29

CHAPTER 3

FLY ASH BASED GEOPOLYMER CONCRETE

3.1 GENERAL

The fresh and hardened properties such as workability, density,

compressive strength, split tensile strength and flexural strength of fly ash
based Geopolymer Concrete (GPC) is presented in this chapter. This chapter
describes the mix design and manufacturing process of geopolymer concrete.
Fly ash collected from two different sources was used in making of the
geopolymer concrete. The effect of concentration of alkaline liquids on the
strength of geopolymer concrete is presented. The effect of curing conditions
on the mechanical properties of geopolymer concrete is also discussed in this
chapter.

3.2 EXPERIMENTAL PROGRAMME

3.2.1 Parameters of Study

The following parameters were considered in this experimental

investigation:

(a) Source of fly ash: Fly ash collected from Mettur and Tuticorin
thermal power stations of TamilNadu, India

(b) Concentration of sodium hydroxide used for preparation of

geopolymer concrete: 8 Molarity (8 M), 12 Molarity (12 M)
and 16 Molarity (16 M)
 30

(c) Curing temperature: Ambient curing at room temperature and

heat curing at 60o C for 24 hours in hot air oven

(d) Age of concrete at the time of testing: 7 days and 28 days

3.2.2 Materials Used

Fly ash : Class F dry fly ash conforming to IS 3812-2003 obtained

from Mettur and Tuticorin thermal power stations of Tamilnadu from
southern part of India was made use of in the casting of the specimens.
Table 3.1 gives the chemical composition of fly ashes used in this
experimental investigation

Table 3.1 Chemical composition of fly ash

Mettur Tuticorin Requirements as

Oxides
Fly ash Fly ash per IS 3812-2003
SiO2 59.93% 63.24%
SiO2 >35%
Al2O3 19.66% 17.35%
Total - >70%
Fe2O3 2.82% 2.63%
CaO 3.33% 2.05% -
Na2O 0.34% 0.24%
<1.5%
K2 O 0.22% 0.32%
MgO 1.12% 0.96% <5%
LOI 1.56% 0.95% <12%

Fine aggregate: Locally available river sand having a fineness

modulus of 2.75, specific gravity of 2.81 and conforming to grading zone-III
as per Indian Standards IS: 383 - 1970 was used. Bulk density of the fine
aggregate is 1693 kg/m3. Details of sieve analysis of sand are given in
Appendix1.
 31

Coarse aggregate: Crushed granite coarse aggregates of maximum

size 19 mm , fineness modulus of 6.64 and a specific gravity of 2.73 were
used. Bulk density of the coarse aggregate is 1527 kg/m3. Details of sieve
analysis of coarse aggregate are given in Appendix 1.

Sodium hydroxide: Sodium hydroxide solids in the form of flakes

as shown in Figure 3.1, with 97% purity manufactured by Merck Specialties
Private Limited, Mumbai was used in the preparation of alkaline activator.

Figure 3.1 Sodium hydroxide flakes

Sodium silicate: Sodium silicate in the form of solution as shown

in Figure 3.2, supplied by Salfa Industries, Madurai was used in the
preparation of alkaline activator. The chemical composition of Sodium
silicate solution supplied by the manufacturer is as follows: 14.7% of Na 2O,
29.4% of SiO2 and 55.9% of water by mass.
 32

Figure 3.2 Sodium silicate solution

Super plasticizer: To achieve workability of fresh geopolymer

Concrete, sulphonated napthalene polymer based super plasticizer Conplast
SP 430 was used in all the mixtures. Conplast SP 430 is available in the form
of a brown liquid that is instantly dispersible in water and is manufactured by
Fosroc Chemicals (India) private limited, Bangalore.

Water: Distilled water was used for the preparation of sodium

hydroxide solution and for extra water added to achieve workability.

3.2.3 Preparation of Alkaline Activator Solution

A combination of sodium hydroxide solution and sodium silicate

solution was used as alkaline activators for geopolymerisation. To prepare
sodium hydroxide solution of 8 molarity (8 M), 320 g (8 x 40 i.e, molarity x
molecular weight) of sodium hydroxide flakes were dissolved in distilled
water and made up to one litre. The mass of NaOH solid mass in a solution
will vary depending on the concentration of the solution expressed in terms of
molarity, M. The mass of solid NaOH was measured as 255 g/kg in the 8 M
NaOH solution, 354.45 g/kg in the 12 M NaOH solution and 444.6 g/kg in the
16 M NaOH solution .This shows that water was the major component in the
 33

sodium hydroxide solution and NaOH solids was only a fraction of the mass
of NaOH solution.

