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Construction and Building Materials 126 (2016) 560–565

Contents lists available at ScienceDirect

Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

Mechanical properties of fly ash based geopolymer concrete with full


and partial cement replacement
Hamdy K. Shehab (Ph.D.), Ahmed S. Eisa (Ph.D.) ⇑, Ahmed M. Wahba
Department of Structural Engineering, Faculty of Engineering, Zagazig University, Zagazig 44519, Egypt

h i g h l i g h t s

 18 concrete mixtures were produced mechanical properties of geopolymer concrete.


 Key factors are binder material, cement replacement ratios, and activator ratio.
 It was found that mechanical properties achieved at a replacement ratio of 50%.

a r t i c l e i n f o a b s t r a c t

Article history: Concrete is the most widely used building material in the construction of infrastructures such as build-
Received 24 February 2016 ings, bridges, highways, dams, and many other facilities. The increasing of worldwide production of ordi-
Received in revised form 8 August 2016 nary Portland cement (OPC) to meet infrastructure developments indicates that concrete will continue to
Accepted 17 September 2016
be a chosen as the most common material of construction in the future. The production of cement con-
sumes a lot of energy and increase CO2 emission to the atmosphere. Another alternative to make
environment-friendly concrete is the development of geopolymer which is an inorganic alumina-
Keywords:
silicate polymer, synthesized from materials of geological origin or by-product materials such as fly
Geopolymer concrete
Fly ash
ash which is rich in silicon and aluminum. In this paper 18 concrete mixtures were produced to evaluate
Compressive strength the effect of key parameters on the mechanical properties of concrete and its behavior. The study key
Bond strength parameters are; binder material content, cement replacement ratios, and the activator solution ratio as
Flexural strength a fly ash based geopolymer. The test results showed that replacement of fly ash as-based geopolymer
improved the mechanical properties of concrete. Compressive strength, splitting tensile strength, flexural
strength and bond strength are on higher side for 50% replacement as compared to those produced from
0%, 25%, 75% and 100% cement replacement ratio.
Ó 2016 Elsevier Ltd. All rights reserved.

1. Introduction cement industry contributes around 2.8 billion tons of the green-
house gas emissions annually, or about 7% of the total man-made
Concrete production and industry increases daily due to the greenhouse gas emissions to the earth’s atmosphere [1].
high demand of infrastructure services [1,2]. The projections for Geopolymer concrete research that has been developed o at
the whole increase in the cement industry will hit the 6 Gt/year Curtin University of Technology was triggered by several studies
[3]. It is well known that CO₂ emissions contribute about 65% of on the geopolymer paste previously conducted by others [10] used
global warming and t is predictable to increase by 100% by 2020 slag to produce geopolymer binders to be used as a supplementary
[4]. The cement industry produces many other environmentally cementing material (SCMs). Geopolymer has been using as an
harmful products like sulfur dioxide (SO3) and nitrogen oxides adhesive in strengthening structural members and showed [11]
(NOx) [5] which contribute to the global warming factors [6–9]. that the compressive strength after 14 days was in the range of
The contamination raised from cement production pushed the con- 5–10 MPa. Production of geopolymer concrete takes into account
crete community to find many alternatives to decrease the CO2 various factors t to be considered and which has a great impact
emission. One of those solutions is the geopolymer concrete. The on the strength; the mixing procedure and the CaO content found
in the fly ash. The higher the content of CaO, the higher strength
⇑ Corresponding author. and lower the porosity. In addition to the aforementioned factors,
E-mail addresses: hshehabeldin@yahoo.com (H.K. Shehab), ahmedeisa@zu.edu. it was found by [12] that the curing temperature and time have a
eg (A.S. Eisa). great influence on the strength as well. To obtain a very high

http://dx.doi.org/10.1016/j.conbuildmat.2016.09.059
0950-0618/Ó 2016 Elsevier Ltd. All rights reserved.
H.K. Shehab et al. / Construction and Building Materials 126 (2016) 560–565 561

strength in geopolymer concrete, it is recommended to add the Table 2


two solutions of NaOH + Na2 O.SiO2. as an activator solution for Properties of cement.

