Team ID: 7868

SAL Institute of Technology & Engineering Research

GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD

2018-2019

Experimental investigation of durability property on Geopolymer

Concrete using Sustainable material

ParthBarvaliya 150670106005
BhavinBhudiya 150670106010
VirendrasinhJadeja 150670106029
NikunjKhetani 150670106038
Kaushal Patel 150670106073
Parth Patel 150670106547

GUIDED BY

Asst. Prof. Jay M. Patel

In fulfilment for the award of the degree

Of

BACHELORS ENGINEERING
IN
CIVIL ENGINEERING
 CERTIFICATE

Date:

This is to certify that dissertation entitled “(Experimental investigation of

durability property on Geopolymer Concrete using Sustainable material)”has
been carried out by Parth Barvaliya, Bhavin Bhudiya, Virendrasinh Jadeja, Nikunj
Khetani, Kaushal Patel, Parth Patel my guidance in fulfilment of the degree of
Bachelor of Engineering in Civil Engineering 7th semester of Gujarat
Technological University, Ahmedabad in Academic year 2018-2019.

Guided by Head of Department

Asst. Prof. – Jay M. Patel Prof. V.G.PATEL
 ACKNOWLEDGEMENTS
I take this opportunity to express my deep and sincere gratitude to our guide Asst. Prof. Jay
Patel for his supervision, advice, and guidance from the very early stage of this research as well
as giving me extraordinary experiences throughout the work. Apart from the subject of our
research, I learnt a lot from him, which I am sure, will be useful in different stages of my life.

I thank with profound honour and regard to Prof. V.G. Patel for his suggestions and strong
support. I would also like to thank Dr.Rupesh Vasani, Director of SALITER and SAL
management, for providing me such a wonderful working atmosphere.

I would like to express our gratitude towards my parents for their kind cooperation and
encouragement which helped me in completion of this project. My thanks and appreciations also
go to my colleague in developing the project and people who have willingly helped me out with
their abilities.

ParthBarvaliya 150670106005
BhavinBhudiya 150670106010
Virendrasinhjadeja 150670106029
NikunjKhetani 150670106038
Kaushal Patel 150670106073
Parth Patel 150670106547
 Table of Content
SR. DESCRIPTION PAGE
NO. NO.
1 INTRODUCTION 1
1.1 General 1
1.2 Types of Geo-polymer Concrete 4
1.2.1 Slag Based Geo-Polymer Concrete 4
1.2.2 Rock Based Geo-Polymer Concrete 5
1.2.3 Fly-ash Based Geo-Polymer Concrete 5
1.3 Application of Geo-Polymer Concrete 5
1.4 Advantages of Geo-Polymer Concrete 5
1.5 Disadvantages of Geo-Polymer Concrete 6
1.6 Source Material 6
1.6.1 Fly-Ash(FA) 8
1.6.2 Ground Granulated Blast Furnace Slag (GGBFS) 9
1.6.3 Silica Fume (SF) 9
1.6.4 Metakaolin 10
1.6.5 Recycled Aggregates 11
1.6.6 Advantages of Source Material 12
1.6.7 Disadvantages of Source Material 13
1.7 Alkaline activator 13
1.7.1 Sodium Hydroxide (NaOH) 14
1.7.2 Sodium silicate (Na2SiO3) 15
1.7.3 Liquid/Binder Ratio 16
1.7.4 Sodium Silicate/Sodium Hydroxide Activator Ratio 17
1.8 Research Objectives 17
1.9 Scope of Work 17
2 Literature review 18
2.1 Literature Review on Geo-Polymer Concrete 18
2.1.1 Enhancement of The Properties of Fly Ash Based Geo-Polymer 18
Paste by Incorporating GGBS
 2.1.2 Strength and Durability Properties of Concrete Made With 19
Granite Industry Waste
2.1.3 Experimental Study on Geo-polymer Concrete With Partial 19
Replacement of Fine Aggregate With Foundry Sand
2.1.4 Study of the Strength Geopolymer Concrete with Alkaline 20
Solution of Varying Molarity
2.1.5 Effects of Foundry Sand As a Fine Aggregate in Concrete 20
2.1.6 Impact Test on Geopolymer Concrete Slab 21
2.2 Conclusion 22
3 Material And Experimental Setup 23
3.1 General 23
3.2 Fly-Ash(FA) 23
3.3 Aggregate (According to IS 383:1970) 24
3.4 Recycled Aggregate 25
3.5 Preliminary properties 26
3.5.1 Fine Aggregate test result 26
3.5.2 Coarse Aggregate test result 28
3.6 Final Mix Proportion 31
3.7 Preparation of Testing Elements 32
3.8 Mixing of concrete 32
3.9 Casting of specimens 32
3.10 Slump test 33
3.11 Compaction Factor Test 34
3.12 Durability Test 35
3.12.1 Resistance against Sulphuric Acid Attack 35
3.12.2 Resistance against Chloride Acid Attack 36
3.12.3 Sorptivity Test 36
3.12.4 Water Absorption Test 37
References 40

Plagiarism Report 41
 LIST OF FIGURES

FIG. TITLE PAGE

NO.
NO.
1.1 Geo-polymer 2
1.2 Geo-polymer Concrete Constituents 2
1.3 Source Material 7
1.4 NaOH Pallets 15
1.5 NaOH Solution 15
1.6 Na2SiO3 Solution 16
3.1 Fly-Ash used in study 24
3.2 Fine and Course (10mm & 20mm) Aggregate used in study 25
3.3 Raw Material of Recycled Aggregate 26
3.4 Types of Concrete Slump 34
3.5 Sorptivity Test Apparatus 35
3.6 Compaction Factor Test Apparatus 37
3.7 Water Absorption Test Apparatus 38
 LIST OF TABLES

TABLE TITLE PAGE

NO. NO.
3.1 Sieve analysis of fine aggregates 27
3.2 Fine aggregate specific gravity test results 27
3.3 20 mm Coarse Aggregate (Kapachi) Sieve Analysis Test Results 28
3.4 20 mm Coarse Aggregate (Kapachi) Specific Gravity Test Results 28
3.5 10 mm Coarse Aggregate (Grit) Sieve Analysis Test Results 29
3.6 10 mm course aggregate (Grit) specific gravity test results 29
3.7 10 mm course aggregate (RCA) sieve analysis test results 30
3.8 10 mm course aggregate (RCA) specific gravity test results 31
3.9 Final mix proportions 31
 CHAPTER 1
INTRODUCTION

1.1 General

India is one of the fastest economically developing countries in the world. Because of
increase in infra-structural activity, it may lead to consume more concrete. It is reported
that the requisites of cement in India is likely to touch ~550 million tons by 2020 with a
shortfall of ~230 million tons (~58%) and the demand for cement has been constantly
increasing as increased infra-structural activities of the country. Extensive amount of
Ordinary Portland Cement (OPC) is used as primary binder material to meet the demand of
the production of concrete. However, vast amount of natural resources are required for
production of OPC, which is also energy extensive process and releases large amount of
green-house gas in the environment. The production of 1 ton of OPC has been found to
emit 1 ton of gaseous CO2 and the cement industry is believed to cause approximately 6%
of global emission of CO2. As a result, care must be taken out for environmental
improvement and protection of natural resources to promote sustainability in the
construction industries. Therefore, usage of increased cementitious materials in concrete
has a great momentum to ensure nature.

