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2099
Matthew Kambic Joshua Hammaker mixture and allow it to be much more workable. [2] However, while ordinary concrete uses cement to bind the aggregates together, geopolymer concrete mixtures use a geopolymer paste. Geopolymer paste is created by combining fly ash, which contains silicon and aluminum, with a sodium hydroxide and sodium silicate solution. This is also known as water glass. The resulting reaction starts the process of geopolymerization which leads to the creation of a geopolymer. GEOPOLYMERIZATION Geopolymerization is the exothermic process that describes the creation of a geopolymer. First, the sodium hydroxide and sodium silicate solution dissolve the silicon and aluminum that is found in fly ash. These dissolved ions then undergo a condensation reaction, forming monomers in the form of Si O Al -O, -Si- O- Al -O- Si -O, or Si -O- AlO- Si-O. [3] Applying heat between the temperatures of 60oC and 80oC for a period of approximately 6 to 12 hours to these monomers causes them to polymerize, or link together and form rigid chains. The polymers are then allowed to harden. It is this process that allows the creation of geopolymer concrete. WHAT IS FLY ASH? Fly ash is one of the most abundant materials on the Earth. It is also a crucial ingredient in the creation of geopolymer concrete due to its role in the geopolymerization process. Fly ash is a powdery pozzolan. A pozzolan is a material that exhibits cementitious properties when combined with calcium hydroxide. Fly ash is the main byproduct created from the combustion of coal in coal-fired power plants. There are two classes of fly ash, Class F and Class C. Each class of fly ash has its own unique properties. Class F fly ash is created from the burning of either anthracite or bituminous coal. [toolbase.org] This Class of fly ash has little to no self-cementing properties and contains very little calcium oxide (also known as lime). In order to apply Class F fly ash in concrete, it must be combined with some type of cementing agent, such as Portland cement, and must also be combined with an air-entraining admixture. This is not a very economic process if it is going to be made into ordinary concrete. Class C fly ash, on the other hand, is produced through the combustion of lignite or subbituminous coal. Unlike Class F fly ash, it has self-cementing properties and a much higher lime concentration which makes it ideal for use in ordinary Portland cement based concrete. Geopolymer concrete generally requires the use of Class F fly ash. In terms of chemistry, fly ash is composed of multiple chemical compounds, including arsenic, lead, cadmium, mercury, and uranium, as well as other harmful chemicals. However, the harmful aspects of these chemicals are neutralized when they undergo a polymerization reaction. [4] The most important compounds in the fly ash when it comes to geopolymer concrete are silicon dioxide and aluminum (III) oxide. Not only do these account for approximately 70% of the total weight of fly ash, [5] but they are the main reactants in the geopolymerization reaction. Currently, fly ash is recycled into ordinary Portland cement based concrete by acting as a substitute for Portland cement at a rate of 1 to 1.5 pounds of fly ash per 1 pound of cement to increase the overall strength of the concrete. [5] According to the Federal Highway Administration, States allow a maximum substitution in the range of 15 to 25 percent, [6] depending on the specific chemical composition and type of fly ash used. The Class of fly ash used depends on the specific application. For example, Class C fly ash should not be used in a an environment in which it may come in contact with sulfate, as this type of fly ash may actually lower resistance to sulfate. On the contrary, class F fly ash will actually increase sulfate resistance.