cement hydration [13] and that will help obtaining an optimum Property Results E.S.S limits⁄
strength at 60 °C for a curing time of 48 h by mixing fly ash, kaolin- Consistency of standard Water content as percentage 26%–33%
ite, sodium silica solution, NaOH, and water. The 60° is the temper- cement paste by weight of cement = 0.5%
ature needed to start the geopolymerization process. Setting time Initial = 1 h, 30 min Min. 45 min
The addition of sucrose and citric acid as an alternative admix- Final = 4 h, 30 min Max. 10 h
Compressive strength 3 days = 250 kg/cm2 Min. 180 kg/cm2
ture in fly ash based geopolymer has portrayed an encouraging 7 days = 340 kg/cm2 Min. 270 kg/cm2
results, particularly in the modification of rheological properties Fineness of cement 3300 cm2/gm Min. 2750 cm2/gm
of geopolymer paste [14]. Sucrose tends to provide a retardation ⁄
E.S.S: Egyptian standard specifications.
effect to the plastic geopolymer paste, while citric acid can be used
to accelerate the stiffening process. Even though improvement on
the compressive strength was not optimized, sucrose-added spec-
imens have a comparable compressive strength to the control
Table 3
specimen. The additional precipitation of dissolved species in the
Physical and chemical properties of Fly Ash.
presence of sucrose has also affected the evaluation of porosity
characteristic. Contrasting to citric acid, sucrose-added specimen Property Measured Value
has an unconventional relationship between porosity and com- Physical properties
pressive strength, where smaller porosity is correlated with lower Color Grey (Blackish)
compressive strength [14]. Nevertheless, these chemical reagents Specific gravity 2.13

have presented a prospective future as the alternative admixture Chemical properties


basis in geopolymer binder [14]. Silica (SiO2) 57.9
Iron Oxide (Fe2O3) 5.07
In this study concrete mixtures were prepared and tested to Alumina (Al2O3) 31.11
investigate the mechanical properties of geopolymer concrete Calcium Oxide (CaO) 1.29
and its behavior under a partial and complete replacement of Magnesium Oxide (MgO) 0.97
cement. The key parameters were; the binder material content, Total Sulphr (SO3) 0.05
Sodium Oxide (Na2O) 0.09
cement replacement ratios, and the activator solution ratio from
Potassium Oxide (K2O) 1.0
fly ash based geopolymer as will be discussed on the coming Loss on ignition(LOI) 0.8
section. CL 0.04

2. Experimental program
erties of fly ash are shown in Table 3. The alkali used consisted of a
2.1. Material properties and mix proportions mixture of NaOH, and Na2SiO3 solution. NaOH pellets of 98% purity
were used to make NaOH solution of desired molarity. The Na2SiO3
Table 1 shows the mix proportions used in this study. Ordinary solution had 34.64% SiO, 16.27% Na2O and 49.09% Water. The
Portland cement type (I) with high grade 52.5N and fly Ash (FA) specific gravity of alkali liquid solution with molarity 10 was 1.54.
was used as cementitious materials. The chemical compositions The mixing procedure used for geopolymer concrete is similar
and physical properties of the cementitious materials are listed to that of conventional P-C concrete. Mixing of all the materials
in Table 2. For all test specimens, a constant w/c ratio of 0.5 was has been done in the laboratory at room temperature. The fly ash
used. Sand with grain size smaller than 5.0 mm was used. and the aggregate were mixed together in concrete pan mixture.
Uncrushed natural gravel graded from 4.76 mm to 15.0 mm was The mixing was allowed to continue for about 3 to 4 min. The
used as a coarse aggregate. Fly ash (FA) used in this study in con- alkaline solution was prepared one day before mixing and was
formance with ASTM C-618 [15]. The chemical and physical prop- added with additional water during the mix. The liquid component

Table 1
Mix proportions.