3.2.4 Mix Design of Geopolymer Concrete

In the design of geopolymer concrete mix, coarse and fine

aggregates together were taken as 77% of entire mixture by mass. This value
is similar to that used in OPC concrete in which it will be in the range of 75%
to 80% of the entire mixture by mass. Fine aggregate was taken as 30% by
mass of the total aggregates. From the past literatures it is clear that the
average density of fly ash-based geopolymer concrete is similar to that of
OPC concrete (2400 kg/m3). Knowing the density of concrete, the combined
mass of alkaline liquid and fly ash can be derived. By assuming the ratio of
alkaline liquid to fly ash as 0.4, mass of fly ash and mass of alkaline liquid
was found out. To obtain mass of sodium hydroxide and sodium silicate
solutions, the ratio of sodium silicate solution to sodium hydroxide solution
was kept as 2.5. Extra water (other than the water used for the preparation of
alkaline solutions) and super plasticizer Conplast SP430 based on sulphonated
napthalene polymers were added to the mix in a proportion of 10% and 3% by
mass of fly ash respectively to achieve workable concrete. The mix design
calculations are given in Appendix 2. The mix proportion is given in
Table 3.2.

Table 3.2 Details of mix proportion of geopolymer concrete

Fly Fine Coarse NaOH Na2SiO3 Extra

SP
ash aggregate aggregate solution solution water 3
3 3 3 3 3 3 kg/m
kg/m kg/m kg/m kg/m kg/m kg/m
394.3 554.4 1293.4 45.1 112.6 39.43 11.83
 34

3.2.5 Preparation of Geopolymer Concrete Specimens

The prepared solution of sodium hydroxide was mixed with sodium

silicate solution one day before mixing the concrete to get the desired
alkalinity in the alkaline activator solution. Initially fine aggregates, fly ash
and coarse aggregates were dry mixed in a horizontal pan mixer for three
minutes. After dry mixing, alkaline activator solution was added to the dry
mix and wet mixing was done for 4 minutes. Finally extra water along with
super plasticizer was added to get workable geopolymer concrete.

Totally 72 cubes (150 mm x 150 mm x 150 mm) for compressive

strength, 72 cylinders (150 mm diameter and 300 mm height) for split tensile
strength and 36 prisms (100 mm x 100 mm x 500 mm) for flexural strength
were cast. Standard cast iron moulds were used for casting the test specimens.
Before casting, machine oil was smeared on the inner surfaces of moulds.
Geopolymer concrete was mixed using a horizontal pan mixer machine and
was poured into the moulds in layers. Each layer of concrete was compacted
using a table vibrator.

3.2.6 Curing of Geopolymer Concrete Specimens

After casting the specimens, they were kept in moulds for a rest
period of four days and then they were demoulded, since the geopolymer
concrete did not harden immediately at room temperature as in conventional
concrete. The term rest period indicates the time taken from the completion of
casting of test specimens to the start of curing at an elevated temperature.
Geopolymer concrete specimens took a minimum of 3 days for complete
setting without leaving a nail impression on the hardened surface. All the
specimens were given an uniform rest period of four days and at the end of
the rest period, thirty six cubes, thirty six cylinders and eighteen prisms were
kept under ambient conditions for curing at room temperature. Remaining
 35

thirty six cubes, thirty six cylinders and eighteen prisms were heat cured at
60oC in hot air oven for 24 hours as shown in Figure 3.3.

Figure 3.3 Specimens under heat curing

3.2.7 Designation of Specimens

Specimens have been given descriptive names, composed of four

terms. Each of these terms gives information about some aspect of the
specimens which is described as follows: The first term describes the source
of fly ash used for casting the specimens. ‘Fm’ refers to fly ash collected from
Mettur thermal power station and ‘F t’ refers to fly ash collected from
Tuticorin thermal power station. The second term which has a number in the
suffix refers to the molarity of sodium hydroxide solution used for the
preparation of alkaline activators. ‘M 8’ refers to 8 M NaOH solution, ‘M 12’
refers to 12 M NaOH solution and ‘M16’ 16 M NaOH solution. The third term
refers to the curing condition of the specimen. ‘C a’ refers to the specimens
that were cured at ambient conditions at room temperature and ‘C h’ refers to
the specimens that were cured at 60 o C in hot air oven. The fourth term refers
to the age of concrete at the time of testing. ‘A7’ refers to tests conducted at
 36

7 days age of concrete and ‘A28’ refers to tests conducted at 28 days age of
concrete.

