Geopolymer Concrete

GEOPOLYMER CONCRETE B.E.
CIVIL2004-05
CHAPTER 1:- INTRODUCTION
Portland cement rod!ct"on "# !nder cr"t"cal re$"e% d!e to &"'& amo!nt
o( car)on d"o*"de 'a# relea#ed to t&e atmo#&ere. In recent +ear#, attemt# to
"ncrea#e t&e !t"l"#at"on o( (l+ a#& to art"all+ relace t&e !#e o( Portland
cement "n concrete are 'at&er"n' moment!m. Mo#t o( t&"# )+-rod!ct
mater"al "# c!rrentl+ d!med "n land("ll#, t&!# creat"n' a t&reat to t&e
en$"ronment.
Geool+mer concrete "# a -ne%. mater"al t&at doe# not need t&e re#ence
o( Portland cement a# a )"nder. In#tead, t&e #o!rce o( mater"al# #!c& a# (l+
a#&, t&at are r"c& "n /"l"con 0/"1 and 2l!m"n"!m 02l1, are act"$ated )+
al3al"ne l"4!"d# to rod!ce t&e )"nder. 5ence, concrete %"t& no cement.
T&e rate o( rod!ct"on o( car)on d"o*"de relea#ed to t&e atmo#&ere
d!r"n' t&e rod!ct"on o( Portland cement and (l+ a#&, a )+-rod!ct (rom
o%er #tat"on# %orld%"de "# "ncrea#"n' %"t& t&e "ncrea#"n' demand on
"n(ra#tr!ct!re de$eloment, and &ence need# roer attent"on and act"on to
m"n"m"6e t&e "mact on t&e #!#ta"na)"l"t+ o( o!r l"$"n' en$"ronment.
7e-car)onat"on o( l"me#tone "n t&e 3"ln d!r"n' man!(act!r"n' o( cement
"# re#on#")le (or t&e l")erat"on o( one ton o( car)on d"o*"de to t&e
atmo#&ere (or eac& ton o( Portland cement, a# can )e #een (rom t&e
(ollo%"n' react"on e4!at"on8

9
GEOPOLYMER CONCRETE B.E. CIVIL2004-05
5 CaCO
:
; 2 /"O
2
: CaO./"O
2
; 2 CaO./"O
2
; 5 CO
2
< 091
T&e rod!ct"on o( Portland cement %orld%"de "# "ncrea#"n' :=
ann!all+. T&e c!rrent contr")!t"on o( 'reen &o!#e 'a# em"##"on (rom t&e
Portland cement rod!ct"on "# a)o!t 9.:5 )"ll"on ton# ann!all+ or a)o!t >=
o( t&e total 'reen&o!#e 'a# em"##"on# to t&e eart&.# atmo#&ere ?9@.
A!rt&ermore, Portland cement "# al#o amon' t&e mo#t ener'+-"nten#"$e
con#tr!ct"on mater"al#, a(ter al!m"n!m and #teel.
Al+ a#&, Bt&e ("nel+ d"$"ded re#"d!e t&at re#!lt# (rom t&e com)!#t"on o(
'ro!nd or o%dered coal and t&at "# tran#orted )+ (l!e 'a#e# (rom t&e
com)!#t"on 6one to t&e art"cle remo$al #+#temC ?2@, "# a$a"la)le a)!ndantl+
%orld%"de. In 2009, t&e (l+ a#& rod!ct"on "n t&e D/2 %a# "n t&e order o( EF
m"ll"on ton#, )!t onl+ :2 ercent %a# !#ed "n $ar"o!# al"cat"on#, #!c& a# "n
concrete, #tr!ct!ral ("ll#, %a#te #ta)"l"#at"onG#ol"d"("cat"on, etc. ?:@.
Horld%"de, t&e e#t"mated rod!ct"on o( coal a#& "n 9IIF %a# more t&an :I0
m"ll"on ton#. T&e ma"n contr")!tor# (or t&"# amo!nt %ere C&"na and Ind"a.
Onl+ a)o!t 94 ercent o( t&"# (l+ a#& %a# !t"l"6ed, %&"le t&e re#t %a# J!#t
d"#o#ed "n land("ll# ?4@. B+ t&e +ear 2090, t&e amo!nt o( (l+ a#& rod!ced
%orld%"de "# e#t"mated to )e a)o!t >F0 m"ll"on ton# ann!all+ ?5@.
T&ere are en$"ronmental )ene("t# "n red!c"n' t&e !#e o( Portland cement
"n concrete, and !#"n' a )+-rod!ct mater"al, #!c& a# (l+ a#&, a# a #!)#t"t!te.
H"t& #"l"con and al!m"n"!m a# t&e ma"n con#t"t!ent#, (l+ a#& &a# 'reat
otent"al a# a cement relacement mater"al "n concrete. T&e #earc& o( an+
a#ect# "n t&"# re'ard "# %ort&+ to !r#!e.
To totall+ relace t&e !#e o( Portland cement a# concrete )"nder, (l+ a#&
need# to )e act"$ated, !#!all+ !#"n' al3al"ne #ol!t"on#. Palomo et al ?E@
2
de#cr")ed t%o d"((erent model# o( act"$at"on o( (l+ a#& or ot&er #"m"lar
mater"al#. In t&e ("r#t model, t&e mater"al conta"n"n' e##ent"all+ #"l"con and
calc"!m "# act"$ated )+ lo% to m"ld concentrat"on o( al3al"ne #ol!t"on. T&e
ma"n rod!ct o( t&e react"on "# calc"!m #"l"cate &+drate 0C-/-51. On t&e
contrar+, t&e mater"al !#ed "n t&e #econd model conta"n# mo#tl+ #"l"con and
al!m"n"!m, and "# act"$ated !#"n' &"'&l+ al3al"ne #ol!t"on. T&e c&em"cal
roce## "n t&"# ca#e "# ol+mer"#at"on.
In$e#t"'at"on# on t&e ("r#t model &a$e a lon' &"#tor+ "n t&e (ormer
/o$"et Dn"on, /cand"na$"an and Ea#tern E!roe co!ntr"e# ?>@. 2 $er+ %ell
3no%n e*amle "# t&e act"$at"on o( )la#t (!rnace #la'. On t&e ot&er &and,
onl+ l"m"ted re#earc& &a# )een carr"ed o!t on t&e #econd model ?E@.
T&ere(ore man+ a#ect# o( t&e mater"al c&aracter"#t"c#, react"on mec&an"#m#
and #o on (or t&e #econd model are #t"ll not clear. Aor t&e )"nder# rod!ced
!#"n' t&e #econd model, al#o 3no%n a# "nor'an"c al!m"no-#"l"cate ol+mer#,
7a$"do$"t# ?F@ co"ned t&e term Geool+mer "n 9I>F to de#cr")e t&e al3al"
act"$ated mater"al (rom 'eolo'"cal or"'"n or )+-rod!ct mater"al# #!c& a# (l+
a#& and r"ce &!#3 a#&. 7a$"do$"t# ?I@ al#o #tated t&at o(ten "n(ormat"on on
'eool+mer mater"al "# t"ed to atent-or"ented l"terat!re. Onl+ (rom t&e end
o( 9II0#, more #c"ent"("c "n(ormat"on are )ecom"n' a$a"la)le and !)l"#&edK
&o%e$er mo#t o( t&e data deal %"t& #mall #"6e #ec"men# made o(
'eool+mer a#te or mortar.
:
CHAPTER 2:-CONCRETE MAKING MATERIALS
Concrete "# t&e mo#t %"del+ !#ed manmade con#tr!ct"on mater"al. It "#
o)ta"ned )+ m"*"n' cement, %ater, ("ne a''re'ate# and coar#e a''re'ate 0and
#ome t"me# adm"*t!re#1 "n re4!"red roort"on#. T&e m"*t!re %&en laced "n
(orm# and allo%ed to c!re )ecome# &ard l"3e #tone. T&e &arden"n' "# ca!#ed
)+ c&em"cal act"on )et%een %ater L t&e cement and "t cont"n!o!# (or a lon'
t"me and con#e4!entl+ t&e concrete 'ro%# #tron'er %"t& a'e. T&e &ardened
concrete ma+ al#o )e con#"dered a# an art"("c"al #tone "n %&"c& t&e $o"d# o(
lar'er art"cle# 0coar#e a''re'ate1 are ("lled )+ t&e #maller art"cle# 0("ne
a''re'ate1 and t&e $o"d# o( ("ne a''re'ate# are ("lled %"t& cement.
