CHAPTER 1

INTRODUCTION

1.1 General

Now a days usage of concrete occupies second place round the world nevertheless the

water. Ordinary Portland concrete primarily consists of cement, aggregates (coarse&

fine) and water. In this, cement is employed as a primary binder to provide the normal

Portland concrete. Around it's calculable that the consumption of cement isquite 2.2

billion tons each year [1].Due to increasing of developments in infrastructure, the usage

of typical concrete are going to be additional and furthermore because the demand of

cement would be will increase within the future.

On the opposite hand,the usageof cement could produce some environmental problems

equivalent toheating, inexperienced house impact etc. as a result of these issues could

generate because of increasing of Co2present within the surroundings, from the past

results nearly one tone of cement releases equal amount of Co 2[2]. So as to avoid these

environmental problems related to cement, there's have to be compelled to use some

alternatives equivalent to fly ash, rise husk fly ashetc. area unit because the binders to

create the eco-friendly concrete. During this respect, Davidovits [1988] planned another

binder for the concrete technology and it shows an honest results. These binders area

unit created by associate degree base-forming liquid reacts with the oxide (Si) and

Aluminium (Al) present within the source. The technology planned by the Davidovits is

often referred to as Geo-polymers or Geo-polymer technology.

1.2 Geo-polymers

In general the source and alkaline liquids area unit treated as major materials within the

Geo-polymers. By mixing the two solutions, named caustic soda (Na OH) associate

degreed soluble glass (Na2So3) we will prepare an alkaline liquid that is employed in

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geo-polymers. The reaction takes place by caustic soda and soluble glass solutions is

treated because the geo-polymerization method for our convenience. And conjointly

we've got to think about that oxide (Si) and Aluminium (Al) area unit key components

in geo-polymers. The proportion of Aluminium and silicon area unit to be taken into

consideration within the materials that area unit used. The source like fly ash, oxide

fume, slag, rice husk-fly ashetc. area unit to be used. The supply materials choice is

additionally economical.

1.2.1 Constituents of Geo Polymer

1.2.1.1 Source Materials
In the present investigation the subsequent materials area unit used as source.
a) Fly ash

Fly ash (ASTM class F) is employed within the producing of Geo polymer concrete and

that is obtained from the by-product of coal-burning power stations. The assembly of fly

ash are going to be will increase day by day in our country, therefore its best chance to

use this by-product within the Geo polymer concrete. Aroundits calculable that the

assembly of fly ash is over 780 million tons p.a. particularly within the countries like

China and India [3]. So, the superabundant handiness of fly ash could produce the nice

chance to use within the producing of Geo polymer concrete.

1.2.1.2 Alkaline Liquids
The aggregate of caustic soda (NaOH) and soluble glass resolution (Na2So3) area unit

used as alkaline liquids [2]. The soluble glass resolution (Na2O= 13.7%, SiO2=29.4%,

and water (H2O) =55.9% by mass) was ready by the manufacturer of needed quantities.

The caustic soda (NaOH) in flakes or pellets from with 97%-98% purity was employed

in the investigation. The caustic soda (NaOH) resolution was ready by dissolving either

the flakes or the pellets in needed amount of water [5]. The mass of caustic soda solids

in a very resolution varied betting on the concentration of the solution expressed in

terms of M (M). Lets say, NaOH resolution with a level of 8M consisted of 8x40 = 320

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grams of NaOH solids (in flake or pellet form) per cubic decimetre of the solution,

where, 40 is that the relative molecular mass of caustic soda (NaOH) pellets or flakes.

1.2.2 Applications of Geo polymers

Geo polymers are used in various day to day applications such as-

Used in industrial floor repairs.

Airfield repairs (in war zones).
Fireproof composite panels.
External repair and structural retrofit for aging infrastructure.
For storage of nephrotoxic and hot wastes.
Potential utilizations in Art and Decoration.
LTGS Brick, railways sleepers, electrical power poles, marine structures, waste

containments etc.

Depending on the molar magnitude relation of Si to Al, the potential applications of geo

polymers were planned by Davidovits (1999) as given in Table 1.1.

Table 1.1. Applications of Geo polymers

Si:Al Application
1 - Bricks
- Ceramics
- Hearth protection
2 - Low CO2 cements and concretes
- Radioactive and toxic waste encapsulation
3 Fire protection fibre glass composite
- Foundry equipments
- Heat resistant composites, 200oC to 1000oC
- Tooling for aeronautics titanium process
>3 - Sealants for industry, 200oC to 600oC
- Tooling for aeronautics SPF aluminium
20-35 - Fire resistant and heat resistant fibre composites

1.2.3 Advantages of Geo polymers

Geo polymer concrete is additional immune to corrosion and hearth, has compressive

and tensile strengths, gains its full strength quickly (cures totally faster), low creep, no

shrinkage, sensible acid resistance, low porousness, immune to sulphate attack and

sturdy finishes.

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1.3 Aim of the Project

The behaviour of geo polymers were studied that several of researches mistreatment

varied kinds of source like Fly ash, rice husk fly ash etc. the current study controlled the

event and also the mechanical properties of Geo polymer concrete incorporating with

fine aggregate and coarse aggregate with completely different replacement levels at

close temperature activity. The results of these studies are delineate in future chapters.
The aims of this study were:

1. To develop aaggregate proportioning method to manufacture fly ash (ASTM class

F) based mostly Geo polymer concrete incorporating with fine aggregates and

coarse aggregates.
2. To spot and study the result of distinguished parameters that affects the properties of

fly ash based mostly Geo polymer concrete incorporating, with fine and coarse

aggregates.
3. To review the mechanical properties of hardened low metal fly ash-based Geo

polymer concrete incorporating with fine and coarse aggregate at close temperature

activity.

