The document discusses the rheological properties of geopolymer concrete incorporating fly ash and metakaolin. It involves an experimental investigation to evaluate the workability, flowability, and stability of the fresh geopolymer concrete mixture. Preliminary results found that the inclusion of 80% fly ash and 20% metakaolin affected the rheological behavior of the concrete. Rheological tests revealed that the fresh concrete exhibited good workability and flowability within a specified range of water-to-binder ratio and superplasticizer dosage.

1. i
A MINI PROJECT REPORT
ON
INVESTIGATION ON RHEOLOGICAL PROPERTIES OF
GEOPOLYMER CONCRETE
Submitted in partial fulfilment for the award of the degree
of
BACHELOR OF TECHNOLOGY
in
CIVIL ENGINEERING
Submitted by
B.VINAY 20B81A0157
MD.SOHEL 20B81A0149
CH.BHARATH 20B81A0112
Under the Guidance of
Dr.Ch. Sonali Sri Durga
Assistant professor
Department of Civil Engineering
CVR COLLEGE OF ENGINEERING
ACCREDITED BY NBA, AICTE & Affiliated to JNTUH
Vastunagar, Mangalpalli(V)
Ibrahimpatnam(M), R. R. District, PIN-501 510

2. ii
CVR COLLEGE OF ENGINEERING
ACCREDITED BY NBA, AICTE & Affiliated to JNTUH
Vastunagar, Mangalpalli(V), Ibrahimpatnam(M), R. R. District, PIN-501 510
Web: http://cvr.ac.in, email: info@cvr.ac.in
DEPARTMENT OF CIVIL ENGINEERING
CERTIFICATE
This is to certify that the Mini project report titled “Investigation on Rheological
properties of Geopolymer Concrete” is a bonafide work done as Mini project and
submitted by
B.VINAY 20B81A0157
MD.SOHEL 20B81A0149
CH.BHARATH 20B81A0112
in partial fulfilment of requirement for the award of Bachelor of Technology degree in Civil
Engineering, CVR College of Engineering, Ibrahimpatnam .This work has not been submittedto any
university or institution for the award of any degree or diploma.
Dr.Ch.Sonali Sri Durga Dr.B.Naga Malleswara Rao
Mini project supervisor Head of the Department
External Examiner

3. iii
ACKNOWLEDGEMENT
We owe a great many thanks to a great many people who helped and supported us during
theMini project work. We express our earnest gratitude to our internal guide, Dr.Ch.Sonali
Sri Durga , Assistant Professor, Department of Civil Engineering, for her constant support,
encouragement and guidance. We are grateful for her cooperation and her valuable
suggestions. We also express our thanks to Dr.B.Naga Malleswara Rao, Head of the
Department of Civil Engineering for the encouragement and support given to us. Finally, we
express our gratitude to Mr.M.Ashok Kumar, Dr.R.Karthik, Mini project coordinators and
all other members who are involved either directly or indirectly for the successful completion
of this project.

4. iv
DECLARATION
We, the undersigned, declare that the Mini project entitled “Investigation on Rheological
properties of Geopolymer Concrete” being submitted in partial fulfilment for the award of
Bachelor of Technology Degree in Civil Engineering, affiliated to Jawaharlal Nehru
Technological University, Hyderabad, is the work carried out by us.
1) B.VINAY
20B81A0157
2) MD.SOHEL
20B81A0149
3) CH.BHARATH
20B81A0112

5. v
ABSTRACT
The Rheological properties of geopolymer concrete were investigated using pozzolanic
materialssuch as fly ash and metakaolin. Geopolymer concrete is a sustainable alternativeto
traditional Portland cement concrete, as it utilizes industrial waste products and has lower
carbon emissions. The project involves finding the physical properties of Ordinary Portland
Cement (OPC) and geopolymer concrete mix (80%flyash+20%metakaolin). The Rheological
properties of the geopolymer concrete with respect to marshal cone was evaluated, and
compared with those of traditional Portland cement concrete. The results of this study will
provide valuable insights into the potential use of waste materials in the production of
geopolymer concrete, which can contribute to reducing the environmental impact of the
construction industry.
The research methodology involved experimental investigations to evaluate the rheological
behavior of the geopolymer concrete mixture. Various parameters, such as water-to-binder
ratio, superplasticizer dosage, and curing conditions, were considered to achieve an optimized
mixture design. The rheological properties were assessed using standard tests, including slump
flow, flow time, and V-funnel flow tests.
Preliminary results indicate that the incorporation of 80% fly ash and 20% metakaolin in
geopolymer concrete affects its rheological behavior. The rheological tests revealed that the
fresh geopolymer concrete exhibited good workability and flowability within a specified range
of water-to-binder ratio and superplasticizer dosage. The slump flow measurements indicated
the ability of the mixture to self-level and spread under its self-weight, while the flow time and
V-funnel flow tests provided insights into the viscosity and flowability characteristics.
The findings suggest that the combination of fly ash and metakaolin in the geopolymer binder
system can effectively improve the rheological properties of the resulting concrete. The
optimized mixture exhibited desirable rheological behavior, facilitating ease of placement and
ensuring proper consolidation during casting. Furthermore, the geopolymer concrete
incorporating fly ash and metakaolin demonstrated improved resistance to segregation and
bleeding, enhancing its overall performance and durability.

