH PROPERTIES OF FLYASH-GGBS BASED GEOPOLYMER
CONCRETE” is the authentic work carried out by me, student of G. PULLA REDDY
ENGINEERING COLLEGE (Autonomous) Kurnool, during 2021 to 2024, has not been
submitted elsewhere for the award of B. Tech degree.

J.SAI RAGHAVA

(Regd No:219X5A01D3)

iv
 ABSTRACT
One of the most user-friendly alternatives to ordinary concrete is geopolymer concrete
(GPC), which achieves the same result. GPC is a unique substance made by activating source
materials with a high concentration of silica and alumina. As a result, geopolymer binders
use less raw resources and emit less carbon dioxide. To develop GPC immediate requirement
of infrastructures is needed to meet the demand. Most of the infrastructures are being
constructed with help of cement concrete, which leads to environment pollutions. To save
the environment we need move forward towards the sustainable development. For
sustainable development it is required to reduce the consumption of cement by replacing
with the industrial waste like Fly Ash, GGBS & Metakaolin.

NaOH and Na2sio3 were used as activator solution. The fixed ratio of sodium silicate to
sodium hydroxide is 1.5 and the concentration of sodium hydroxide is 10 Molarity. The
geopolymer concrete specimens are casted and tested in the laboratory for compressive
strength, Split Tensile Strength and Flexural strength for 28 days and cured at ambient
temperature. This study helps in gaining knowledge about the morphological compositions
of geopolymer concrete of which might result in pathbreaking trends in research and
construction industry.

v
 LIST OF TABLES
TABLE NO PAGE NO

Table.1 Physical Properties of Fly Ash 7

Table.2 Physical Properties of GGBS 8

Table.3 Chemical Composition of GGBS 9

Table.4 Physical Properties of Metakaolin 10

Table.5 Chemical Composition of Metakaolin 10

Table.6 Physical Properties of Fine Aggregates 12

Table.7 Sieve Analysis of Fine Aggregate 12

Table.8 Physical Properties of Coarse Aggregates 14

Table.9 Sieve Analysis of Coarse Aggregate 14

Table.10 Physical and Chemical composition of Sodium Silicate 17

Table.11 Strength Properties of GPC for different mixes 21

Table.12 Compressive Strength of Geopolymer Concrete 26

Table.13 Split Tensile Strength of Geopolymer Concrete 27

Table.14 Flexural Strength of Geopolymer Concrete 28

vi
 LIST OF FIGURES

FIGURE NO PAGE NO

Figure.1 Fly Ash 8

Figure.2 Ground Granulated Blast Furnace Slag 9

Figure.3 Metakaolin 11

Figure.4 Fine Aggregate 13

Figure.5 Gradation Curve of Fine Aggregate 13

Figure.6 Coarse Aggregate 15

Figure.7 Gradation Curve of Coarse Aggregate 15

Figure.8 Sodium Hydroxide (NaOH) 16

Figure.9 Sodium Silicate (Na2SiO3) 17

Figure.10 Alkaline Activator Solution 18

Figure.11 Cast Specimens of GPC 20

Figure.12 Compressive Strength Test Set Up 22

Figure.13 Split Tensile Strength Test Set Up 24

Figure.14 Flexural Strength Test Set Up 25

Figure.15 Compressive Strength GPC for 28 days 27

Figure.16 Split Tensile Strength GPC for 28 days 28

Figure.17 Flexural Strength GPC for 28 days 29

vii
 CONTENTS
Abstract V
List of Figures VI
List of Tables VII
1 INTRODUCTION 1
1 General 1
1.1 Geopolymers 2
1.2 Base Materials and Alkaline Liquids 2
1.3 Properties of Geopolymer Concrete 2
1.4 Advantages of Geopolymer Concrete 3
1.5 Disadvantages of Geopolymer Concrete 3
2 LITERATURE REVIEW 4
3 EXPERIMENTAL PROGRAMME 7
3.1 General 7
3.2 Materials 7
3.2.1 Fly Ash 7
3.2.2 GGBS 8
3.2.3 Metakaolin 10
3.2.4 Aggregates 11
3.2.4.1 Fine Aggregates 11
3.2.4.2 Coarse Aggregates 14
3.2.5 Alkaline Solution 16
3.2.5.1 Sodium Hydroxide 16
3.2.5.2 Sodium Silicate 16
3.3 Preparation of Alkaline Activator 17
3.4 Mix Design 18
3.4.1 Mix Proportion for Geopolymer Concrete 19
3.4.2 Test Programme 19
3.4.3 Preparation of fresh GPC and Casting for reference mix 19
3.5 Curing Methodology 20
3.6 Tests on Hardened Concrete 20
3.6.1 Compressive Strength Test 21
3.6.2 Split Tensile Strength Test 23
3.6.3 Flexural Strength Test 24

viii
4 RESULTS AND DISCUSSIONS 26
4.1 General 26
4.2 Compressive Strength of Geopolymer Concrete 26
4.3 Split Tensile Strength of Geopolymer Concrete 27
4.4 Flexural Strength of Geopolymer Concrete 28
5 CONCLUSIONS 30
REFERENCE 31
APPENDIX 33
MIX DESIGN FOR GEOPOLYMER CONCRETE

ix
 CHAPTER-1
INTRODUCTION

1.GENERAL

Usage of cement by the construction industry is increasing enormously which causes major
environment imbalance through greenhouse gases.