1.4 Scope of work

The analysis utilised fly ash (ASTM class F), fine and coarse aggregates because the

base materials for creating geo chemical compound concrete. As so much as attainable,

the innovation and also the hardware as of currently accustomed build OPC concrete

were utilised to create the geo chemical compound concrete. The geo chemical

compound concrete properties studied enclosed the compressive strength, split strength,

flexural strength, the elastic constants and also the compressive strength by rebound

hammer and also the experimental results were compared with foreseen results.

1.5 Organization of thesis

The remainder of the thesis is organized as follow:

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Chapter-1 describes the temporary introduction concerning geo chemical compound,

constituents of geochemical compound, applications and blessings of geo chemical

compound concrete, aim of the project and at last discuss concerning scope of work.

Chapter-2 describes a short literature review. This chapter describes intimately the

assorted varieties of works allotted by the researchers to grasp the behaviour of geo

chemical compound concrete.

Chapter-3 describes the materials and ways of tests that area unit conducting the geo

chemical compound concrete. The tests performed to check the mechanical properties of

the hardened geo chemical compound concrete area unit delineate.

Chapter-4 describes the results and discussion of the experiments conducted on the geo

chemical compound concrete.

Chapter-5 describes the conclusions created within the project and suggestions of

future work.
CHAPTER 2
LITERATURE SURVEY

This chapter presents the Historical review of the geo chemical compound concrete,

language and Chemistry of the geo polymers. The study of literature survey adore the

geo chemical compound concrete technology has exhausted this chapter.

2.1Historical Review
The phenomenal sturdiness of ancient concretes and mortars compared to those being

employed in trendy time prompted analysis into the character of those ancient

compounds. Results from varied studies, summarized by Davidovits, [6] verified that

there's of course a awfully distinct distinction between ancient mortars and also the

cement based mostly building materials in use these days.

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The ancient merchandise appear to be not solely physically additional sturdy, however

conjointly additional immune to acid attack and freeze-thaw-cycles. Initially it was

thought that this distinction is that the consequence of atomic number 20 salt hydrates

(of the C-S-H-gel type) that represent the most a part of cement. Later, however, it

absolutely was discovered that these ancient concretes conjointly contain amounts of C-

S-H gel and consequently researchers turned their attention to the big amounts of

zeolitic phases conjointly found within the ancient merchandise [6]. it absolutely was

later terminated that the future sturdiness of ancient mortars is that the results of high

levels of zeolitic and amorphous compounds in their integrative make-up.

The use of pozzolanic materials within the manufacture of concrete features a long,

victorious history. In fact, their use pre-dates the invention of contemporary day cement

by nearly two hundred years. Today, most concrete producers worldwide acknowledge

the worth of pozzolanic enhancements to their merchandise and, wherever they are

available; they're turning into a basic concrete ingredient. Mineral admixtures akin to fly

ash and oxide fume area unit usually employed in concrete as a result of they improve

sturdiness cut back consistence and improve the interface with the mixture.

Economics (lower cement requirement), energy, and environmental issues have had a

job within the mineral admixture usage furthermore as higher engineering and

performance properties. The lower cement demand conjointly ends up in a discount for

greenhouse emission generated by the assembly of cement. The engineering advantages

from the utilization of mineral admixtures in concrete result part from their particle size

distribution characteristics, and part from the pozzolanic and building material

reactivity. Experimental programs conducted with the aim of proving this theory part

resulted within the uncovering of a brand new family of mineral binders named "Geo

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polymers" owing to similarities with organic condensation polymers as so much as their

hydrothermal synthesis conditions were involved.

2.2 Terminology and Chemistry

Davidovits, [7-9] created and applied the term Geo polymer. For the chemical

designation of geo polymers supported silicon-aluminates, "Poly (sialate)" was prompt.

Sialate is associate abbreviation for silicon-oxo-aluminate.

Polysialates area unit chain and ring polymers with Si4+ and Al3+ in IV-fold

coordination with, gas and vary from amorphous to semi-crystalline. Additionally

positive ions comparable to Na2+, Ca2+, K2+ and alternative aluminiferous cat ions should

be present in framework cavities to balance the charge of Al 3+. The structural link of

theSialate was shown in Figure 2.1.The amorphous to semi-crystalline three

dimensional silico-aluminate structures were christened Geo polymers of the subsequent

types:

Si:Al>3 Sialate link

Figure 2.1. Structural link of silicate

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As explicit by Rangan (2008), [10] "the polymerisation process involves a quick

chemical action below alkaline conditions on silicon-aluminium minerals that leads to a

three-dimensional chemical compound chain and ring structure...." the ultimate structure

of the geo polymer depends for the most part on the quantitative relation of Si to Al (Si:

Al), with the materials most frequently thought-about to be used in transportation

infrastructure generally having Si: Al between 2and 3.5 (Hardjito et al. 2004;

Davidovits 2008). this sort of geo polymer can take one among the subsequent 3 basic

forms (where "sialate" is associate abbreviation for silicon-oxo-aluminate) (Davidovits