Group Cement (kg/m3) Fly ash (kg/m3) Solution (kg/m3) Water (kg/m3) Sand (kg/m3) Gravel(kg/m3) Gravel(kg/m3)
NaOH LSS 4.76-10 mm 10–15 mm
Group(1) G10 300 0 0 0 150 809.70 607.27 607.27
G125 225 75 11.786 29.46 125.19 795.35 596.51 596.51
G150 150 150 23.57 58.93 100.38 780.99 585.74 585.74
G175 75 225 35.36 88.39 75.57 766.64 574.98 574.98
G1100 0 300 47.14 117.86 50.76 752.29 564.22 564.22
Group(2) G225 225 75 9.64 24.10 129.70 795.73 596.79 596.79
G250 150 150 19.29 48.21 109.40 781.76 586.32 586.32
G275 75 225 28.93 72.32 89.11 767.79 575.85 575.85
G2100 0 300 38.57 96.43 68.81 753.83 565.37 565.37
Group(3) G30 350 0.00 0.00 0.00 175.00 765.85 574.39 574.39
G325 262.5 87.5 13.75 34.38 146.06 749.11 561.83 561.83
G350 175 175 27.5 68.75 117.11 732.36 549.27 549.27
G375 87.5 262.5 41.25 103.13 88.17 715.62 536.71 536.71
G3100 0 350 55 137.50 59.23 698.87 524.15 524.15
Group(4) G425 262.5 87.5 11.25 28.13 151.32 749.56 562.17 562.167
G450 175 175 22.5 56.25 127.64 733.26 549.95 549.95
G475 87.5 262.5 33.75 84.38 103.96 716.97 537.72 537.72
G4100 0 350 45 112.50 80.28 700.67 525.50 525.50
562 H.K. Shehab et al. / Construction and Building Materials 126 (2016) 560–565

was added to the dry material and the mixing was continued for allowed to cure for 28 days. ASTM C78/C78M-16 [17] (Flexural
another 3 to 4 min. The fresh concrete was cast into the molds strength under four point bending) was used to investigate the
immediately after mixing in two layers for prismatic specimens. flexural strength of the proposed mixtures. This test consists of
The compaction of the concrete specimens was performed for mul- loading a small-scale prism at the middle third points, to create a
tiple layers each given 25 to 35 manual strokes using 20 mm rod. constant moment region. The load and deflection were recorded
Concrete specimens were vibrated using vibration table for so the data could be analyzed to give the, and the flexural strength
another 10 to 15 s. Three specimens were tested at 7 days and of the tested specimen. All defections measurements were taken
three at 28-days, for the compressive strength test. Three speci- using LVDTs at the midspan of all beams. The flexural strength
mens were tested at 28-days to investigate the tensile strength was calculated as follows:
test. The samples were left for 24 h and then the samples were
3PL
demolded and placed in the oven under a temperature of F tb ¼ 2
ð1Þ
(100 °C) for 24 h and then taken out of the oven to be air cured 2bd
for 5–6 h at room temperature and after that all specimens were where
stored in the a temperature controlled water (40 °C) till the day
of testing at 28 days of curing as shown in Fig. 1. P = Failure load;
L = Centre to center distance between the support = 400 mm;
2.2. Mechanical properties and the testing procedure b = Average specimen width = 100 mm;
d = Average specimen depth = 100 mm.
2.2.1. Compression test
The compression test was carried – out on cube specimens 2.2.3. Split-tension Test
(100  100  100) mm at 28 days of curing. The calculated values Splitting or indirect tensile test was carried out on cylindrical
of compressive strength represented the average results of three specimens of 100 mm diameter and 200 mm height according to
specimens. Compression tests were performed according to the ASTM C 496-11 [18] at 28 days curing. ASTM C496 indicates that
ASTM C39/C39M-16a [16] standard test method for cubes. The the maximum tensile stress can be calculated based on Eq. (2). In
compressive strength test was performed using a compression this equation, P is the applied load applied r, L and D are the length
machine with 1500 kN capacity and at a loading rate of 140 to and diameter, respectively and Fh is the tensile strength.
300 kPa = s until failure.
F h ¼ 2P=p LD ð2Þ
2.2.2. Flexural strength test
Flexural strength test was conducted on (100  100  500) mm 2.2.4. Bond stress test
prism specimens. The specimens were demolded after 24 h of Pull out test was carried out according to ASTM C900-15 [19]
casting and were transferred to curing tank where they were (100 mm diameter and 200 mm height) cylindrical specimens.

Fig. 1. a) Specimens in Oven and b) air cured specimens.