One a well-known example is inorganic cementitious binders known as “Geo-polymeric

cements”. Geo-polymers are inorganic polymeric materials formed by activating Alumina-
Silica rich minerals with alkali or alkali-silicate solution at higher or ambient temperature
level. As such, Geo-polymers are produced at ambient temperature and release about 80%
less CO2 into atmosphere than does Portland cement. Geo-polymers can also exhibit a wide
range of properties and characteristics, including high compressive strength, low shrinkage,
fast setting acid and fire resistance, high chemical, excellent adhesive behaviour and low
thermal conductivity, depending on raw material selection and processing condition. Main
constituents of geo-polymer concrete are by-product materials from different industries

1
such as source material (e.g. RHA, FLY ASH, GGBFS etc.) which is rich in aluminium
(Al) and silica (Si) and alkaline solution (e.g. NaOH, , Na2SiO3, K2SiO3).

Fig 1.1: Geo-Polymer Concrete

Fig 1.2: Geo-polymer Concrete Constituents

2
 th
In the 17 century, Prof. Davidovits proposed “Geo-polymer” as materials described by
chains or system of inorganic atoms consisting of –Si–O–Al–O– bonds and low Ca(OH)2
content. Ordinary Portland cement paste generally acquires strength by the development of
C–S–H gel whereas Geo-polymer helps to acquire strength by the poly-condensation of
Alumina & Silica precursors.

Geo-polymer is a type of amorphous Alumina-Silicate cementitious material and can be

synthesized by poly-condensation reaction of Geo-polymeric precursor and alkali poly-
silicates known as Geo-polymerization process. Geo-polymerization is an innovative and
new technology that can transform several Alumina-Silicate materials into utilizable
products called Geo-polymers or inorganic polymers. Geo-polymerization is a very
complex multiphase exothermic process, involving a series of dissolution-reorientation-
solidification reaction similar to zeolite structure. High alkaline solutions are used to induce
the aluminium and silicon atoms in the source material to dissolve, forming 3-D polymeric
structures consisting –Si–O–Al–O– bonds, represented as follows :-

Mn [–(SiO2)Z – AlO2]n . wH2O

Where,
+ + +
M = the alkaline element or cation such as Na , K , Ca ;
The symbol – indicates the presence of a bond;
n is the degree of poly-condensation or polymerization;
z is 1, 2, 3,4 or higher.
The exact reaction mechanism that shows the setting and hardening of Geo-polymer is yet
not understood, although it is thought to be dependent on the Alumina-Silicate base
material as well as on the composition of alkali activator. Optimization of such a
complicated system requires systematic study of a number of synthesizing parameters as
well as of their interactions.

The Geo-polymerization process has been characterized by following stages:

1. Under high alkaline condition,

2. Dissolving of oxide from the alumina-silica rich source materials,

3
 3. Transportation/orientation of dissolved oxide minerals followed by coagulation/
gelation,
4. Poly-condensation for develop 3-d stable network of silica-aluminates structure.

Based on the types of chemical bonding various types of structure can be formed through a
process of Geo-polymerization Silico-oxide (Si–O–Si), Sialate (–Si–O–Al–O–), Sialate-
siloxo (–Si–O–Al–O–Si–O), Sialate-disiloxo (–Si–O–Al–O–Si–O–Si–O), Ferro-silico-
aluminate (–Fe–O–Si–O–Al–O–) and Alumino-phosphate (–Al–O–P–O–).

The schematic formation of Geo-polymer material is described as below [8].

1.2 Types of Geo-Polymer Concrete:-

Based on source material different types of Geo-polymer concrete are:-

1.2.1 Slag Based Geo-Polymer Concrete:-

When slag material is used as source material in production of Geo-Polymer concrete, it is

known as slag based Geo-polymer concrete. Slag is the glass-like by-product left over after
a desired metal has been separated from its raw ore. Slag is typically a mixture of silicon
dioxide and metal oxides. Ground granulated slag in combination with Portland cement is
frequently utilized as a part of concrete. Ground granulated blast furnace slag reacts with
water to produce cementitious properties. Concrete containing ground granulated blast
furnace slag develops strength over a longer period, leading to better durability and reduced
permeability. Since the unit volume of Portland cement is decreased, this concrete is less
liable to sulphate attack and alkali silicate reaction. However, OPC replace with slag
improves workability and reduce life-cycle costs. It also increases compressive strength of
concrete.Ex. Corex Slag, Steel Slag, Iron Blast Furnace Slag.

4
1.2.2 Rock Based Geo-Polymer Concrete:-
When natural rock forming minerals are used as source material then it is known as Rock
based Geo-polymer concrete. The replacement of a certain amount of MK-750 with
selected volcanic ash makes Geo-polymer cement with better properties and less CO2
emission than the simple slag-based Geo-polymer cement.Ex. Feldspar, Quartz.

1.2.3 Fly-ash Based Geo-Polymer Concrete:-

When Fly-ash is used as source material then it is known as Fly-ash based Geo-polymer
concrete. It is the most commonly known artificial Pozzolans and is produced through the
combustion of pulverized coal at lower temperature in electric power plants. Fly-ashes are
classified into two classes which satisfy with ASTM C 618 for mineral admixtures in PPC
as:

1. ClassB :- Produced from burning sub-bituminous coal & gain faster strength,
2. Class F :- Produced from burning bituminous coal & has higher ultimate strength

Mostly Class- F Fly-ash is used. Uses of Fly-ash as source material reduced cost of OPC
along with CO2 emission reduce drying and improve workability as well as compressive
strength.

1.3 Application of Geo-Polymer Concrete:-

 As a light pavement or in pavement block
 As clay brick
 In retaining wall
 Pre-cast concrete products like railway sleepers, electric power poles etc.
 Boat ramp
 Water tank
 In road construction
1.4 Advantages of Geo-Polymer Concrete:-
 Cutting the world’s carbon
 The price of source material is low as compared to cement
 Better compressive strength

5
  High tensile strength
 Fire proof
 Low creep
 Low drying shrinkage
 Chemically resistant
 Highly durable
 Low permeability
 Eco- friendly
 Excellent properties within both acid and salt environment

1.5 Disadvantages of Geo-Polymer Concrete:-

 Difficult to create
 Requires special handling
 Chemicals like sodium hydroxide are harmful to humans
 High cost of alkaline solution
 Geo-polymerization process is sensitive
 Lacks uniformity

1.6 Source Material:-

These materials are inorganic and are by-product of different industries. These are
pozzolanic material. According to ACI 116R defines “Pozzolans” is defined as “siliceous
or siliceous and aluminous material, which in itself possesses little or no cementing
property, but will in a finely divided form and chemically reacts with calcium hydroxide at
ordinary temperature to form compounds possessing cementitious properties”. While in
Geo-polymer concrete pozzolanic material reacts with alkaline activator at ordinary
temperature to form compounds possessing cementitious properties.Pozzolans are silicate-
based materials that react with alkaline liquid to form additional cementitious material and
chains or network of inorganic molecules consisting of –Si–O– Al–O– bonds are
developed. Strength in such concrete is gain through the poly-condensation of silica and
alumina precursors.

6
 Generally, 45μm (microns) are specified as the maximum particle size.
Typical source materials are:-
1. Fly-Ash
2. Metakaolin
3. Silica Fume
4. Recycled Aggregates
5. Granulate Blast Furnace Slag

Many Pozzolans are waste products from industrial processes. Depending upon the particle
size, chemical composition, and dosage, different Pozzolans will affect the concrete
strength differently and at different times during curing.

Fig 1.3: Source Material Left to Right: (1) Class B Fly-Ash (2) Metakaolin (3) Silica Fume,
(4) Class F Fly-Ash (5) GGBS (6) Recycled Aggregates

7
1.6.1 Fly-Ash (FA):-
Fly-ash is the most commonly known artificial Pozzolans and is produced through the
combustion of pulverized coal at lower temperature in electric power plant. Fly-ash carries
amorphous glass like spherical particles, which are the active pozzolanic portion of it. On
an average, Fly-ash is 70-72% glass. Class-F fly-ash is highly pozzolanic and readily reacts
with excess lime & alkalis to form cementitious compounds.