2008):

Poly (sialate) Si: Al = one, that has [-Si-O-Al- O-] because the continuation unit.
Poly (sialate-siloxo) Si: Al = two, that has [-Si-O-Al-O-Si-O-] because the

continuation unit.
Poly (sialate-disiloxo) Si:Al = three, that has [-Si-O-Al-O-Si-O-Si-O-] because the

continuation unit

Although the mechanism of chemical process is nevertheless to be absolutely

understood, a crucial feature is that water is present solely to facilitate workability and

doesn't become a region of the ensuing geo polymer structure. In alternative words,

water isn't concerned within the chemical action and instead is expelled throughout

hardening and sequent drying. This can be in distinction to the association reactions that

occur once cement is mixed with water, that manufacture the first association

merchandise calcium silicate hydrate and calcium hydroxide. This distinction

incorporates an important impact on the mechanical and chemical properties of the

ensuingGeo polymer concrete, and additionally renders it additional immune to heat,

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water ingress, alkali-aggregate reactivity, and alternative styles of chemical attack

(Davidovits 2008; Harold Clayton Lloyd and Rangan 2009) [9&10].

The chemical composition of the geo polymer material is comparable to natural zeolitic

materials, however the microstructure is amorphous rather than crystalline (Palomo et

al. 1999; Xu and van Deventer 2000, [11]. Thepolymerizationprocess involves a well

quick chemical action below alkali condition on Si-Al minerals, which ends up in an

exceedingly 3 dimensional chemical compound chain and ring structure consisting of

Si-O-Al-O bonds, as follows (Davidovits 1999), [12]:

Mn [-(SiO2) z-A1O2] n. wH2O (2-1)
Where,
M = the alkaline component or cat particle comparable to K, metallic element or

calcium; the image - indicates the presence of a bond, n is that the degree of

polycondensation or polymerization; z is l, 2, 3, or above to 32.

2.3Literature Survey on Geo polymer Concrete

Rangan (2008) has reportable on the fly ash-based Geo polymer concrete. He study the

results of salient factors that influence the short and future properties of the Geo

polymer concrete within the recent and hardened states. He describes the applications

and economic deserves of Geo polymer concrete within the industry. He finally finished

that the low-calcium fly ash-based Geo polymer concrete has wonderful compressive

strength and is appropriate for structural applications. The salient factors that influence

the short and future properties of the recent concrete and hardened concrete area unit

known.

Lloyd and Rangan (2010) have reportable on the Geo polymer concrete with fly ash.

They in depth studies conducted on the mechanical properties of fly ash-based Geo

polymer concrete. He determined the silent options that result the properties of the Geo

polymer concrete with fly ash. The report describes the transient details of fly ash-based

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Geo polymer concrete associated an easy methodology to style Geo polymer concrete

mixtures has been represented and illustrated by an example.

Sumajouw and Rangan (2006) have reportable on the low-calcium fly ash-based Geo

polymer concrete: reinforced beams and columns. This analysis Report describes the

behaviour and strength of bolstered low-calcium fly ash-based Geo polymer concrete

structural beams and columns, the event, the mixture proportions, the short properties,

and therefore the semi-permanent properties of low-calcium fly ash-based Geo polymer

concrete. Heat-cured low-calcium fly ash-based Geo polymer concrete has wonderful

compressive strength, suffers little or no drying shrinkage and low creep, wonderful

resistance to sulphate attack, and sensible acid resistance.

VijayaRangan (2008) has applied a study to research the factors that influence the

recent and hardened fly ash based mostly Geo polymer concrete and additionally

studied the long and short term properties of Geo polymer concrete. During this present

investigation the mixture of aggregates (coarse and fine) and low calcium fly ashis

employed. An alkaline activator of sodium hydroxide and sodium silicate is used as a

binder solution.Furthermore, the alkaline/fly ash quantitative relation and therefore the

metallic element silicate/sodium hydroxide quantitative relation (by mass) for the binder

were 0.3-0.45 and 2.5 respectively. The specimens were cured on each dry and stream

temperature and therefore the results area unit studied. it's determined that the

compressive check results were high just in case of dry hardening condition as compare

to the stream hardening.

Cheng and Chiu (2003) reportable the investigation of constructing incombustible Geo

polymer mistreatmentslag combined with metakolinite. The mixture of pot fly ash

(KOH) and glass (Na2So3) was used alkaline liquids.

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Supraja and Kanta Rao (2011) have investigated the Geo polymer concrete is

absolutely replaced with alkaline liquids area unit used for the binding of materials.

Totally different molarities of the hydroxide solution i.e. 3M, 5M, and 7M and 9M area

unit taken to arrange totally different mixes and studied the mechanical properties of

Geo polymer concrete. Two totally different hardening area unit carried i.e. kitchen

appliance hardening at 500-degree centigrade and hardening directly by inserting the

specimens to direct daylight. He determined that the compressive strength is accrued

with the rise within the molarities of hydroxide. The kitchen appliance cured specimens

gave best results as compared to specimens cured by direct daylight, kitchen appliance

cured specimens provides the upper compressive strength. He counselled that daylight

hardening is convenient for sensible conditions.