3.2.8 Instrumentation and Testing Procedure

All the freshly prepared geopolymer concrete mixes were tested for
workability by using the standard slump cone apparatus. The slump cone was
filled with freshly mixed geopolymer concrete and was compacted with a
tamping bar in four layers. The top of the slump cone was leveled off, then
the cone was lifted vertically up and the slump of the sample was immediately
measured. The compressive and flexural strengths were evaluated as per the
test procedure given in Indian Standards IS.516.

For the evaluation of compressive strength, all the cube specimens

were subjected to compressive load in a digital compression testing machine
with a loading capacity of 2000 kN. Before subjected to the test, weight of
each specimen was recorded and density of each specimen was calculated by
dividing the weight of the specimen by its volume. Specimens were placed in
the machine in such a manner that the load shall be applied to opposite sides
of the cubes as cast, that is, not to the top and bottom. Test set up is shown in
Figure 3.4.The load was applied without shock and increased continuously at
a rate of approximately 14 N/mm2/min until the resistance of the specimen to
the increasing load breaks down and no greater load can be sustained. The
maximum load applied to the specimen was recorded. The compressive
strength of the specimen was calculated using Equation (3.1)

P
fc (3.1)
A

where fc is the compressive strength, P is the maximum load applied to the

specimen and A is the cross-sectional area of the specimen.
 37

Figure 3.4 Test set-up for compressive strength

Split tensile strength was evaluated as per the test procedure given
in Indian Standards IS.5816. In order to evaluate the splitting tensile strength
of geopolymer concrete, all the cylinder specimens were subjected to split
tensile strength test in a 2000 kN digital compression testing machine.
Specimens were placed in the machine in a horizontal manner in between the
two parallel steel strips one at top and another at the bottom such that the load
shall be applied along the 300 mm length as shown in Figure 3.5. The load
was applied without shock and increased continuously at a nominal rate
within the range of 1.2 N/(mm2/min) to 2.4 N/(mm2/min) until the specimen
failed. The maximum load applied to the specimen was recorded and the split
tensile strength of the specimen was calculated using Equation (3.2)

2P
ft (3.2)
DL

where ft is the split tensile strength, P is the maximum load applied to the
specimen , D is the diameter of the specimen and L is the length of the
specimen.
 38

Figure 3.5 Test set-up for split tensile strength

Flexural strength of geopolymer concrete was determined using

prism specimens by subjecting them to two point bending in Universal
Testing Machine having a capacity of 1000 kN. Specimens were placed in the
machine in such a manner that the load shall be applied to the uppermost
surface as cast in the mould along two lines spaced at 13.3 cm apart as shown
in Figure 3.6. The load was applied without shock and increased continuously
at a rate of 1800 N/min until the specimen failed. The maximum load applied
to the specimen was recorded and the flexural strength of the specimen was
calculated using Equation (3.3)

Pl
fr (3.3)
bd 2

where fr is the flexural strength, P is the maximum load applied to the

specimen , l is the supported length of the specimen , b is the width of the
specimen and d is the depth of the specimen.
 39

Figure 3.6 Test set-up for flexural strength

3.3 RESULTS AND DISCUSSION

3.3.1 Workability

Workability of freshly prepared geopolymer concrete mixes was

measured in terms of its slump using the conventional slump cone apparatus.
All the mixtures were generally cohesive and shiny in appearance due to the
presence of sodium silicate. Even though the measured slump values are more
than 150mm, all the mixtures were generally stiff and the workability was
poor. Geopolymer concrete prepared by using fly ash from Tuticorin thermal
power station has better workability than the geopolymer concrete prepared
from Mettur fly ash. Workability of geopolymer concrete decreases as the
concentration of NaOH in the alkaline activator solution increases irrespective
of the source of fly ash as shown in Figure 3.7. This may be due to the reason
that increasing the concentration of NaOH increases the total solid content in
the mixture thereby reducing the water content.
 40

210
202 MFA
200 TFA
194
190
190
182
180
180
173
170

160

150
8M 12M 16M

Figure 3.7 Effect of concentration of NaOH on workability

3.3.2 Density

Density of geopolymer concrete for all the mixes is given in

Table 3.3. Average density values of geopolymer concrete range from 2337 to
2405 kg/m3 and 2316 kg/m3 to 2397 kg/m3 for Mettur fly ash and Tuticorin fly
ash, respectively as shown in Figure 3.8. Variation of density is not much
significant with respect to the source of fly ash, the concentration of NaOH
solution, the type of curing and the age of concrete. The density of
geopolymer concrete was found approximately equivalent to that of
conventional concrete.
 41