6. vi
CONTENTS
CHAPTER NO. TITLE PAGE
Abstract v
Contents vi
List of Figures viii
List of Tables xi
CHAPTER-I INTRODUCTION
1.1 Introduction 01
1.2 Importance of geopolymer concrete 03
1.3 Material Used 04
CHAPTER-2 LITERATURE REVIEW
2.1 Introduction 05
2.2 Concrete and Environment 05
2.3 Geopolymer 08
CHAPTER-3 OBJECTIVES
3.1 Objectives 11
CHAPTER-4 METHODOLOGY
4.1 Methodology 12
4.1.1 Fineness Test 14
4.1.2 Normal Consistency Test 15
4.1.3 Setting time Test 17
4.1.4 Specific gravity Test 20
4.1.5 Soundness Test by Le-chatlier’s
Method
23
4.1.6 Marsh cone test 25

7. vii
CHAPTER-5 RESULTS AND DISCUSSION
5.1 Results 27
CHAPTER-6
Conclusion 32
References 33

8. vi
viii
LIST OF FIGURES
PAGE NO
1.Geopolymer Concrete 01
2.material used in geopolymer 03
3.Is Sieve 14
4.1Plunger Penetration 17
.2 Vicat mould with paste 17
5.Preparation of test block 19
6.Specific gravity bottle 21
7.1 Le-chatelier apparatus 25
.2 Water bath 25
8. Marsh cone apparatus 26

9. ix
LIST OF TABLES
TITLE PAGE NO
1. Results 27

10. 1
CHAPTER - 1
INTRODUCTION
The geopolymer concrete technology proposed by Davidovits ensures efficient
application of Byproducts as an alternative material to the Portland cement. Use of the geopolymer
technology could reduce the CO2
emission in to the atmosphere, caused by cement and aggregate
industries about 80%. Geopolymer concrete has been emerging as an environmental friendly
construction material for sustainable development, using Fly ash andMetakaolin in place of Portland
Cement as the binding agent. The objective of this study to investigate the physical andrheological
properties of Fly-Ash and Metakaolin based GPC mixes .
Fig 1 Geopolymer Concrete

11. 2
In recent years, researchers have focused on investigating the rheological behavior
of geopolymer concrete to enhance its practical applications. Geopolymer binders are typically
composed of a combination of fly ash, a fine-grained waste material generated from coal
combustion, and metakaolin, a thermally treated form of kaolinite clay. The unique properties of
these materials, when activated with alkali solutions, lead to the formation of a geopolymeric gel,
which acts as the binding agent in concrete.
The rheological properties of geopolymer concrete formulated with high fly ash and metakaolin
content have become a subject of interest due to their potential impact on the concrete's fresh
state characteristics. Understanding the effects of varying factors, such as water-to-binder ratio,
superplasticizer dosage, and curing conditions, is crucial for achieving optimal workability,
flowability, and stability.
This study aims to explore and evaluate the rheological properties of geopolymer concrete
incorporating 80% fly ash and 20% metakaolin. The investigation involves experimental testing
and analysis to assess the workability, flowability, and stability of the fresh concrete mixture. The
findings from this research will contribute to the understanding of the rheological behavior of
geopolymer concrete with a specific focus on the influence of fly ash and metakaolin proportions.
By optimizing the rheological properties of geopolymer concrete, engineers and researchers can
design sustainable and high-performance structures with reduced environmental impact.
Furthermore, improving the workability and flowability of geopolymer concrete enhances its
practicality and ease of construction, facilitating broader adoption in various construction
applications.
Overall, this study addresses an essential aspect of geopolymer concrete research by
investigating the rheological properties of a mixture composed predominantly of fly ash and
metakaolin. The findings will provide valuable insights into the fresh state behavior of this
geopolymer concrete, contributing to the development of innovative and sustainable
construction materials.