Sekhar et al. (2014) have studied the Strength Studies on fly ash mixed Geo polymer

concrete. During this present investigation, the result of fly ash (class F) on the

mechanical properties of Geo polymer concrete (GPC) at totally different replacement

levels area unit to be found. Glass(Na2SiO3) associated hydroxide (NaOH) solution has

been used as an alkaline matter. Within the present investigation, it's planned to review

the mechanical properties viz. compressive strength once 7, 14 and 28 days and split

durability once 28 days of close temperature hardening.

Pavan (2012) reportable that the result of fly ash (class F) on the mechanical properties

of Geo polymer concreteat totally different replacement levels area unit to be found.

Glass (Na2SiO3) associated hydroxide (NaOH) solution has been used as an alkaline

matter. Within the present investigation, it's planned to review the mechanical properties

viz. compressive strength once 7, 14 and 28 days and split durability once 28 days of

close temperature hardening. From the results, it's finished that the accrued level of fly

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ash accrued the compressive strength of GPC in the least hardening periods and split

durability once twenty eight days of hardening. Results discovered that fly ash mixed

GPC mixes have earned increased mechanical properties in the least hardening periods.

Additionally during this study, the mechanical properties of GPC (FA100) were

compared to M25 grade of standard concrete (CC).

Sudarsan (2013) has reportable on performance of fourteen M based mostly geo

polymer mortar with fly ash. He studied the flow on totally different binder

composition, compressive strength of geo polymer mortar at totally different ages like 1,

3, 7 days and additionally study the microstructure properties of geo polymer mortar.

From the results, it's finished that the compressive strength is accrued with increase in

fly ash content and it shows most compressive strength F/B =0.5 and so decreases.

From SEM pictures it's finished that microstructure is densified with age. This densified

microstructure is chargeable for higher strength of the mortar.

Sanjay Kumar et al. (2005) worked on high strength Geo chemical compound

materials through mechanical activation of fly ash. They ready fly ash based mostly geo

polymers mistreatment raw and automatically activated fly ash. A remarkably higher

strength was determined in automatically activated fly ash based mostly geo polymers,

the compressive strength additionally will increase with a rise in alkaline matter.

Relying upon the mechanical activation device used, geo polymers having compressive

strength within 45-120 Mpa can be ready. TGA/DTA studies indicated the bigger

formation of geo chemical process product just in case of automatically activated fly ash

and this was supported by a compact microstructure throughout SEM examination of

the samples.

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VenkateshBabu and Divya Mohan (2005) studied the strength properties of fly ash

based mostly Geo polymer concrete-concrete while not cement. They investigated the

performance characteristics of source, strength and small structural properties of Geo

polymer concrete. The variables thought-about in their study were the M of chemical

activators and therefore the quantitative relation of glass to hydroxide. The result shows

that molarity and the ratio of sodium silicate to sodium hydroxide increase the

compressive strength of GPC also will increase. The most compressive strength of

25.50 Mpa was obtained, among 24 hours by kitchen appliance hardening at 90C

temperature.

Satia et al. (2008) the target of the current work is to review the fly ash based mostly

geo polymer ready with glass and hydroxide as alkaline activators. The concrete was

ready with variable fly ash content 350,450 and 550 kg/m3 and matter solution to fly ash

quantitative relation of 0.40 and 0.50. The compressive strength within the range of

10-60 Mpa was obtained. The performance of those concrete in aggressive setting was

additionally studied, mistreatment tests on absorption, acid resistance and potential.

Results indicated that water absorption diminished with increase in strength of concrete

and fly ash content. All Geo polymer concrete showed wonderful resistance to acid

attack compared to traditional.

Cold Climate Housing research centre (2010) has investigated the potential for

manufacturing geo polymer cement mistreatment native materials and creating

merchandise for the Alaskan market place. Supported this review, CCHRC is optimistic

regarding the possibility for a commercially viable enterprise to develop. Change of

integrity our optimism is that the potential for brand new Geo polymer industry to build

native jobs and economic opportunities and make merchandise that facilitate address

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extreme challenges of our Geographical settings and considerably reduces carbon

dioxide emissions related to cement producing. Geo polymers need30-60% less energy

to create and unharness regarding eightieth less greenhouse gas into the atmosphere.

Not like cement, which needs immense planting cost accounting upwards 150$ million

to manufacture, geo polymer cement production need solely a concrete batch cost

accounting between $50,000 and $ 200,000. In part, this can be as a result of the supply

material for Geo polymer is by-products that have already felt combustion within the

station or edge in an exceedingly mine that area unit processes analogous reworking

lime stones into cement clinker.

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 CHAPTER-3
MATERIALS AND METHODOLOGY
3.1 General
This Chapter presents the small print of development of the method of constructing low

metal (ASTM class F) fly ash primarily based Geo polymer concrete and during this

investigation traditional fine aggregate has been taken. First, the materials, mix

proportions, manufacturing and curing of the test specimens are explained.

The physical and chemical properties of fly ash, aggregate and water utilized in the

investigation were analysed supported commonplace experimental procedures arranged

down in IS, ASTM and BS codes. The experiments conducted on coarse aggregate

square measure relative density and water absorption, Bulk density & Sieve analysis by

victimization individual codes [39-44]. The experiments conducted on fine aggregates

square measure relative density, wet content, sieve analysis and bulking of fine

aggregate victimization volume technique. The tests conducted on Geo polymer

concrete square measure Compressive strength [45-47], Split strength [48&49].