T&e #tren't&, d!ra)"l"t+ and ot&er c&aracter"#t"c# o( concrete deend#
!on t&e roert"e# o( "t# "n'red"ent, on t&e roort"on# o( m"*, t&e met&od
o( comact"on and ot&er control# d!r"n' lac"n', comact"on and c!r"n'.
PORTLAND CEMENT:
T&e cement commonl+ !#ed "# Portland cement. It "# o)ta"ned )+
)!rn"n' to'et&er "n a de("n"te roort"on, a m"*t!re o( nat!rall+ occ!rr"n'
ar'"llaceo!# 0conta"n"n' al!m"na1 and calcareo!# 0conta"n"n' calc"!m
car)onate or l"me1 mater"al# to a art"al (!#"on at &"'& temerat!re 0a)o!t
9450 de'ree Cel#"!#1. T&e rod!ct o)ta"ned on )!rn"n' called cl"n3er, "#
cooled and 'ro!nd to t&e re4!"red ("nene## to rod!ce a mater"al, 3no%n a#
cement. It# "n$entor, Mo#e& 2#d"n, called "t Portland cement )eca!#e %&en
"t &ardened "t rod!ced a mater"al re#em)l"n' #tone (rom t&e 4!arr"e# near
Portland "n En'land.
4
It "# "mortant to note t&at t&e #tren't& roert"e# o( cement are
con#"dera)l+ "n(l!enced )+ t&e cool"n' rate o( cl"n3er.
Main compoun! o" Po#$%an c&m&n$:-
In add"t"on to t&e (o!r maJor como!nd#, t&ere are man+ m"nor
como!nd# (ormed "n t&e 3"ln. T&e "n(l!ence o( t&e#e m"nor como!nd# on
t&e roert"e# o( cement "# not #"'n"("cant. T%o o( t&e m"nor como!nd#
namel+ N2O and N22O re(erred to a# al3al"e# "n cement are o( #ome
"mortance. Tr"calc"!m #"l"cate and d"calc"!m #"l"cate are t&e mo#t "mortant
como!nd# re#on#")le (or t&e #tren't&. To'et&er t&e+ con#t"t!te >0 to F0=
o( cement.
H'#a$ion o" c&m&n$:-
T&e e*tent o( &+drat"on o( cement and t&e re#!ltant m"cro#tr!ct!re o(
&+drated cement "n(l!ence# t&e &+#"cal roert"e# o( concrete. H&en t&e
cement come# "n contact %"t& %ater, t&e &+drat"on o( rod!ct# 'et#
deo#"ted. On t&e o!ter er"&er+ and n!cle!# o( t&e !n&+drated cement
"n#"de 'et# 'rad!all+ d"m"n"#&ed "n $ol!me.
T&e react"on o( cement %"t& %ater "# e*ot&erm"c. T&e react"on
l")erate# con#"dera)le 4!ant"t+ o( &eat a con#"dera)le 4!ant"t+ o( &eat. T&"#
l")erat"on o( &eat "# called &eat o( &+drat"on. T&e #t!d+ and control o( t&e
&eat o( &+drat"on )ecome# "mortant "n t&e con#tr!ct"on.
AGGREGATES:-
Cr!#&ed or !ncr!#&ed mater"al der"$ed (rom t&e nat!ral #o!rce# #!c&
a# roc3#, 'ra$el# )o!lder# and #and (or rod!ct"on o( concrete are called a#
a''re'ate#.
5
T&e a''re'ate# ro$"de a)o!t >5= o( t&e )od+ o( t&e concrete and
&ence "t# "n(l!ence "# e*tremel+ "mortant.
C%a!!i"ica$ion o" A((#&(a$&!:-
T&e a''re'ate# are cla##"("ed a#8
a1 A"ne a''re'ate#
)1 Coar#e a''re'ate#
c1 2ll-"n-a''re'ate
d1 /"n'le-#"6e-a''re'ate
a1 A"ne a''re'ate8-
"t "# t&e a''re'ate mo#t o( %&"c& a##e# 4.>5 mm I/ #"e$e. /and "#
'enerall+ con#"dered a# ("ne a''re'ate.
)1 Coar#e a''re'ate8-
T&e a''re'ate# mo#t o( %&"c& are reta"ned on t&e 4.>5 mm I/ #"e$e
and conta"n onl+ #o m!c& o( ("ne mater"al a# "# erm"tted )+ t&e
#ec"("cat"on# are termed coar#e a''re'ate#. T&e 'raded coar#e a''re'ate "#
de#cr")ed )+ "t# nom"nal #"6e, ".e. 40 mm, 20mm, 9Emm and 92.5 mm, etc.
c1 2ll-"n-a''re'ate8-
/omet"me# com)"ned a''re'ate# are a$a"la)le "n nat!re comr"#"n'
d"((erent (ract"on# o( ("ne and coar#e a''re'ate#, %&"c& are 3no%n a# all-"n-
a''re'ate#. T&e all-"n- a''re'ate# are not 'enerall+ !#ed (or ma3"n' &"'&
4!al"t+ concrete.
d1 /"n'le-/"6e- 2''re'ate8
2''re'ate# comr"#"n' art"cle# (all"n' e##ent"all+ %"t&"n a narro%
l"m"t o( #"6e (ract"on# are called #"n'le-#"6e-a''re'ate#. Aor e*amle, a
20mm #"n'le-#"6e-a''re'ate mean# an a''re'ate mo#t o( %&"c& a##e#
E
t&ro!'& a 20 mm I/ #"e$e and t&e maJor ort"on o( %&"c& "# reta"ned "n a
90mm I/ #"e$e.
)in&n&!! Mou%u!:-
T&e ("nene## "# a n!mer"cal "nde* o( ("nene##, '"$"n' #ome "dea o( t&e mean
#"6e o( t&e art"cle# re#ent "n t&e ent"re )od+ o( t&e a''re'ate. T&e #"e$e#
t&at are to )e !#ed (or t&e #"e$e anal+#"# o( t&e a''re'ate (or concrete a# er
I/8 2:FE 0Part 91- 9IE:, are-
F0mm,40mm,20mm,90mm,4.>5mm,2.:>mm,9.9Fmm,E00 m"cron,:00
m"cron, and 950 m"cron.
T&e !ro#e o( t&e ("nene## mod!l!# "# to 3no% t&e c&aracter o( t&e
a''re'ate to )e !#ed, a# to %&et&er "t "# ("ne, med"!m or coar#e.
WATER:-
Hater "# t&e mo#t "mortant and lea#t e*en#"$e "n'red"ent o(
concrete. Generall+, cement re4!"re# a)o!t :G90 o( "t# %e"'&t o( %ater (or
&+drat"on. 5ence, t&e m"n"m!m %ater-cement rat"o re4!"red "# 0.:5.
2ccord"n' to I/8 45E-9I>F, t&e re#ence o( tann"c ac"d or "ron como!nd# "n
t&e c!r"n' %ater "# o)Ject"ona)le.
>
CHAPTER *:-CONCRETE
T&e 'ood 4!al"t+ o( concrete "# a &omo'eno!# m"*t!re o( %ater,
cement, a''re'ate and ot&er adm"*t!re#. Concrete ma3"n' "# not J!#t a
matter o( m"*"n' "n'rad"ent# to rod!ce a la#t"c ma##, )!t 'ood concrete
&a# to #at"#(+ er(ormance re4!"rement# "n t&e la#t"c o( 'reen #tate and al#o
t&e &ardened #tate. In t&e la#t"c #tate t&e concrete #&o!ld )e %or3a)le and
(ree (rom #e're'at"on and )leed"n'. /e're'at"on "# t&e #earat"on o( coar#e
a''re'ate and )leed"n' "# t&e #earat"on o( cement a#te (rom t&e ma"n
ma##. T&e #e're'at"on and )leed"n' re#!lt# "n a oor 4!al"t+ concrete. In "t#
&ardened #tate concrete #&o!ld )e #tron', d!ra)le and "mermea)le and "t
#&o!ld &a$e m"n"m!m d"men#"onal c&an'e#.
2mon' t&e $ar"o!# roert"e# o( concrete, "t# comre##"$e #tren't& "#
con#"dered to )e t&e mo#t "mortant and "# ta3en a#, an "nde* o( "t# o$erall
4!al"t+. Man+ ot&er roert"e# o( concrete aear to )e 'enerall+ related to
"t# comre##"$e #tren't&.
FACTORS AFFECTING STRENGTH OF CONCRETE:
T&e (ollo%"n' are d"((erent (actor# a((ect"n' t&e #tren't& o( concrete8
1+ ,a$&# C&m&n$ #a$io:
/tren't& o( t&e concrete deend# on t&e #tren't& o( t&e cement a#te.
