The document describes a project to develop light weight geopolymer bricks using fly ash, sludge ash, and polypropylene fiber. The objectives are to design geopolymer light weight concrete using foam and study the compressive strength and water absorption of the bricks. Materials that will be used include fly ash, sludge ash, alkaline solution of sodium hydroxide and sodium silicate, and foaming agent. The methodology involves selecting materials, designing mixes, casting bricks, and testing them for properties like compressive strength and water absorption.

1. LIGHT WEIGHT GEOPOLYMER ECO FRIENDLY
BRICK USING FLY ASH, SLUDGE ASH AND
POLYPROPLENE FIBER
MUDHOL – 587313, KARNATAKA, INDIA.
2021-2022
Project co-ordinator
Prof. G S Jirali
Head of Department
Dr. M S Gadagi
Principal
Dr. Shravankumar B Kerur
MALLIKARJUN S BALMI 2LB19CV415
MANJUNATH HOSAMANI 2LB19CV417
PADMAVATI R JANOJI 2LB19CV425
SACHIN NAYAK 2LB19CV428
Under the guidence of:
Prof. Adinath N Doddamani

2. CONTENT
INTRODUCTION
LITERATURE REVIEW
OBJECTIVE
MATERIALS USED
METHODOLOGY

3. INTRODUCTION
Light weight brick is an innovative and eco-friendly
material.
It is used as replacement of cement.
It is used as alternative material for normal bricks.
In this bricks, we also use fly ash, sludge ash and
polypropylene fiber.
Polypropylene fiber have used high strength of
Geopolymer brick over an conventional brick.

4. LITERATURE REVIEW
 Mohd Mustafa Al bakri Abdullahetal: In this paper we studied “Fly Ash-
based Geopolymer Lightweight Concrete Using Foaming Agent” the results of
their investigation on the possibility of producing foam concrete by using a
geopolymer system. The stated material in this experiment.
• Fly ash class c
• NaOH pellets
• Na₂SiO₃ jet solution
• Distilled water
Preparation of motor has been explained i.e., first proportion of
alkaline solution before casting to 24hr.The solution includes the mixture of
NaOH & Na₂SiO₃ chemicals then foam is added to the dilute solution of
NaOH & Na₂SiO₃. As per requirement of one cube, fly ash is added and
moulded then oven dried at two different temperatures 60 0C and room
temperature about 24hrs. After curing to 1, 7 and 28 days compressive strength
test done.

5.  Z. Abdollahnejad , F. Pacheco-Torgal, T. Félix, W. Tahri, J. Barroso
Aguiar
In this paper we studied “Mix design, properties
and cost analysis of fly ash-based geopolymer foam” This study has
investigated the joint effect of several mix parameters on the properties
of foam geopolymers. The mix parameters analyzed through a
laboratory experiment of 54 different mortar mixes were, sodium
silicate/sodium hydroxide mass ratio (2.5, 3.5, 4.5), activator/binder
mass ratio (0.6, 0.8, 1.0), chemical foaming agent type (hydrogen
peroxide (H₂O₂) and sodium per borate (NaBO₃)) and foaming agent
mass ratio content (1%, 2%, 3%). Properties, SEM and FTIR analysis
and cost analysis are included. The results show that the sodium per
borate over performs hydrogen peroxide leading to a lower overall
thermal conductibility of foam geopolymers. Mixtures with a low
thermal conductivity of around 0.1 W,and a compressive strength of
around 6 MPa were achieved. The cost analysis show that the foaming
agents are responsible for a small percentage of foam geopolymers total
cost being that the alkaline activators is responsible for more than 80%.

6.  Piyathida Yoosuk, Chedsak Suksiripattanapong, Piti Sukontasukkul,
Prinya chindaprasirt
In this paper we studied “Properties of polypropylene
fiber reinforced cellular lightweight high calcium fly ash geopolymer” In
recent years, attempts to increase the utilization of fly ash to partially
replace the use of Portland cement in concrete are gathering momentum.
Geopolymer concrete is new‟ material that does not need the presence of
Portland cement as a binder. Instead, activating the source materials such
as fly ash that and polypropylene fiber are rich in Silicon (Si)and Aluminum
(Al) using high alkaline liquids produces the binder required to manufacture
the concrete. Hence, concrete with no cement. This paper presents
information on fly ash-based geopolymer concrete. The addition of
polypropylene fiber ranged from 0%, 0.5%, 1%, 1.5%, 2%, 2.5% and 3% by
the weight of fly ash.. As per requirement of one cube, fly ash is added and
moulded then oven dried at two different temperatures 60 0C and room
temperature about 24hrs. After curing to 1, 7 and 28 days compressive
strength test done. The paper covers the material and the mixture
proportions, the manufacturing process, and the influence of various
parameters on the properties of fresh and hardened concrete.