12. 3
.
Fig-2 Materials used in Geopolymer.
1.2 Importance of geopolymer cementconcretes
Producing one tonne of cement requires about 2 tonnes of raw materials
(shale and limestone) and releases 0.87tonne (≈ 1 tonne) of CO2, about 3 kg of Nitrogen
Oxide(NOx), an air contaminant that contributes to ground level smog and 0.4 kg of PM10
(particulate matter of size 10 µm), an air borne particulate matter that is harmful to the
respiratory tract when inhaled. The global release of CO2 from all sources is estimated at 23
billion tonnes ayear and the Portland cement production accounts forabout 7% of total
CO2 emissions. The cement industry has been making significant progress in reducing
CO2 emissions through improvements in process technology and enhancements in process
efficiency, but further improvements are limited because CO2 production is inherent to the
basic process of calcinations of limestone. Mining of limestone has impact on land-use
patterns, local water regimes and ambient air quality and thus remains as one of the
principal reasons for the high environmental impact of the industry. Dust emissionsduring
cement manufacturing have long been accepted as one of the main issues facing the
industry. Theindustry handles millions of tonnes of dry material. Evenif 0.1 per cent of this
is lost to the atmosphere, it can causehavoc environmentally. Fugitive emissions are therefore
a huge problem, compounded by the fact that there is neither an encouraging economic

13. 4
incentive nor stricter regulatory pressure to prevent emissions.
The cement industry does not fit the contemporary picture of a sustainable industry because
it uses rawmaterials and energy that are non-renewable; extracts its raw materials by mining
and manufactures a product that cannot be recycled. Through waste management,by utilizing
the waste by-products from thermal power plants, fertiliser units and steel factories, energy
used in the production can be considerably reduced. This cuts energy bills, raw material costs
as well as green house gas emissions. In the process, it can turn abundantlyavailable wastes,
such as fly ash and slag into valuable products, such as geopolymer concretes.
‘Geopolymer cement concretes’ (GPCC) are inorganic polymer composites,
which are prospective concreteswith the potential to form a substantial element of
an environmentally sustainable construction by replacing/ supplementing the
conventional concretes. GPCC have high strength, with good resistance to chloride
penetration, acid attack, etc. These are commonly formed by alkali activation of
industrial aluminosilicate waste materials such as FA and GGBS, and have a very
small greenhouse footprint when compared to traditional concretes.
1.3 MATERIAL USED
The fly ash: Class F (low calcium) fly ash which is a modern side-effect from power
plant age. The fineness ofFly Ash majorly affects the quality of Zero Cement Concrete
(geopolymer concrete). As the fineness of fly ash remains increment the quality of GPC
increment on account of increasingly surface territory with more Si-Al bond for
polymerization [10].The different chemical composition types of fly ash
Chemical composition and physical properties of cement and fly-ash
Chemical composition/physical properties Cement Fly-ash
Silica (SiO2, %) 22.93 57.60
Alumina (Al2O3, %) 4.29 21.90
Iron oxide (Fe2O3, %) 2.89 2.70
Calcium oxide (CaO, %) 66.23 7.80
Magnesium oxide (MgO, %) 1.92 1.68
Sulfur trioxide (SO3, %) 0.35 0.41
Sodium oxide (Na2O (eq), %) 0.70 1.05
Free calcium oxide (CaO (f), %) 0.64 –
Chloride (Cl, %) 0.006 –
Loss on ignition (LOI, %) 1.70 7.05
Density (g/ml)
Specific area (m /kg)
3.12
343
2.06
355

14. 5
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This chapter presents a background to the needs on the development of a fly ash based geopolymer
technology. The available published literature on geopolymer technology is also briefly reviewed.
2.2 CONCRETE AND ENVIRONMENT
The trading of carbon dioxide (CO2) emissions is a critical factor for the industries, including
the cement industries, as the greenhouse effect created by the emissions is considered to produce an
increase in the global temperature that may result in climatechanges. The ‘tradable emissions’ refers
to the economic mechanisms that are expected to help the countries worldwide to meet the emission
reduction targets established by the 1997 Kyoto Protocol. Speculation has arisen that one ton of
emissions can have a trading value about US$10 (Malhotra 1999; Malhotra 2004).
The climate change is attributed to not only the global warming, but also to theparadoxical
global dimming due to the pollution in the atmosphere. Global dimming is associated with the
reduction of the amount of sunlight reaching the earth due to pollution particles in the air blocking
the sunlight. With the effort to reduce the air pollution that has been taken into implementation, the
effect of global dimming may be reduced, however it will increase the effect of global warming
(Fortune 2005). In this view, the global warming phenomenon should be considered more seriously,
andany action to reduce the effect should be given more attention and effort.
The production of cement is increasing about 3% annually (McCaffrey 2002). The
production of one ton of cement liberates about one ton of CO2 to the atmosphere,as the result of de-
carbonation of limestone in the kiln during manufacturing of cementand the combustion of fossil fuels
.