Concrete made with Class-C fly-ash has higher early strength because it contains more lime
content than Class-F fly-ash. In addition to that, it may also exhibit self-cementing
properties. Due to this pozzolanic activity begins at very earlier stage. Class-C behaves
similarly like Class-F by gaining higher strengths than conventional concrete at later stage.

Fly-ashes are classified into two classes that satisfy with ASTM C 618 for mineral
admixtures in PCC as:

1. Class-B :- Produced from burning sub-bituminous coal & gain faster strength,
2. Class-F :- Produced from burning bituminous coal & has higher ultimate strength

Generally, fly-ash can be utilized as a partial replacement of Portland cement, up to 30%

(by mass) of cementitious material. Fly-ash must replace at least 20% of the Portland
cement to lower down the effects of alkali silica reaction (ASR). Fly-ash should not be
used in sulphate exposure or hydraulic applications if it possesses has high calcium content.

Loss on ignition (LOI) refers to the carbon content in the ash. If more carbon content is
present, more the weight will lose upon combusting the ash. If possible, there should not be
loss of weight at all. By utilizing only 4% of coal in the without aggregate cement mix will
prevent the concrete hardening. However, 2% does not seem to be a problem at all, thus the
gap is pretty narrow.

Uses:-
• Grout & flow-able fill production
• In concrete production as a substitute material for Portland cement and sand
• Embankments & other structural fills
• Cement clinker production

8
1.6.2 Ground Granulated Blast Furnace Slag (GGBFS):-
It is an industrial by-product material of steel and iron production, and is resulted from a
blast furnace in water or steam by quenching molten iron slag. After quenching, to produce
glassy material, granular product is to be dried and ground into a fine powder. It has an
advantageous property for the concrete industry, as the cost of its production is relatively
very low, its ability to resist against chemical attack and possess high as well as excellent
thermal properties. From structural point of view, GGBFS replacement enhances lower
heat of hydration, higher durability, and higher resistance to sulphate and chloride attack
when compared with normal ordinary concrete. On the other hand, it also contributes to
environmental protection because it minimizes the use of cement during the production of
concrete. SiO2, Al2O3, CaO, and MgO are major components of the slag product. Typical
slag products are ground granulated and mixed with 4-6% (by mass) water glass or sodium
hydroxide. This product is also called as alkali-activated slag (AAS). Alkali-activation
yields a highly amorphous calcium-silicate-hydrate (C-S-H) gel product possessing high
aluminium content.

The specific gravity of slag ranges from 2.85-2.95, compared with 3.15 for Portland
cement; thus, a given replacement of cement by slag on a weight basis results in a higher
volume of paste in a concrete mixture. The compressive strength development of slag
concrete depends primarily on the fineness, activity index, type, and proportions of slag
used in concrete mixture.

1.6.3 Silica Fume (SF):-

It is a waste by-product resulting from Ferro-silicon or other silicon alloys production
industry and is a super fine powder of almost pure amorphous silica. Silica fume is dark
gray or light in colour. It consists of spherical particles with an average particle diameter of
150nm and contains more than 90% of amorphous silicon dioxide (SiO2). Despite the fact
that due to difficult in handling, transporting and mixing, it becomes mainly preferable for
very high-strength concretes such as for high rise building etc., often in combination with
both fly-ash & cement. When silica fume powder is collected without any treatment from
waste gases is generally called un-densified silica fume.

9
Properties:-
 It is an ultrafine material with spherical particle less than 1μm in diameter, the
average being about 0.15μm.
 This makes it approximately 100 times smaller than the average cement particle.
3
 Bulk density is depends on degree of densification in silo from 130-600 kg/m .

 Specific gravity is from 2.2 to 2.3

2
 Specific area is from 15000-30000 m /kg.

Application:-
 Because of high silica content and its extreme fineness, it is very effective as
pozzolanic material for high performance concrete.

 Silica fume is added to Portland cement to improve its properties like compressive
strength, abrasion resistance and bond strength.
 It reduces permeability of concrete.

 It reduces segregation and bleeding of concrete.

1.6.4 Metakaolin:-
Metakaolin is refined clay mineral kaolinite that is calcined under controlled condition to
create an amorphous reactive alumino-silicate. The particle size of Metakaolin is smaller
than cement particles, however not as fine as silica fume. Metakaolin can be manufactured
from various sources such as high purity kaolin deposits, kaolinite deposits or tropical soils
of lower purity, paper sludge waste (if containing kaolinite), oil sand tailings.

Metakaolin is a precious admixture for concrete application as it is considered to have

twice the reactivity of most Pozzolans. When Portland cement is replaced Metakaolin up to
20% (by weight) in concrete mix exhibits favourable engineering properties, including; the
pozzolanic reaction, the acceleration of heat of hydration in OPC, and the filler effect. The
filler effect is immediate, while the pozzolanic reaction effect occurs between 3 to 14 days.

10
Uses:-
 Used for high strength and lightweight concrete production
 In precast and poured- mould concrete & glass fibre reinforced concrete production
 In fibre-cement and Ferro-cement products
 In manufacturing of Countertops
 In Art sculpture

Advantages:-
 Increases compressive strength and flexural strength
 Reduce permeability & drying shrinkage
 Reduce potential for efflorescence
 Increases resistance to chemical attack
 Increases durability of concrete
 Reduce effect of ASR

1.6.5 Recycled Aggregates:-

When structures made of concrete are demolished or renovated, concreterecycling is an
increasingly common method of utilizing the rubble. Concrete was once routinely trucked
to landfills for disposal, but recycling has a number of benefits that have made it a more
attractive option in this age of greater environmental awareness, more environmentallaws,
and the desire to keep construction costs down.
Concrete aggregate collected from demolition sites is put through a crushingmachine.
Crushing facilities accept only uncontaminated concrete, which must be free
of trash, wood, paper and other such materials. Metals such as rebar are accepted, since
they can be removed with magnets and other sorting devices and melted down for recycling
elsewhere. The remaining aggregate chunks are sorted by size. Larger chunks may go
through the crusher again. After crushing has taken place, other particulates are filtered out
through a variety of methods including hand-picking and water flotation
Crushing at the actual construction site using portable crushers reduces construction costs
and the pollution generated when compared with transporting material to and from

11
a quarry. Large road-portable plants can crush concrete and asphalt rubble at 600 tons per
hour or more. These systems normally consist of a rubble crusher, side discharge conveyor,
screening plant, and a return conveyor from the screen to the crusher inlet for reprocessing
oversize materials. Compact, self-contained mini-crushers are also available that can
handle up to 150 tons per hour and fit into tighter areas. With the advent of crusher
attachments - those connected to various construction equipment, such as excavators - the
trend towards recycling on-site with smaller volumes of material is growing rapidly. These
attachments encompass volumes of 100 tons/hour and less.

Uses:-
 Smaller pieces of concrete are used as gravel for new construction projects. Sub-
base gravel is laid down as the lowest layer in a road, with fresh concrete or asphalt
poured over it.
 The US FederalHighwayAdministration may use techniques such as these to build
new highways from the materials of old highways.
 Crushed recycled concrete can also be used as the dry aggregate for brand new
concrete if it is free of contaminants. Also, concrete pavements can be broken in
place and used as a base layer for an asphalt pavement through a process
called rubblization.

Advantages:-

 Save landfill space.

 Then used as the base material for roadways, reduces pollution from waste transport
to landfills and dumps.
 Create employment opportunities.
 Drags down material and waste transport expenses.
 Recycling one ton of cement could save 1,360 gallons water, 900 kg of CO2.