T&e #tren't& "ncrea#e %"t& "ncrea#e "n cement art"cle#. 2ccord"n' to
F
2)ra&am 09I9I1 t&e #tren't& o( concrete "# onl+ deendent !on
%aterGcement rat"o ro$"d"n' t&e m"* "# %or3a)le.
2+ C&m&n$:
T&e e((ect o( cement on concrete #tren't& deend# o( t&e c&em"cal
como#"t"on and ("nene## o( t&e cement. H"t& "ncrea#er "n ("nene## lead# to
&"'&er #tren't& and al#o 'a"n #tren't& more ra"dl+.
*+ A((#&(a$&:
T&e a''re'ate arameter# t&at are #&ae, te*t!re and ma*"m!m #"6e o(
a''re'ate are mo#t "mortant. T&e lar'er ma*"m!m #"6e a''re'ate '"$e#
lo%er #!r(ace (or de$eloment o( 'el )ond# %&"c& "# re#on#")le (or t&e
lo%er #tren't& o( t&e concrete. /econdl+ )"''er a''re'ate #"6e ca!#e# more
&etero'ene"t+ "n t&e concrete %&"c& %"ll re$ent t&e !n"(orm d"#tr")!t"on o(
load %&en #tre##ed. Generall+, &"'& #tren't& concrete or r"c& concrete "#
ad$er#el+ a((ected )+ t&e !#e o( t&e lar'er #"6e a''re'ate#. B!t "n lean m"*e#
or %ea3er concrete, t&e "n(l!ence o( #"6e o( t&e a''re'ate 'et# red!ced. It "#
"ntere#t"n' to note t&at "n lean m"*e# lar'er a''re'ate# '"$e# &"'&e#t #tren't&
%&"le "n r"c& m"*e# "t t&e #maller a''re'ate +"eld# &"'&er #tren't&.
-+ Compac$ion:
Comact"on can )e done )+ )ot& re##!re and $")rat"on. Comact"on
"# nece##ar+ to red!ce or el"m"nate t&e a"r re#ent "n t&e concrete. B+ t&"#
den#"t+ o( concrete "ncrea#e#. Lac3 o( comact"on %"ll re#!lt "n a"r $o"d#
%&o#e dama'"n' e((ect on #tren't& and d!ra)"l"t+ "# e4!all+ or more
redom"nant t&an t&e re#ence o( ca"llar+ ca$"t"e#.
I
To ena)le t&e concrete to )e (!ll+ comacted %"t& '"$en e((ort#,
normall+ a &"'&er %aterG cement rat"o t&an t&at calc!lated )+ t&eoret"call+
con#"derat"on# ma+ )e re4!"red. T&at "# to #a+ t&e (!nct"on o( %ater "# al#o to
l!)r"cate t&e concrete.
T&e (ollo%"n' met&od# are adoted (or comact"on o( concrete8
a1 5and comact"on
)1 Rodd"n'
c1 Ramm"n'
d1 Tam"n'
e1 Comact"on )+ V")rat"on
(1 Internal $")rator 0 Needle $")rator1
'1 Aorm%or3 $")rator 0E*ternal $")rator1
&1 Ta)le $")rator
"1 Plat(orm $")rator
J1 /!r(ace $")rator 0 /creed $")rator1
31 Comact"on )+ re##!re and Jolt"n'
l1 Comact"on )+ /"nn"n'
.+ Cu#in(:
Concrete %&"le &+drat"n' relea#e# &"'& &eat o( &+drat"on. T&"# &eat "#
&arm(!l (rom t&e o"nt o( $"e% o( $ol!me #ta)"l"t+. I( t&e &eat 'enerated "#
remo$ed )+ #ome mean#, t&e ad$er#e e((ect d!e to t&e 'enerat"on o( &eat can
)e red!ced. T&"# can )e done )+ a t&oro!'& %ater c!r"n'.
T&e re#ent concrete "tem# are normall+ "mmer#ed "n c!r"n' tan3# (or
certa"n d!rat"on. Pa$ement #la)#, roo( #la)# etc. are co$ered !nder %ater )+
ma3"n' #mall ond#. Vert"cal reta"n"n' %all or la#tered #!r(ace# or concrete
90
col!mn# etc. are c!red )+ #ra+"n' %ater. In #ome ca#e#, %et co$er"n'# #!c&
a# %et '!nn+ )a'#, 5e##"an clot, J!te matt"n', #tra% etc. are %raed to
$ert"cal #!r(ace (or 3ee"n' t&e concrete %et. Aor &or"6ontal #!r(ace# #a%
d!#t, eart& or #and are !#ed a# %et co$er"n' to 3ee t&e concrete "n %et
cond"t"on (or a lon'er t"me #o t&at t&e concrete "# not !nd!l+ dr"ed to
re$ent &+drat"on.
WORKABILITY:
T&e d"$er#e re4!"rement# o( m"*a)"l"t+, #ta)"l"t+, tran#orta)"l"t+,
lacea)"l"t+, mo)"l"t+, comact")"l"t+ and ("n"#&a)"l"t+ o( (re#& concrete are
re(erred to a# %or3a)"l"t+. T&e %or3a)"l"t+ o( (re#& concrete "# t&!# a
como#"te roert+. It "# d"(("c!lt to de("ne rec"#el+ all t&e a#ect# o( t&e
%or3a)"l"t+ "n a #"n'le de("n"t"on. I/8 E4E9 0Part V991 O 9I>: de("ne#
%or3a)"l"t+ a# t&at roert+ o( (re#&l+ m"*ed concrete o( mortar %&"c&
determ"ne# t&e ea#e and &omo'ene"t+ %"t& %&"c& "t can )e m"*ed, laced,
comacted and ("n"#&ed.
/omet"me# t&e term# con#"#tenc+ and la#t"c"t+ are !#ed to denote t&e
%or3a)"l"t+ o( a concrete m"* and a %etter m"* need not &a$e all t&e a)o$e
de#"red roert"e#. On t&e ot&er &and an e*tremel+ %et m"* ma+ ca!#e
#e''rat"on and ma+ )e d"(("c!lt to lace "n mo!ld#. Pla#t"c"t+ "# t&e
co&e#"$ene## o( t&e m"* to &old t&e "nd"$"d!al 'ra"n# to'et&er )+ t&e cement
matr"*.
)ac$o#! A""&c$in( ,o#/a0i%i$':
99
a1 Hater content
)1 M"* roort"on
c1 /"6e o( a''re'ate
d1 /&ae o( a''re'ate#
e1 /!r(ace te*t!re# o( a''re'ate#
(1 Grad"n' o( a''re'ate#
'1 D#e o( adm"*t!re#
a+ ,a$&# Con$&n$:
Hater content "n a '"$en $ol!me o( concrete %"ll &a$e #"'n"("cant
"n(l!ence# on t&e %or3a)"l"t+. T&e &"'&er t&e %ater content er c!)"c meter
o( concrete, t&e &"'&er %"ll )e t&e (l!"d"t+ o( concrete %&"c& "# one o( t&e
"mortant (actor# a((ect"n' t&e %or3a)"l"t+.
0+ Mi1 p#opo#$ion!:
2''re'ateGCement rat"o "# an "mortant (actor "n(l!enc"n'
%or3a)"l"t+. T&e &"'&er t&e a''re'ateGcement rat"o, t&e leaner "# t&e
concrete. In leaner concrete, le## 4!ant"t+ o( a#te "# a$a"la)le (or ro$"d"n'
l!)r"cat"on er !n"t #!r(ace area o( a''re'ate and &ence t&e mo)"l"t+ o(
a''re'ate "# re#tra"ned. On t&e ot&er &and "n ca#e o( r"c& concrete %"t& lo%er
a''re'ateG cement rat"o, more a#te "# a$a"la)le to ma3e t&e m"* co&e#"$e
and (att+ to '"$e )etter %or3a)"l"t+.
c+ Si2& o" A((#&(a$&:
T&e )"''er t&e #"6e o( t&e a''re'ate t&e le## "# t&e #!r(ace area and
&ence le## amo!nt o( %ater "# re4!"red (or %ett"n' t&e #!r(ace and le##
92
matr"* or a#te "# re4!"red (or l!)r"cat"n' t&e #!r(ace to red!ce "nternal
(r"ct"on. Aor a '"$en 4!ant"t+ o( %ater and a#te a )"''er #"6e o( a''re'ate
%"ll '"$e &"'&er %or3a)"l"t+.