3.2 Materials
3.2.1 Fly ash
According to ASTM C 618 (2003) [52] the fly ash are often divided into 2 sorts

supported quantity of metal present within the fly ash. The classified Fly ashes square

measure class F (low-calcium) and sophistication C (high-calcium). Within the present

investigation class F fly ash [53] made from Rayalaseema Thermal station (RTPP),

Muddanur, A.P was used. The chemical and physical properties square measure

conferred within the Table 3.1.

Table 3.1 Chemical and Physical Properties of Class F Fly Ash

Particulars Class F fly ash ASTM C 618 Class F fly ash

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 Chemical composition

% Silica(SiO2) 65.6

% Alumina(Al2O3) 28.0

% Iron Oxide(Fe2O3) 3.0 SiO2+ Al2O3+ Fe2O3>70

% Lime(CaO) 1.0

% Magnesia(MgO) 1.0

% Titanium Oxide (TiO2) 0.5

% Sulphur Trioxide (SO3) 0.2 Max. 5.0

Loss on Ignition 0.29 Max. 6.0

Physical properties

Specific gravity 2.24

Fineness (m2/Kg) 360 Min.225 m2/kg

3.2.2 Coarse aggregate

Coarse aggregate of size 20 mm and 10 mm are to be used. The bulk specific gravity in

oven dry condition and water absorption of the coarse aggregate 20 mm and 10mm as

per IS code [42] were 2.58 and 0.3% respectively.

The gradation of the coarse aggregate was determined by sieve analysis as per IS code

[43] and presented in the Tables 3.2 and 3.3. The grading curves of the coarse

aggregates as per IS code are shown in Figure 3.1 and 3.2. (Quantity taken=5 Kg)

Table 3.2 Sieve analysis of 20 mm Coarse aggregate

Cumulative
Cumulative
Sieve Weight percent passing
S.N Percentage percentage
size retained IS 383
o weight retained weight 20
(mm) (gm) (1970)
retained mm
Limits

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 1 20 358 7.16 7.16 92.84 85-100

2 16 2428 48.56 55.72 44.28 N/A

3 12.5 1249 24.98 80.7 19.3 N/A

4 10 582 11.64 92.34 7.66 0-20

5 4.75 376 7.52 99.86 0.14 0-5

Table 3.3 Sieve analysis of 10 mm Coarse aggregate

Cumulative percent
Sieve Cumulative
Weight Percentage passing
S.N size percentage
weight IS 383
(mm retained
o weight
(gm) retained 10 mm (1970)
) retained
limits
1 10 16 0.32 0.32 99.68 85-100
2 4.75 4546 90.92 91.24 8.76 0-20

3 2.36 318 6.36 97.6 2.4 0-5

120

100

80

Percentage Passing 60
Lower Limit (IS 393:1970) Coarse Aggregate Upper Limit (IS 383:1970)
40

20

IS Seive Size (mm)

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 Figure 3.1 Grading curve of 20 mm Coarse aggregate

120

100

80

Percentage Passing 60
Lower Limit (IS 393:1970) Coarse Aggregate Upper Limit (IS 383:1970)
40

20

IS Seive Size (mm)

Figure 3.2 Grading curve of 10 mm Coarse aggregate

3.2.3 Fine aggregate

The slag used throughout the experimental work was obtained from the Lanko

industries near Srikalahasthi in Chittoor district. The bulk specific gravity in oven dry

condition and water absorption of the slag as per IS code were 2.62 and 1%

respectively. The gradation of the slag was determined by sieve analysis as per IS code

and presented in the Table 3.4. The grading curve of the fine aggregate as per IS code is

shown in Figure 3.3. Fineness modulus of sand was 2.59.(Quantity taken=1 Kg)

Table 3.4 Sieve analysis of Fine Aggregate (Slag)

S.No Sieve No/ Weight Percentage Cumulative Cumulative percent
size retained weight percentage passing
(gm) Fine IS 383
retained weight
aggregate (1970)
retained
Zone II

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 requirement

1 3/8 (10mm) 0 0 0 100 100

No.4
2 12 1.2 1.2 98.8 90-100
(4.75mm)
No.8
3 35 3.5 4.7 95.3 75-100
(2.36mm)
No.16
4 135 13.5 18.2 81.8 55-90
(1.18mm)
No.30
5 366 36.6 54.8 45.2 35-59
(600m)
No.50
6 290 29.0 83.8 16.2 8-30
(300m)
No.100
7 132 13.2 97.0 3.0 0-10
(150m)
110
100
90
80
70
60
Percentage Passing
50
Lower Limit (IS 383:1970) Fine Aggregate Upper Limit (IS 383: 1970)
40
30
20
10
0

IS Seive Size (mm)

Figure 3.3 Grading curve of fine aggregate

3.2.4 Alkaline Liquid

The alkaline liquid used was a mixture of water glass solution and hydroxide solution.

The water glass solution (Na2O= 13.7%, SiO2=29.4%, and water=55.9% by mass) was

purchased from an area provider. The hydroxide (NaOH) in flakes or pellets from with

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97%-98% purity was conjointly purchased from an area provider. The hydroxide

(NaOH) solution was ready by dissolving either the flakes or the pellets in needed

amount of water. The mass of NaOH solids in an exceedingly solution varied betting on

the concentration of the solution expressed in terms of concentration, M. Let's say,

NaOH solution with a amount of 8M consisted of 8x40 = 320 grams of NaOH solids (in

flake or pellet form) per metric capacity unit of the solution, where, 40 is that the

relative molecular mass of hydroxide (NaOH) pellets or flakes.