Matthew Kambic Joshua Hammaker HEAT AND COLD RESISTANCE In addition, geopolymer concrete shows excellent fire and heat resistance. It has the ability to remain stable in temperatures of more than 1200 o C (about 2200o F.) Although no type of concrete is flammable, excessive heat (such heat from a fire) is very dangerous. Not only does it reduce the strength of the concrete, but it may also cause the concrete to spall. Spalling is the breaking off of layers of concrete and may be seen in the form of an explosion. In terms of concrete, an explosion refers to a loud popping noise, not necessarily the act of dangerously launching pieces of concrete at high velocities. Since geopolymer concrete has such a high resistance to heat and fire, it is less likely to suffer the negative effects of spalling, and is fully immune to explosive spalling. Not only does geopolymer concrete perform well under high-heat conditions, but it is also resistant to freezing. This is important due to the tendency of thawing to harm the structure of the concrete. Even though its pores are very small, concrete is still considered a porous material. Water enters the concrete through these pores and remains there until it evaporates. However, if the temperature drops below freezing, the water inside the concrete will freeze and expand. [8] After freezing, the water, now in the form of ice, will occupy approximately 9% more volume than it did as a liquid. This expansion will destroy the concretes structure by causing the concrete to spall. This process, known as the freeze-thaw cycle, will continue throughout the life of the concrete, causing continuous damage. Fly ash helps reduce the permeability of geopolymer concrete, preventing water from invading. Since the damage of the freeze-thaw cycle in concrete is directly linked to the amount of water that is permitted to enter a concrete sample, geopolymer concrete will not experience as much damage as ordinary concrete. CHEMICAL RESISTANCE Geopolymer concrete also has very low shrinkage and creep. Shrinkage is the tendency of concrete to shrink due to the drying and heating of the concrete and the evaporation of water from the concrete. Shrinkage causes dangerous cracks in the material. As opposed to standard concrete, geopolymer concrete does not hydrate, and therefore will not experience shrinkage to nearly the same extent. In fact, it has 4/5 lower shrinkage than standard concrete. [1] Geopolymer concrete additionally has very low creep. Creep is the tendency of a material to become permanently deformed as a result of constant forces being applied to it. In order to create a safe, long lasting structure, it is essential to have a material that is affected as little as possible by these major deformations. Since geopolymer concrete is not drastically affected by these two factors, it maintains a strong advantage over ordinary concrete. Geopolymer concrete also has a strong chemical resistance. It is highly resistant to acids, toxic waste, and salt water. According to one study, geopolymer concrete has significantly higher resistance to acid then ordinary concrete. After 8 weeks of immersion in sulfuric acid, geopolymer concrete made with Class F fly ash lost only about 5% of its compressive strength. This is due to its alkalinity. Ordinary concrete, on the other hand, lost around 85% of its strength. [7] Geopolymer concrete also has the ability to contain toxic and radioactive waste. Obviously, it is hazardous to the health of both the environment and to humans to allow toxic and radioactive wastes to be released into the environment. Geopolymer concrete immobilizes dangerous wastes such as uranium, trapping the toxic waste to prevent it from leaking into the environment. As a matter of fact, these dangerous wastes can be mixed with geopolymer concrete and neutralized. This mixture then hardens to form an
FIGURE 1
COMPRESSIVE STRENGTH OF OPC AND GPC OVER TIME [7]
Not only does this graph show geopolymer concretes high maximum compressive strength, but it also shows a rapid strength gain. Geopolymer concrete reached its maximum strength in less than 20 days. Ordinary concrete did not perform quite as well; it took close to 100 days to reach its maximum strength. Even so, the ordinary concretes max compressive strength is still much less than that of geopolymer concrete. The lack of tensile strength is a major drawback of ordinary concrete. Its tensile strength is dangerously low when compared to the high magnitude of its compressive strength. This means that concrete is brittle in situations like earthquakes, where numerous compressive and tensile forces act on the material. In addition to its high compressive strength, geopolymer concrete also has a high tensile strength compared to ordinary concrete. Although this does not make geopolymer concrete earthquake-proof, a higher tensile strength is certainly an advantage in many situations. LOW SHRINKAGE AND CREEP
Matthew Kambic Joshua Hammaker impermeable solid, with the waste trapped inside. When applied in this way, geopolymer concrete can help to improve the health and safety of the public. [9] Unlike regular concrete, geopolymer concrete is also resistant to salt water. Corrosion due to salt water is a major problem with normal concrete. In Portland cement based concrete, salt water continuously attacks and destroys the material, causing cracks which allow more water to enter and cause further damage. Although geopolymer concrete does feel some of the effects of salt water corrosion, it is not affected nearly on nearly the same level. This can be seen in the following graph which shows Time vs. milliamperes. To prove that geopolymer concrete is well-suited to withstand salt water applications, a scientist measured the amount of corrosion due to salt water on samples of both geopolymer and ordinary concrete. As salt water corroded the materials, water penetrated the concrete. A direct current between the water and steel beams inside the samples was created. In the graph, if higher amperage was recorded, this indicates that the sample of concrete was corroded more compared to lower recorded amperage.