+ S3ap& o" A((#&(a$&:
T&e #&ae o( t&e a''re'ate con#"dera)l+ "n(l!ence# %or3a)"l"t+.
2n'!lar, elon'ated, or (la3+ a''re'ate ma3e# t&e concrete $er+ &ar#& %&en
comared to ro!nded a''re'ate or c!)"cal #&aed a''re'ate. Contr")!t"on to
)etter %or3a)"l"t+ o( ro!nded a''re'ate %"ll come t&e (act t&at (or t&e '"$en
$ol!me or %e"'&t "t %"ll &a$e le## #!r(ace area and al#o le## $o"d# t&an
an'!lar or (la3+ a''re'ate.
&+ Su#"ac& T&1$u#&:
T&e "n(l!ence o( #!r(ace te*t!re on %or3a)"l"t+ "# a'a"n d!e to t&e
(act t&at t&e total #!r(ace area o( ro!'& te*t!red a''re'ate "# more t&an t&e
#!r(ace area o( #moot& ro!nded a''re'ate "# o( #ame $ol!me. 2 red!ct"on o(
"nter art"cle (r"ct"onal re#"#tance o((ered )+ #moot& a''re'ate# al#o
contr")!te# to t&e %or3a)"l"t+.
"+ G#ain( o" a((#&(a$&:
T&"# "# one o( t&e (actor# %&"c& %"ll &a$e ma*"m!m "n(l!ence on
%or3a)"l"t+. 2 %ell 'raded a''re'ate "# t&e one %&"c& &a# (e%er amo!nt# o(
$o"d# "n a '"$en $ol!me. Ot&er (actor# )e"n' con#tant, %&en t&e total $o"d#
are le##, e*ce## a#te "# a$a"la)le to '"$e )etter l!)r"cat"n' e((ect. H"t&
e*ce## amo!nt o( a#te t&e m"*t!re )ecome# co&e#"$e and (att+ %&"c&
re$ent# #e're'at"on o( art"cle#. 2''re'ate art"cle# %"ll #l"de a#te eac&
9:
ot&er %"t& t&e lea#t amo!nt o( comact"n' e((ort#. T&e )etter t&e 'rad"n' t&e
le## "# t&e $o"d content and &"'&er t&e %or3a)"l"t+.
(+ U!& o" ami1$u#&!:
Certa"n adm"*t!re# 'reatl+ "n(l!ence t&e %or3a)"l"t+. D#e o( a"r
entra"n"n' a'ent and #!er la#t"c"6"n' adm"*t!re# 'reatl+ "ncrea#e t&e
%or3a)"l"t+ %&en ot&er cond"t"on# are con#tant. It can )e $"e%ed t&at t&e a"r
)!))le# act a# a #ort o( )all )ear"n' )et%een t&e art"cle# to #l"de a#t eac&
ot&er and '"$e ea#+ mo)"l"t+ to t&e art"cle#.
MEASUREMENT OF WORKABILITY8
T&e term %or3a)"l"t+ &a# )een 'enerall+ !#ed (or concrete and can
mean t&e (ollo%"n'8
Comact")"l"t+ or t&e ea#e %"t& %&"c& concrete can (lo% "nto t&e
(orm%or3, aro!nd #teel and remolded.
/ta)"l"t+ or a)"l"t+ o( t&e concrete to rema"n a #ta)le, co&e#"$e and
&omo'eno!# ma## %&"le &andl"n' and $")rat"n' %"t&o!t t&e con#t"t!ent#
#e're'at"n'.
T&e (ollo%"n' te#t# are commonl+ emlo+ed to mea#!re %or3a)"l"t+.
a1 /l!m te#t
)1 Comact"on (actor te#t
c1 Alo% te#t
d1 Vee Bee Con#"#tometer te#t
94
a+ S%ump $&!$:
/l!m te#t "# t&e mo#t commonl+ !#ed met&od o( mea#!r"n'
con#"#tenc+ o( concrete %&"c& can )e emlo+ed e"t&er "n la)orator+ or at #"te
o( %or3. It "# not a #!"ta)le met&od (or a $er+ %et or $er+ dr+ concrete. I(
one &al( o( t&e cone #l"de# do%n, "t "# called #&ear #l!m. In ca#e o( a #&ear
#l!m t&e #l!m $al!e "# mea#!red a# t&e d"((erence "n &e"'&t )et%een t&e
&e"'&t o( t&e mo!ld and t&e a$era'e $al!e o( t&e #!)#"dence.
0+ Compac$ion )ac$o# $&!$:
T&e comact"on (actor te#t "# de#"'ned r"mar"l+ (or !#e "n t&e
la)orator+ )!t "t can al#o )e !#ed "n t&e ("eld. It "# more rec"#e and #en#"t"$e
t&an t&e #l!m te#t and art"c!larl+ !#e(!l (or concrete "# to )e comacted )+
$")rat"on.
T&e comact"on (actorPHe"'&t o( art"all+ comacted concrete
He"'&t o( (!ll+ comacted concrete
95
CHAPTER -:-EN4IRONMENTAL PRO5LEMS
,ITH CONCRETE
T&e en$"ronmental ro)lem# %"t& concrete are '"$en )elo%.
CO2 &mi!!ion!
T&e mo#t #er"o!# ro)lem %"t& o!r cement "nd!#tr+ "# t&at "t "# a
maJor CO2 em"tter ca!#"n' 'lo)al %arm"n'. H"t& e$er+ ton o( cement
rod!ced, almo#t a ton o( CO2 "# em"tted. 2)o!t 0.5 ton# come# (rom t&e
decomo#"t"on o( t&e l"me#tone and t&e )alance "# 'enerated )+ t&e o%er
lant #!l+"n' t&e electr"c"t+ to t!rn t&e 3"ln and )all m"ll# to 'r"nd t&e
cement l!# t&e (!el )!rned to ("re t&e 3"ln. 2ll ot&er 'enerat"on #!c& a#
oerat"n' read+ m"* tr!c3# add# onl+ a m"nor amo!nt to t&e CO2 em"##"on#.
In term# o( con$ent"onal concrete m"*t!re# 0".e. not !#"n' (l+
a#&, #la' or #"l"ca (!me1, a)o!t 4F0 3' o( CO2 "# em"tted er c!)"c meter o(
concrete or 20 3' o( CO2 er 900 3' o( concrete rod!ced. 2ll o( t&"#
amo!nt# to a)o!t >= o( t&e total CO2 'enerated %orld%"de.
En&anced e(("c"enc+ "# not l"3el+ to c&an'e t&"# )!t relacement o( #ome o(
t&e cement )+ a #!lementar+ cement"n' mater"al not a##oc"ated %"t& CO2
em"##"on can #!)#tant"all+ red!ce t&e#e em"##"on#.
Ni$#ou! o1i& &mi!!ion!
9E
N"tro!# o*"de em"##"on# come (rom )!rn"n' 'a#ol"ne, coal or ot&er
(o##"l (!el#. O6one "# (ormed %&en n"tro'en o*"de# and $olat"le or'an"c
como!nd# m"* "n #!nl"'&t. T&e $olat"le or'an"c como!nd# come (rom
#o!rce# ran'"n' (rom "nd!#tr"al #ol$ent# to $olat"le re#"n# "n tree#. O6one
near t&e 'ro!nd can ca!#e a n!m)er o( &ealt& ro)lem# #!c& a# a#t&ma
attac3, #ore t&roat, co!'&"n' and ot&er &ealt& d"(("c!lt"e#. In add"t"on, n"tro!#
o*"de, car)on d"o*"de and met&ane are t&e mo#t "mortant 'reen&o!#e 'a#e#.
T&e N"tro!# o*"de em"##"on# (rom Canad"an cement 3"ln# ran'e
(rom 9.5 to I.5 3'Gtonne o( cl"n3er rod!ced %"t& a roo#ed l"m"t o( 2.: 3'
o( N"tro!# o*"de er tonne. D#"n' 2.: 3' o( N"tro!# o*"de er tonne, t&e
%orld relea#e o( N"tro!# o*"de )+ t&e 9E25 m"ll"on ton# o( cement rod!ced
"n t&e +ear 2000 %o!ld )e :.> m"ll"on ton# o( N"tro!# o*"de. T&"# "# a ("(t& o(
t&e N"tro!# o*"de relea#ed "n all o( cont"nental 2#"a "n a +ear
Red!ct"on "n n"tro!# o*"de# "# normall+ ac&"e$ed )+ red!c"n'
t&e )!rn"n' temerat!re or )+ "nJect"n' ammon"a como!nd# "nto t&e &"'&
temerat!re e*&a!#t #tream 041. T&"# #eem# l"3e a 'ood "dea )!t %&en t&e#e
act"on# are ta3en to red!ce t&e N"tro!# o*"de "n coal ("red electr"c o%er
'enerat"n' #tat"on#, "t ad$er#el+ a((ect# t&e 4!al"t+ o( t&e (l+ a#& rod!ced.