Table 3.3 Density of geopolymer concrete

Avg. Weight Avg. Density

Spec.
in kg kg/m3

Fm M8 Ca A7 8.075 2392.59
Fm M8 Ch A7 7.980 2364.44
Fm M8 Ca A28 8.052 2385.68
Fm M8 Ch A28 7.888 2337.28
Fm M12 Ca A7 7.922 2347.16
Fm M12 Ch A7 8.022 2376.79
Fm M12 Ca A28 8.047 2384.20
Fm M12 Ch A28 8.027 2378.27
Fm M16 Ca A7 8.118 2405.43
Fm M16 Ch A7 8.045 2383.70
Fm M16 Ca A28 7.943 2353.58
Fm M16 Ch A28 8.050 2385.19
Ft M8 Ca A7 8.047 2384.20
Ft M8 Ch A7 8.090 2397.04
Ft M8 Ca A28 7.978 2363.95
Ft M8 Ch A28 7.968 2360.99
Ft M12 Ca A7 7.975 2362.96
Ft M12 Ch A7 8.050 2385.19
Ft M12 Ca A28 7.883 2335.80
Ft M12 Ch A28 7.975 2362.96
Ft M16 Ca A7 7.952 2356.05
Ft M16 Ch A7 8.080 2394.07
Ft M16 Ca A28 7.815 2315.56
Ft M16 Ch A28 8.068 2390.62
 42

MFA, AC MFA, HC TFA, AC TFA, HC

2440

2400

2360

2320

2280
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Specimen number

Figure 3.8 Ranges of density of geopolymer concrete

3.3.3 Compressive Strength

The effect of various factors such as the source of fly ash, the
concentration of NaOH solution in terms of molarity, the curing temperature
namely room temperature curing and heat curing at 60 oC and the age of
concrete at the time of testing, on the compressive strength of geopolymer
concrete has been investigated and presented. Test results of compressive
strength are presented in Table 3.4.

The effect of source of fly ash on the compressive strength of

geopolymer concrete is discussed in terms of compressive strength index. The
compressive strength index is the ratio between the compressive strength of
geopolymer concrete prepared by using Mettur fly ash and the compressive
strength of geopolymer concrete prepared from Tuticorin fly ash for the same
concentration of NaOH, identical curing temperature and at the same age of
concrete.

It was observed that, in case of ambient curing at room temperature,

the compressive strength index is greater than one for all the three molarities
of NaOH solution both at 7 days and 28 days age of concrete as shown in
Figure 3.9. This indicates that the compressive strength of geopolymer
 43

concrete prepared by using Mettur fly ash is higher than that of geopolymer
concrete prepared from Tuticorin fly ash in ambient curing at room
temperature. But in heat curing, compressive strength indices for most of the
cases is less than one which indicates that the compressive strength of
geopolymer concrete prepared by using Tuticorin flyash is greater than that of
geopolymer concrete prepared by using Mettur fly ash in heat curing as
shown in Figure 3.10.

Table 3.4 Compressive strength of geopolymer concrete

Avg. Compressive
Avg. Ultimate load
Spec. Strength
in kN
MPa
Fm M8 Ca A7 124.70 5.54
Fm M8 Ch A7 362.37 16.11
Fm M8 Ca A28 400.70 17.81
Fm M8 Ch A28 434.10 19.29
Fm M12 Ca A7 177.73 7.90
Fm M12 Ch A7 481.87 21.42
Fm M12 Ca A28 498.97 22.18
Fm M12 Ch A28 640.93 28.49
Fm M16 Ca A7 195.13 8.67
Fm M16 Ch A7 489.20 21.74
Fm M16 Ca A28 576.60 25.63
Fm M16 Ch A28 654.87 29.11
Ft M8 Ca A7 85.17 3.79
Ft M8 Ch A7 322.27 14.32
Ft M8 Ca A28 393.37 17.48
Ft M8 Ch A28 463.63 20.61
Ft M12 Ca A7 99.57 4.43
Ft M12 Ch A7 500.83 22.26
Ft M12 Ca A28 399.77 17.77
Ft M12 Ch A28 585.57 26.03
Ft M16 Ca A7 125.13 5.56
Ft M16 Ch A7 560.77 24.92
Ft M16 Ca A28 443.47 19.71
Ft M16 Ch A28 695.83 30.93
 44