3.3 Mixture Proportions

Based on the restricted past analysis on GPC (Hardjito&Rangan, 2005), the subsequent

proportions were selected for the constituents of the mixtures [1-5].

The combined mass of coarse and fine aggregates square measure taken as 77% of

the mass of concrete.

Alkaline liquid as given in Section 3.2.5.
Ratio of matter solution-to-fly ash and slag, by mass, within the range of0.3 and 0.4.

This magnitude relation was fastened at 0.35.

Class F fly ash (FA100)
Ratio of water glass solution-to-sodium hydroxide solution, by mass, of 0.4 to 2.5.

For the foremost of the cases the magnitude relation was fixed at 2.5, as a result of

the water glass solution is significantly cheaper than the hydroxide solution.
Concentration of hydroxide (NaOH) solution was unbroken at 4M, 6M, 8M &10M
Calculate water-to-geo polymer solids.
Extra water, when added, in mass.

The following state of affairs describes the GPC combine style of this study:

Assume that normal-density aggregates in SSD (Saturated surface Dry) condition

square measure to be used and also the unit-weight of concrete is 2400 kg/m 3. During

this study, take the mass of combined aggregates as 77% of the overall mass of

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concrete, i.e. 0.77x2400=1848 kg/m3. The coarse and fine aggregates is also elite to

match the quality grading curves utilized in the look of Portland cement concrete

mixtures.
For instance, the coarse aggregates (70%) might comprise 776 kg/m 3 (60%) of 20mm

aggregates, 518 kg/m3 (40%) of 10 mm aggregates, and 554 kg/m3 (30%) of fine

aggregate to fulfil the necessities of ordinary grading curves. The adjusted values of

coarse and fine aggregates square measure 774 kg/m3 of 20 mm aggregates, 516 kg/m3

of 10 mmaggregates and 549 kg/m3 (30%) of fine aggregate, when considering the

water absorption values of coarse and fine aggregates.

The mass of geo polymer binders (fly ash) and the alkaline liquid = 2400 1848 = 552

kg/m3. Take the alkaline liquid-to-fly ash ratio by mass as 0.35; the mass of fly ash =

552/ (1+0.35) = 409 kg/m3 and the mass of alkaline liquid = 552 409 = 143 kg/m 3.

Take the ratio of sodium silicate (Na2Sio3) solution-to-sodium hydroxide (NaOH)

solution by mass as 2.5; the mass of sodium hydroxide (NaOH) solution = 144/ (1+2.5)

= 41 kg/m3; the mass of sodium silicate solution = 143 41 =102 kg/m3.

The sodium hydroxide solid (NaOH) is mixed with water to make a solution with a

concentration of 4M, 6M, 8M &10M. This solution comprises 40% of NaOH solids and

60% water, by mass.

For the trial mixture, water-to-geo polymer solids ratio by mass is calculated as follows:
In sodium silicate solution, Water = 0.559x102 = 57 kg, and solids = 102 57 = 45 kg.
In sodium hydroxide solution, solids = 0.40x41 = 16 kg, and water = 41 16 = 25 kg.
Therefore, total mass of water = 57+25 = 82 kg, and the mass of geo polymer solids =

409 (i.e. mass of fly ash) + 45 + 16 = 470 kg.

Hence, the water-to-geo polymer solids ratio by mass = 82/470 = 0.17.
Extra water of 55 liters is calculated on trial basis to get adequate workability.
The geo polymer concrete mixture proportions are given as follows:

Table 3.5 GPC Mix Proportions

Materials Mass (kg/m3)

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 M25 4M 6M 8M 10M
20 mm 683.4 774 774 774 774
Coarse aggregate
10 mm 455.6 516 516 516 516
Fine aggregate Slag - 549 549 549 549
Fly ash (Class F) - 409 409 409 409
Sodium silicate solution 102 102 102 102
Sodium hydroxide solution 41 41 41 41
Extra water 192 55 55 55 55
Alkaline solution/ (FA)
- 0.35 0.35 0.35 0.35
(by weight)

Water/ geo polymer solids

- 0.35 0.33 0.31 0.29
(by weight)

3.4 Manufacture of Test Specimens

3.4.1 Preparation of Alkaline Liquid
In this study, NaOH solids of 8x40=320 grams are dissolved in 680 millilitre of water to

arrange one cubic decimetre of NaOHsolution with a amount of 8 M. Where, forty is

that the relative molecular mass of NaOH pellets. The glass solution and also the

hydrated oxide solution were mixed along at some point before before use.
3.4.2 Manufacture of Fresh concrete
The aggregates were ready in saturated-surface-dry (SSD) condition. Fly ash and

aggregates were mixed for about three minutes. 70% of additional water was accessorial

to the combo and mixed for one minute. Then, the alkaline liquid was accessorial with

remaining half-hour of additional water and also the combine was completely mixed for

regarding two minutes. The recent concrete was solid and compacted by the standard

ways utilized in the case of cement concrete (Hardjito and Rangan, 2005). Recentfly ash

primarily based geochemical compound concrete was typically cohesive. The

workability of the recent fly ash primarily based geochemical compound concrete was

measured by means that of the traditional slump check.

3.4.3 Curing of Test Specimens

After casting and demoulding, the check specimens were unbroken for action at close

temperature until the execution of the testing on the specimens.