On the other side the climate change due to global warming has become a major environmentalissue.
Global warming is induced by the emission of greenhouse gases such as CO2 into the atmosphere
by human operations. The carbon dioxide severity in cement production is increased by 0.7 percent
per year.

There are many efforts taken to decrease the use of cement. These attempts include the use of extra
cementing products like fly ash, silica fume, ground granulated blast furnace slag, metakaolin, rice
husk ash etc.

In this regard, the geopolymer mechanism proposed by Davidovits demonstrates important

improvements in the concrete sector as a substitute binder for Portland cement. With regard to
global warming, the geopolymer mechanism could considerably decrease the CO2 emission from
the cement industries to the atmosphere.

Raw materials have a major impact on the chemical reactions that are required for geopolymer
concrete synthesis and therefore affect their properties.

1|Page
1.1GEOPOLYMERS

The term “geopolymer” was popularized by French scientist and engineer Prof. JosephDavidovits
in the 1970s and applied to a group of solid materials produced by an alumina silicate powder
reaction using an alkaline solution. The primary meaning of synthesizing geopolymers is to
incorporate an alkaline solution with a reactive aluminosilicates powder, in general metakaolin
(calcined kaolinite clay) or fly ash (coal-burning by- product), GGBS etc. There are two primary
components of geopolymers, namely base materials and alkaline liquids.The base materials should
be rich in silicon and aluminum for alumina-silicate-based geopolymers. This can be natural
minerals like kaolinite, clays, micas, etc. whose scientific composition includes si, al, and oxygen.
By products like fly ash, fumes from silica, slag, ricehusk ash, etc.

1.2 BASE MATERIALS AND ALKALINE LIQUIDS

There are two primary components of geopolymers, namely base materials and alkaline liquids. The
base materials should be rich in silicon and aluminum for alumino-silicate-based geopolymers. This
can be natural minerals like kaolinite, clays, micas, etc. Whose scientific composition includes si,
al, and oxygen. By-products like fly ash, fumes from silica, slag, rice husk ash, etc can also be used.
The selection of source materials for creating geopolymers depends on variables such as
accessibility, price and type of application and user particular demand. Alkaline liquids are derived
from soluble alkaline metals that are usually based on sodium or potassium.

1.3 PROPERTIES OF GEOPOLYMER CONCRETE

• In compression to cement concrete, the drying shrinkage is much less. This allows it suitable
for dense and highly restricted structural components of concrete.
• In comparison with cement concrete, it has low hydration heat.
• The fire strength is much better than that of concrete based on OPC.
• It provides better protection against corrosion for reinforcement steel than conventional
cement.
• Recent studies showed that by adding ground granulated blast furnace slag the setting and

2|Page
 strength development can be improved.

1.2 ADVANTAGES OF GEOPOLYMER CONCRETE:

Geopolymer concrete have following advantages over conventional concrete

• High strength
• Low shrinkage and creep
• Resistant to heat and cold
• Geopolymer concrete shall be used in repairs and rehabilitation works
• Chemical resistant
• Fire proof
• Highly durable
• Environmental benefits

1.3 DISADVANTAGES OF GEOPOLYMER CONCRETE:

• Geopolymer concrete requires special handling and it requires skilled labor.

• It requires the use of chemicals, such as sodium hydroxide, that can be harmful to humans.
• The process of geo polymerization is sensitive.

3|Page
 CHAPTER-2
LITERATURE REVIEW
P. Nath and P. K. Sarker studied on effect of GGBS on setting, workability and early
strength properties of fly ash geopolymer concrete cured in ambient condition.[1]
Eight geopolymer concrete and eight corresponding geopolymer mortar mixtures were designed
adding ground granulated blast furnace slag up to 30% of total binder in order to improve the early
age properties. The activating liquid was a mixture of sodium silicate and sodium hydroxide
solutions. No extra water or superplasticizer was added to the mixtures. Testspecimens were cured
in ambient temperature and tested for setting time, workability and compressive strength. Adding
slag up to 30% of the total binder achieved compressive strengthof concrete up to 55 MPa and that
of mortar up to 63 MPa at 28 days. Compressive strength decreased with the increase of alkaline
solution content from 35% to 45% of total binder. 0Variation of sodium silicate to sodium
hydroxide ratio from 1.5 to 2.5 decreased the Na2O/SiO2 molar ratio and led to slight drop in
strength over the age.
P. S. Deb, P. p Nath, and P. K. Sarker studied on the effects of ground granulated blast-
furnace slag blending with fly ash and activator content on the workability and strength
properties of geopolymer concrete cured at ambient temperature.[2]
Compressive strength at all ages up to 180 days increased with the increase of the slag content.
Strength development of the slag blended fly ash geopolymer concrete cured at ambient
temperature was similar to that of water-cured OPC concrete. The strength gain slowed down after
the age of 28 days and continued to increase at a slower rate until 180 days. The 28-day compressive
strength reached up to 51 MPa in geopolymer concrete containing 20% slag and 80% fly ash in the
binder and 40% activator liquid with SS/SH ratio of 1.5 when cured at 20 °C.
J. G. S. Jaarsveld, J. S. J. Deventer, and G. C. Lukey studied on the effect of compositionand
temperature on the properties of fly ash and kaolinite-based geopolymers.[3]
There exists an interrelationship among the various material parameters that affect the final
structure and property of fly ash-based geopolymers. It was shown that the water content, curing
as well as calcining conditions affect the final properties of a geopolymer with less waternot always
being desirable when mix designs are considered. The clay content also impacts onthe structural
properties with a surface reaction expected to bind the clay into the structure, although unreacted
clay.
U. Rattanasak and P. Chindaprasirt studied on Influence of NaOH Solution on the Synthesis
of Fly Ash Geopolymer.[4]
When fly ash came into contact with NaOH, leaching of Si, Al and other minor ions started. The
amount of leaching was dependent on NaOH concentration and leaching time. The resultsindicated
that leaching time of 5–10 min was sufficient as an increase in leaching time to 20 and 30 min did
not significantly increase the concentration of Si4+ and Al3+ ions. The mixing of fly ash with 10 M
NaOH for 10 min was, therefore, appropriate for synthesis of geopolymer when economy and
practicality were taken.