T&e (l+ a#& t&en need# to )e treated to remo$e t&e !n)!rnt coal and
ammon"a 'a# )e(ore "t can )e !#ed "n concrete m"*t!re# and #e$eral lant#
do"n' t&"# are "n oerat"on. /e$eral re#earc& ro'ram# are c!rrentl+
!nder%a+ to ("nd o!t &o% )e#t to )ene("c"ate (l+ a#& to correct t&"# ro)lem.
A6&#!& 3&a%$3 &""&c$!
C!rrentl+ t&e &ealt& o( emlo+ee# "# )e"n' ad$er#el+ a((ected )+
t&e "ncrea#ed c&rom"!m content o( t&e cement. T&e "ncrea#ed c&rom"!m
content "n t&e cement "# mo#tl+ der"$ed (rom t&e )!rn"n' o( %a#te rod!ct#.
9>
T&e onl+ #ol!t"on #eem# to )e to re$ent contact o( (re#& concrete %"t&
&!man (le#& and mo#t conta"ner# o( cement carr+ #!c& a %arn"n'.
,a$&# po%%u$ion
On a$era'e eac& read+ m"* tr!c3 ret!rn# a)o!t one &al( c!)"c
meter o( cement er da+. 2(ter t&"# concrete "# d"#c&ar'ed t&ere "# #t"ll a)o!t
:00 3' o( #ol"d# 0cement, #and and #tone1 t&at "# %a#&ed o!t %"t& a)o!t 9000
l"ter# o( %ater. In t&e a#t t&e ret!rned concrete and t&e #ol"d# %ere d!med
"n a "t at t&e Jo) #"te or at t&e lant. Con#"der"n' t&at t&"# rere#ent# 2 to 4=
o( t&e total concrete rod!ced, "t "# no% con#"dered too $al!a)le to %a#te
and can )e rec+cled or recla"med a# #and and 'ra$el. To recla"m t&e #and and
'ra$el a Brecla"merC "# !#ed. It "n$ol$e# add"n' %ater to t&e ret!rned
concrete and t&en a'"tat"n' "t (ollo%ed )+ %et #creen"n' to o)ta"n t&e #and
and 'ra$el.
2l#o, t&e cement-%ater #l!rr+ (rom t&e recla"mer, t&e %a#& o!t
%ater, %ater to clean t&e o!t#"de o( t&e tr!c3, l!# an+ #torm %ater "n t&e
a#t !#!all+ %a# d"rected "nto #ome%&at "ne(("c"ent #ettl"n' )a#"n# and t&en
"nto a local %ater co!r#e.
Recent de$eloment# &a$e ena)led t&e concrete reta"ned and
an+ concrete cl"n'"n' to t&e "n#"de o( t&e tr!c3 dr!m l!# an+ %a#& o!t
%ater to )e #ta)"l"6ed o$ern"'&t or o$er t&e %ee3end )+ t&e add"t"on o( a
&+drat"on #ta)"l"6"n' adm"*t!re.
9F
CHAPTER .:-GEOPOL7MER CONCRETE
Geool+mer "# !#ed a# t&e )"nder, "n#tead o( cement a#te, to
rod!ce concrete. T&e 'eool+mer a#te )"nd# t&e loo#e coar#e a''re'ate#,
("ne a''re'ate# and ot&er !n-reacted mater"al# to'et&er to (orm t&e
'eool+mer concrete. T&e man!(act!re o( 'eool+mer concrete "# carr"ed
o!t !#"n' t&e !#!al concrete tec&nolo'+ met&od#.
2# "n t&e Portland cement concrete, t&e a''re'ate# occ!+ t&e
lar'e#t $ol!me, ".e. a)o!t >5-F0 = )+ ma##, "n 'eool+mer concrete. T&e
#"l"con and t&e al!m"n"!m "n t&e (l+ a#& are act"$ated )+ a com)"nat"on o(
#od"!m &+dro*"de and #od"!m #"l"cate #ol!t"on# to (orm t&e 'eool+mer
a#te t&at )"nd# t&e a''re'ate# and ot&er !n-reacted mater"al#.
PAST RESEARCH ON GEOPOLYMER MATERIAL:-
In 'eool+mer#, t&e ol+mer"#at"on roce## "n$ol$e# a c&em"cal
react"on !nder &"'&l+ al3al"ne cond"t"on# on 2l-/" m"neral#, +"eld"n'
ol+mer"c /"-O-2l-O )ond#, a# de#cr")ed )+ ?F@8
9I
M
n
? O 0 /" O O
2
1
6
O 2l O O @
n
. %5
2
O 021
%&ere M "# t&e al3al"ne element, t&e #+m)ol 8 "nd"cate# t&e re#ence o( a
)ond, 6 "# 9,2, or :, and n "# t&e de'ree o( ol+mer"#at"on.
T&e c&em"cal como#"t"on o( 'eool+mer# "# #"m"lar to 6eol"te#,
)!t #&o%# an amor&o!# m"cro#tr!ct!re ?90@. T&e #tr!ct!ral model o(
'eool+mer mater"al "# #t"ll !nder "n$e#t"'at"onK &ence t&e e*act mec&an"#m
)+ %&"c& 'eool+mer #ett"n' and &arden"n' occ!r "# not +et clear ?F, 99@.
T&e mec&an"#m o( 'eool+mer"#at"on ma+ con#"#t o( d"##ol!t"on,
tran#ortat"on or or"entat"on, and ol+conden#at"on ?90@, and ta3e# lace
t&ro!'& an e*ot&erm"c roce## ?E, F@.
T&e #tren't& o( 'eool+mer deend# on t&e nat!re o( #o!rce
mater"al#. Geool+mer# made (rom calc"ned #o!rce mater"al#, #!c& a#
meta3aol"n 0calc"ned 3aol"n1, (l+ a#&, #la' etc., +"eld &"'&er comre##"$e
#tren't& %&en comared to t&o#e #+nt&e#"#ed (rom non-calc"ned mater"al#,
#!c& a# 3aol"n cla+. T&e #o!rce mater"al !#ed (or 'eool+mer"#at"on can )e a
#"n'le mater"al or a com)"nat"on o( #e$eral t+e# o( mater"al# ?92@. 2
com)"nat"on o( #od"!m or ota##"!m #"l"cate and #od"!m or ota##"!m
&+dro*"de &a# )een %"del+ !#ed a# t&e al3al"ne act"$ator ?E, 90, 99, 9:@, %"t&
t&e act"$ator l"4!"d-to-#o!rce mater"al rat"o )+ ma## "n t&e ran'e o( 0.25-0.:0
?E, 9:@.
Beca!#e &eat "# a react"on accelerator, c!r"n' o( (re#& 'eool+mer
"# carr"ed o!t mo#tl+ at an ele$ated temerat!re ?E@. H&en c!r"n' at ele$ated
temerat!re#, care m!#t )e ta3en to m"n"m"6e t&e lo## o( %ater. 5o%e$er,
c!r"n' at room temerat!re &a# #!cce##(!ll+ )een carr"ed o!t )+ !#"n'
20
calc"ned #o!rce mater"al o( !re 'eolo'"cal or"'"n, #!c& a# meta3aol"n ?F,
94@.
T&e 'eool+mer mater"al can )e !#ed "n $ar"o!# al"cat"on#, #!c&
a# ("re and &eat re#"#tant (")re como#"te#, #ealant#, concrete#, ceram"c#, etc.,
deend"n' on t&e c&em"cal como#"t"on o( t&e #o!rce mater"al# and t&e
act"$ator#. 7a$"do$"t# ?F@ #!''e#ted t&at t&e atom"c rat"o o( /"-to-2l o( a)o!t
2 (or ma3"n' cement and concrete. Geool+mer can al#o )e !#ed a# %a#te
enca#!lat"on to "mmo)"l"#e to*"c metal# ?95@.
WHAT IS FLY ASH?
