Fly ash is activated by using alkaline activators and cement is totally replaced from mortar/ concrete.

1. Presented
by
Dr. Subhash V. Patankar
Dr. Sanjay S. Jamkar
Dr. Yuwaraj M. Ghugal
Department of Civil Engineering,
SRES’s, C.O.Engg., Kopargaon

2. INTRODUCTION
Concrete/Mortar:
Abundant resources
Easy operation
Mechanical properties
Durability
Low cost
The world’s cement production
Year 1900 > 10 million tons
Year 2000 > 1.5 billion tons
Year 2009 > 3.0 billion tons
Year 2014 > 3.5 billion tons

3. Source- Thermal Power Station
Annual Production World India
Year 2002 550 million tons 100 million tons
Year 2010 780 million tons 180 million tons
Year 2012 1000 million tons 210 million tons
Utilisation 35-50%
For every ton of fly ash used in place of PC about a ton of
carbon dioxide is prevented from entering the Earth’s
atmosphere and equivalent of 55 gallons of oil[6].
Fly Ash : It is the waste material of thermal power plant,
available abundantly but creates disposal problem.

4. Geopolymer Mortar/Concrete
• Fly Ash – 100 %
+
•Alkaline solution
Inorganic Alumino-Silicate polymer
(Geopolymer)
Polymerization
Fly Ash when in contact with highly alkaline
solutions forms inorganic alumino-silicate polymer
product known as Geopolymer.

5. Davidovits [1979] (Father of Geopolymer)
Palomo
[1999]
Fernandez-Jimenez
[2006]
Wallah
[2005]
Rangan
[2003]
Balguru
[1999]
Dody
[2005]
Rajmane
[2005]
Hardjito
[2005]
Djwantoro
[2003]
Barbosa
[1999]
Anuradha
[2012]
Kong Daniel
[2008]
Zhu Pan
[2009]
Bakharev
[2005]
Kovalchuk
[2007]

6. Low cost
Easily available
Good properties
Geopolymer
Simple processing
Low energy consumption
Low CO2 generation
Low water requirement
Fly ash

7. Cement concrete Geopolymer concrete
Water curing. Temperature curing.
Max. strength is achieved in
28 days.
Max. strength is achieved in
24 hours.
Not Eco-friendly. Eco-friendly.
Cement used as a binding
material.
Alkaline activators react
with Fly ash and forms
binding material.
Reaction is hydration. Reaction is polymerization.
COMPARISION

8. AIM OF THE INVESTIGATION
The main aim of the investigation is to
reduce green house effect due to cement and
concrete/Mortar industries by replacing
cement totally from concrete and the
utilisation of industrial waste like fly ash
and reduce the self weight of structural
element using Ferrocement Technology.

9. OBJECTIVES OF THE INVESTIGATION
 The objective of the investigation is to produce
Geopolymer Mortar using Fly ash as source material
instead of cement and activated by alkaline solutions like
Sodium hydroxide and Sodium silicate under natural
sunlight curing.
 To study the effect of concentration of sodium
hydroxide, solution-to-fly ash ratio on workability and
compressive strength for different natural curing period.

10. • Low calcium fly ash obtained from National Thermal
Power plant at Eklahare, Nashik was used as source
material.
• Godavari River Sand graded similar to standard sand
after sieving and mixing as per IS 650 was used as a filler
material.
• Laboratory grade sodium hydroxide in flake form (97.8 %
purity) and Sodium silicate (50.72% solids) solution were
used as alkaline activators.
• The alkaline solution-to-fly ash were considered as 0.40,
0.45 and 0.50.
EXPERIMENTAL WORK

11. * Mix proportion of Mortar : 1 : 3
* Sand (Grade – I) : 1/3
* Sand (Grade – II) : 1/3
* Sand (Grade – III) : 1/3
* Water-to-Geopolymer binder ratio : 0.2625
* No. of alkaline activators used : 2
* Sodium silicate–to-sodium hydroxide rate : 1
* Concentration of Sodium silicate solution
(a) Na2O : 16.37%
(b) SiO2 : 34.35%
(c) H2O : 49.28%
* Type of curing : Natural Sunlight
Constant Parameters Used for Production
of GPM

12. Sr.
No
.
Physical properties Processed
fly ash
Specification as
per
IS 3812-1981
1 Colour Light gray ----
2 Residue retained on 45 µm 07.67 % 34 % max.
3 Specific Surface Area
(Blaine)
589 m2/Kg 320 m2/Kg
4 Specific gravity 2.25 ----
5 Moisture content 0.45 % 2 % max.
6 Autoclave expansion 0.024% 0.8 %
7
Lime Reactivity- N/mm2
8.2
----
8 Strength Factor at 28 days
-% of control
96.41
----
Physical Properties of Fly ash

13. Sr. No. Chemical composition Percentage
1 SiO2 77.10
2 Al2O3 17.71
3 Fe2O3 01.21
4 MgO 0.90
5 SO3 2.20
6 Na2O 0.80
7 CaO 0.62
8 Total chlorides 0.03
9 Loss of ignition 0.87
Chemical Compositions of Fly Ash

14. Effect of NaOH Concentration on Flow of GPM at
Solution-to-fly ash ratio of 0.40

15. Effect of NaOH Concentration on Flow of GPM at
Solution-to-fly ash ratio of 0.45

16. Effect of NaOH Concentration on Flow of GPM at
Solution-to-fly ash ratio of 0.50

17. Effect of NaOH Conc. on Compressive
Strength for Solutions-to-Fly ash Ratio of 0.40

18. Effect of NaOH Conc. on Compressive Strength for
Solutions-to-Fly ash Ratio of 0.45

19. Effect of NaOH Conc. on Compressive
Strength for Solutions-to-Fly ash Ratio of 0.50

20. Conclusions
 Geopolyner mortar is the best alternative to the
cement mortar which utilized the industrial waste
and help in reducing environmental pollution.
 Higher concentration of sodium hydroxide solution
in terms of molarity, results in higher workability
and compressive strength .
 But higher concentration of NaOH solution gives
viscous mix which ultimately reduces workability
specifically after 11M NaOH concentration.
 Higher solution-to-fly ash ratio did not show
significant variation in compressive strength of
geopolymer mortar at later stage of curing.

21. REFERENCES
 Davidovits J. (1991), “Geopolymers: inorganic polymeric new
materials”, Journal of Thermal Analysis, Vol. 37, pp. 1633-1656.
 Hardjito, D., Wallah S.E., Sumajouw D.M.J. and Rangan B.V.
(2004), “On the development of fly ash-based geopolymer
concrete”, ACI Materials Journal, Vol.101, No.6, pp 467-472.
 Davidovits J. (1994), “Geopolymers: Man-made geosynthesis and
the resulting development of very early high strength cement”, J.
Materials Education, Vol.16, pp. 91-139.
 Malhotra V.M. (1999), “Making concrete greener with fly ash”,
ACI Concrete International, Vol. 21, No.5, pp. 61-66.
 Davidovits J. (1994), “Global warming impact on the cement and
aggregate industries”, World Resource review, Vol. 6, No. 2, pp.
263-278.

22. Geopolymer Mortar- Flow Test and Hardebed Mortar Cubes at
Various Solution-to-Fly Ash Ratios

23. Construction of Ferro-Geo Roof Slab at Happy Thoughts
Centre, Kopargaon

24. Construction of
Ferro-Geo Roof Slab
at
Happy Thoughts
Centre, Kopargaon

25. Thank
You
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