4|Page
M. Albitar, M. S. Mohamed Ali, P. Visintin, and M. Drechsler studied on Durability
evaluation of Geopolymer and conventional concretes.[5]
This paper has presented the results of an experimental study that was undertaken to investigate
the behavior geopolymer concretes exposed to 5% sodium chloride, 5% sodium sulphate, 5%
sodium sulphate + 5% magnesium sulphate and 3% sulphuric acid. OPC concrete suffers more
deterioration than geopolymer concretes due to sodium sulphate exposure with a reduction
magnitude of 15.4% compared to 13.4% and 12.3% corresponding reduction magnitude of fly
ash and GLSS geopolymer concretes respectively.
T. Phoo-ngernkham, A. Maekawa, N. Mishima, S. Hatanaka, and P. Chindaprasirt
studied on Effects of Sodium Hydroxide and Sodium Silicate Solutions on Compressive
and Shear Bond Strengths of FA–GBFS Geopolymer.[6]
he effect of using sodium hydroxide and sodium silicate solutions as liquid portions in the
mixture on properties of FA–GBFS geopolymer was investigated in this study. The FA paste
contains amorphous NASH gel and some crystalline phases of the remain of fly ash. The
increase in GBFS content enhanced the compressive strength and microstructure of
geopolymer pastes due to the formation of additional CSH. The use of NH and NHNS solutions
resulted in crystalline CSH and amorphous gel, whereas the use of NS solution resulted in
mainly the amorphous products.

For the FA and FA + GBFS pastes, the use of NH solution or NS solution alone gave low
strengths when cured at ambient temperature. Better strength development was obtained with
the use of NHNS solution. For the GBFS paste, the presence of silicate enhanced the strength
development and thus pastes containing NS solution performed better. Relatively high 28-day
compressive strengths of 171.7 and 173.0 MPa were obtained for GBFS pastes with NHNS and
NS solutions, respectively.

S.A. Bernal, J. L. Provis studied on Engineering and Durability Properties of Concretes

Based on Alkali-Activated Granulated Blast Furnace Slag/Metakaolin Blends.[7]

Several engineering and durability-related properties of concretes based on alkali silicate-

activated blends of granulated blast furnace slag and metakaolin have been assessed, and
compared as a function of curing duration and mix design parameters (expressed as overall
oxide molar ratios). The concretes assessed have high alkali activator content, which leads to
satisfactory early strength development and in most cases high (>50 MPa) final compressive
strengths after 90–180 days. Flexural strength at later age is enhanced by the incorporation of
metakaolin into the binder mix, and the flexural strengths of all samples fall well above the
values predicted by the ACI 318 standard correlation for flexural strength as a function of
compressive strength.

Almost all durability parameters tested fall within the range’s characteristic of highly durable
concretes, assuming that the correlations developed for Portland cement concretes also hold for
alkali-activated concretes. Water absorption and accessible pore volume measurements show
densification and pore refinement as during the evolution of gel structure with time, although
this is less notable at higher MK content. The results of the rapid chloride penetrationtest are
dominated by pore solution chemistry, and show almost no change from 28 to 90 daysof curing,
contrasting other measures of the pore system. Accelerated carbonation testing shows rather
rapid carbonation accompanied by a loss in strength, and this occurs faster at

5|Page
 higher metakaolin content, but the full interpretation of the test data also requires consideration
of the evolution of the sample structures during the long duration of the tests.

F. N. Okoye, J. Durga prasad, and N. B. Singh studied on Effect of silica fume on the
mechanical properties of fly ash based geopolymer concrete.[8]
The effect of different concentration of silica fume on mechanical properties of fly ash based
geopolymer concrete was studied and results are discussed. It is found that in the presence of
silica fume, the workability of the paste decreases. The geopolymer concrete containing silica
fume showed higher compressive, tensile and flexural strengths as compared to that of control
and these values increased with the increase of silica fume content. This was due to an increase
in compactness.
P. Duan, C. Yan, and W. Zhou studied on Compressive strength and microstructure of flyash
based Geopolymer blended with silica fume under thermal cycle.[9]
In this study durability properties of fly ash based geopolymer concretes in the presence and
absence of silica fume have been studied in the corrosive atmosphere of 2% H2SO4 and 5%
NaCl solutions. Results were compared with that of the control. Visual observations revealed
that there was surface erosion and cutting of edges in the case of OPC concrete but no erosion
in the case of geopolymer concrete containing 20% silica fume when exposed to 2% H2SO4 and
5% NaCl solution for 90 d. 2% H2SO4
F. N. Okoye, S. Prakash, and N. B. Singh studied on Durability of fly ash based
geopolymer concrete in the presence of silica fume.[10]
In this study durability properties of fly ash based geopolymer concretes in the presence and
absence of silica fume have been studied in the corrosive atmosphere of 2% H2SO4 and 5%
NaCl solutions. Results were compared with that of the control. Visual observations revealed
that there was surface erosion and cutting of edges in the case of OPC concrete but no erosion
in the case of geopolymer concrete containing 20% silica fume when exposed to 2% H2SO4 and
5% NaCl solution for 90 d. 2% H2SO4
P. w. ken c.c.ban studied on an overview on the Influence of Various Factors on The
Properties of Geopolymer Concrete Derived from Industrial by-products.[11]
The present literatures provide a detailed elucidation of various factors that influence the
properties of geopolymers concrete. With reference to the current body of knowledge in
geopolymer technology, rigorous amount of study has been performed to cover the various
aspects of established geopolymers such as FA and GGBFS based geopolymers. However,
there is still a significant gap of knowledge related to the geopolymerization reaction kinetics,
material properties and rheological behavior of a number of emerging geopolymers such
blended geopolymers and biomass ash geopolymers. Hence, detailed studies such as those
related to the derivation and modelling of reaction kinetics under various treatment and
fabrication conditions of the emerging class of geopolymers source materials such as POFA,
RHA and blended geopolymers are required.