H.K. Shehab et al. / Construction and Building Materials 126 (2016) 560–565 563

Conventional steel bars with diameter 12 mm was embedded into F h ¼ 2P=p Ld ð3Þ
standard cylinder. The reported values for bond strength represent
where: P: the failure load, L: specimen length, and d: specimen
the average results of three specimens per mixture; the bond
diameter.
strength was calculated as follows:

3. Experimental results and dissusion


Table 4
Compressive strength results.
3.1. Compressive strength
Group Mixture Replacement ratios Compressive
strength (kg/cm2)
Table 4 summarizes the compressive strength test results
7 days 28 day where it showed that the compressive strength increase from a
Group(1) G10 0% 177 250 replacement ratio of 50%, binder material content of 350 kg and
G125 25% 262 302 an activator solution ratio of 0.55% compared with the other test
G150 50% 317 359
parameters. Fig. 2 represents the effect of cement replacement
G175 75% 309 345
G1100 100% 290 320 ratio (binder material content, activator solution ratio) on the com-
pressive strength at age of 28 days. From Fig. 2, it is observed that
Group(2) G225 25% 225 260
G250 50% 266 302 the compressive strength increased by increasing the replacement
G275 75% 259 291 ratio up to 50% then it then decreasing with higher replacement
G2100 100% 244 269 ratios. The compressive strength with binder material content of
Group(3) G30 0% 212 300 300 kg and activator solution ratio of 0.55% increased by 20.8%
G325 25% 310 357 for cement replacement ratio equals.
G350 50% 335 379
25%, by 43.6% for replacement ratio equals 50%, by 38.0% for
G375 75% 335 370
G3100 100% 330 362 replacement ratio equals 75%, and by 28% for replacement ratio
equals 100%, compared to the mixtures with no replacement,
Group(4) G425 25% 262 302
G450 50% 291 329 respectively. It was also observed that the compressive strength
G475 75% 281 310 is increasing when binder material content equal was 350 kg com-
G4100 100% 277 304 pared with the binder material content of 300 kg. The average
results showed that compressive strength at test age of 7 days
roughly equal 89.0% of the compressive strength at 28 days as
400
shown in Fig. 3.
Compressive Strength (Kg/cm2)

350
For geopolymer concrete : Fc ð7 daysÞ ¼ 0:89 Fc ð28 daysÞ ð4Þ
300
250 For Normal Weight concrete : Fc ð7 daysÞ ¼ 0:70 Fc ð28 daysÞ ð5Þ
200
150 cement contant 300Kg and soluon rao0.55% 3.2. Flexural strength behavior
cement contant 300Kg and soluon rao0.45%
100 cement contant 350Kg and soluon rao0.55%
50 cement contant 350Kg and soluon rao0.45% Table 5 lists the results of the flexural testing for different
cement replacement ratios. The first-crack flexural is used as an
0
0% 20% 40% 60% 80% 100% 120% indicator of the maximum tensile stress for the geopolymer con-
Replacment Rao crete. Fig. 4 shows the effect of replacement ratio on flexure
strength from and it can be seen that the flexural strength
Fig. 2. Compressive strength at different replacement ratios. increases by increasing the replacement ratio up to 50% then no
379
370
362

359
357

345
335

335
330
329

320

317
310

310

309
304

302

302

302
300
291

291

290
281
277

269

266
262

262
260
259

250
Compressive Strenth (kg/cm2)

244

225
212

177

Mixture

Fig. 3. Compressive strength at age 7 and 28 days.


564 H.K. Shehab et al. / Construction and Building Materials 126 (2016) 560–565

Table 5 Table 6
Flexural strength results. Splitting Tensile strength results (splitting test).

Group Mixture Replacement ratios Flexure strength (kg/cm2) Group Mixture Replacement ratios Splitting tensile
strength (kg/cm2)
Group(1) G10 0% 29
G125 25% 33.36 Group(1) G10 0% 32.27
G150 50% 39.46 G125 25% 40.59
G175 75% 38 G150 50% 48.77
G1100 100% 34.8 G175 75% 45.22
G1100 100% 42.22
Group(2) G225 25% 29.66
G250 50% 32.9 Group(2) G225 25% 36.06
G275 75% 31.486 G250 50% 41.01
G2100 100% 29.26 G275 75% 38.28
G2100 100% 35.33
Group(3) G30 0% 33.96
G325 25% 39.4 Group(3) G30 0% 38.94
G350 50% 40.8 G325 25% 46.73
G375 75% 39.5 G350 50% 49.58
G3100 100% 35.2 G375 75% 48.08
G3100 100% 43.91
Group(4) G425 25% 35.9
G450 50% 37.71 Group(4) G425 25% 41.26
G475 75% 34.4 G450 50% 44.13
G4100 100% 33.8 G475 75% 41.83
G4100 100% 41.68