15. 6
The contribution of Portland cement production worldwide to the greenhouse gas emission is
estimated to be about 1.35 billion tons annually or about 7% of the total greenhouse gas emissions to
the earth’s atmosphere (Malhotra 2002). Cement is also among the most energy-intensive
construction materials, after aluminium and steel. Furthermore, it has been reported that the durability
of ordinary Portland cement (OPC)concrete is under examination, as many concrete structures,
especially those built in corrosive environments, start to deteriorate after 20 to 30 years, even though
they havebeen designed for more than 50 years of service life (Mehta and Burrows 2001).
The concrete industry has recognized these issues. For example, the U.S. Concrete Industry
has developed plans to address these issues in ‘Vision 2030: AVision for the U.S. Concrete Industry’.
The document states that ‘concrete technologists are faced with the challenge of leading future
development in a way that protects environmentalquality while projecting concrete as a construction
material of choice. Public concernwill be responsibly addressed regarding climate change resulting
from the increased concentration of global warming gases. In this document, strategies to retain
concreteas a construction material of choice for infrastructure development, and at the same time to
make it an environmentally friendly material for the future have been outlined(Mehta 2001; Plenge
2001).
In order to produce environmentally friendly concrete, Mehta (2002) suggested the useof fewer
natural resources, less energy, and minimise carbon dioxide emissions. He categorised these short-
term efforts as ‘industrial ecology’. The long-term goal of reducing the impact of unwanted by-
products of industry can be attained by lowering the rate of material consumption. Likewise,
McCaffrey (2002) suggested three alternatives to reduce the amount of carbon dioxide (CO2)
emissions by the cement industries, i.e. to decrease the amount of calcined material in cement, to
decrease the amount of cement in concrete, and to decrease the number of buildings using cement
FLY ASH
According to the American Concrete Institute (ACI) Committee 116R, fly ash is defined as ‘the finely
divided residue that results from the combustion of ground or powdered coal and that is transported
by flue gasses from the combustion zone to the particle removal system’ (ACI Committee 232 2004).
Fly ash is removed from the combustion gases by the dust collection system, either mechanically or
by using electrostatic precipitators, before they aredischarged to the atmosphere. Fly ash particles are
typically spherical, finer than Portland cement and lime, ranging in diameter from less than 1 µm to
no more than 150 µm.

16. 7
The types and relative amounts of incombustible matter in the coal determine the chemical composition
of fly ash. The chemical composition is mainly composed of the oxides of silicon(SiO2), aluminium
(Al2O3), iron (Fe2O3), and calcium (Ca O), whereas magnesium, potassium, sodium, titanium, and
sulphur are also present in a lesser amount. The major influence on the fly ash chemical composition
comes from the type of coal. The combustionof sub-bituminous coal contains more calcium and less
iron than fly ash from bituminous coal. The physical and chemical characteristics depend on the
combustion methods, coal source and particle shape. The chemical compositions of various fly ashes
show a wide range,indicating that there is a wide variations in the coal used in power plants all over the
world (Malhotra and Ramezanianpour 1994).
Fly ash that results from burning sub-bituminous coals is referred as ASTM Class C fly ash or
high calcium fly ash, as it typically contains more than 20 percent of Cao. On the other hand, fly ash
from the bituminous and anthracite coals is referred as ASTM Class F fly ash or low calcium fly ash.
It consists of mainly an aluminosilicate glass, and has less than 10 percent of Cao. The colour of fly
ash can be tan to dark grey, depending upon the chemical and mineral constituents (Malhotra and
Ramezanianpour 1994; ACAA 2003). The typical fly ash produced from Australian power stations is
light to mid-grey in colour, similar to the colour of cement powder. The majority of Australian fly
ash falls in the category of ASTM Class F fly ash, and contains 80 to 85% of silica and alumina
(Heidrich 2002).
A side from the chemical composition, the other characteristics of fly ash that generally
considered are loss on ignition (LOI), fineness and uniformity. LOI is a measurement of
unburnt carbon remaining in the ash. Fineness of fly ash mostly depends on the operating
conditions of coal crushers and the grinding process of the 8 coal itself. Finer gradation
generally results in a more reactive ash and contains less carbon

17. 8
THE USE OF FLY ASH IN CONCRETE
One of the efforts to produce more environmentally friendly concrete is to reduce the use ofOPC
by partially replacing the amount of cement in concrete with by-products materials suchas fly ash. As
a cement replacement, fly ash plays the role of an artificial pozzolan, where itssilicon dioxide content
reacts with the calcium hydroxide from the cement hydration processto form the calcium silicate
hydrate (CS-H) gel. The spherical shape of fly ash often helps toimprove the workability of the fresh
concrete, while its small particle size also plays as fillerof voids in the concrete, hence to produce dense
and durable concrete. Generally, the effective amount of cement that can be replaced by fly ash is not
more than 30% (Neville 2000).
An important achievement in the use of fly ash in concrete is the development of high volumefly
ash (HVFA) concrete that successfully replaces the use of OPC in concrete up to 60% andyet possesses
excellent mechanical properties with enhanced 9 durability performance. HVFA concrete has been proved
to be more durable and resource-efficient than the OPC concrete (Malhotra 2002). The HVFA
technology has been put into practice, for example the construction of roads in India, which implemented
50% OPC replacement by the fly ash (Desai 2004).
2.3 GEOPOLYMERS
Polymer is a class of materials made from large molecules that are composed of a large
number of repeating units (monomers). The molecular structure of the unit that makes up the
large molecules controls the properties of the material. The non crystalline or amorphous state
is the state when the regularity of atomic packing is 10 completely absent. The most familiar
kind of an amorphous solid is glass (Young, Mindness et al. 1998).