6|Page
 CHAPTER-3
EXPERIMENTAL PROGRAMME

3.1 GENERAL

The main aim of this study is to find the effect of Metakaolin on strength properties of Fly ash-
GGBS based on geopolymer concrete for Alkali activator to Binder content ratio. The various
tests performed on concrete samples are discussed in this chapter, followed by a brief
description about mix design. Following strength properties of GPC such as compressive
strength, split tensile strength, and flexural strength, are studied in the Project work.

3.2 MATERIALS

The materials used for making GPC are Fly ash, GGBS, Metakaolin as the source materials,
Coarse and Fine aggregates, Alkaline liquids.

3.2.1 Fly Ash

Fly ash is a fine grey powder consisting mostly of spherical, glassy particles that are produced
as a byproduct in coal-fired power stations. Fly ash has pozzolanic properties, meaning that it
reacts with lime to form cementitious compounds. It is commonly known as a supplementary
cementitious material. The physical properties of Fly ash are shown in Table.1. Figure.1 shows
the photograph of Fly ash.

Table.1 Physical Properties of Fly Ash

SI.NO Property Values

1. color Dark grey

2. Physical form Powder

3. Specific Gravity 2.5

7|Page
 .

Figure.1 Fly ash

3.2.2 Ground Granulated Blast Furnace Slag (GGBS)

Ground granulated blast-furnace slag (GGBS) is obtained by quenching molten iron slag (a by-
product of iron and steel-making) from a blast furnace in water or steam, to produce a
glassy, granular product that is then dried and ground into a fine powder. The physical properties
of GGBS are shown in Table.2 and chemical composition of GGBS are shown in Table.3.
Figure.2 shows the photography of the GGBS.

Table.2 Physical Properties of GGBS

SI.NO Property Values
1. Specific Gravity 2.82
2. Colour White
3. Physical form Powder

8|Page
 Table.3 Chemical Composition of GGBS
SI.NO Oxide Percentage by mass (%)

1. Cao 37.34

2. Al2O3 14.42

3. Fe2O3 1.11

4. SiO2 37.73

5. MgO 8.71

6. LOI 1.41

7. MnO 0.02

Figure.2 GGBS

9|Page
3.2.3 Metakaolin

Metakaolin is the anhydrous calcined form of the clay mineral kaolinite. Minerals that are rich
in kaolinite are known as China clay or kaolin, traditionally used in the manufacture of
porcelain. The particle size of metakaolin is smaller than cement particles, but not as fine as
fume. The T-O clay mineral kaolinite does not contain interlayer cations or interlayer water.
The temperature of de hydroxylation depends on the structural layer stacking order. Disordered
kaolinite dehydroxylates between 530 and 570 °C, ordered kaolinite between 570 and 630 °C.
Dehydroxylated disordered kaolinite shows higher pozzolanic activity than ordered. The
physical properties of Metakaolin are shown in Table.4 and chemical composition of Metakaolin
are shown in Table.5. Figure.3 shows the photograph of Metakaolin.

Table.4 Physical Properties of Metakaolin

SI.NO Property Values

1. color White

2. Physical form Powder

3. Specific Gravity 2.3

Table.5 Chemical Composition of Metakaolin

SI.NO Oxide Percentage by mass (%)

1. SiO2 59.6

2. Al2O3 38.0

3. Cao 0.14

4. MgO 0.24

5. K2O 0.32

6. L.O.I 1.02

10 | P a g e
 Figure.3 Metakaolin

3.2.4 Aggregates

Aggregates are the important ingredient materials in concrete. They impart bulk volume to the
concrete and reduce the shrinkage effect. They occupy 80 percent of the total volume of
concrete.

3.2.4.1Fine Aggregates

Locally available sand from the Tungabhadra River bed was used. The following tests are
conducted on fine aggregate according to IS: 383-1987.

Sieve Analysis of Fine Aggregate (F.A.)

The sieve analysis of fine aggregate was carried out as per code IS: 383-1987 and is shown in
Table.7 a n d Table.6 shows the physical properties of fine aggregates. Figure.4 shows the
photography of the fine aggregates and Figure.5 shows the photography of the gradation curve
of the fine aggregate.