1.6.6 Advantages of Source Material:-

 The particles of these materials are absolutely spherical in shape, allowing them to
Combine freely in mixture

12
  More costly cement can be replaced with cheaper Pozzolans in higher volume;
therefore, cost of concrete production is also reduced.
 High structural strength is achieved over time
 Reduces permeability and increase durability of concrete
 Reduce effect of efflorescence, drying shrinkage and ASR
 Improved finishing
 Reduced segregation & bleeding
 More resistant to sea-water & Sulphate attack
 Water tightness is improved due to the formation of expansive gels effectively seals
the concrete
 Freezing cannot cause destructive expansion, the hardened concrete does not allow
water to penetrate
1.6.7 Disadvantages of Source Material:-
 Low heat of hydration (for some climate condition)
There are low early age strengthens and delays in construction rate
 Workability decreased for some Pozzolans (example: silica fume may prevent
bleeding, but increase water requirement)
 It is not resistant to erosion and weathering action.
 In case of high dosage of fly-ash in cold weather the durability of the concrete can
be reduced in relation to de-icing salt scaling and carbonation

1.7 Alkaline activator:-

Activation of the selected pozzolanic material is the most essential factor in creating a
mechanically stable cementitious material by means of Geo-polymerization process. The
activators prompt the precipitation and crystallization of the aluminous and siliceous
-
species present in the solution. OH acts as a catalyst for reactivity, while the metal cation

accommodates to compose a structural element and stabilize the negative framework

carried by the tetrahedral aluminium. The initial mechanism of the reaction depends on
theability of the alkaline solution to dissolve the pozzolanic material and release reactive

13
aluminium and silicon into solution. When Pozzolans are mixed with alkaline solutions,
their glassy component is rapidly dissolved. There is not adequate time or space for the
resulting gel to develop into a well-crystallized structure. Thus, microcrystalline,
amorphous, or semi-amorphous structure is composed.

Following is a classification of different groups of activators where M represents an

+ +
alkaline ion (Na , K ) :

• Alkalis, MOH

• Weak acid salts, M2CO3, M2SO3, M3PO4

• Strong salt acids, M2SO4

• Aluminates, M2O * nAl2O3

• Silicates, M2O * nSiO3

• Alumina-silicates, M2O * n Al2SO3 * (2-6)SiO2

While familiar activators include NaOH, Na2SO4, K2SO4, water glass, Na2CO3, and K2CO3.
Generally, mixture of sodium or potassium hydroxides (NaOH) and sodium water glass
(nSiO2.Na2O) or potassium water glass (nSiO2.K2O) are utilized as alkaline solution.

The performance of final cement products strongly depends upon pH level of the activating
solution. However, a pH level of activating solution ranges from 12-14 is most favourable
for the formation of Geo-polymers with higher mechanical strengths.

1.7.1 Sodium Hydroxide (NaOH):-

NaOH is commonly utilized as an alkali activator in Geo-polymer concrete. Sodium
+
cations are smaller than potassium cations. However, Na ion does not maintain the level
+
of activation as a K ion, these sodium cations can migrate throughout the network of paste

with much less effort promoting better zeolization. The properties of resulting paste largely
depend upon the molarities and concentration of this activating solution. Higher
concentration of NaOH promote higher strengths at early stage of reaction, but the strength

14
 -
of aged materials were compromised due to excessive OH in solution causing undesirable

morphology and non-uniformity of the final products. It is found that Geo-polymer

activated with NaOH develops greater crystalline thus improving stability concrete
undersulphates and acids attack. However, increasing concentration of NaOH increases
rate of heat of hydration and directly affect the formation of main C-S-H products in Geo-
polymer pastes. Thus, there will be a linear relationship between concentrations of NaOH
and the time at which maximum heat of hydration occurs.

Fig. 1.4: NaOH Pallets Fig 1.5: NaOH Solution

1.7.2 Sodium silicate (Na2SiO3):-

Sodium silicate are manufactured by fusing sand (SiO2) with sodium carbonate (Na2CO3) at
temperature in excess of 1100 ˚C and dissolving the product with high pressure steam into
a semi-viscous liquid referred to as water glass. Water glass does not have enough
activation capacity to initiate pozzolanicreaction alone thus it is rarely utilized as an
independent activator. Rather, it is commonly mixed with NaOH as a fortifying agent to
improve alkalinity and increase overall strength of specimen. Combination of sodium
hydroxide (NaOH) solution and sodium silicate (Na2SiO3) solution is mostly utilized as an

15
alkaline solution in Geo-polymerization process. Sodium silicate solution is commercially
available in various grades, but it should be noted that powdered water glass leads to lower
performance compared to the liquid form. The most significant property of silicate solution
is its ratio of SiO2 to Na2O (by mass), which is commercially available in range of 1.5 to
3.2, however, best result is achieved at ratio of SiO2 to Na2O (by mass) is nearly about 2.0.
Soluble silicates promote greater inter-particle bonding property with both Geo-polymer
binders and aggregates. Testing has revealed that Geo-polymers activated with solutions
containing little or no concentration of soluble silicates produced significantly weaker
mechanical strengths than those activated with high concentration of soluble silicates. On
the contrary, additional research shows that under increasing temperature, specimen-
containing solution of only a base activator (NaOH) produce higher strength than those
containing solution of both base activator and soluble silicate.

Fig. 1.6: Na2SiO3 Solution

1.7.3 Liquid/Binder Ratio:-
The ratio of binder (F.A, GGBFS, and RHA) material to a selected activator affects
important properties like overall strength of the Geo-polymer concrete. As the liquid to
binder ratio, increase strength is also increased. Thus, the ratio of alkaline liquid-to-binder
(by mass) must be maintained in range of 0.30 to 0.45. However, beyond liquid-to binder
ratio of 0.45, the gain of strength is not very much improved.

16
1.7.4 Sodium Silicate/Sodium Hydroxide Activator Ratio:-
Firstly, single activator either sodium hydroxide or sodium silicate alone is not effective.
Therefore, the combination of sodium hydroxide to sodium silicate solutions are used for
the activation of slag based Geo-polymer concrete. However, compressive strength of Geo-
polymer concrete increase with increase in concentration of sodium hydroxide solution or
sodium silicate solution. As concentration of both solutions, increase in terms of molarities
(M) makes the concrete more brittle. Secondly, sodium hydroxide is very costly and its
preparation is very caustic. Similarly extra water is required to achieve desired degree of
workability, which is ultimately reducing the concentration of sodium hydroxide solution.

1.8 Research Objectives:-

 Alternative to OPC concrete.
 For cutting the world’s carbon which is produced while manufacturing of OPC.
Thus, provide a practical solution to waste management as well as environmental
protection methods.
 Investigate the effect of different mix variables on the workability and mechanical
properties of FA/GGBS-based Geopolymer concrete.
1.9 Scope of Work:-
 The Present work is based on Recycled Aggregates replacement with Some
percentage of Coarse Aggregates and find which gives best Durability properties
and workability.
 Study of physical properties of aggregates; it includes determination of specific
gravity, moisture content and sieve analysis of course and fine aggregates.
 Scheduling of works to be carried out.
 Development of high strength geo-polymer concrete manufacture with silicate and
hydroxides if sodium and the effects of higher strength in the flexural behaviour of
geo-polymer concrete.

17
 CHAPTER – 2
LITERATURE REVIEW

2.1 Literature Review on Geo-Polymer Concrete

2.1.1 Suman Saha, C. Rajasekaran, “Enhancement of The Properties of Fly Ash

Based Geo-Polymer Paste by Incorporating Ground Granulated Blast Furnace
Slag” @ 2017 Elsevier Ltd. All rights reserved.