18. 9
Geopolymers are a member of the family of inorganic polymers, and are a chain
structures formed on a backbone of Al and Si ions. The chemical composition of this
geopolymer material is similar to natural zeolitic materials, but they have amorphous
microstructure instead of crystalline . The polymerisation process involves a substantially fast
chemical reaction under highly alkaline condition on Si-Al minerals, that results in a three
dimensionalpolymeric chain and ring structure consisting of Si-O-Al-O bonds, as follows
(Davidovits 1999):
Mn [-(SiO2) z–AlO2] n . wH2O
Where: M = the alkaline element or cation such as potassium, sodium or calcium; the symbol
– indicates the presence of a bond, n is the degree of polycondensation or polymerisation; z
is1,2,3, or higher, up to 32.
The schematic formation of geopolymer material can be shown as described by Equations
(22) and (2-3) (van Jaarsveld, van Deventer et al. 1997; Davidovits 1999). These formations
indicate that all materials containing mostly Silicon (Si) and Aluminium (Al) can be
processed to make the geopolymer material

19. 10
n(Si2O5,Al2O2)+2nSiO2+4nH2O+NaOH or KOH Na+ ,K+ + n(OH)3-Si-O-Al- -O-Si-(OH)3
|
(Si-Al materials) (OH)2
(Geopolymer precursor)
| | |
n(OH)3-Si-O-Al- -O-Si-(OH)3 + NaOH or KOH (Na+K)-(-Si-O-Al- -O-Si-O-) +
4nH2O | | | |
(OH)2 O O O
(Geopolymer backbone)
To date, the exact mechanism of setting and hardening of the geopolymer material is
notclear, as well as its reaction kinetics. However, most proposed mechanism consist of the
following (Davidovits 1999; Xu and van Deventer 2000):
• Dissolution of Si and Al atoms from the source material through the action of hydroxide
ions.
• Transportation or orientation or condensation of precursor ions into monomers.
• Setting or polycondensation/polymerisation of monomers into polymeric structures.
.

20. 11
CHAPTER 3
OBJECTIVES
3.1 Objectives
Evaluate the feasibility of geopolymer concrete as an alternative to Ordinary
PortlandCement (OPC) concrete by analysing its raw materials, including fly ash,
Metakaolin,and alkaline activators.
➢To assess the physical properties of geopolymer mix, such as fineness test,normal
consistency test, setting time test, soundness test by le-chatlier’s method, specific
gravityand comparethem with OPC.
➢To investigate the rheological properties of geopolymer mix using marsh cone test.

21. 12
CHAPTER 4
METHODOLOGY
4.1 Methodology
This chapter presents the details of development of the process of making fly ash
based geopolymer concrete. In 2001, very little knowledge and know-how of making
of fly ash-based geopolymer concrete were availablein the published literature. Due to
this lack of information, the study beganbased on limited available literature on
geopolymer pastes and mortars
PHYSICAL AND RHEOLOGICAL PROPERTIES :
1. Fineness Test by Sieve Analysis.
2. Normal Consistency Test.
3. Setting Time Test.
4. Specific Gravity Test.
5. Soundness Test by Le-Chatelier’s Method.
6. Marsh Cone Test.

22. 13
Now let us see about the Tests in detail:
This includes:
o Aim
o Apparatus
o Introduction/Theory
o Procedure

23. 14
4.1.1 Fineness Test
OBJECT: To determine the fineness of geopolymer by dry sieving.
APPARATUS:
a) Standard balance with 100 gm. Weighing capacity.
b) IS: 90micron sieve confirming to IS: 460-and a Brush.
PROCEDURE:
a) Break down any air-set lumps in the cement sample with fingers.
b) Weigh accurately 100 g of cement and
place it on a standard 90 micron IS
sieve.
c) Break down any air-set lumps in the
cement sample with fingers.
d) Continuously sieve the sample giving
circular and vertical motion for a period
of15 minutes.
e) Weigh the residue left on the sieve. Fig-3 IS SIEVE
f) As per IS code the percentage residue should not exceed 10%.
RESULT: The percentage weight of residue over the total sample is reported %
Weightof Residue = Wt. of sample retained on the sieve
. Total weight of the sample
LIMITS: The percentage residue should not exceed 10%.