2.00 1.78
7 days
1.56
1.46 28 days
1.50 1.30
1.25
1.02
1.00

0.50

0.00
8M 12M 16M

Concentration of NaOH Solution

Figure 3.9 Compressive strength index - ambient curing

1.50
7 days
1.12 1.09 28 days
0.94 0.96 0.94
1.00 0.87

0.50

0.00
8M 12M 16M

Concentration of NaOH Solution

Figure 3.10 Compressive strength index - heat curing

The effect of concentration of NaOH solution on the compressive

strength of geopolymer concrete prepared by using Mettur fly ash is presented
in Figure 3.11. From the test results, it was found that for all the cases,
compressive strength of geopolymer concrete increases as the concentration
of NaOH solution increases. Under heat curing conditions, increasing the
concentration of NaOH from 8 M to 12 M resulted in an enhancement of
compressive strength by about 33% and 48% for 7 days and 28 days
respectively. When the concentration of NaOH solution is further increased
 45

from 12 M to 16 M, the compressive strength also increases by about 2% for

both 7 days and 28 days. Similarly under ambient curing conditions,
increasing the concentration of NaOH from 8 M to 12 M resulted in an
improvement of compressive strength by about 43% and 25% for 7 days and
28 days respectively. When the concentration of NaOH solution is further
increased from 12M to 16M, the compressive strength also increases by 10%
and 16% for 7 days and 28 days respectively.

35
AC, 7days
30
HC, 7 da ys
25 AC, 28 da ys
20 HC, 28 days
15
10
5
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.11 Effect of concentration of NaOH -Mettur fly ash

For geopolymer concrete prepared by using Tuticorin fly ash, the

effect of concentration of NaOH solution on the compressive strength is
presented in Figure 3.12. From the test results, it can be seen that the
compressive strength of geopolymer concrete increases as the concentration
of NaOH solution increases for all the cases. Under heat curing conditions,
increasing the concentration of NaOH solution from 8 M to 12 M resulted in
the compressive strength enhancement of 55% and 26% for 7 days and
28 days respectively. When the concentration of NaOH solution is further
increased from 12 M to 16 M, the compressive strength also increases by
about 12% and 19% for 7 days and 28 days respectively. Similarly under
ambient curing conditions, increasing the concentration of NaOH from 8 M to
 46

12 M resulted in an improvement of compressive strength by about 17% and

2% for 7 days and 28 days respectively. When the concentration of NaOH
solution is further increased from 12 M to 16 M, the compressive strength
also increases by 26% and 11% for 7 days and 28 days respectively.

35
AC, 7days
30 HC, 7 da ys
25 AC, 28 days
20 HC, 28 days

15
10
5
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.12 Effect of concentration of NaOH - Tuticorin fly ash

Due to heat curing, the compressive strength is improved for both

the sources of fly ash at all concentrations of NaOH solution in 7 days and 28
days. The gain in compressive strength due to heat curing for geopolymer
concrete prepared by using Mettur fly ash and Tuticorin fly ash is presented in
Figure 3.13 and Figure 3.14 respectively. For geopolymer concrete prepared
by using Mettur fly ash, at 7 days age of concrete, the gain in compressive
strength due to heat curing is about 191%, 171% and 151% for 8 M, 12 M and
16 M concentrations of NaOH solution respectively. Similarly at 28 days, the
gain in compressive strength is about 8%, 28% and 14% for 8 M, 12 M and
16 M concentrations of NaOH solution respectively. In case of geopolymer
concrete prepared by using Tuticorin fly ash, at 7 days age of concrete, the
gain in compressive strength due to heat curing is about 278%, 403% and
348% for 8 M, 12 M and 16 M concentration of NaOH solution respectively.
Similarly at 28 days, the gain in compressive strength is about 18%, 46% and
 47

57% for 8 M, 12 M and 16 M concentration of NaOH solution respectively.

From the test results it was observed that heat curing resulted in an
enhancement of compressive strength at early ages only and the increase in
compressive strength is not much significant after 7 days.

200 190.59
171.12
175 7 days
150.70
150 28 days

125
100
75
50 28.45
25 8.34 13.57
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.13 Effect of heat curing - Mettur fly ash

450 403.01 7 days

400
348.14 28 days
350
300 278.40
250
200
150
100 56.91
46.48
50 17.86
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.14 Effect of heat curing - Tuticorin fly ash

From the test results it was observed that, as the age of the concrete
increases from 7 days to 28 days, the compressive strength also increases for
all the specimens. But the rate of increase in compressive strength with age of
 48

concrete is more significant in case of ambient curing at room temperature

when compared with heat curing at 60oC.