Fly-ash is mainly used as source material for the production of Geo-polymer concrete. But
results of most of the study showed that, setting time of fly-ash based Geo-polymer
concrete was more when curing was done at ambient temperature. Thus Suman Saha et al.
author of this paper carried out an investigation to strengthen the properties of fly-ash
based Geo-polymer concrete by incorporating GGBFS at various percentage levels.

In this paper, experimental investigation were presented to determine the properties of fly-
ash based Geo-polymer concrete with the incorporation of Ground granulated blast furnace
slag (GGBFS) at various percentage levels and produced with different concentration of
sodium hydroxide (NaOH) solution. Here, GGBFS was incorporated at Five level (10%,
20%, 30%, 40% and 50%) to the total binders and concentration of sodium hydroxide
solution were at 6M, 8M, 10M, 12M, 14M, 16M. Micro-structure of the Geo-polymer paste
was examined using Scanning Electron Microscopy (SEM).

The results showed that, Compressive strength of Geo-polymer concrete increased with the
increase in the concentration of the sodium hydroxide solution and also increased with the
increase in the percentage level of incorporation of GGBFS. Highest compressive strength
of Geo-polymer concrete paste mix was as 78.2 Mpa with 16 M concentration of sodium
hydroxide solution and 50% incorporation of GGBFS. It has been observed that increment
of GGBFS in mixes significantly reduces the initial and final setting time of Geo-polymer
concrete. Initial setting time of Geo-polymer concrete paste was observed to be reduced by
69-90% and final setting time was reduced by 80-95% with addition of GGBFS.

18
2.1.2 M. Vijayalakshmi, A.S.S. Sekar, G. Ganesh Prabhu, “Strength and Durability
Properties of Concrete Made With Granite Industry Waste” @ 2013 Elsevier
Ltd. All rights reserved.

Aim of this paper was to study the suitability of granite slurry as a substitution of
fine/natural aggregate in production of concrete. Concrete mixtures were prepared where
percentage of substitution of granite slurry ranging from 0%, 5%, 10%, 15%, 20%, and
25% by mass to total mass of fine aggregate. All mechanical properties like split tensile
strength, compressive strength, flexural strength, Ultrasonic pulse velocity (UPV) and
elastic modulus were classified. To make sure the reliability of its usage in aggressive
environments, the durability properties such as sulphate resistance, water permeability,
carbonation depth, rapid chloride penetration (RCPT), and electrical resistivity was also
classified.

Up to 15% replacement, mechanical properties showed significant improvement.

Increasing the substitute rate of granite slurry there was increment in the chloride
penetration rate, the water permeability of the concrete and carbonation depth. However, up
to 15% replacement per chloride penetration value, permeability and carbonation were
equivalent to value of Cement mortar.

The obtained results indicated that the substitution rate of fine aggregate by granite slurry
up to 15% was favourable without adversely influencing the strength & durability criteria
for the concrete.

2.1.3 Namita Patiyal, Jitender Kumar, Abhilesh Kant Sharma, “Experimental Study
on Geo-polymer Concrete With Partial Replacement of Fine Aggregate With
Foundry Sand” International Journal of Recent Research Aspects (IJRRA)
ISSN: 2349-7688, Vol. 3, Issue 2, June 2016

Author presented the results of experiments carried out to investigate the effectiveness of
using foundry sand as an alternate material for fine aggregate in Geo-polymer concrete.
The percentage of replacement were 0%, 5%, 10%, 15%, 20% and 25% by weight of fine
aggregate by foundry sand. Result showed that maximum compressive strength was

19
achieved for 15% replacement of fine aggregate. Thus 15% was optimum percentage for
replacement of foundry sand with natural sand.

2.1.4 A.Maria Rajesh, M.Adams Joe, Roy Mammen, “Study of the Strength
Geopolymer Concrete with Alkaline Solution of Varying Molarity” IOSR
Journal of Engineering (IOSRJEN), Vol. 04, Issue 06 ,June. 2014

Manufacture of Portland cement produces large of volumes of carbon dioxide and other
gases. Releasing these gases causes atmospheric pollution and subsequent environmental
degradation. Finding a suitable alternative solution to mitigate the environmental
degradation caused by using Portland cement is very important for environmental
sustainability. The use of geopolymer concrete as an alternative material over Portland
cement concrete to reduce the adverse effects on the environment is investigated in this
paper. The paper also critically analyses the economic and environmental benefits of
geopolymer concrete and address the financial and environmental issues associated with
the production and use of Portland cement. Geopolymer cement utilizes industrial waste
materials such as fly ash from thermal power stations to provide a practical solution to
waste management as well as environmental protection methods.

Geopolymer concrete products are known to possess far better durability and strength
properties than Portland cement concrete. These properties are investigated extensively in
laboratory to verify and confirm the superior durability and strength properties. The paper
also discusses the factors which restrict the use of geopolymer concrete as an alternative to
Portland cement concrete. Laboratory tests are conducted on compressive strength, split
tensile strength and flexural tests for specimens with combination of different molarity. The
results obtained are compared analytically and graphically

2.1.5 Yun Yong Kim, Jung Hwan Hyun, G. Ganesh Prabhu, “Effects of Foundry
Sand As a Fine Aggregate in Concrete Production” @ 2014 Elsevier Ltd. All
rights reserved.

Author presented the results of experiments carried out to investigate the possibility of
using foundry sand as an alternate material for fine aggregate in production of

20
concrete.Fine aggregate will be replaced with five different percentages (10%, 20%, 30%,
40%, & 50%). Several tests, including, slump cone, split tensile strength, flexural strength,
and compressive strength tests were performed to understand the effects of foundry sand on
the behaviour of concrete.

Here it was concluded that replacement up to 20% can be successfully utilized in good
concrete production. Beyond the replacement of 20%, the concrete mixtures showed
inferior behaviour when compared to the control mix due to presence of clay, sawdust &
due to fineness of foundry sand.

2.1.6 T Kiran, Sadath Ali Khan Zai, Srikant Reddy S, “Impact Test on Geopolymer
Concrete Slabs”@ IJRET: International Journal of Research in Engineering
and Technology

Geopolymer is an eco-friendly binding material alternative for Ordinary Portland Cement

(OPC). Geopolymer concrete is produced by mixing fly ash, GGBS, alkaline solution, fine
aggregate and coarse aggregate. Alkaline solution is composed of NaOH and Na2SiO3
solution. This paper deals with the study of impact resistance capacity of geopolymer
concrete slabs subjected to impact loading. For this study, ten specimens of size 600 mm
(length) × 600 mm (width) × 60 mm (thick) were casted with nine different combination of
geopolymer concrete mix using different molar sodium hydroxide solutions and different
percentages of mineral admixtures and a normal concrete slab as control slab. The molarity
of NaOH solution used was 8M, 12Mand 16M. Fly ash and GGBS admixtures were used in
three different ratios of 100:0, 75:25 and 50:50.The slabs were oven cured at 600C for 24
hours. These slabs were subjected to impact loading by drop weight test method. All the
slabs were tested under a drop weight of 75.50 N through a guide pipe from a height of
700mm. The results obtained from this study showed that with the increase in molarity of
NaOH solution, the strength characteristics and the impact resistance capacity of the
specimen increases. Also increase in percentage of GGBS content as replacement for Fly
ash content increases the impact resistance and overall strength characteristics of
geopolymer concrete. From the test results, geopolymer concrete slab with 16M NaOH
solution using 50:50 Fly ash and GGBS content showed higher impact energy absorption
capacity as compared other geopolymer mixes.

