Introduction

The demand for concrete is increasing day by day in order to meet the development of
infrastructure facilities. Cement, being the principal binder, requires high energy intensive
processes that consumes natural resources as well as high energy. It has been estimated
that approximately 1.5 t of natural resources are consumed in addition to the emission of
green house gases to the tune of 1 t per tonne while producing 1 tonne of cement. In order
to conserve the natural resources and to prevent the green house gas emission, there is an
urgent need to develop alternatives to cement in the concrete.
Davidovits proposed the synthesis of geopolymerization by mixing aluminosilicate-reactive
material with strong alkaline solutions. The process of geopolymerization involves the
transformation of aluminosilicate materials in to a hardened state through the use of strong
alkaline activator solutions. The basic source materials which are rich in alumina and silica
are used in the above process. Fly ash, metakaolin, GGBS, rice husk, etc which are rich in
alumina and silica can be used as basic source materials. These source materials are mixed
with strong alkaline solution called as activator to trigger the chemical reactions that lead to
the formation of a geopolymer binder. The strong alkali activator solutions such as sodium
hydroxide (NaOH), potassium hydroxide (KOH), sodium silicate or potassium silicate are
considered in the above process. The geopolymerization reaction involves the dissolution of
the source materials into the formation of polymeric aluminosilicate gel, and the
subsequent hardening of the material. The resulting geopolymer exhibits similar structural
and strength properties to traditional Portland cement-based concrete.
Thermal power plants are the main source of energy in the world and produces Ash as a
byproduct during power generation and the byproduct is being dumped in the ash mounds
created near the plant. In India, Nearly 30 to 35% of the volume of the coal fired in Thermal
power plants converted in to the Ash. Elsewhere, the percentage of volume may be less
depending upon calorific value. Millions of metric tonnes of ash is already dumped and
continued to be dumped which is creating nuisance to the general public in the area. The
dumped Ash already creating dust nuisance, land pollution and landbank consumption due
to which maintenance of Ash dyke creates an important parameter during the operation
stage of Thermal power plant. To avoid such issues, the part of ash presently utilised in land
fills, Brick manufacturing, Cement manufacturing. In the recent past, the land fills are
objected due to the environmental issues limiting the utilisation of Ash.
In view of the above, New methods of utilisaiton of Ash needs to be explored urgently to
dispose the same. Since the coal fired Ash from thermal power plants is rich in Silica and
Alumina, the material can be used as precursor in geopolymer concrete.
There is no additional energy required as Ash is formed as a bye product of power
generation. This low calcium fly ash confirming to class-F is rich in silicon and aluminium
oxides with Si to Al ratio of more than 2, with less or no calcium is suitable perfectly as a
precursor without any further process modification
Fly Ash based Geopolymer concrete is becoming an attractive alternative concrete because
the precursor is entirely of industrial by products, in contrast to ordinary Portland cement
(OPC), which is extremely energy and carbon intensive to produce. During
geopolymerization, N-A-S-H gel is formed instead of formation of C-S-H gel as formed in
cement concrete,CSH
Fly ash-based geopolymer concrete provides excellent engineering properties that make them
suitable materials for structural applications (Rangan et al. 2005; Fernández-Jiménez et al. 2006)

Mix Design

In various countries, conventional mix proportions for cement concrete upto M20 grade are
developed. For grades over and above M20, mix design methodology developed and standardized
based on the binder/cement and aggregate properties. Various parameters like exposure conditions,
workability, MSA of aggregates, admixture properties, etc are well defined. The standard mix design
consists of selection of Cement content, W/C ratio, admixture content and air entrainment based on
target strength, the exposure conditions and workability. The rest of the volume, after excluding
cement, water, admixture and air entrapment, consists of aggregates that can be divided in to
various proportions of coarse aggregates and sand. The coarse aggregates consists of predominantly
20 mm/25 mm and 12mm/10mm size and natural or Manufactured sand will be used. The ratio of
sand to aggregates is around 0.5 and the ratio of 20mm/25 mm to 12mm/10mm size is 0.3 to 0.4
based on their unit weight, sp gravity and void content. Some times 40mm size of aggregates are
proposed to be used in pavement design.