Al+ a#& "# t&e ("ner art o( t&e Coal Com)!#t"on Prod!ct# 0CCP1
cat!red )+ t&e electro-#tat"c rec""tator# "n coal ("red t&ermal o%er lant#
0A"'!re 91. Al+ a#& clo#el+ re#em)le# $olcan"c a#&e# !#ed "n rod!ct"on o(
t&e earl"e#t 3no%n &+dra!l"c cement# a)o!t 2,:00 +ear# a'o. /ome o( t&e#e
cement# %ere made near t&e #mall Ital"an to%n o( Po66!ol" - %&"c& later
'a$e "t# name to t&e term Qo66olan.Q 2)o!t E00 m"ll"on tone# o( (l+a#& %a#
rod!ced "n +ear 2000 accord"n' to Man6 09IFI1. T&"# o#e# a maJor
c&allen'e "n term# o( t&e"r #a(e d"#o#al re(era)l+ $"a )!l3 !t"l"#at"on "n a
commerc"all+ ro("ta)le manner. 2t re#ent onl+ a)o!t 20= o( all (l+ a#&
'et# rod!ct"$el+ !#ed %&"le t&e re#t 'et d!med "n land("ll# one %a+ or t&e
ot&er.
Al+ a#& "# d"$"ded ma"nl+ "nto t%o cate'or"e# )a#ed ma"nl+ on "t#
calc"!m content 0Ta)le 91. 2/TM Cla## A (l+ a#& "# lo% "n calc"!m and
ma"nl+ o66olan"c 0".e., t&e+ react %"t& calc"!m &+dro*"de "n mo"#t
cond"t"on to rod!ce cement"t"o!# como!nd#1, %&erea# cla## C (l+ a#& &a#
&"'&er (ract"on o( calc"!m o*"de#, %&"c& '"$e t&em cement"t"o!#
29
c&aracter"#t"c#. Cla## C (l+ a#& "# o(ten mar3eted d"rectl+ "n man+ co!ntr"e#
and ("nd# ea#+ al"cat"on "n concrete a# a art relacement o( cement.
Cla## A (l+ a#& 0mo#t Ind"an (l+ a#& (all "n t&"# cate'or+1 "#
r"mar"l+ !#ed a# a cement relacement !nder certa"n cond"t"on# o( 4!al"t+
"n term# o( c&em"cal como#"t"on, art"cle #"6e d"#tr")!t"on and lo## on
"'n"t"on 0%&"c& "# an "nd"cator o( car)on content1. Ot&er al"cat"on# (or
cla## A (l+ a#& )e#"de# 5"'& Vol!me Al+ a#& Concrete 05VAC1 #t!d"ed "n
deta"l )+ Mal&otra 09III1, are "n t&e area o( al3al" act"$ated concrete,
)lended cement#, ternar+ )lend# "ncl!d"n' (l+ a#& and #la' or #"l"ca (!me or
l"me. 2 lot o( re#earc& %a# carr"ed o!t "n t&e e*-#o$"et )loc3 co!ntr"e#,
art"c!larl+ at t&e N"e$ In#t"t!te "n D3ra"ne. Pro(e##or# Nr"$"en3o and
Glo!3&o$#3+ led t&e %a+ "n t&e re#earc& "n to al3al"-act"$ated cement# )a#ed
on (l+ a#&, #la' and ot&er "nd!#tr"al )+-rod!ct# 0Nr"$"en3o, 09II41,
Glo!3&o$#3+, 09II411.
ACTIVATION OF FLY ASH:-
M&c3ani!m o" ac$i6a$ion o" "%' a!3:
T&e mec&an"#m# o( act"$at"on o( (l+ a#& can )e d"$"ded "n t%o
ma"n #ta'e#8
Di!!o%u$ion:
In"t"all+ t&e $"treo!# comonent o( t&e (l+ a#& 0al!m"no#"l"cate
'la##1 "n contact %"t& t&e al3al" #ol!t"on "# d"##ol$ed, (orm"n' a #er"e# o(
comle* "on"c #ec"e#K
Po%'m&#i2a$ion:
22
T&e#e #mall molec!le# re#ent "n t&e d"##ol!t"on can Jo"n eac&
ot&er and (orm lar'e molec!le# t&at rec""tate "n t&e (orm o( 'el, "n %&"c&
#ome de'ree o( #&ort ran'e #tr!ct!ral order can )e "dent"("ed 0901. T&e
como#"t"on and #tr!ct!re o( t&"# al3al" al!m"no#"c"late 'el deend#
e##ent"all+ on t&e #"6e, #tr!ct!re and concentrat"on o( t&e "on"c #ec"e#
re#ent "n t&e med"!m, a# %ell a# on t&e #+nt&e#"# temerat!re on t&e c!r"n'
t"me, and t&e 5 o( t&e m"*t!re. T&e &+ot&et"cal e$ol!t"on o( t&"# 'el %o!ld
)e to (orm #ome #ort o( 6eol"te cr+#tal.
5o%e$er, d!e to t&e $er+ lo% Bal3al"ne #ol!t"on G (l+ a#&C rat"o
!#ed "n t&e #+nt&e#"# o( t&"# t+e o( mater"al# 0or prevailing under
experimental conditions1, t&"# e$ol!t"on "# e*tremel+ #lo%. T&e #t!d"e# done
! to toda+ concern"n' t&e man!(act!r"n' o( mortar# andGor concrete# o(
act"$ated (l+ a#& (ollo%"n' t&e al3al"ne roce## 0%"t&o!t Portland cement1
t!rned o!t "nto $er+ rom"#"n' re#!lt#. T&e a)o$e ment"oned #t!d"e# &a$e
demon#trated (or e*amle t&at t&e roert"e# o( t&e concrete o( al3al"
act"$ated (l+ a#& are "n(l!enced, l"3e t&o#e o( t&e con$ent"onal concrete, )+ a
#et o( (actor# related to t&e do#"n' o( t&e m"*t!re and to t&e cond"t"on# o( t&e
c!r"n' roce##. Ne$ert&ele##, t&e#e ne% concrete can mana'e to de$elo
$er+ &"'& mec&an"cal #tren't& %"t&"n a (e% &o!r#. T&e#e #tren't&# cont"n!e
to 'ro% more #lo%l+ %"t& t"me. 2l#o, t&e ment"oned #t!d"e# &a$e man"(e#ted
t&e &"'& otent"al o( t&e#e mater"al# t&at co!ld )e !#ed "n t&e near (!t!re "n
t&e con#tr!ct"on "nd!#tr+, e#ec"all+ "n t&e reca#t "nd!#tr+. T&"# "# t&e
rea#on %&+ t&e 'oal o( t&"# %or3 "# (oc!#ed on t&e e#ta)l"#&ment o( #ome
en'"neer"n' roert"e# (or t&"# t+e o( mater"al# 0mec&an"cal #tren't&
de$eloment, matr"*-#teel ad&erence and #&r"n3a'e1. A"nall+, t&ere "# a
#ec"("c ca#e o( an "nd!#tr"al al"cat"on o( t&e#e ne% concrete (or t&e
man!(act!r"n' o( re-#tre##ed mono-)loc3 #leeer #on ra"lroad#.
2:
GEOPOLYMER CONCRETE:
Geool+mer "# an "nor'an"c al!m"no-#"l"cate ol+mer
#+nt&e#"6ed (rom redom"nantl+ #"l"con and al!m"n"!m mater"al# o(
'eolo'"cal or"'"n or )+-rod!ct mater"al# #!c& a# (l+ a#&. T&e term
'eool+mer %a# "ntrod!ced )+ 7a$"do$"t# rere#ent t&e m"neral ol+mer#
re#!lt"n' (rom 'eoc&em"#tr+. T&e ol+mer"#at"on roce## "n$ol$e# a
c&em"cal react"on !nder &"'&l+ al3al"ne cond"t"on# on 2l-/" m"neral#,
+"eld"n' ol+mer"c /"-O-2l-O )ond# T&e ol+mer"#at"on roce## ma+ )e
a##"#ted )+ al"ed &eat, (ollo%ed )+ dr+"n'. T&e c&em"cal react"on er"od "#
(a#t and t&e re4!"red c!r"n' er"od ma+ )e %"t&"n 24 to 4F &o!r#.
Geool+mer "# !#ed a# t&e )"nder, "n#tead o( cement a#te, to
rod!ce concrete. T&e 'eool+mer a#te )"nd# t&e loo#e coar#e a''re'ate#,
("ne a''re'ate# and ot&er !n-reacted mater"al# to'et&er to (orm t&e
'eool+mer concrete. T&e man!(act!re o( 'eool+mer concrete "# carr"ed
o!t !#"n' t&e !#!al concrete tec&nolo'+ met&od#.