21
2.2 Conclusion:-
• Slag based Geo-polymer concrete significantly improve setting time of than Fly-ash
based Geo-polymer concrete.
• Higher quantity of slag in Geo-polymer concrete mixes helps to form denser
structure to gain higher strength.
• GGBFS also shows resistance to high temperature and surface abrasion.

• Heat cured Geo-polymer concrete usually accelerate the Geo-polymerization

process and thereby there will be increment in the mechanical properties of the
Geo-polymer concrete.
• Foundry sand can be utilized in various construction applications that can deal with
the problem of disposal of foundry sand and other purpose.
• Use of foundry sand in concrete is to make batter strength and other durability
factor.
• Strength properties of concrete mixtures increase with the increase in foundry sand
contents and also with the age.
• A number of studies have been carried out on utilization of foundry sand in
concrete, wherein, optimum replacement level is obtained as 20-30% for most of
the properties.
• If granite slurry left on its own and isn’t properly collected and stored, the fine
Granite slurry can be easily be airborne and will cause health problem and
environmental contamination.
• Granite slurry can be utilized in various construction application and building
materials as a suitable replacement for fine aggregate and cement up to certain
optimum percentage level.
• The usefulness of using granite slurry as a partial substitution for fine aggregate in
concrete is well established as far as mechanical strength parameter.
• Granite slurry as substituting fine aggregate can be used as a space filler material to
reduce the void content in concrete.

22
 CHAPTER-3
Materials and Experimental Setup
3.1 General
This chapter represent the material used in study and methodology of the entire work. In
this section preliminary test results on ingredients of concrete are given which are used in
mix design. Also illustrate the necessary test on the material before casting of the concrete.
Various test methodology on concrete like test on fresh concrete as well as test on harden
concrete explained as per relevant IS standards.

3.2Fly-Ash (FA):-
Fly-ash is the most commonly known artificial Pozzolans and is produced through the
combustion of pulverized coal at lower temperature in electric power plant. Fly-ash carries
amorphous glass like spherical particles, which are the active pozzolanic portion of it. On
an average, Fly-ash is 70-72% glass. Class-F fly-ash is highly pozzolanic and readily reacts
with excess lime & alkalis to form cementitious compounds.

Concrete made with Class-C fly-ash has higher early strength because it contains more lime
content than Class-F fly-ash. In addition to that, it may also exhibit self-cementing
properties. Due to this pozzolanic activity begins at very earlier stage. Class-C behaves
similarly like Class-F by gaining higher strengths than conventional concrete at later stage.

Fly-ashes are classified into two classes that satisfy with ASTM C 618 for mineral
admixtures in PCC as:

1. Class-B :- Produced from burning sub-bituminous coal & gain faster strength,
2. Class-F :- Produced from burning bituminous coal & has higher ultimate strength

Generally, fly-ash can be utilized as a partial replacement of Portland cement, up to 30%

(by mass) of cementitious material. Fly-ash must replace at least 20% of the Portland
cement to lower down the effects of alkali silica reaction (ASR). Fly-ash should not be
used in sulphate exposure or hydraulic applications if it possesses has high calcium content.

23
Loss on ignition (LOI) refers to the carbon content in the ash. If more carbon content is
present, more the weight will lose upon combusting the ash. If possible, there should not be
loss of weight at all. By utilizing only 4% of coal in the without aggregate cement mix will
prevent the concrete hardening. However, 2% does not seem to be a problem at all, thus the
gap is pretty narrow.

Fig 3.1 Fly-Ash used in study

3.3 Aggregates:-

Aggregate properties greatly influence the behavior of concrete, since they occupy about
80% of the total volume of concrete. The aggregate are classified as
 Fine aggregate
 Coarse aggregate
Fine aggregate are material passing through an IS sieve that is less than 4.75mm gauge
beyond which they are known as coarse aggregate. Coarse aggregate form the main matrix
of the concrete, whereas fine aggregate form the filler matrix between the courses
aggregate. The most important function of the fine aggregate is to provide workability and
uniformity in the mixture. The fine aggregate also helps the cement paste to hold the coarse
aggregate particle in suspension.
According to IS 383:1970 the fine aggregate is being classified in to four different zone,
that is Zone-I, Zone-II, Zone-III, Zone-IV. Also in case of coarse aggregate maximum 20
mm coarse aggregate is suitable for concrete work. But where there is no restriction 40 mm
or large size may be permitted. In case of close reinforcement 10mm size also used.

24
Sand was tested for the gradation purpose and found to be confirmed to zone-III as per IS:
383-1970 recommendations and checked physical properties also.

Fig 3.2 Fine and Course (10mm & 20mm) Aggregate used in study

3.4 Recycled Aggregate:

When structures made of concrete are demolished or renovated, concreterecycling is an

increasingly common method of utilizing the rubble. Concrete was once routinely trucked
to landfills for disposal, but recycling has a number of benefits that have made it a more
attractive option in this age of greater environmental awareness, more environmentallaws,
and the desire to keep construction costs down.
Concrete aggregate collected from demolition sites is put through a crushingmachine.
Crushing facilities accept only uncontaminated concrete, which must be free
of trash, wood, paper and other such materials. Metals such as rebar are accepted, since
they can be removed with magnets and other sorting devices and melted down for
recycling elsewhere. The remaining aggregate chunks are sorted by size. Larger chunks
may go through the crusher again. After crushing has taken place, other particulates are
filtered out through a variety of methods including hand-picking and water flotation
Crushing at the actual construction site using portable crushers reduces construction costs
and the pollution generated when compared with transporting material to and from
a quarry. Large road-portable plants can crush concrete and asphalt rubble at 600 tons per

25
hour or more. These systems normally consist of a rubble crusher, side discharge
conveyor, screening plant, and a return conveyor from the screen to the crusher inlet for
reprocessing oversize materials. Compact, self-contained mini-crushers are also available
that can handle up to 150 tons per hour and fit into tighter areas. With the advent of
crusher attachments - those connected to various construction equipment, such as
excavators - the trend towards recycling on-site with smaller volumes of material is
growing rapidly. These attachments encompass volumes of 100 tons/hour and less.

Fig 3.3 Raw Material of Recycled Aggregate

3.5Preliminary Properties

In any concrete work before carried out the mix design some important properties are
evaluated which are,

3.5.1Fine Aggregate Test Results: Below table 3.1 and 3.2 shows the sieve analysis
and Specific Gravity Test Results and Water Absorption Test Result results respectively.
As per IS 383 zone of fine aggregate being zone-III

26
 Table 3.1 Sieve analysis of fine aggregates
I.S Weight Cumulative Cumulative Cumulative
Sieve retained (gm) weight retained percentage percentage
(gm) retained passing

4.75mm 110 110 7.3 92.7

2.36mm 35 145 9.67 90.33

1.18mm 185 330 22 78

600µ 116 446 29.73 70.27

300µ 380 826 55.06 44.94

150µ 601 1427 95.13 4.87

Receiver 73 1500 100 0.0

Total 1500 =318.89

cumulative percentage retained 3.19

Fineness Modulus= 100

Table 3.2 Fine Aggregate Specific Gravity Test Results

Particulars Value

Wt. of container+ water+ fine aggregate in gm (W1) 1780

Wt. of container+ water in gm (W2) 2592

Wt. of air dried sample in gm (W3) 500

Wt. of oven dried sample in gm (W4) 480

Specific gravity = W4 0.365

W3-(W1-W2)
Water absorption = (W3-W4)100 4.167
W4

27
3.5.2Coarse Aggregate Test Results: Below table 3.3, 3.4, 3.5, 3.6, 3.7 and 3.8
shows the sieve analysis and Specific Gravity Test Results and Water Absorption Test
Result results respectively.