3.3.4 Split Tensile Strength

The effect of various factors such as the source of fly ash, the
concentration of NaOH solution, the curing temperature and the age of
concrete on the split tensile strength of geopolymer concrete has been
investigated and presented. Test results of split tensile strength are presented
in Table 3.5.

The effect of source of fly ash on the split tensile strength of

geopolymer concrete is discussed in terms of split tensile strength index. Split
tensile strength index is the ratio between the split tensile strength of
geopolymer concrete prepared by using Mettur fly ash and the split tensile
strength of geopolymer concrete prepared by using Tuticorin fly ash for the
same concentration of NaOH, identical curing temperature and at the same
age of concrete. It was observed that, in case of ambient curing at
room temperature, the split tensile strength index is greater than one for all the
three molarities of NaOH solution both at 7 days and 28 days as shown in
Figure 3.15. This indicates that the split tensile strength of geopolymer
concrete prepared by using Mettur fly ash is higher than that of geopolymer
concrete prepared by using Tuticorin fly ash in ambient curing at room
temperature. Similarly in heat curing, split tensile strength indices for most of
the cases is greater than one which indicates that the split tensile strength of
geopolymer concrete prepared by using Mettur fly ash is higher than that
of geopolymer concrete prepared by using Tuticorin fly ash as shown in
Figure 3.16.
 49

Table 3.5 Split tensile strength of geopolymer concrete

Avg. Split
Avg.
tensile
Spec. Ultimate
Strength
load in kN
MPa
Fm M8 Ca A7 14.33 0.20
Fm M8 Ch A7 63.60 0.90
Fm M8 Ca A28 68.43 0.97
Fm M8 Ch A28 88.10 1.25
Fm M12 Ca A7 18.93 0.27
Fm M12 Ch A7 76.70 1.09
Fm M12 Ca A28 82.47 1.17
Fm M12 Ch A28 94.13 1.33
Fm M16 Ca A7 24.63 0.35
Fm M16 Ch A7 102.73 1.45
Fm M16 Ca A28 97.20 1.38
Fm M16 Ch A28 107.57 1.52
Ft M8 Ca A7 8.30 0.12
Ft M8 Ch A7 52.77 0.75
Ft M8 Ca A28 57.23 0.81
Ft M8 Ch A28 65.97 0.93
Ft M12 Ca A7 14.80 0.21
Ft M12 Ch A7 72.53 1.03
Ft M12 Ca A28 65.67 0.93
Ft M12 Ch A28 101.67 1.44
Ft M16 Ca A7 24.00 0.34
Ft M16 Ch A7 100.10 1.42
Ft M16 Ca A28 83.47 1.18
Ft M16 Ch A28 172.20 2.44
 50

1.80 1.67
7 days
1.50 28 da ys
1.29 1.26
1.20 1.17
1.20 1.03

0.90

0.60

0.30

0.00
8M 12M 16M

Concentration of NaOH Solution

Figure 3.15 Split tensile strength index - ambient curing

1.50 1.34
7 days
1.20
1.20 1.06 28 da ys
1.02
0.92
0.90
0.62
0.60

0.30

0.00
8M 12M 16M

Concentration of NaOH

Figure 3.16 Split tensile strength index - heat curing

The effect of concentration of NaOH solution on the split tensile

strength of geopolymer concrete prepared by using Mettur fly ash is presented
in Figure 3.17. From the test results, it was found that split tensile strength of
geopolymer concrete increases as the concentration of NaOH solution
increases for all the cases. Under heat curing conditions, increasing the
concentration of NaOH solution from 8 M to 12 M resulted in an
enhancement of split tensile strength by about 21% and 7% for 7 days and 28
days respectively. When the concentration of NaOH solution is further
 51

increased from 12 M to 16 M, the split tensile strength also increases by about

34% and 14% for 7 days and 28 days respectively. Similarly under ambient
curing conditions, increasing the concentration of NaOH from 8 M to 12 M
resulted in an enhancement of split tensile strength by about 32% and 21% for
7 days and 28 days respectively. When the concentration of NaOH solution is
further increased from 12 M to 16 M, the split tensile strength also increases
by 30% and 18% for 7 days and 28 days respectively.