APPLICATIONS OF GEOPOLYMER CONCRETE Due to its wide range of properties, geopolymer concrete has many possible areas of application that give the material another huge advantage over standard concrete. Ideally, geopolymer concrete will gain more publicity and support as it is actually applied in various areas. Once again, it is important to note that a single mixture of geopolymer concrete will not necessarily have all of the properties for each of the following applications. One possible application of geopolymer concrete is in the construction and repair of highways, roads, and airport runways. [5] In fact, geopolymer concrete is already being used by the United States military due to its ability to withstand heat, which is created from aircraft taking off. [5] According to one source, after 1 hour it can withstand a walking person, after 4 hours it can hold a car, and after only 6 hours, due to its rapid strength gain, a runway made out of geopolymer concrete has gained enough strength to withstand the pressure of an Airbus or Boeing airplane. The same runway made from regular cement based concrete would have taken several days to achieve a similar level of strength. This property of rapid strength gain permits geopolymer concrete to be applied in areas where a fast and reliable fix is required such as on highways. The faster a highway can be repaired, the sooner it can be reopened to restore the traffic flow. Since geopolymer concrete also has a high resistance to chloride, it will suffer less damage in the winter than roads and highways made from ordinary concrete when calcium chloride road salts are used to lower the freezing point of water and keep roads operational. Another possible application of geopolymer concrete is in maritime settings. Due to its high resistance to salt water, geopolymer concrete may be used for concrete structures that will be under constant attack from salt water. Piers, coastal bridges, and underwater concrete supports are excellent examples of areas in which geopolymer concrete would perform superbly. A major issue with maritime concrete structures, such as bridges, is the corrosion of the steel supports contained within the concrete. Since steel corrodes when in contact with a substance of a pH less than 11, and the pH of seawater is 8, seawater will easily cause the corrosion of steel. In order to prevent this corrosion, the concrete that encases the steel must be immune to chloride corrosion. As a result of its resistance to chloride corrosion, geopolymer concrete could be applied in order to prevent seawater from reaching the steel supports. Geopolymer concrete is also much more suited than ordinary concrete to be used in cold climates. Due to its high resistance to freezing, geopolymer concrete may find widespread use in northern regions, where the freezing of concrete is a common problem. Because of its high resistance to acids and toxic waste, geopolymer concrete can be applied in various highly acidic and toxic environments. Examples of this type of setting
FIGURE 2
VARIATIONS OF CURRENT WITH TIME IN OPC AND GPC [10]
As shown by the graphs, geopolymer concrete allowed less current to pass through its body, showing that it experienced negligible corrosion, especially when compared to that of the ordinary concrete.
Matthew Kambic Joshua Hammaker include sewer pipes and landfills. Geopolymer concrete can ensure long lasting structures that will prevent dangerous chemicals from escaping into the environment. Preventing corrosion in sewer pipes is especially important. Since the pipes are underground, it is very expensive and wasteful to try and repair them, especially if a pipe is under a road, which would have to be partially demolished in order to accomplish repairs. ECONOMIC VIABILITY OF GEOPOLYMER CONCRETE Although geopolymer concrete has demonstrated itself superior to ordinary Portland cement based concrete in various areas, it must also be an economically viable option in order to replace the more traditional material in any application. If it would prove to be too expensive, it would not be a reasonable substitute. Therefore, the financial obligations must be considered as well as the performance of the material. Geopolymer concrete is significantly cheaper than Portland cement based concrete in terms of the cost of materials. First of all, fly ash is very inexpensive. In fact, it may be possible to acquire the material at no cost, since it is a waste product. Even if the vendor sells the fly ash, its price per ton would be considerably less than that of a ton of Portland cement due to the incredibly high supply of fly ash. The price of fly ash is between 10% and 30% less than the price of Portland cement. Even if the price of the activating chemicals needed to create geopolymer concrete is considered, it is estimated that enough sodium silicate solution and sodium hydroxide to convert 1 ton of fly ash to 2.5 cubic meters of geopolymer concrete can be purchased for about $55. [13] Geopolymer concrete can also save money over its lifetime when compared to current concrete technology. It has been clearly shown that geopolymer concrete is not nearly as prone to damage as ordinary concrete. It is not nearly as affected by damaging factors such as spalling, freezing, and exposure to chemicals. This allows it to last much longer. By maintaining a longer lifespan, it will not be necessary to constantly fix the many problems associated with concrete, saving the large amounts of money conventionally spent on repair costs. if not handled properly. Sodium hydroxide can be very harmful to health if mishandled. It has been rated with a classification of 3 in terms of danger to health (0 being the least hazardous, and 4 being the most). Since it is a strong base with a pH of 14, sodium hydroxide is also very corrosive to areas such as the eyes, skin, and nose. [14] If engineers are able to find a less hazardous method of activating the geopolymer concrete, it will be safer to prepare, especially if is prepared outside of a lab setting. Due to the dangers of handling chemicals and the liability issues that ensue, geopolymer concrete is generally sold as a pre-cast or pre-mixed material. A second problem that must be solved is the sensitivity of the geopolymerization process. Present research in the field seems to lack a degree of uniformity. Many scientists have come to conflicting conclusions. For example, while it seems clear that elevated temperatures are necessary to increase the strength of geopolymer concrete, data has been collected suggesting that longer curing time increases the strength of the material. On the contrary, other researchers found that a longer cure time actually lowered the quality of the final product. [2] It is apparent that more time and effort needs to be dedicated to the research and development of geopolymer concrete. Unless researchers can provide consistent data related to the properties and production of geopolymer concrete, it will be difficult for it to replace a product that has been used throughout the world since the development of modern Portland cement in the 1840s. Although the challenges of geopolymer concrete are few compared to its benefits, they still pose a threat to the possibility of its application.