Table 3.3 20 mm Coarse Aggregate (Kapachi) Sieve Analysis Test Results

I.S. Sieve Weight Retained Cumulative Cumulative Cumulative
size (gm.) weight retained percentage Percentage
(gm.) retained Passing
20 mm 361 361 36.1 63.9

16 mm 225 586 58.6 41.4

12.5 mm 379 965 96.5 3.5

10 mm 34 999 99.9 0.1

6.3 mm 0 0 0 0

4.75 mm 0 0 0 0

2.36 mm 0 0 0 0

1.18 mm 0 0 0 0

Receiver 0 0 0 0
Total 999 ∑= 291.1

Table 3.4 20 mm Coarse Aggregate (Kapachi) Specific Gravity Test Results

Particulars Value

Wt. of container+ water+ fine aggregate in gm (W1) 3010

Wt. of container+ water in gm (W2) 2406

Wt. of air dried sample in gm (W3) 1000

28
Wt. of oven dried sample in gm (W4) 990

Specific gravity = W4 2.68

W3-(W1-W2)
Water absorption = (W3-W4)100 1.01%
W4

Table 3.5 10 mm Coarse Aggregate (Grit) Sieve Analysis Test Results

I.S. Sieve Weight Cumulative Cumulative Cumulative
size Retained weight percentage Percentage
(gm.) retained retained Passing
(gm.)
12.5 mm 39 39 3.9 96.1

10 mm 169 208 20.8 79.2

6.3 mm 724 932 93.2 6.8

4.75 mm 57 989 98.9 1.1

2.36 mm 6 995 99.5 0.5

1.18 mm 0 0 0 0

Receiver 0 0 0 0

Total 995 ∑=351.4

Table 3.6 10 mm Coarse Aggregate (Grit) Specific Gravity Test Results

Particulars Value

Wt. of container+ water+ fine aggregate in gm (W1) 3053

29
Wt. of container+ water in gm (W2) 2406

Wt. of air dried sample in gm (W3) 1000

Wt. of oven dried sample in gm (W4) 978

Specific gravity = W4 2.7

W3-(W1-W2)
Water absorption = (W3-W4)100 2.24%
W4

Table 3.7 10 mm Coarse Aggregate (RCA) Sieve Analysis Test Results

I.S. Sieve Weight Cumulative Cumulative Cumulative
size Retained weight percentage Percentage
(gm.) retained retained Passing
(gm.)
12.5 mm 25 25 1.67 98.33

10 mm 376 401 26.73 73.27

6.3 mm 1084 1485 99 1.0

4.75 mm 15 1500 100 0.0

2.36 mm 0 1500 100 0.0

1.18 mm 0 1500 100 0.0

Receiver 0 1500 100 0.0

Total 1500 ∑=527.4

30
 Table 3.8 10 mm Coarse Aggregate (RCA) Specific Gravity Test Results

Particulars Value

Wt. of container+ water+ fine aggregate in gm (W1) 3000

Wt. of container+ water in gm (W2) 2398

Wt. of air dried sample in gm (W3) 1000

Wt. of oven dried sample in gm (W4) 988

Specific gravity = W4 2.48%

W3-(W1-W2)
Water absorption = (W3-W4)100 1.21%
W4

3.6 Final mix proportion

Based on experience and according to literature review mix design was carried out is shown
below table no. 3.9
Table 3.9 Final mix proportion
Flyash Fine Coarse Aggregate Kg/m3 Na2sio3/NaOH
Aggregate ratio
Kg/m3 10 mm (grit) 20 mm
Kg/m3 (kapchi)
kg/m3
kg/m3

400 516 682 535 1.5

31
3.7 Preparation of Testing Elements
In order to estimate and compare compressive strength, split tensile strength, flexural strength
of concrete, cube of size 150mm x 150mm x 150mm, cylinder of size with diameter of
150mm and length of 300mm, and beam with size 700mm x 150mm x 150mm were casted in
gunmetal moulds. The moulds were made so as to facilitate to removal of moulded specimen
without any damage. Each mould was inspected to prevent any leakage during compaction
and that the dimension of the mould was accurate within allowable limits. Before filling the
concrete the moulds were cleaned and the inner surface mould was oiled to prevent sticking of
the concrete to the sides of the moulds.

3.8 Mixing of concrete

All the materials were stored at the room temperature after arrival at the laboratory. Sand and
coarse aggregates and Recycled Aggregates used for experimental study were well washed to
remove all the impurities and then allowed to dry. The Flyash, GGBS, Metakaolin and the
aggregates were first mixed together in the electrical tilting drum mixer machine about three
minutes. After 2 to 3 minutes of dry mix of the material the AlkaliActivators
(NaOH&Na2sio3) of required quantity was added in the mixture by weight and the mix was
mixed again for 2 to 3 minutes. In order to get the proper mix and the properties of mix could
not change, buttering of the mixture machine was carried out at the first time the mix started.
This procedure was followed every time when the first time mix started. Then the mix was
taken out in the concrete tray after buttering of concrete tray was carried out. The mix was
then hand mixed and taken for the fresh concrete testing and casting of the specimens. Proper
care was also taken that the testing on fresh concrete can be completed within the proper time
limit.

3.9 Casting of specimens

Right after mixing, the slump test and compaction test of normal concrete and concrete with
Poly Ethylene Glycol was carried out. The slump value of the fresh concrete was measured by
the slump cone apparatus. The Fresh concrete was then poured in the mould after proper
mixing. All the surfaces of the moulds were cleaned using the wire brush each and every time
before pouring the concrete. The bolts of the mould were also changed after every four
concrete batches so that there should not be any leakage problem. After pouring the concrete

32
in moulds the mould were put on the plate vibrator for proper compaction. The vibrator was
then stopped and after finishing top surface of mould the moulds were kept as it is for 24
hours. The moulds were then opened by taking care that the surface of the concrete should not
be disturbed. The specimens were then put for the curing in curing tank after marking on
them. The specimens were marked with w/c ratio, date of casting using the marker pen. The
curing period was kept 7 And 28 days and for proper curing the curing tank was cleaned at
every 15 days. In present study various curing conditions are considered After 28 days of
curing the specimens were kept for drying the surfaces of the specimen at normal temperature.
The dry specimens were then taken for testing on harden concrete.

3.10 Slump test (IS: 1199 – 1959)

The concrete slump test is used for the measurement of a property of fresh concrete. The test
is an empirical test that measures the workability of fresh concrete. The test is popular due to
the simplicity of apparatus used and simple procedure. The slump test is used to make sure
uniformity for different batches of similar concrete under field condition and to ascertain the
effects of plasticizers on their introduction. The slump test is a means of assessing the
consistency of fresh concrete. Different types of slump can be observed during slump test.
Collapse, shear and true slump are the different types of slump. In a collapse slump the
concrete collapses completely. In a shear slump the top portion of the concrete shears off and
slips sideways. In a true slump the concrete simply subsides, keeping more or less to shape.