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3.5 Methodology

3.5.1 General
In the course of investigation, traditional fine mixture for the study of varied properties,

completely different specimens are solid and tested. The physical and chemical

properties of fly ash, scoria and water utilized in the investigation were analysed

supported customary experimental procedures arranged down in IS ASTM and BS

codes. The tests conducted on Geo chemical compound concrete area unit Compressive

strength, Split enduringness, as per the various IS, BS and ASTM codes [45-51].
3.5.2 Compressive Strength test
Compression check is one in all the foremost common check conducted on hardened

concrete, part as a result of its most vital and it's straightforward to perform additional

most of the fascinating characteristic properties of concrete area unit qualitatively

concerning its strength.

The compression check is dispensed on specimens like cuboidal or cylindrical in form

generally prisms are used. The tip components of beam area unit left intact when failure

in flexure and since of the square cross section of the beam this a part of the beam may

well be well accustomed determine the compressive strength. The compressive strength

of concrete is that the most vital and helpful property of Concrete. The compression

check was dispensed mistreatment 2000 KN compression testing machine.

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 Figure3.4 Testing of cubes for compressive strength

The compressive strength of the GPC was conducted on the cubical specimens for all

the mixes after 7, 28 and 90 days of curing as per code [45-47]. 9 Nos of 150 mm cube

specimen were made for each mix and 3 samples in each were cast and tested for 7

days, 28 days and 90 days respectively. The average value of these 3 specimens was

taken for study.

The compressive strength (f c) of the specimen was calculated by dividing the

maximum load applied to the specimen by the cross-sectional area of the specimen as

given below.
f c = P/ A

Where, fc= Compressive strength of the concrete (in N/mm2)

P = Maximum load applied to the specimen (in Newton)
A = Cross-sectional area of the specimen (in mm2)

3.5.3 Split Tensile Strength test

Splitting Tensile Strength (STS) test was conducted on the specimens for all the mixes

after 28 days of curing as per code [48-49]. Three cylindrical specimens of size 150 mm

x 300 mm were cast and tested for each age and each mix. The load was applied

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gradually till the failure of the specimen occurs. The maximum load applied was then

noted. Length and cross-section of the specimen was measured. The splitting tensile

strength (fct) was calculated as follows:

fct = 2P/ ( l d)
Where, fct = Splitting tensile strength of concrete (in N/mm2)
P = Maximum load applied to the specimen (in Newton)
l = Length of the specimen (in mm)
d = cross-sectional diameter of the specimen (in mm)
The experimental results were compared to the predicted STS values of all mixes are

given in Table 4.4.

Figure3.5 Testing of cylinders for Split tensile strength

CHAPTER-4
RESULTS AND DISCUSSIONS
4.1 Introduction
This chapter describes the Compressive strength, Split tensile strength and flexural

strength of GPC at ambient room temperature curing. The compressive strength values

of GPC mixes were measured after 7, 14, 28, 56and 112 days of curing. The split tensile

strength values of GPC mixes were measured after 28, 56 and 112 days of curing. The

flexural strength values of GPC mixes were measured at 28, 56 and 112 days of curing.

The above all strengths are also based on different molarities like 4M, 6M, 8M&10M.

4.2 Compressive Strength

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 Table 4.1 Compressive strength of GPC
Mix type
Age
Mechanical property
(days) M25 4M 6M 8M 10M

7 10.98 9.8 20.5 29.1 39.1

Compressive 14 22.3 14.7 27.2 37.6 45.4

strength, f c (MPa) 28 31.12 18.3 32.3 42.4 50.2
56 35.84 24.6 38.1 50.2 59.3
112 39.05 25.5 40.2 53.1 61.2

The compressive strength of GPC mixes with fly ash (FA100) at different molarities like

4M, 6M, 8M &10M as shown in the above table. In the table we also noticed that the

average strengths test specimens are calculated for 7days, 14days, 28days, 56days and

also 112days. From the table we also noticed that the strengths are going to increase

whenever the molarities are increased. So, Molarity of solution gives further strength to

the sample after curing.

It was observed that there was a significant increase in compressive strength in the

percent Fly ash 100% in all curing periods as shown in Figure 4.1. The GPC with 100%

fly ash sample exhibited compressive strength values of 9.8MPa, 20.5 MPa, 29.1 MPa&

39.1MPa in 4M, 6M, 8M & 10M condition for 7days. Usually 14.7 MPa, 27.2MPa

37.6MPa, 45.4MPa in 4M, 6M, 8M & 10M conditions after 14days Similarly 18.3MPa,

32.3MPa, 42.4MPa & 50.2MPa strengths are attained in 4M, 6M, 8M &10M after

28days. Similarly, for 56days the strengths are as follows 24.6MPa, 38.1MPa, 50.2MPa

& 59.3MPa in 4M, 6M,8M &10M situations and similarly 25.5MPa, 40.2MPa,

53.1MPa & 61.2MPa strengths are gained in 4M, 6M,8M & 10M conditions after 112

days of curing respectively at ambient room temperature.

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 70

60

50

40
Compressive Strngth MPa 30
M25 4M 6M 8M 10M
20

10

0
7 14 28 56 112

Age in days

Figure 4.1 Compressive strength versus Age

4.3 Split Tensile Strength
Table 4.2 shows the split tensile strength of GPC mixes with fly ash (FA100) at different

molarities like 4M, 6M, 8M & 10M at different curing periods. The tensile strengths are

increased slightly based on the increasing level of molarities. The simple thing that we

have to observe here is we no need to consider 7days, 14days.