2# "n t&e Portland cement concrete, t&e a''re'ate# occ!+ t&e
lar'e#t $ol!me, ".e. a)o!t >5-F0 = )+ ma##, "n 'eool+mer concrete. T&e
#"l"con and t&e al!m"n"!m "n t&e (l+ a#& are act"$ated )+ a com)"nat"on o(
#od"!m &+dro*"de and #od"!m #"l"cate #ol!t"on# to (orm t&e 'eool+mer
a#te t&at )"nd# t&e a''re'ate# and ot&er !n-reacted mater"al#.
Geool+mer-)a#ed mater"al# are en$"ronmentall+ (r"endl+, and
need onl+ moderate ener'+ to rod!ce. T&e+ can )e made !#"n' "nd!#tr"al
)+-rod!ct#, #!c& a# (l+ a#&, a# t&e #o!rce mater"al. In 'eool+mer concrete,
t&e 'eool+mer a#te #er$e# to )"nd t&e coar#e and ("ne a''re'ate#, and an+
!n-reacted mater"al. Geool+mer concrete can )e !t"l"#ed to man!(act!re
reca#t concrete #tr!ct!ral and
24
non-#tr!ct!ral element#, to ma3e concrete a$ement#, to "mmo)"l"6e to*"c
%a#te#, and to rod!ce concrete rod!ct# t&at are re#"#tant to &eat and
a''re##"$e en$"ronment#.
7a$"do$"t# roo#ed t&at t&e ran'e# o( t&e o*"de molar rat"o#
#!"ta)le to rod!ce 'eool+mer"c mater"al# ma+ )e a# (ollo%#8
91 0.2RNa2OG/"O2R0.2F,
21 :.5R/"O2 G2l2O:R4.5, and
:1 95R52OGNa2OR9>.5,
%&ere Na2O, /"O2, 2l2O: are re#ect"$el+ t&e #od"!m, #"l"con and
al!m"n"!m o*"de#, and 52O "# t&e %ater.
Ba#ed on te#t# er(ormed on 'eool+mer a#te# !#"n' calc"ned
3aol"n a# t&e #o!rce mater"al, Bar)o#a et al (o!nd t&at t&e ot"m!m
como#"t"on occ!rred %&en t&e rat"o o( Na2OG/"O2 %a# 0.25 and t&e rat"o o(
52OGNa2O %a# 90.0. T&"# aer re#ent# t&e re#!lt# o( e*er"mental %or3
on t&e e((ect o( t&e molar rat"o o( 52OGNa2O and Na2OG/"O2 o( t&e m"*t!re
como#"t"on on t&e comre##"$e #tren't& o( (l+ a#&-)a#ed 'eool+mer
concrete.
IMPORTANT PROPERTIES:-
S&$$in( $im&:
T&e #ett"n' t"me o( 'eool+mer a#te %a# a((ected )+ t&e c!r"n'
temerat!re, t+e o( al3al"ne act"$ator, and t&e como#"t"on o( t&e #o!rce
mater"al. T&e #ett"n' t"me o( 'eool+mer a#te %a# )et%een 95 to 45
m"n!te# at E0o C. The presence of compounds other than Al2O3
and SiO2 in the source material may also delay the setting.
25
In materials of pure geological origin (say calcined kaolin),
the dominant chemical contents are only Al2O3 and SiO2 ,
hereas !y"product materials such as #y ash may contain
other compounds, e.g. $e2O3. It appears that pure geological
materials may !e more reacti%e to the alkaline acti%ators,
and hence a reduction in initial setting time.
Comp#&!!i6& !$#&n($3
T&ere are man+ d"((erent $"e%# re'ard"n' t&e ma"n arameter# a((ect"n' t&e
comre##"$e #tren't& and ot&er mec&an"cal roert"e# o( &ardened
'eool+mer mater"al#. Ae% #c"ent"#t #tate# t&at t&e #"'n"("cant (actor#
a((ect"n' t&e comre##"$e #tren't& are t&e c!r"n' temerat!re, c!r"n' t"me,
and t&e t+e o( al3al"ne act"$ator. Ot&er re#earc&er# &a$e reorted t&at t&e
"mortant arameter# (or #at"#(actor+ ol+mer"#at"on are %ater content, t&e
relat"$e amo!nt# o( /", 2l and Na, t&e t+e o( al3al"ne act"$ator, t&e e*tent o(
d"##ol!t"on o( /" and t&e molar /"-to-2l rat"o "n #ol!t"on, t&e rat"o o( (l+ a#&
to- 3aol"n"te, and c!r"n' temerat!re 2, >, 95. Lon'er c!r"n' t"me and &"'&er
c!r"n' temerat!re "ncrea#ed t&e comre##"$e
2E
CHAPTER 9: ANAL7SIS O) RESULTS
GRADE OF CONCRETE :- M
20
MIX PROPORTION :- 1 : 1. : ! "N#$%&'()
W*C RATIO :- 0.
MATERIAL USED IN CONVENTIONAL CONCRETE
CEMENT :-
21 TYPE 8- O.P.C. 05: 'rade1
B1 M2NE 8- L L T
)INE AGGREGATE :-
21 TYPE L GR27ING 8- N2TDR2L /2N7 CONAIRMING TO
GR27ING SONE III OA I./. :F:-9I>0
2>
B1 /PECIAIC GR2VITY 8- 2.E5I
C1 H2TER 2B/ORPTION 8- 9.E:=
71 H2TER CONTENT 8- NIL
E1 M2TERI2L/ AINER T52N >5T 8- 9.25=
COARSE AGGREGATE :-
PROPERTIES CA-I CA-II
M2UIMDM /ISE 20mm 92.5mm
/PECIAIC
GR2VITY
2.E:2 2.E2I
GR27ING CONAIRMING TO
I./. :F:-9I>0
CONAIRMING TO
I./. :F:-9I>0
TYPE CRD/5E7
2NGDL2R
CRD/5E7
2NGDL2R
H2TER
2B/ORPTION
0.E:= 0.F04=
H2TER CONTENT NIL NIL
2F
RESULTS FOR COMPRESSIVE STRENGTH:-
I. CONVENTIONAL CONCRETE :-
21 TYPE OA MIU 8- NOMIN2L
B1 GR27E OA CONCRETE 8- M
20
C1 MIU PROPORTION 8- 9 8 9.5 8 :
71 HGC 8- 0.5
E1 /ISE OA CDBE 8- 950mm * 950mm * 950mm
A1 72TE OA C2/TING 8- 0E-09-2005
G1 NO. OA CDBE/ TE/TE7 8- : 0 (or eac& c!r"n' er"od1
TA5LE NO. 1
2I
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 C.C.I : 2E2I.I2 95.>9 CONVENTION2L
2 C.C.I > 2E:4.0> 9I.:I CONCRETE
: C.C.I 2F 2E:2.5I 2E.FI
II. PARTIAL REPLACEMENT OF CEMENT BY FLY
ASH:-
TA5LE NO. 2
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 A.C.C.I : 25E2.IE 92.99 20=
2 A.C.C.I > 2E5:.:: 95.>4 relacement
: A.C.C.I 2F 25:>.>F 2:.E> o( cement
:0
TA5LE NO. *
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 A.C.C.II : 2529.4F 0I.FI 40=
2 A.C.C.II > 25:9.F5 92.IE relacement
: A.C.C.II 2F 250F.95 22.4F o( cement
TA5LE NO. -
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 A.C.C.III : 24II.25 F.:5 E0=
2 A.C.C.III > 25FF.94 99.0E relacement
: A.C.C.III 2F 25I4.IE 9:.042 o( cement
:9
TA5LE NO. .
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 A.C.C.IV : 25I9.99 >.00 F0=
2 A.C.C.IV > 294:.>0 I.F5 relacement
: A.C.C.IV 2F 2E2I.E2 90.22 o( cement
NOTE8- Aor I0= relacement o( cement, t&ere "# a ro)lem (or #ett"n' o(
concrete.