11 | P a g e
 Table.6 Physical Properties of Fine Aggregates

SI.NO Properties Results

1. Fineness Modulus 2.83
2. Specific gravity 2.63
3. Water absorption 2.0%

Table.7Sieve Analysis of Fine Aggregate

Cumulative Cumulative
SI.NO Sieve size Weight Cumulative percentage percentage
(mm) Retained weight weight weight
(gms) retained retained passing
(gms) (gms)

1 4.75 0 0 0 100

2 2.36 20 2 2 98

3 1.18 250 25 27 73

4 600µ 320 32 59 41

5 300µ 364 36.50 95.50 4.50

6 150µ 40 4 99.50 0.50

7 pan 5 0.5 100 0

Fineness Modulus of Fine aggregate=2.8

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Page
 Figure.4 Fine aggregate

Figure.5 Gradation curve of Fine Aggregate

13 |
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3.2.4.2Coarse Aggregates

The crushed aggregate used in this project work was obtained from local quarry. In this work the
aggregate was used of 20mm down and tested as per IS: 2386-1963( I, II, III ) specification.The
following tests are conducted on coarse aggregate. Figure.6 shows the photography of the coarse
aggregates and Figure.7shows the photography of the gradation curve of the coarse aggregate.

sieve Analysis of Coarse Aggregate

The sieve analysis of coarse aggregate in shown in the Table.9 and Table.8 shows the physical
properties of coarse aggregate.

Table.8 Physical Properties of Coarse Aggregate

SI.NO Property Test Results

1. Maximum normal size 20mm
2. Bulk density(kg/m3) 1536
3. Specific gravity 2.72

Table.9 Sieve Analysis of Coarse Aggregate

SI.NO Sieve size in Weight retained Percentage Cumulative Percentage

mm ingrams weight retained percentage passing
weight
retained
1. 80 0 - 0 100
2. 63 0 - 0 100
3. 50 0 - 0 100
4. 40 0 - 0 100
5. 31.5 0 - 0 100
6. 25 0 - 0 100
7. 20 3100 31 31 69
8. 12.5 6450 64.50 95.5 4.5
9. 10 375 3.75 99.25 0.75
10. 6.3 65 0.65 99.9 0.1
11. 4.75 10 0.1 100 0

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Page
 Figure.6 coarse aggregate

Particle size distribution curve

120

100
Percentage Passing

80

60

40

20

-20
1 10 100
Sieve size in mm

Figure.7 Gradation curve of Course Aggregate

15 |
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3.2.5 Alkaline Solution

3.2.5.1Sodium Hydroxide

Sodium Hydroxide available in solid state by means of pellets and flakes form was used in this
project is as shown in Figure-8. The cost of the sodium hydroxide is varied accordingly to thepurity
of the sodium hydroxide. Since geopolymer concrete is heterogenous material and its main process
is to activate the sodium silicate, sodium hydroxide are used.

Figure.8 Sodium hydroxide (NaOH)

3.2.5.2Sodium Silicate

Sodium silicate used in this project work comes in the gel form and is shown in Figure-9. As per
the manufacture, silicate was also used in detergent and textile industry as bonding agent. The
physical and chemical composition of silicate are shown in Table.10

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Page
 Figure.9 Sodium silicate (Na2Sio3)

Table.10 Physical and Chemical composition of Sodium Silicate

SI.NO Physical and Chemical Properties Composition
1 Na2O 15.9%
2 SiO2 31.4%
3 H2O 52.7%
4 Appearance Liquid gel
5 Color Light yellow liquid
6 Specific Gravity 1.6

3.3 PREPARATION OF ALKALINE ACTIVATOR

The preparation of alkaline activator solution (AAS) plays a major role in Geopolymer concrete. The
AAS is the combination of sodium hydroxide (NaOH) solution and sodium silicate (Na2SiO3)
solution. The Sodium hydroxide (NaOH) solids were dissolved in water to make the solution. The
mass of NaOH solids in a solution were varied depending on the concentration of the solution
expressed in terms of molar, “M”. In this study, NaOH solution with a concentration of 10M

17 |
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consisting of 400 grams of NaOH solids (10×40, in flake or pellet form) per litre of the solution,
where 40 is the molecular weight of NaOH.

Sodium
Hydroxide

Alkaline
Activator
Solution
Sodium
Silicate

Figure.10 Alkaline Activator Solution

3.4 MIX DESIGN

A systematic procedure for the casting and testing of geopolymer specimens is essential for achieving
control in quality of concrete. A preliminary study was carried out on Geopolymer concrete to fix the
proportion of GGBS and Fly ash maintaining the alkaline liquid to binder ratio, molar ratio of sodium
silicate solution, curing mode and the ratio of alkaline liquids constant based on 28 days compressive
strength. In secondary mixes changes the proportion of fly ash and metakaolin and fix the alkaline
activator solution to binder ratio.

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3.4.1 Mix Proportions for Geopolymer Concrete

To date, there has been very limited research on the mix design of geopolymer concrete. In 2008,
(Lloyd and Rangan 2010; Rangan 2008a; Rangan 2008b) proposed a method for a mix design of fly
ash-based geopolymer concrete but it did not discuss how to deal with the effects of the ingredients,
specific gravities or the air content volume on the mix design. A constant concrete density of 2400
kg/m3 was assumed by Lloyd and Rangan which is not realistic because the density of concrete varies
from one mix to another depending on the amount of ingredients in the mix. Sometimes, extra water
or a super-plasticiser is needed to improve the workability of fresh geopolymer concrete which has
an effect on the total volume of the concrete. Their method did not explore the design for workability
which in geopolymer concrete seems to assume a yet more important effect than other types of
concrete. Now, it is believed necessary that a rigorous, but still easy, method for geopolymer concrete
mix design be used.