1.6
AC, 7da ys
1.2 HC, 7 da ys
AC, 28 days

0.8 HC, 28 da ys

0.4

0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.17 Effect of concentration of NaOH - Mettur fly ash

The effect of concentration of NaOH solution on the split tensile

strength of geopolymer concrete prepared by using Tuticorin fly ash is
presented in Figure 3.18. From the test results, it was found that split tensile
strength of geopolymer concrete increases as the concentration of NaOH
solution increases for all the cases. Under heat curing conditions, increasing
the concentration of NaOH from 8 M to 12 M resulted in an enhancement of
split tensile strength by about 37% and 54% for 7 days and 28 days
respectively. When the concentration of NaOH solution is further increased
from 12 M to 16 M, the split tensile strength also increases by about 38% and
69% for 7 days and 28 days respectively. Similarly under ambient curing
conditions, increasing the concentration of NaOH solution from 8 M to 12 M
 52

resulted in an improvement of split tensile strength by about 78% and 15% for
7 days and 28 days respectively. When the concentration of NaOH solution is
further increased from 12 M to 16 M, the split tensile strength also increases
by 62% and 27% for 7 days and 28 days respectively.

2.5
AC, 7da ys
2 HC, 7 days
AC, 28 da ys
1.5 HC, 28 days

0.5

0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.18 Effect of concentration of NaOH - Tuticorin fly ash

Due to heat curing, the split tensile strength is improved for both
the sources of fly ash, at all the concentrations of NaOH solution in 7 days
and 28 days. The gain in split tensile strength due to heat curing for
geopolymer concrete prepared by using Mettur fly ash and Tuticorin fly ash is
presented in Figure 3.19 and Figure 3.20 respectively. For geopolymer
concrete prepared by using Mettur fly ash, at the age of 7 days, the gain in
split tensile strength due to heat curing is about 344%, 305% and 317% for 8
M, 12 M and 16 M concentrations of NaOH solution respectively. Similarly at
28 days, the gain in split tensile strength is about 29%, 14% and 11% for 8 M,
12 M and 16 M concentrations of NaOH solution respectively. In case of
geopolymer concrete prepared by using Tuticorin fly ash, at 7 days, the gain
in split tensile strength due to heat curing is about 536%, 390% and 317% for
8 M, 12 M and 16 M concentrations of NaOH solution respectively. Similarly
at the age of 28 days, the gain in split tensile strength is about 15%, 55% and
 53

106% for 8 M, 12 M and 16 M concentrations of NaOH solution respectively.

From the test results it was observed that heat curing resulted in an
enhancement of split tensile strength at early ages only. The effect of heat
curing on the increase in split tensile strength is not much significant after
7 days as evidenced from the test results.

350 343.72
305.11 317.05
7 days
300
28 da ys
250
200
150
100
50 28.74
14.15 10.67
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.19 Effect of heat curing - Mettur fly ash

600 535.74
500
390.09
400
317.08
300
7 days
200
106.31 28 da ys
100 54.82
15.26
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.20 Effect of heat curing - Tuticorin fly ash

From the test results it was also noted that, as the age of the
concrete increases from 7 days to 28 days, the split tensile strength also
 54

increases for all the specimens. But the rate of increase in split tensile strength
with age of concrete is more significant in case of ambient curing at room
temperature in comparison with heat curing at 60oC.

3.3.5 Flexural Strength

The effect of various factors such as the source of fly ash, the
concentration of NaOH solution and the curing temperature on the flexural
strength of geopolymer concrete has been investigated and presented. Test
results of flexural strength are presented in Table 3.6.

Table 3.6 Flexural strength of geopolymer concrete

Avg.
Avg. Ultimate Flexural
Spec.
load in kN Strength
MPa
Fm M8 Ca A28 10.0 4.00
Fm M8 Ch A28 11.7 4.67
Fm M12 Ca A28 12.5 5.00
Fm M12 Ch A28 13.5 5.40
Fm M16 Ca A28 15.0 6.00
Fm M16 Ch A28 19.2 7.67
Ft M8 Ca A28 7.7 3.07
Ft M8 Ch A28 9.7 3.87
Ft M12 Ca A28 11.0 4.40
Ft M12 Ch A28 12.2 4.87
Ft M16 Ca A28 14.0 5.60
Ft M16 Ch A28 17.0 6.80

The effect of source of fly ash on the flexural strength of

geopolymer concrete is discussed in terms of flexural strength index. Flexural
strength index is the ratio between the flexural strength of geopolymer
 55

concrete prepared by using Mettur fly ash and the flexural strength of
geopolymer concrete prepared by using Tuticorin fly ash for the same
concentration of NaOH, identical curing temperature and at 28 days age of
concrete. It was observed that, the flexural strength index is greater than one
for all the three molarities of NaOH solution both in ambient curing and heat
curing as shown in Figure 3.21. This indicates that the flexural strength of
geopolymer concrete prepared by using Mettur fly ash is greater than that of
geopolymer concrete prepared by using Tuticorin fly ash.