45
40 60
Flexural Strength (Kg/cm2)

Splling Tensile Strength (Kg/cm2)


35
50
30
25 40
20
cement contant 300Kg and soluon rao0.55%
15 30
cement contant 300Kg and soluon rao0.45%
10 cement contant 300Kg and soluon rao0.55%
cement contant 350Kg and soluon rao0.55% 20
5 cement contant 300Kg and soluon rao0.45%
cement contant 350Kg and soluon rao0.45%
0 10
cement contant 350Kg and soluon rao0.55%
0% 20% 40% 60% 80% 100% 120%
cement contant 350Kg and soluon rao0.45%
Replacement Rao 0
0% 20% 40% 60% 80% 100% 120%
Fig. 4. Effect of replacement ratios on flexural strength.
Replacement Rao

Fig. 5. The effect of replacement ratio on tensile strength.


significant change was observed, also that the compressive
strength increasing when binder material content equal to 3.4. Bond strength test
350 kg compared with the binder material content equal of
300 kg. From the average results of compressive strength and the A total of 54 cylindrical specimens were casted with several
results of flexure strength shown in Table 5, the relation between cement replacement ratios. The load required for pulling the free
the compressive strength and the flexure strength wasn’t improved end of the steel bar or moving loaded end 0.25 mm was used to cal-
as shown in Eqs. ((6) and (7)). culate the bond strength. Table 7 presents the bond strength
For geopolymer : F ctr ¼ 0:1098F cu ð6Þ
Table 7
For Normal Weight concrete; F ctr ¼ 0:1146 F cu ð7Þ Bond strength results (splitting test).

Group Mixture Replacement ratios Bond strength (kg/cm2)


3.3. Splitting-tension behavior Group(1) G10 0% 42.06
G125 25% 50.38
G150 50% 56.74
Splitting or the indirect tensile test was conducted to determine
G175 75% 54.23
the tensile properties of fly ash based geopolymer concrete. A total G1100 100% 52.3
of 54 cylindrical specimens with diameter 100 mm and height
Group(2) G225 25% 42.39
200 mm were cast with different cement replacement ratios, G250 50% 48.22
Table 6 shows the effect of the cement replacement ratio had on G275 75% 45.73
the tensile strength. Fig. 5 shows that the tensile strength increases G2100 100% 43.87
by increasing replacement ratio up to 50% then decreases with a Group(3) G30 0% 50.53
very slow rate. From the results of compressive strength and the G325 25% 54.72
results of tensile strength as shown in Table 6, Relation between G350 50% 61.04
G375 75% 59.57
average compressive strength and indirect tensile strength was
G3100 100% 58.39
improved as shown in Eqs. ((8) and (9)).
Group(4) G425 25% 50.89
For geopolymer : F t ¼ 0:133 F cu ð8Þ G450 50% 52.96
G475 75% 51.84
G4100 100% 50.96
For Normal Weight concrete F t ¼ 0:129 F cu ð9Þ
H.K. Shehab et al. / Construction and Building Materials 126 (2016) 560–565 565

70 6. It was concluded that the flexural strength equal 10.98% from


compressive strength, the tensile strength equal 13.3% from
Bond Strength (Kg/cm2)

60
compressive strength, and the bond strength equal 16.18% from
50 compressive strength.
7. It was observed that the flexural strength reached 40.8 kg/cm2
40
cement contant 300Kg and soluon rao0.55% at a cement replacement ratio of 50%, with binder material con-
30 tent of 350 kg and an activator solution ratio of 0.55%.
cement contant 300Kg and soluon rao0.45%
8. It was observed that splitting tensile strength have large value
20 cement contant 350Kg and soluon rao0.55%
of 49.58 kg/cm2 at replacement ratio equal 50%, bonder mate-
10 cement contant 350Kg and soluon rao0.45% rial content of 350 kg and activator solution ratio of 0.55%.
9. It was observed that bond strength have large value 61.04 kg/
0
0% 20% 40% 60% 80% 100% 120% cm2 at replacement ratio equal 50%, bonder material content
Replecement Rao 350 kg and activator solution ratio of 0.55%.

Fig. 6. The effect of replacement ratios on bond strength.


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