Several authors worked on the same methodology of mix design as explained above for cement
concrete and almost all authors have proposed the similar methodology except selection precursor
in place of cement and W/C ratio and admixture content. The precursors selection was based on the
guide lines prepared by conducting several experiments and development of few charts and based
on their experience.

Pavitra et el (2016) proposed a methodology with fixed SS/SH ratio as 1.5 and 16 M NAOH solution.
The quantum of Activator solution was taken as per IS 10262 max water content and the binder
content, in this case only Fly Ash, is finalised as per ACI curve for 28 days strength vs W/C ratio. The
aggregate content was finalised based on the IS:10262 and Hot curing was used for validating the
results. The methodology has its own limitations by fixing the Molarity, SS/SH, W/C ratio, binder and
hot oven curing .

Anuradha et al. (2012) suggested a design pro-

cedure for different grade of GPC by using Indian standards. In this
method, fly ash content and activator solution to fly ash ratio was
selected based on the strength required and by keeping fine
aggregate percentage as constant. Later, correction to fine aggre-
gate percentage was performed based on its zone. The activator
solution content employed was observed to be excess for the cor-
responding strength reported. Ferdous et al. (2013) proposed a mix
design for fly ash based GPC by considering the concrete density
variability, specific gravity of the materials, air content, workability,
and the strength requirement.

Patankar et al (2015) proposed mix design with AAS/FA ratio as 0.35, SS/SH ratio of 1.0 and
13 M NAOH were fixed. Fly ash content, aggregate content for a given mix are the variables
to be decided. Comp strength vs qty of fly ash, Fineness modulus vs Fine/Total aggregate
content graph, fineness of flyash vs density of GPC and water content tables were
developed and the same were used in finalising the mix designs as per target strength.
However, hot oven curing conditions at 60 degrees for 24 hours recommended and mix
design ratios were proposed. The proposed method may be recommended for precast
members.
Chaitanya Srikrishna et al (2018) proposed a mix design for GPC with GGBS as
source material and NAOH as activator solution. No Silicate is proposed as GGBS
is having higher calcium content resulting in hydration reaction as well as
geopolymerization. Developed workability and compressive strength vs Molarity
vs binder content relations for different AAS ratios. Based on these relations,
GGBS content, quantity of Alkaline solution and NAOH Molarity. The rest of the
aggregate content was based on Particle packing theory.

Mallikarjuna Rao et el (2018) developed graphs for replacement of flyash with GGBS at
30%, 40% and 50%. AAS ratio is varied at 0.45, 0.5, 0.55 and 0.6 with a binder quantity of
360 kg, 420 kg and 450 kg. compressive strength curves under ambient curing conditions
were developed with 8M NAOH and SS/SH ratio was fixed at 2.5. Based on these curves, mix
design methodology was proposed under ambient curing conditions which was validated by
conducting the trail mix.
The procedure for
The common point in all the proposed mix design methodologies are one or more fixed
parameter like SS/SH ratio, Molarity, Binder content. Further, the authors have worked on
compressive strength curves and gave reference to these curves or selection of various
parameters.
Based on

either Considering the above methodologies, the procedures have been calculated based
on there seems to be no specific procedure which considers all the essential parameters.

Therefore, in this method an attempt has been made to propose a mix design procedure
which takes into account the aforesaid
drawbacks of the earlier proposed methods. Major emphasis has been kept on the cost
reduction without compromising on the desired strength and workability All mix design

The major issue in the mix design process is the selection of quantum of activator solution
and basic source materials. Eventhough in GPC, the basic source materials may be cheaply
and abundantly available, the cost of the alkaline solution plays a major role and from the
economic design point of view, use of alkaline solution must be minimised for a given target
strength and workability.
On account of

methodology proposed the selection of xxxx (ADD ALL AUTHORS WORKS).