7.  Younesse haddaji, Hasna hamdane, Hicham majdoubi, Said
mansouri, Driss allaoui, Mehdi el bouchti, Youssef
tamraoui, Bouchaib manoun, Mina Oumam & Hassan hannache
In this paper we studied “Eco-friendly Geopolymer
Composite Based on Non-heat-treated Phosphate Sludge Reinforced
With Polypropylene Fibers” Geopolymers produced with metakaolin
(MK) and thermally untreated phosphate sludge (PS) are beneficial and
environmentally advantageous materials, but their fragility limits its
applications. The present research aims to evaluate the influence of
polypropylene fibers PPF inclusion in MK/PS based geopolymers in
view of overcoming the brittleness of these materials. The geopolymer
matrix was prepared by mixing the thermally untreated phosphate
sludge with the metakaolin in a proportion of 50% by weight, then short
polypropylene fibers (PPFs) as reinforcement material were
incorporated in amounts of 0.25, 0.50, 1, and 1.5%. Composite
performances were assessed in the fresh state through flow
measurement, and in the hardened state through the properties of the

8. composites under bending and compressive loading conditions. In
addition, the fiber/matrix interfacial contact area was examined using
scanning electron microscopy (SEM). The outcomes demonstrate that
the PPF incorporation of up to 1.5% by weight into MK/PS based
geopolymer paste significantly improves the flexural strength with an
increase of 41% (6.41 and 9.62 MPa), as well as leads to a slight
decrease of compressive strength and density. The findings of the
current research reveals also that MK/PS based geopolymers can
achieve a high ductility with an adequate reinforcement.

9. OBJECTIVES
To mix design of geopolymer light weight concrete using
foam.
To study the Compressive strength and Water absorption
strength etc of geopolymer light weight brick.
To cast and compare the behavior of light weight
geopolymer bricks with normal bricks.

10. MATERIALS USED
Fly ash
Sludge ash
Alkaline solution
 Sodium hydroxide( NaOH )
 Sodium meta silicate (Na2SiO3)
 Foaming agent

11. FLY ASH:-
 Fly ash, also known as flue-ash, is one of the residues generated
in coal combustion, product that is composed of fine particles
that rise with the flue gases
 The particles of fly ash are spherical in shape with size ranginig
from 0.5 micron to 100 micron
The main constituent of fly ash silicon dioxide, which is present
in 2 forms-Amorphous and crystalline.

12. SLUDGE ASH:-
 Water treatment plant sludge ash is primarilly a silty
material with some sand-size particles.
It is the by-product of the combustion of dewatered sludge
in an incinerator.

13. FINE AGGREGATE:-
The locally available sand which is used for concrete works
can be used for geopolymer Bricks for IS standards.
The locally available sand which is used for concrete works
can be used for geopolymer Bricks.

14. POLYPROPLENE FIBER:-
PROPERTIES:-
 Low physical properties.
 Low heat resistance.
 Excellent chemical resistance.
 Trasulcent to opoque.
 Low price.
 Easy to process.

15. ALKALINE SOLUTION:-
The most common alkaline activator used in geopolymerization
is a combination of sodium hydroxide (NaOH).
The type and concentration of alkali solution affect the
dissolution of fly ash.
SODIUM HYDROXIDE
(NaOH).

16. Sodium Meta Silicate (Na2SiO3 5H2O )
 The liquid phase is important as a fluid transport medium
permitting the activator to reach and react with the fly ash
particles.
 Sodium silicate are colourless glassy or crystalline solids or
white powders. Except for the most silicon-rich one’s, they are
readily soluble in water, producing alkaline solutions.

17. FOAMING AGENT:-
It helps to make concrete light weight.
Foam produce no chemical reaction on mortar but it serves
as a layer which is air entrapped and forms no fumes or
toxic.
Protein based foaming agent takes comparatively more
energy to make foam.

18. METHODOLOGY
Selection of material based on availability.
Procurement of material required.
Study of material properties.
Design mix for Geo-polymer light weight concrete.
Design molds of bricks size to cast bricks.
Testing of light weight concrete bricks.
 Tests on compressive strength, water absorption test etc