1.40 1.30
1.21 AC
1.20 1.14 1.11 1.13
1.07 HC
1.00
0.80
0.60
0.40
0.20
0.00
8M 12M 16M

Concentration of NaOH Solution

Figure 3.21 Flexural strength index

The effect of concentration of NaOH solution on the flexural

strength of geopolymer concrete is presented in Figure 3.22. From the test
results, it was found that flexural strength of geopolymer concrete increases as
the concentration of NaOH solution increases for all the cases. For
geopolymer concrete prepared by using Mettur fly ash, increasing the
concentration of NaOH solution from 8 M to 12 M resulted in an
improvement of flexural strength by about 16% under heat curing conditions.
The flexural strength also increases by about 42% when the concentration of
NaOH solution is further increased from 12 M to 16 M. Similarly under
ambient curing conditions, increasing the concentration of NaOH from 8 M to
 56

12 M resulted in an enhancement of flexural strength by 25%. When the

concentration of NaOH solution is further increased from 12 M to 16 M, the
flexural strength gets increased by 20%. In case of geopolymer concrete
prepared by using Tuticorin fly ash, increasing the concentration of NaOH
from 8 M to 12 M resulted in an improvement of flexural strength by about
26% when cured at 60 oC. The flexural strength also increases by about 40%
when the concentration of NaOH solution is further increased from 12 M to
16 M. Similarly under ambient curing conditions, increasing the concentration
of NaOH from 8 M to 12 M resulted in an enhancement of flexural strength
by 43%. When the concentration of NaOH solution is further increased from
12 M to 16 M, the flexural strength gets increased by 27%.

8
MFA, AC
7
MFA, HC
6
TFA, AC
5
TFA, HC
4
3
2
1
0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.22 Effect of concentration of NaOH on flexural strength

The flexural strength is improved due to heat curing for both

sources of fly ash at all concentrations of NaOH solution. The gain in flexural
strength due to heat curing is presented in Figure 3.23. For Mettur fly ash
geopolymer concrete, the gain in flexural strength due to heat curing is about
17%, 8% and 28% for 8 M, 12 M and 16 M concentrations of NaOH solution
respectively. In case of Tuticorin fly ash geopolymer concrete, the gain in
 57

flexural strength due to heat curing is about 26%, 11% and 21% for 8 M, 12
M and 16 M concentrations of NaOH solution respectively.

30 27.78
26.09 MFA
25 TFA
21.43
20 16.67
15
10.61
10 8

0
8M 12M 16M

Concentration of NaOH Solution

Figure 3.23 Gain in flexural strength due to heat curing

3.4 CONCLUSIONS

Based on the results obtained in this investigation, the following

conclusions are drawn:

Geopolymer concrete prepared by using fly ash obtained from

Tuticorin thermal power station has better workability than the
geopolymer concrete prepared from Mettur based fly ash.
Irrespective of the source of fly ash, workability of geopolymer
concrete decreases as the concentration of sodium hydroxide in
the alkaline activator solution increases.

The average density values of geopolymer concrete ranges from

2316 kg/m3 to 2405 kg/m3 which was found approximately
closer to that of ordinary Portland cement concrete. Variation of
density is not much significant with respect to the source of fly
ash, the concentration of NaOH solution, the type of curing and
the age of concrete.
 58

Compressive strength of Mettur fly ash geopolymer concrete is

higher than that of Tuticorin fly ash based geopolymer concrete
in ambient curing at room temperature.

Compressive strength of geopolymer concrete increases as the

concentration of NaOH solution increases. This is applicable
for all the curing temperatures, age of concrete and sources of
fly ash.

Rate of increase in compressive strength and split tensile

strength with respect to the age of concrete is more significant
in case of ambient curing at room temperature in comparison
with heat curing at 60 oC.Heat curing resulted in an enhancement
of compressive strength and split tensile strength at early ages
only. The effect of heat curing on the increase in compressive
strength and split tensile strength is not much significant after
7 days.

For the same concentrations of NaOH, identical curing

temperature and the age of concrete, split tensile strength and
flexural strength is higher in case of mettur fly ash based
geopolymer concrete.

Geopolymer concrete did not harden immediately at room

temperature as in conventional concrete. Geopolymer concrete
specimens took a minimum of 3 days for complete setting
without leaving a nail impression on the hardened surface.
These two observations are considered as drawbacks of this
concrete to be used for practical applications.