Table 4.2Split tensile strength of GPC

Mechanical Age M25 Mix type

4M 6M 8M 10M
property (days)
Splitting tensile 28 3.68 2.25 3.75 4.83 5.44
56 3.96 2.35 3.97 5.14 5.96
strength, fct 112 4.24 2.52 4.27 5.45 6.4

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 7

4 M25
Split te nsile stre ngth 4M
3
6M
2 8M
10M
1

0
28 56 112

Age in days

Figure 4.2 Split tensile strength of mixes

It was observed that there was a significant increase in splitting tensile strength with the

percentage of 100% Fly ash in all curing periods as shown in Figure 4.2. The GPC with

100% Fly ash sample exhibited splitting tensile strength values of 2.25 MPa, 3.72 MPa,

4.83 MPa, & 5.44MPa after 28days. And 2.35MPa, 3.97MPa, 5.14MPa & 5.96MPa

strengths after 56days and 2.52MPa, 4.27MPa, 5.45MPa &6.4MPa strengths after 112

days of curing respectively at 4M, 6M,8M and 10M conditions at ambient room

temperature.
4.4 PERFORMANCE OF GPC AFTER ACID ATTACK

Table shows loss of compressive strength and

unit weight of GPC mixes FA 100% with

different molarities at 28 days curing period

before and after acid attack.

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 Fig 4.3 :Acid

curing for GPC

Table 4.3
M2 Mix type
property 10
5
4M 6M 8M
M
Initi

al 226 227
225 234 240
5.5
Unit 4.81 3.7 5.93
wei 9.5 6

wei
ght
Afte
ght
r
Kg/ 22 229
212 217 238
acid 12. 7.2
m 3 3.5 9.2
3.4 3 3
attac

k
Loss of 6.4 3.6 2.7 1.9 0.6
3 0 7 8 9
unit weight

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 % for 28

days
Init

ial
Com 31. 18. 32. 42. 50.
stre 12 3 3 4 2
press
ngt
ive
h
Aft
stren
er
gth
aci 28. 15. 29. 39. 47.
(mpa
76 92 89 42 23
d
)
curi

ng
Loss of 7.5
835
13. 7.4 7.0 5.9
strength in 48
005 61 283 163
46 3 02 35
28 days

Table 4.3 shows loss of compressive strength

and unit weight of GPC mixes FA 100% with

different molarities at 28 days curing period

before and after acid attack.

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 Table 4.4

property Mix type

M25
4M 6M 8M 10M

Initi
227
al 226 225 234 240
5.5
Unit weig 9.5 4.81 3.7 5.93
6
weig ht

ht Afte

Kg/ r
210 210 22
228 235
m 3 acid 5.3 05.
9.5 8.8
2.5 2 32
attac

k
Loss of unit 7.3
5 6.6 3.0 2.3 1.9
weight %
2 8 1 5
for 56 days
Initi

Com al 31.1 32.

18.3 42.4 50.2
pressi stre 2 3

ve ngth

stren Afte

gth r
27.
12 14. 28. 37. 45.
(mpa acid
58 13 91 89
) curi

ng
Loss of 12.
85 20. 12. 10. 8.5
strength in
32 91 58 8
56 days

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Table 4.4 shows loss of compressive strength and unit weight of GPC mixes FA 100% with

different molarities at 56 days curing period before and after acid attack.

4
Loss of unit weight % for
Unit weight 3
28 days
2 Loss of unit weight % for
56 days
1

0
2 4 6 8 10 12

Molarity

Fig: 4.4 Graphical representation of % Loss of unit weight

25

20

15

Loss of strength in 28
compressive strength Mpa 10
days
Loss of strength in 56
5 days

0
4 8 12
2 6 10

Molarity

Fig:4.5 Graphical representation of Loss of compressive strength

By graphical representations and tabular column explains as increasing the molarity in GPC the

loss of unit weight decreases in acid curing for 28 days and 56 days and also loss of strength

decreases with increases the molarity.

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10M shows better results for high resisting against acid attack.For 4M and 6M shows a poor

results against acid attack . M25 grade concrete results are coincides with the 6M results in acid

environment.8M and 10M results are shows better resistance against acid attack for both 28

days and 56 days curing period. Compare to 28 days and 56 days acid curing periods there is

loss increases in all molarities of GPC.

CHAPTER-5
CONCLUSIONS AND SCOPE OF FUTURE WORK
5.1 Conclusions
The primary aim of this analysis was to develop GPC with the fine aggregate and study

the mechanical properties of GPC mixes at close temperature. Supported the

investigation, the subsequent conclusions are drawn.

1. There was an increase in compressive strength and split tensile strength with

increase in molarity.
2. The 28th day strength of GPC mix with 6M is equivalent to M25 grade of concrete.
3. The percentage loss of unit weight and compressive strength is decreased with

increasing molarity in acid environment.

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4. Eco-friendly GPC can be recommended as sustainable construction material.

5.2 Scope of future work

The following suggestions are recommended for future study-

1. Further analysis is suggested to review the bond strength between concrete and steel

reinforcement.
2. Further analysis is suggested to perform durability viz. water absorption, chloride

penetration of GPC mixes.

3. Development of cost effective FA based GPC mixes.

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