3.4.2 Test Programme

In the present study, the effects of the different percentages of metakaolin and fly ash on the strength
properties of geopolymer concrete. In this we put the constant ratio of alkaline to binder ratio. Strength
properties of geopolymer concrete such as Compressive strength, Flexural strength and split tensile
strength are observed.

3.4.3 Preparation of Fresh GPC and Casting

The dry materials such as fly ash, GGBS, Metakaolin and the aggregates were first mixed together in
the pan mixer for about 3 minutes. Alkaline activator is prepared using NaOH of 10 molar
concentration mixed with Na2SiO3 solution. The liquid component of the mixture was then added to
the dry materials and the mixing continued for further about 3-4 minutes to prepare the fresh concrete.
The specimens include cubes for compression test, cylinders for split tensile test and beam for flexural
test. The moulds should be clean and properly oiled then fresh concrete is placed in the moulds in 3
layers and each layer is tamped and vibrated on vibration table. Demoulding is done after the setting
of geopolymer concrete. Figure.11 represents the cast specimens of GPC.

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 Figure.11 Cast specimens of GPC

3.5 CURING METHODOLOGY

The geopolymer concrete specimens were removed from the mould after 24h of casting and were
cured at ambient temperature (27±2℃) until the testing. For GGBS based geopolymer concrete
samples oven curing was not necessary, only air curing was done.

3.6 TESTS ON HARDENED CONCRETE

After casting and curing the cubes, cylinders and beams were tested to obtain respective strength of
GPC. Strength properties of GPC for all mixes are shown in Table.11

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 Table.11 Strength properties of GPC for different mixes

Binder (Kg/m3) Compressive Split Flexural

NaOH Na2Sio3 Strength Tensile Strength
Mix Fly- GGBS MK (Kg/m3) (Kg/m3) (Mpa) 28days Strength (Mpa)
ash (Mpa) 28days
28days

G.P.C-1 80% 20% 00% 80 120 23.33 2.38 3.78

G.P.C-2 75% 20% 05% 80 120 30.50 3.00 4.20

G.P.C-3 70% 20% 10% 80 120 36.67 3.65 4.50

G.P.C-4 65% 20% 15% 80 120 32.67 3.10 4.30

3.6.1 Compressive Strength Test

Compression test is the most common test conducted on hardened concrete to determine its
compressive strength. The test set up was shown in below figure.12

Apparatus

Compressive testing machine, concrete specimens of 150mm × 150mm × 150mm

Procedure

• The bearing surfaces of the testing machine shall be wiped clear and any loose sand or other
materials extract from the surfaces of the specimen which are to be interposer with the
compression platens.
• The specimens shall be placed in the machine such a manner that the load shall be applied to
the opposite sides of the cubes as cast, that is not to the top and bottom.
• The axis of the specimen shall be carefully aligned with the centre of thrust of the spherically
seated platen.
• As the spherically seated block is brought to bear on the specimen, the movable portion shall
be rotated gently by hand so that uniform seating may be obtained.
• The load shall be applied without shock and continuously till the specimen fails.
• Record the maximum load applied to the specimen and any unusual features in the type of

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 failure shall be noted.

Interpretation of results

Minimum three specimens should be tested at each selected age. If strength of any specimen varies
by more than 15 percent of average strength, results of such specimens should be rejected. Average
of three specimens gives the crushing strength of concrete.

Compressive Strength = Load / Area

=P/A

Figure.12 Compressive Strength Test set up

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3.6.2 Split Tensile Strength Test

Split tensile strength is one of the basic and important properties of concrete. Splitting tensile strength
normally done to measure the tensile strength of brittle materials like concrete, mortar etc. Because
direct tensile strength test cannot be done on such type of materials. Therefore, splitting tensile test is
done where the cylindrical concrete/mortar spilt across vertical diameter under the compressive force.
The test set up was shown below figure.13.

Apparatus

Compressive machine test, Concrete specimen with 150mm diameter and 300mm length

Procedure

• Set the compression testing machine for the requisite range.

• Place the steel strip on the lower plate and place the specimen.
• Align the specimen so that lines marked on the ends are vertical and centred over the bottom
plate.
• Place the other steel strip above the specimen.
• Bring down the upper plate so that it just touches the steel strip.
• Apply the load gradually without shock till the specimen fails.
• Finally, note down the breaking load (P).

Interpretation of results

The magnitude of this tensile strength is given by the formula:

бsp=2P/ПDL

Where ‘P’ is the maximum load at failure in KN.

‘L’ and ‘D’ are the length and diameter of the cylindrical specimen in mm.

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 Figure.13 Split Tensile Strength Test Set Up

3.6.3 Flexural Strength Test

Flexural strength is the ability of the materials to withstand bending forces applied perpendicular to
its longitudinal axis. This test is performed on Beam specimens to determine Flexural strength of
concrete by using Universal Testing Machine (UTM).

Apparatus

Concrete specimen of 500mm × 100mm × 100mm, Universal Testing Machine (UTM).

Procedure

• The test for flexural strength of concrete beams under two-point loading utilizes a beam
testing machine which permits the load to be applied normal to the loaded surface of the beam.
• Clean the bearing surfaces of the supporting and loading rollers, and remove any loose sand
or other materials from the surfaces of the specimen where they are to make contact with the

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 rollers.
• The specimen is tested on its side with respect to its moulded position.