24. 15
PRECAUTIONS:
Sieving shall be done holding the sieve in both hands and gentle wrist
motion. This will involve no danger of spilling the cement. Which shall be kept
well spread out on the screen. More or less continuous rotation of the sieve shall be
carried out throughout sieving. Washers, shots and slugs shall not be used on the
sieve. The underside of the sieve shall be lightly brushed with a 25 or 40 mm bristle
brush after every five minutes of sieving. Mechanical sieving devices may be used,
but the cement shall not be rejectedif it meets the fineness requirement when tested
by the hand method.
4.1.2 Normal Consistency Test
AIM:
To determine the quantity of water required to produce a Geopolymer cement
paste ofstandard consistency as per IS:4031 (Part 4) reaffirmed 2005.
DEFNITION:
Standard consistency is defined as that consistency which will permit the Vicat’s
plunger to penetrate to a point 5 to 7 mm from the bottom of the Vicat’s mould when
the cement is tested.
APPARATUS:
1. Vicat’s apparatus, Mould, Plunger confirming to IS:5513
2. Standard trowel confirming to IS:10086

25. 16
3. Stop watch.
4. Weighing balance
DESCRIPTION:
The Vicat’s apparatus consists of a frame and a moving rod weighing 300 gm. A
cylindrical plunger of 10 mm diameter is kept at the lower end of the rod. A pointer connected
to the rod will move along with it when it is released, over a graduated scale kept in front of
it. The cement paste to be tested is kept in the Vicat’s mould kept below the rod on a glass
plate.
PROCEDURE:
1. Prepare a paste of weighed quantity of cement (400 grams) with a weighed quantity of
potable or distilled water, starting with 26% water of 400g of cement.
2. Take care that the time of gauging is not less than 3 minutes, not more than 5 minutes and
the gauging shall be completed before setting occurs.
3. The gauging time shall be counted from the time of adding the water to the dry cement
until commencing to fill the mould.
4. Fill the vicat mould with this paste, the mould resting upon a non-porous plate.
5. After completely filling the mould, trim off the surface of the paste, making it in level with
the top of the mould. The mould may slightly be shaken to expel the air.
6. Place the test block with the mould, together with the non-porous resting plate, under the
rod bearing the plunger (10mm diameter), lower the plunger gently to touch the surface of
the test block and quickly release, allowing it to penetrate into the paste.
7. This operation shall be carried out immediately after filling the mould.
8. Prepare trial pastes with varying percentages of water and test as described above until the
amount of water necessary for making the standard consistency as defined above is
obtained.

26. 17
Fig-4.1 plunger penetration Fig-4.2 Vicat mould with past
4.1.3 SETTING TIME TEST
REFERENCE: IS: 4031(part-4) -1988, IS: 4031 (part-5) - 1988, IS: 5513-1976
AIM:
To determine the initial and final setting time of geopolymer as per IS:4031.
APPARATUS:
The Vicat’s apparatus, Needle, Annular ring, Trays, Balance and Weights.

27. 18
2
PROCEDURE:
1. Preparation of Test Block: Prepare a neat cement paste by gauging the
cement with 0.85 times the water required to give the paste of standard
consistency. Start a stopwatch at the instant when water is added to the cement.
Fill the Vicat’s mould with a cement paste with in three to five minutes after
addition of water. Fill the mould completely and smooth off the surface of this
paste making it level with the top of the mould. The cement block thus
prepared in the mould is test block.
2. Clean appliances shall be used for gauging. The temperature of water and
that of the test room at the time of gauging shall be within (27 )0C.
3. During the test the block shall be kept at a temperature of (27 2)0C and
at least 90% relative humidity.
A)DETERMINATION OF INITIAL SETTING TIME:
Place the test block confined in the mould and resting on the nonporous
plate, under the rod bearing the needle, lower the needle gently in contact
with the surface of the test block and quickly release, allowing it to penetrate
into the test block. In the beginning the needle will completely pierce the test
block. Repeat this procedure until the needle, when broughtin contact with
the test block and released as described above, fails to pierce the block for 5
to 7 mm measured from the bottom of the mould. The period elapsing
between the time when water is added to the cement and this time shall be
initial setting time.

28. 19
B) DETERMINATION OF FINAL SETTING TIME:
Replace the needle of the Vicat’s apparatus with the needle with an circular
attachment. The cement shall be considered as finally set, when upon
lowering the needle gently to the surface of the test block the needle makes
an impression there on, while the attachment fails to do so. In other words
the paste has attained such hardness that the centre needle does not pierce
through the paste more than 0.5mm. The period elapsing between the time
when water is added to the cement and the time at which the needle makes
an impression on the surface on the test block while the attachment fails to
do so shall be the final setting time.
Fig-5 Preparation of Test Block

29. 20
.
4.1.4 SPECIFIC GRAVITY TEST
REFERENCE: IS: 2027 (PART 3)
AIM:
To determine the Specific gravity of Geopolymer.
DEFINITION:
Specific gravity of cement is defined as the ratio of weight of a given volume
of cement at a given temperature to the weight of an equal volume of distilled water at
the same temperature both weights being taken in air.
APPARATUS: Specific gravity bottle, weighing balance
MATERIAL:
Kerosene free of water, naphtha having a specific gravity not less than0.7313 shall
be used in the specific gravity determination.
PROCEDURE:
1. Clean and dry the specific gravity bottle and weigh it with the stopper (W1).
2. Fill the specific gravity bottle with cement sample at least half of the bottle and
weigh with stopper (W2).
3. Fill the specific gravity bottle containing the cement, with kerosene (free of water)
placing the stopper and weigh it (W3).