The internal surface of the mould was thoroughly cleaned and treed from super flows
moisture and set concrete. The mould was placed on a smooth, horizontal, rigid and non-
absorbent surface, such as carefully levelled metal plate. The mould was held firmly in place
before concrete was filled in. In slump test fresh concrete was filled in slump cone in four
layers, each layer of concrete was compacted 25 times with the help of steel rod 0.6m long
and 16mm in diameter. The slump cone was removed carefully in the vertical direction
without affecting the shape of concrete slump. This allows the concrete to subside. The
subsidence is referred as SLUMP of concrete. The slump of concrete was measured with help
of steel rod nearest 1 mm measurement after removal of slump cone as shown in figure.3.16

33
 Fig 3.4 Types of Concrete Slump

3.11 Compaction Factor Test:-

Objective of compaction factor test is to calculate the compaction factor, and to know more
about workability. These tests were developed in the United Kingdom by Glanville (Road
Research Laboratory) in 1947 and it is measure the degree of compaction for the standard
amount of work and thus offers a direct and reasonably reliable assessment of the workability
of concrete. The test require measurement of the weight of the partially and fully compacted
concrete and the ratio of partially compacted weight to the fully compacted weight, which is
always less than one, is known as compaction factor . For the normal range of concrete the
compacting factor lies 0.80 to 0.92. This test is particularly useful for dryer mixes for which
the slump test is not satisfactory. The sensitivity of the compaction factor is reduced outside
the normal range of workability and is generally unsatisfactory for compacting factor greater
than 0.92. Very lower quantity of oil applies in all inside surfaces of hoppers to reduce
friction. In compaction factor test the concrete should freely fall in one hopper two second
hopper without any external effort. Figure shows the apparatus for compaction factor test.
Procedure:
1. First of all, concrete was properly mixed in tray after fall it in mixer machine and then
concrete was tilled up in level gently in the upper hopper.
2. Trap clear of upper hopper was opened to allow the concrete in next lower hopper.
3. Concrete sticking to the side of hopper was pushed gently from top with the help of rod.
4. Trap drop of bottom hopper was opened to allow the concrete to fall down in to cylinder
and similar process was followed.
5. Excess concrete remaining above the level of the top of the cylinder.
6. Cylinder was cleaned from outside.

34
7. Mass of the cylinder was determined. This gives mass of partially compacted concrete.
8. Cylinder was refilled from the same concrete and vibrated on a table.
9. Outside of cylinder was cleaned and mass was of concrete was determined. This gives mass
of belly compacted concrete.
Compaction factor for a mix can be found by taking the ratio at weight of partially compacted
to fully compacted concrete.

Compacting Factor,
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑎𝑙𝑙𝑦 𝑐𝑜𝑚𝑝𝑒𝑐𝑡𝑒𝑑 𝑐𝑜𝑛𝑐𝑟𝑒𝑡𝑒 𝑊1 − 𝑊2
= =
𝑤𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑓𝑢𝑙𝑙𝑦 𝑐𝑜𝑚𝑝𝑒𝑐𝑡𝑒𝑑 𝑐𝑜𝑛𝑐𝑟𝑒𝑡𝑒 𝑊2 − 𝑊

3.12 Durability Test

Elements of all types of concrete have been left exposed for future assessment of durability
but some preliminary tests have been carried out.

3.12.1 Resistance against Sulphuric Acid Attack:-

The resistance of Geo-polymer concrete to acid attack is studied by determining the loss of
compressive strength or variation in compressive strength of concrete cubes immersed in
Sulphuric acid (H2SO4/Na2SO4). The Geo-polymer concrete cubes of 150mm x 150mm x

35
150mm size were immersed in sulphuric acid of 5% concentration after one day of de-
moulding for 91 days. The solution was replaced at regular interval to maintain the
concentration of solution throughout test period. After 91 days immersion period, theGeo-
polymer concrete cubes were removed for visual inspection of deterioration and washed in tap
water before weighting in digital balance. The changes in mass were noted down.

3.12.2 Resistance against Chloride Acid Attack:-

Cubes of sizes 150 X 150 X 150 mm were casting and have cured for 28 days. After 28 days
curing cubes were taken out and allowed for drying for 24 hours and weights were taken. For
Chloride Attack Test 5% dilute NaCl is used. The cubes were to be immersed in solution for a
period of 30 days. The concentration is to be maintained throughout this period. After 30 days
the specimens were taken from acid solution. The surface of specimen has cleaned and
weights were measured. The specimen was tested in the compression testing machine under a
uniform rate of loading 140Kg/cm2 as per IS 516. The loss of mass and loss of strength of
specimen due to Chloride Attack was determined.

3.12.3 Sorptivity Test:-

The sorptivity can be determined by the measurement of the capillary rise absorption rate on
reasonably homogeneous material. Water was used of the test fluid. The cylinders after
casting were immersed in water for 90 days curing. The specimen size 100mm dia x 50 mm
height after drying in oven at temperature of 100 + 10 °C were drowned as shown in figure
4with water level not more than 5 mm above the base of specimen and the flow from the
peripheral surface is prevented by sealing it properly with non-absorbent coating. The quantity
of water absorbed in time period of 30 minutes was measured by weighting the specimen on a
top pan balance weighting upto 0.1 mg. surface water on the specimen was wiped off with a
dampened tissue and each weighting operation was completed within 30 seconds. Sorptivity
(S) is a material property which characterizes the tendency of a porous material to absorb and
transmit water by capillarity. The cumulative water absorption (per unit area of the inflow
surface) increases as the square root of elapsed time (t) I=S.t½ therefore S=I/ t½ Where; S=
sorptivity in mm, t= elapsed time in mint. I=Δw/Ad Δw= change in weight = W2-W1 W1 =
Oven dry weight of cylinder in grams W2 = Weight of cylinder after30 minutes capillary

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suction of water in grams. A= surface area of the specimen through which water penetrated.
d= density of water

Fig3.5 Sorptivity TestApparatus

3.12.4 Water Absorption Test:-

There are a few Standard methods for water absorption measurement in laboratory conditions.
ASTM C1585 and ASTM C642 are the most used Standard approaches for 20 concrete water
absorption. Although there are some other British Standards like BS 7263 and LUM A4, their
testing principles are similar to ASTM Standards (Wilson et al., 1999). The need for
cylindrical concrete samples in both of these former methods generally limits them to
laboratory situations. In order to perform these tests on existing structures, it is necessary to
take cores from concrete elements. This limitation makes these approaches to be categorized
as destructive testing methods for existing structures.

ASTM C1585:-

ASTM C1585 was developed based on Hall’s (1989) investigations and became a Standard in
2004. This test defines the rate of water absorbed by concrete samples due to capillary forces
in unsaturated conditions. This rate, as discussed before, is called sorptivity. According to the
ASTM C1585 Standard, the test should be done using disc concrete specimens of 100 ±6 mm

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diameter with length of 50±3 mm. These samples may be obtained from either moulded
cylinders or drilled cores of concrete elements . Samples should be conditioned in an
environment with temperature of 50 ± 2 ̊ C and RH of 80 ± 3 % for 3 days. This
preconditioning result in providing samples with 50 to 70 % of internal relative humidity
which is found to be the typical RH in cover Crete zone of some in field structures (D’Souza
et al., 1997, D’Souza et al., 1998). Next, each sample is placed in a sealed container at 23 ± 2 ̊
C for at least 15 days. This step provides enough time for moisture to be well distributed
throughout the specimen. This avoids a moisture gradient in concrete depth which can cause
misleading sorptivity values (Bentz et al., 2001). After the conditioning steps, the samples are
removed from containers and the mass determined. The side surfaces of the samples are
sealed and a plastic sheet is used to cover 21 the top surface of the specimens to prevent water
evaporation of concrete. Lastly, the sealed concrete sample is placed in pan which filled with
water as is shown in Figure

Fig 3.7Water Absorption Test Apparatus

The specimens are removed from the pan and their mass recorded at intervals up to 7 to 9
days. Equation 2.12 presents the calculation of the absorption, I, which is the change in
specimen’s mass divided by the product of the cross-sectional area of the sample and the
density of water which is considered as 0.001 g/mm3.

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 I=Mt/a*d

Where; I = absorption (mm),

mt = specimen mass in grams at time t (g),

a = exposed area of the sample (mm2).

d = the density of water in (g/mm3).

The calculated absorption value at each time will be plotted against the square root of time
(√𝑠) to investigate the slope of its linear trend, sorptivity.

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