• The beam is centred on the bearing supports. The dial indicator of the proving ring is placed
at the zero reading.
• The load is applied at a uniform rate and in a way to avoid shock. The load required to cause
specimen failure is obtained from the dial indicator’s final reading.
• The arrangement for flexural strength test is shown in Figure.14

Interpretation of results

Flexural strength of the concrete

fb= PL / bd2 When a ≥ 13.33cm

When ‘a’ is greater than 20cm for 15cm specimen or greater than 13.33cm for a 10cm specimen

Or

fb= 3Pa / bd2 When 13.33cm ≥ a ≥ 11cm

Figure.14 Flexural Strength Test Set Up

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 CHAPTER-4

RESULTS AND DISCUSSIONS

4.1 GENERAL

In this chapter strength properties like Compressive strength, split tensile strength and Flexural
strength are discussed. All the tests conducted were in accordance with the methods described in
chapter three.

4.2 COMPRESSIVE STRENGTH OF GEOPOLYMER CONCRETE

The compressive strength is one of the most important properties of hardened concrete and is
considered as the characteristic material value for the classification of concrete.

The compressive strength of Metakaolin and GGBS based geopolymer concrete mixes with variation
of alkaline activator to binder ratio are shown in Table.12.

Variation of compressive strength of metakaolin and GGBS based geopolymer concrete is as shown
in Figure.15. It can be seen from the figure that compressive strengths of the mixes will increase by
increasing the content of metakaolin. The highest 28-day compressive strength in this series was
observed for the mix with 10% metakaolin (GPC-3). Metakaolin which is commonly used as an
admixture or partial replacement of fly ash owing to its most effective pozzolanic properties, which
improve the microstructure and strengthen the mechanical and durability properties of geopolymer
concrete.

Table.12 Compressive Strength of Geopolymer Concrete

Mix Percentage of Metakaolin Compressive strength Percentage improvement

added (N/mm2) - 28days
G.P.C-1 00% 23.33 -

G.P.C-2 05% 30.50 +23.50

G.P.C-3 10% 36.67 +16.82

G.P.C-4 15% 32.67 -12.24

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 Compressive Strength
40 36.67
Compressive Strength (N/mm2)
35 32.67
30.5
30
23.33
25
20
15
10
5
0
0% 5% 10% 15%
Metakaolin Percentages

Figure.15 Compressive Strength GPC for 28 days

4.3 SPLIT TENSILE STRENGTH OF CONCRETE

Split tensile strength test is common test to determine the tensile strength of the concrete indirectly.
Split tensile strength of various mixes are shown in Table.13 and figure.16 indicates the variation of
split tensile strength of geopolymer concrete with different metakaolin percentages added. The
maximum split tensile strength of all mixes is obtained for mix GPC-3 which is equal to 3.65N/mm2.

Table.13 Split Tensile Strength of Geopolymer Concrete

Mix Percentage of Metakaolin Split tensile strength Percentage improvement

added (N/mm2) - 28days
G.P.C-1 00% 2.38 -

G.P.C-2 05% 3.00 +20.66

G.P.C-3 10% 3.65 +17.80

G.P.C-4 15% 3.10 -17.74

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 Split Tensile Strength
4 3.65
Split Tensile Strength (N/mm2)
3.5 3.1
3
3
2.38
2.5
2
1.5
1
0.5
0
0% 5% 10% 15%
Metakaolin Percentages

Figure.16 Split Tensile Strength GPC for 28 days

4.4 FLEXURAL STRENGTH OF CONCRETE

Flexural Strength of different GPC mixes were found and variation of flexural strength of geopolymer
concrete with different metakaolin percentages is as shown in Table.14 and figure.17. The maximum
flexural strength of all mixes is obtained for mix GPC-3 which is equal to 4.50N/mm2.

Table.14 Flexural Strength of Geopolymer Concrete

Percentage of Metakaolin Flexural strength
Mix added (N/mm2) - 28days Percentage improvement

G.P.C-1 00% 3.78 -

G.P.C-2 05% 4.20 +10.00

G.P.C-3 10% 4.50 +6.66

G.P.C-4 15% 4.30 -4.65

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 Flexural Strength
4.6 4.5

Flexural Strength (N/mm2) 4.4 4.3

4.2
4.2

4
3.78
3.8

3.6

3.4
0% 5% 10% 15%
Metakaolin Percentages

Figure.17 Flexural Strength GPC for 28 days

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 CHAPTER-5

CONCLUSIONS
Based on experimental results the following conclusions are drawn

• In the present study the influence of Metakaolin on strength properties of Fly ash-GGBS based
Geopolymer concrete has been investigated.

• Preliminary study has been carried out only added fly ash and GGBS in Geopolymer concrete
mix keeping Alkaline Activator to Binder ratio 0.5 and Na2Sio3/NaOH to 1.5 constant based
on 28 days Compressive Strength, Split tensile Strength and Flexural Strength.

• Fly ash and GGBS ratio in GPC was found at 80:20 from preliminary study.

• From secondary studies we add 5%metakaolin which is replacement of 5%fly ash. From these
the maximum strength results are came for metakaolin 10% added.

• We increase the metakaolin percentage again 5% then strength was decreased. We conclude
the maximum strength was reached at the time when we add 10% metakaolin.

• The incorporation of GGBS could facilitate the curing of Fly ash-GGBS based geopolymer at
room temperature and produce a dense structure with both calcium silicate hydrate (C-S-H)
and sodium aluminosilicate hydrate (N-A-S-H) gels.