30. 21
4. While doing the above do not allow any air bubbles to remain in the specific gravity
bottle. 5. After weighing the bottle, the bottle shall be cleaned and dried again.
6. Then fill it with fresh kerosene and weigh it with stopper (W4).
7. Remove the kerosene from the bottle and fill it with full of water and weigh it with
stopper (W5).
8. All the above weighing should be done at the room temperature of 27c + 1 0 c.
Fig-6 Specific gravity bottle

31. 22
OBSERVATIONS:
1. Wt. of empty dry specific gravity bottle = W1
2. Wt. of bottle + Cement (filled 1/4 to 1/3 ) = W2
3. Wt. of bottle + Cement (Partly filled ) + Kerosene = W3
4. Wt. of bottle + Kerosene (full). = W4
5. Wt. of bottle + water (full) = W5
Specific gravity of kerosene Sk = (W4 – W1) / (W5 – W1)
(W2 –W1) x Sk
Specific gravity of Cement = ---------------------------
(W4 – W1) – (W3 – W2)

32. 23
4.1.5 SOUNDNESS TEST BY LE-CHATLIER’S METHOD
REFERENCE: IS: 4031 (PAT 3) - 1988
AIM:
To determine the Soundness of given Geopolymer by "Le Chatelier" Method.
APPARATUS:
Le Chatelier apparatus conforming to IS 5514-1969, Balance, Weights, Water bath.
INTRODUCTION:
It is essential that the cement concrete shall not undergo appreciable change in volume
after setting. This is ensured by limiting the quantities of free lime, magnesia and sulphates
in cement which are the causes of the change in volume known as unsoundness.
Unsoundness in cement does not come to surface for a considerable period of time. This
test is designed to accelerate the slaking process by the application of heat and discovering
the defects in a short time. Unsoundness produces cracks, distortion and disintegration
there by giving passage to water and atmospheric gases which may have injurious effects
on concrete and reinforcement. The apparatus for conducting the test consists of small
split cylinder of spring brass or other suitable metal of 0.5mm thickness forming a mould
30 mm internal diameter and 30mm high. On either side of the split mould are attached to
indicators with pointed ends, the distance from these ends to the center of the cylinder
being 165 mm. The mould shall be kept in good condition with the jaws not more than
50mm apart.

33. 24
PROCEDURE:
1. Place the lightly oiled mould on a lightly oiled glass sheet and fill it with cement
paste formed by gauging cement with 0.78 times the water required to give a paste
of standard consistency.
2. The paste shall be gauged in the manner and under the conditions prescribed in
determination of consistency of standard cement paste, taking care to keep the edges
of the mould gently together
3. While this operation is being performed cover the mould with another piece of
glass sheet, place a small weight on this covering glass sheet and immediately
submerge the whole assembly in water at a temperature of 27 0 - 2 0 C and keep
there for 24 hours.
4. Measure the distance separating the indicator points.
5. Submerge the moulds again in water at the temperature prescribed above.
6. Bring the water to boiling, with the mould kept submerged for 25 to 30 minutes,
and keep it boiling for three hours.
7. Remove the mould from the water allow it to cool and measure the distance
between the indicator points.
8. The difference between these two measurements represents the expansion of
thecement.
9. For good quality cement this expansion should not be more than 10mm.

34. 25
Fig-7.1 Le Chatelier apparatus Fig-7.2 Water bath
4.1.6 MARSH CONE TEST
AIM:
To determine the Marsh cone test of geopolymer.
Apparatus
• It's consist of a conical brass vessel held on a wooden stand with an orifice of 8mm at its
bottom.
• A stop watch is needed to measure the time taken by 1 litre of cement or mortar to pass
through the vessel.
A mortar mixer is also needed to prepare the cement paste with desired w/c ratio.