CHALLENGES
It has been shown that geopolymer concrete has numerous advantages over ordinary Portland cement based concrete. However, there are challenges that must be overcome before geopolymer concrete can see widespread application. One challenge that engineers must overcome is the special handling needs and difficulty related to the creation of geopolymer concrete. First and foremost, geopolymer concrete requires the use of chemicals which can be harmful
Matthew Kambic Joshua Hammaker water sources. Additionally, little has been done so far to recycle fly ash and to keep it out of landfills. [4] One of the main ways calamities, like the one Kingston, Tennessee experienced, can be prevented is to integrate fly ash into a material that would be widely produced and demanded. The solution is geopolymer concrete. Geopolymer concrete recycles fly ash and thus keeps it out of landfills. HOW IS GEOPOLYMER CONCRETE AN ETHICAL SOLUTION TO THE CURRENT FLY ASH PROBLEM? There are multiple factors that must be considered when determining whether a new or developing technology can be considered ethical. One could postulate that since geopolymer concrete uses fly ash and will lead to less fly ash in landfills and fly ash is a material that is extremely toxic and has been proven to be carcinogenic, that geopolymer concrete can automatically be considered ethical. This is a very valid viewpoint and is one of the contributing factors confirming that geopolymer concrete is in fact an ethical technology. The ethicality of geopolymer concrete can be further confirmed by the National Society of Professional Engineers (NSPE) and the American Society of Civil Engineers (ASCE). Both of these very well respected organizations have drawn out their own code of ethics and they describe exactly what is considered to be ethical in the realm of engineering. In the code of ethics drawn out by the National Society of Professional Engineers there is a section that states Engineers shall at all times strive to serve the public interest and are encouraged to adhere to the principles of sustainable development in order to protect the environment for future generations. [17] The principle of sustainable development is defined by the National Society of Professional Engineers as a practice that assures that the environment and other resources essential for future development are conserved. Geopolymer concrete is an excellent example of a sustainable technology. By using geopolymer concrete, fly ash will not end up in landfills. This means that it will not be able to contaminate the environment it would have otherwise been exposed to. The use of geopolymer concrete accomplishes the exact task outlined in the NSPE code of ethics. The American Society of Civil Engineers code of ethics is specifically geared towards civil engineering. The section that is most relevant to geopolymer concrete states Engineers [will] uphold and advance the integrity, honor and dignity of the engineering profession by using their knowledge and skill for the enhancement of human welfare and the environment. [18] The concrete that is currently used is made from ordinary Portland cement (OPC). The amount of CO2 released in the production of OPC is about a 1:1 ratio. This means that for every ton of ordinary Portland cement produced, about one ton of CO 2 is released into the atmosphere. Portland cement is the most abundantly used man-made material in the world, and it certainly has a carbon footprint to confirm this. 5-8 percent of yearly worldwide CO2 emissions are due to the production of Portland cement. Over 2.6 billion tons of OPC was produced in 2009. This number is now increasing at a steady rate of 5 percent every year. If this same rate is continued, the amount of CO2 released into the atmosphere due to the production of ordinary Portland cement will be double that amount in as little as 10 years. This means that yearly worldwide CO2 emissions due to the production of Portland cement could be over 10 percent. Geopolymer concrete, on the other hand, is produced utilizing processes that release 90 percent less CO 2 [19]. Furthermore, for every ton of Portland cement, about 1.5 tons of raw materials are needed. This suggests that the production of Portland cement is a very inefficient process and results in the wasting of an incredible amount of raw materials. Conversely, the production of geopolymer concrete is much more efficient. Another area in which geopolymer concrete outperforms OPC is in the amount of energy required to produce these materials. The production of geopolymer concrete requires 3/5 less energy to produce than ordinary Portland cement. The worldwide use of geopolymer concrete will clearly be a step in the right direction for curbing CO2 emissions and will thus lead to the enhancement of human welfare and the environment. [18]
REFERENCES
[1] Z. Li and Y. Zhang. "DEVELOPMENT OF SUSTAINABLE CEMENTITIOUS MATERIALS." Hong Kong University of Science and Technology. [Online]. Available: http://constructionz.com/articles/development-of-sustainable-cementitiousmaterials.html [2] D. Hardjito, S. Wallah, D. Sumajouw, and B. Rangan. (2004, December). "On the Development of Fly Ash-Based Geopolymer
ACKNOWLEDGEMENTS
We would like to thank Andrew Bell for helping to review and edit our paper throughout the process. We would also like to thank our writing instructor, Caroline Hamilton, for providing valuable feedback throughout the process.