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 REFERENCES

1. P. Nath and P. K. Sarker studied on effect of GGBS on setting, workability and early strength
properties of fly ash geopolymer concrete cured in ambient condition.

2. P. S. Deb, P. p Nath, and P. K. Sarker studied on the effects of ground granulated blast-furnace
slag blending with fly ash and activator content on the workability and strengthproperties of
geopolymer concrete cured at ambient temperature.

3. J. G. S. Jaarsveld, J. S. J. Deventer, and G. C. Lukey studied on the effect of compositionand

temperature on the properties of fly ash and kaolinite-based geopolymers.

4. U. Rattanasak and P. Chindaprasirt studied on Influence of NaOH Solution on the Synthesis

of Fly Ash Geopolymer.

5. M. Albitar, M. S. Mohamed Ali, P. Visintin, and M. Drechsler studied on Durability

evaluation of Geopolymer and conventional concretes

6. T. Phoo-ngernkham, A. Maekawa, N. Mishima, S. Hatanaka, and P. Chindaprasirt studied on

Effects of Sodium Hydroxide and Sodium Silicate Solutions on Compressive and Shear
Bond Strengths of FA–GBFS Geopolymer.

7. S.A. Bernal, J. L. Provis studied on Engineering and Durability Properties of Concretes

Based on Alkali-Activated Granulated Blast Furnace Slag/Metakaolin Blends.

8. F. N. Okoye, J. Durga prasad, and N. B. Singh studied on Effect of silica fume on the
mechanical properties of fly ash based geopolymer concrete.

9. P. Duan, C. Yan, and W. Zhou studied on Compressive strength and microstructure of flyash
based Geopolymer blended with silica fume under thermal cycle.

10. F. N. Okoye, S. Prakash, and N. B. Singh studied on Durability of fly ash basedgeopolymer
concrete in the presence of silica fume.

11. P. w. ken c.c.ban studied on an overview on the Influence of Various Factors on The
Properties of Geopolymer Concrete Derived from Industrial by-products.

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12. GabrielSamson, MartinCyr, XiaoGao, “Formulation and characterization of blended alkali-
activated materials based on flash-calcined metakaolin, fly ash and GGBS™, Elsevier,
Construction and Building Materials, 30 July (2017).

13. Buchwald A, Hilbig H, Kaps CH, “Alkali-activated metakaolin-slag blends performance and
structure in dependence of their composition”, Springer, (2007).

14. Mufiiz- Villarreal M.S, Manzano-Ramirez A, Sampieri-Bulbarela S, Ramon Gasca-Tirado J

Reyes-Araiza J.L, Rubio-Avalos J.C, Pérez-Bueno J.J, Apatiga L.M, Zaldivar-Cadena A,
Amig6-BorrasV, “The effect of temperature on the geopolymerization process of 2
metakaolin-based geopolymer, Elsevier, Volume 65, (2011).

15. Pavithra P, Srinivasula Reddy M, Pasala Dinakar, Hanumantha Rao B, Satpathy, A.N.
Mohanty B.K, “A mix design procedure for geopolymer concrete with fly ash”,
ScienceDirect, Journal of Cleaner Production. (2016)

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 APPENDIX

MIX DESIGN FOR GEOPOLYMER CONCRETE

STEP 1 Fix the alkaline activator solution (AAS) content:
From the trials carried out in the laboratory it was found that at an AAS content of 200kg/(m3) GPC
can be developed effectively with better strength, workability and economy.

STEP 2 Alkaline activator solution to binder content (AAS / B.R) = 0.5

STEP 3 Calculation of Binder Content

Binder content (BC) = AAS content / (AAS / B)
= 200/0.5
= 400 kg / (m3)

STEP 4 Calculation of activator solution contents

For all the mixes the Na2SiO3 and NaOH ratio employed was 1.5Mass
of AAS = Mass of (Na2SiO3+ NaOH)
200 = Mass of NaOH (1.5+1) V Mass of NaOH = 200/2.5
Mass of NaOH = 80 kg / (m3)
Mass of Na2SiO3 = 1.5XMassofNaOH
= 1.5 * 80
= 120kg / (m3)
STEP 5 Molarity

10M NaOH solution is prepared for the mix.

STEP 6 Determination of Total Aggregates

The volume of total aggregates (VTA) is obtained by using the absolute volume method as
follows:
Total aggregates = 0.98 - [wt. Of fly ash/sp.gt of fly ash*1000 + wt. Of GGBS/sp.gt of
GGBS*1000 + wt. Of NaOH/sp.gt of NaOH*1000 + wt. Of Na2SiO3 /sp.gt of Na2SiO3
*1000]
Total aggregates = 0.98 – [320/1.90*1000 + 80/2.85*1000 + 80/1.52*1000 + 120/1.2*1000]
=0.63

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STEP 7 Calculation of Fine and Coarse Aggregate Content
Proportion of fine aggregate = 0.63*0.38
=0.240
Proportion of coarse aggregate = 0.63*0.62
=0.390
Mass of fine aggregate =0.240*1000*2.5
=600 kg/m3 Mass of
coarse aggregate =0.390*1000*2.5
=1045.2 kg/m3

MIX PROPORTIONS
MATERIALS PROPORTIONS

Fly ash 320 kg/m3

GGBS 80 kg/m3

Fine aggregate 600 kg/m3

Coarse aggregate 1045.2 kg/m3

NaOH 80 kg/m3

Na2SiO3 120 kg/m3

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