35. 26
PROCEDURE
• 1L of cement paste is prepared in mortar mixer using 2 kg of cement and w/c ratio of
0.32-0.35 High strength Concrete designs typically have w/c ratios less than 0.35.
• Water is added in two steps- 70% of water is added in beginning of mixing and rest
30% of water is mixed with super plasticizer, and added afterwards.
• Cement slurry is prepared with the w/c ratio of 0.32 and admixture dosage of 0.5 %.
litre of cement slurry is made to flow through marsh cone after 5 min and 60 min of
mixing and time in seconds is measured using a stopwatch.
• The procedure is repeated gradually increasing the S.P. Dosage in steps of 0.2%.Similar
tests are conducted for rest of super plasticizers and graphs are plotted with time as Y
axis and S.P. dosage as X-axis.
Fig-8 Marsh cone Apparatus

36. 27
CHAPTER 5
RESULTS AND DISCUSSION
5.1 Results
Following are the test results of various mixes performed according to codal standards:
TABLE -1 PHYSICAL AND REHOLOGICAL PROPERTIES
TEST IS Code Cement Fly ash Metakaolin Geopolymer
(80%FA+20
%MK)
Fineness Test IS:4031(part-1) 3.33% 2.9% 2.4% 6.4%
Normal
Consistency
IS:4031(part-4) 31% 35% 29% 30.33%
Initial setting time IS:4031(part-5) 54 min 62 min 34 min 45 min
Final setting time IS:4031(part-5) 160 min 250 min 320 min 220 min
Specific Gravity IS:2027(part-3) 2.225
g/cc
2.081
g/cc
2.47 g/cc 2.65 g/cc
Soundness IS:4031(part-3) 1 mm 0 mm 2 mm 0.5 mm
Marsh cone ASTN D6910-
04
37 sec 42 sec 46 sec 51 sec

37. 28
3.33%
2.9%
2.4%
4.5%
0
1
2
3
4
5
6
7
cement fly ash metakaolin geopolymer
fineness
percentage
value
material
5.1 Fineness Test
31%
35%
29%
30.33
0
5
10
15
20
25
30
35
40
cement fly ash metakaolin geopolymer
normal
consistency
value
material
5.2 Normal Consistency Test

38. 29
54 min
62 min
34 min
45 min
0
10
20
30
40
50
60
70
cement fly ash metakaolin geopolymer
initial
settine
time
in
minutes
material
5.3 Initial setting time test
160 min
250 min
320 min
220 min
0
50
100
150
200
250
300
350
cement fly ash metakaolin geopolymer
final
setting
time
in
minutes
material
5.4 Final setting time Test

39. 30
2.225 g/cc
2.081 g/cc
2.47 g/cc
2.65 g/cc
0
0.5
1
1.5
2
2.5
3
cement fly ash metakaolin geopolymer
specific
gravity
values
in
g/cc
material
5.5 Specific gravity Test
1 mm
0 mm
2 mm
0.5
0
0.5
1
1.5
2
2.5
cement fly ash metakaolin geopolymer
soundness
value
in
mm
material
5.6 Soundness Test

40. 31
37 sec
42 sec
46 sec
51 sec
0
1
2
3
4
5
6
7
cement fly ash metakaolin geopolymer
marsh
cone
values
in
seconds
material
5.7 Marsh cone Test

41. 32
CHAPTER 6
CONCLUSION
User-friendly geopolymer concrete can be used under conditions similar to
those suitable for ordinary portland cement concrete. These constituents of
Geopolymer Concrete shall be capable of being mixed with a relatively low-alkali
activating solution and must be curable in a reasonable time under ambient
conditions. The production of versatile, cost-effective geopolymer concrete can be
mixed and hardened essentially like portland cement.
➢ Geopolymer Concrete shall be used in repairs and rehabilitation works.
➢ Due to the high early strength Geopolymer Concrete shall be effectively used in the
precast industries, so that huge production is possible in short duration and the
breakage during transportation shall also be minimized.
➢ The Geopolymer Concreteshall be effectively used for the beam column junction
of a reinforced concrete structure.
➢ Geopolymer Concrete shall also be used in the Infrastructure works. In addition
to that the Fly ash shall be effectively used and hence no landfills are required to
dump the fly ash.
➢ The government can make necessary steps to extract sodiumhydroxideandsodium
silicate solution from the waste materials of chemicalindustries, so that the cost of
alkaline solutions required for the geopolymer concreteshall be reduced.

42. 33
References
1. Davidovits, J. 1984. “Pyramids of Egypt Made of Man- Made Stone, Myth or
Fact?” Symposium on Archaeometry 1984. Smithsonian Institution, Washington,
DC.
2. Davidovits, J. 2008. Geopolymer Chemistry and Applications. Institute
Geopolymer, Saint□Quentin, France.
3. Geopolymer Institute. 2010. What Is a Geopolymer? Introduction. Institute
Geopolymer, Saint Quentin, France. Accessed on January 29, 2010, at
http://www.geopolymer.org/science/introduction.
4. Hardjito, D., S. Wallah, D. M. J. Sumajouw, and B. V. Rangan. 2004. “On the
Development of Fly Ash– Based Geopolymer Concrete.” ACI Materials Journal,
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43. 34
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