III. FULL REPLACEMENT OF CEMENT BY FLY ASH
ALONGWITH ALKALINE ACTIVATORS " SODIUM
SILICATE + SODIUM HYDROXIDE ):-
1+ )o# 1:M NaOH So%u$ion:
a1 V!ant"t+ o( Al+ a#& !#ed P 4.003'
)1 Na
2
/"O
:
G NaO5 rat"o P 2.5
c1 V!ant"t+ o( Na
2
/"O
:
L NaO5 Re4!"red
Samp%& ca%cu%a$ion:
Na
2
/"O
:
G NaO5 rat"o P 2.5
Let 4!ant"t+ o( NaO5 )e P *
V!ant"t+ o( Na
2
/"O
:
re4!"red P 2.5*
Aor 0Na
2
/"O
:
; NaO51 G Al+ a#& P 0.:
02.5* ; *1 G 4000 P 0.:
:2
* P :4: ml
V!ant"t+ o( NaO5 re4!"red P :4: ml
V!ant"t+ o( Na
2
/"O
:
re4!"red P F5F ml
9M P 40'm NaO5 "n 900ml %ater
Aor 90M #ol!t"on 4!ant"t+ o( NaO5 re4!"red P 400'm.
NOTE:- Aor rearat"on o( NaO5 #ol!t"on, t&e NaO5 "n (la3e (orm %a#
added to %ater at >0
0
C to F0
0
C. 7!e to t&"# t&e #ett"n' t"me o( Geool+mer
concrete red!ced to nearl+ 90m"n. T&!#, %e co!ld not mea#!re t&e
%or3a)"l"t+ o( t&"# concrete.
Aor ot&er como#"t"on# t&e 4!ant"t"e# Na
2
/"O
:
L NaO5 re4!"red are a#
)elo%8-
0Na
2
/"O
:
;
NaO51GAl+a#&
V!ant"t+ o( Na
2
/"O
:
Re4!"red "n 0ml1
V!ant"t+ o( NaO5
Re4!"red "n 0ml1
0.: F5F :4:
0.:5 9000 400
0.40 994: 45>
TA5LE NO. 9
::
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 G.P.C.I : 2494.F9 :.99 H"t&
00.:1 L
2 G.P.C.I > 2400.00 4.44 90M
NaO5
: G.P.C.I 2F 2:22.IE F.00 /ol!t"on
TA5LE NO. ;
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 G.P.C.II : 24F2.IE :.:: H"t&
00.:51 L
2 G.P.C.II > 25:I.25 4.E> 90M
NaO5
: G.P.C.II 2F 254F.94 90.00 /ol!t"on
TA5LE NO. <
:4
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 G.P.C.III : 24F2.IE >.:: H"t&
00.401 L
2 G.P.C.III > 24F2.IE I.99 90M
NaO5
: G.P.C.III 2F 24F2.IE 22.II /ol!t"on
NOTE8- Aor 00.:1 rat"o, t&e mater"al "# not m"*ed roerl+.
2+ )o# 1*M NaOH So%u$ion =i$3 > =i$3ou$ S$&am
Cu#in(:
a1 V!ant"t+ o( Al+ a#& !#ed P E.203'
)1 Na
2
/"O
:
G NaO5 rat"o P 2.5
T&e 4!ant"t"e# o( Na
2
/"O
:
L NaO5 re4!"red are calc!lated "n
#"m"lar manner a# done re$"o!#l+. T&e 4!ant"t"e# calc!lated are a# (ollo%#8-
0Na
2
/"O
:
;
NaO51GAl+a#&
V!ant"t+ o( Na
2
/"O
:
Re4!"red "n 0ml1
V!ant"t+ o( NaO5
Re4!"red "n 0ml1
0.:5 955> :4:
0.40 9>F5 >95
:5
TA5LE NO. ?
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 G.P.C.IV 2F 2594.0> 29.:: 00.:51 L
9:M
2 G.P.C.IV : da+#
%"t& 2.5
&r#.
#team
c!r"n'
W990
0
C
2425.9F 22.44 00.:51 L
9:M %"t&
#team
c!r"n'
TA5LE NO. 1:
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma##
7en#"t+
N'Gm
:
Comre##"$e
/tren't&
NGmm
2
Remar3
9 G.P.C.V 2F 2595.55 9F.22 00.401 L
9:M
2 G.P.C.V : da+#
%"t& 2.5
&r#.
#team
c!r"n'
W990
0
C
2522.IE 42.22 00.401 L
9:M %"t&
#team
c!r"n'
:E
RESULTS FOR FLEXURAL STRENGTH:-
FOR 1!M CONCENTRATION:-
/2MPLE C2LCDL2TION8-
91 AOR 0Na
2
/"O
:
; NaO51GAl+a#& P 0.:5,
AIG.
M G I P X
)
G Y
X
)
P M Y Y G I
%&ere,
M P HL G E
Y P ) G 2
I P )
:
G 92
X
)
P 4HG)
2
Arom ta)le )elo%, H P 9:00YI.F9 P 92>5: N
) P d P 900 mm
:>
X
)
P 4Y92>5:G900
2
X
)
P 5.909 NGmm
2
/r.
No.
Ident"("cat"on
Mar3
2'e "n
7a+#
Ma*"m!m
Load
N
Mod!l!# o(
R!t!re 0X
)
1
NGmm
2
Remar3
9 B.I 2F I5E4.>5 :.F25 90M 0.401
2 B.II 2F 92>5: 5.909 9:M 00.:51
: B.III 2F IF90 :.I24 9:M 00.401
DISCUSSIONS
In 'eneral term#, t&e act"$at"on roce## o( (l+ a#&e# allo%# 'ett"n' a mater"al
%"t& #"m"lar cement"n' (eat!re# a# t&e Ord"nar+ Portland Cement. Be#"de#,
t&"# roce## "# t&e or"'"n o( "mortant econom"cal and en$"ronmental
)ene("t# %&en comared %"t& t&e trad"t"onal (a)r"cat"on o( OPC.
Y T&e re#!lt #&o%# t&at t&e mater"al o)ta"ned )+ act"$at"on o( (l+ a#&e#
t&o!'& t&e al3al"ne roce## de$elo# e*cellent mec&an"cal #tren't& "n a
relat"$el+ #&ort er"od o( t"me
Y T&e temerat!re o( c!r"n' la+# a $er+ "mortant role, J!#t l"3e %"t&
t&e Portland cement concrete.
Y It d"((er# (rom t&e ne% cement"n' mater"al "n t&at "t doe# not #!((er
(rom t&e e((ect o( temerat!re or ot&er alterat"on# t&at remar3a)l+ a((ect "t#
d!ra)"l"t+.
Y It &a# e*cellent d"men#"onal #ta)"l"t+ o( t&"# ne% con'lomerate.
Y T&e #&r"n3a'e "# one o( t&e mo#t !n%anted roert"e# o( t&e concrete.
T&e 'eool+mer concrete #&o%# $er+ le## #&r"n3a'e a# "t conta"n le## %ater.
:F
Y 7e$elo"n' co!ntr+ l"3e Ind"a #econd ran3 "# '"$en to con#tr!ct"on
de$eloment, %&"c& !#e# concrete "n lar'e amo!nt L at t&e #ame t"me
rod!ce# %a#te "n t&e (orm o( concrete mater"al.
/o !#e o( rod!ct l"3e Geool+mer concrete, 'reen concrete etc "n
(!t!re %"ll not onl+ red!ce t&e em"##"on o( CO
2
"n en$"ronment )!t al#o
econom"cal to rod!ce.
:I
40
49
CHAPTER ;:-AD4ANTAGES O) GEOPOL7MER
CONCRETE
91 Z[Red!ct"on o( t&e concrete "nd!#tr+\# CO2-emm"#"on.
21Z [ Increa#ed concrete "nd!#tr+\# !#e o( %a#te rod!ct#.
:1[ Red!ct"on o( t&e concrete "nd!#tr+\# !#e o( non-rene%al (!el#.
41 Z[No en$"ronmental oll!t"on and #!#ta"na)le de$eloment.
51Z[ No "ncrea#ed no"#e L d!#t em"##"on.
E1 Pol+mer GGreen concrete re4!"re# le## ma"ntenance and rea"r#.
>1 Good Corro#"on re#"#tant.
F1 Ener'+ #a$"n' mater"al.
I1 Pol+mer concrete &a$"n' )etter %or3a)"l"t+ t&an con$ent"onal concrete.
901 Comre##"$e #tren't& )e&a$"o!r o( concrete "# m!c& more t&an
con$ent"onal concrete.
991 Ale*!ral #tren't& o( Pol+mer concrete "# al#o more t&an t&at o(
con$ent"onal concrete.
921 D#e o( concrete "nd!#tr"e# o%n re#"d!al rod!ct#.
9:1 Le## e*en#"$e to rod!ce "t.
941 Good t&ermal re#"#tant and ("re re#"#tant.
951 Good #o!nd "n#!lat"on t&an trad"t"onal concrete.
9E1 Imro$e dam"n' re#"#tant o( )!"ld"n'#.
42
4:

Geopolymer Concrete

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