The precursor materials proposed consists of basic materials, that are rich in Silica and Alumina, and
Alkaline solutions. The basic materials can be GGBS, metakaolin, Flay Ash, rice husk or combination
of the these materials. The present study is limited to the combination of Fly Ash and GGBS and
hence these materials only discussed here after. Palomo et al. 1999 described that the type and
quantum of alkaline liquid plays an important role during the geopolymerization process. Hardjito
and Rangan 2005 indicated that Sodium hydroxide (NaOH) with sodium silicate (Na2SiO3) and
potassium hydroxide (KOH) with potassium silicate (K2SiO3) are the most common alkaline liquids
used in geopolymerization. The present study is limited to Sodium Hydrooxide and Sodium Silcate

The detail properties of the materials will be discussed in the following paragraphs.

FLY ASH

Low calcium fly ash confirming to Class – F is the most suitable basic materials. With Silicon to
Alumina ratio nearly 2.0 makes the fly ash ideal for precursor materials. Fly ash confirming to Class -
C is also suitable for the geopolymer concrete except that the additional formation of C-S-H gel.
However, the properties of the fly ash needs to be checked before recommending for Geopolymer
concrete. The mineral properties of the fly ash changes due to change of source of coal production.
The mineral properties needs to be evaluated before mix design to look for the content of silica,
Alumina and calcium. The ratio of silica to Alumina should be more than 2.0 for a good source
materials. Authors have opinion that this ratio has an impact on selection of Alkaline activators. The
presence of calcium plays an important role and reduces the quantum of Alkaline solutions there by
reduction in consumption of resources consumed for preparation of solutions.

GGBS

Ground Granulated Blast slag is a byproduct produced in Iron metal industry. The major mineral
composition of GGBS consists of Silica, Alumina (both in the ratio of greater than 2.0) and calcium.
Ferrous mineral also present to some extent also. The presence of calcium in GGBS creates C-S-H gel
in addition to the N-A-S-H gel. Fly ash based mix design methodologies recommended for hot oven
curing Patankar et el (2015) Pavitra et el (2016) which may be suitable for heat cured GPC members.
For ambient curing conditions, additives like GGBS or Cement is must for Geopolymer Concrete to
augment the reactions. In the initial phase, , the and and not Addition of GGBS into the fly ash The C-
S-H gel creates immediate.

Sodium Hydroxide (NAOH)

Sodium Hydroxide pellets of 95% or more purity (commercial grade) is available in the market. The
same to be mixed in water as per the requirement of concertation called in terms of molarity. The
effect of molarity (M) was a big subject and several authors have worked on the same. (Xxxxx et el)
indicated that with increase in molarity, the compressive strength of the geopolymer concrete
increases. At the same time, the workability needs to be studied in detail. While preparing the
solution from pellets, heat will be developed due to exothermic reaction which needs to be taken
care.

Sodium Silicate (Na2SiO3)

Sodium Silicate or water glass available in the market is to be analysed in detail. The concentration
of the silicate and sodium in the solution is very important as it affects the strength of the
geopolymer concrete. Accordingly the dosage needs to be adjusted. Several authors have proved
that the optimum ratio of sodium silicate (SS) to Sodium Hydroxide (SH) is 2.5 while preparing the
activator solution. Mixing of SS and SH resulting into exothermic reaction which emits heat energy.

The admixture is not taken in to account while proposing the mix design. Detail studies are needed
for the for the
The variables in the basic components and As, the mix design for geopolymer concrete consists of
selection of

Proposed Mix Design Methodology:

A general mix design methodology is prepared based on the experience of the authors of present
paper. The methodology is for blended fly ash with GGBS precursor for ambient curing conditions to
be adopted directly for site.

1. Define the Target strength of the GPC concrete with the help of standard deviations as
defined in various codes
2. Select MSA of the aggregates to be used based on the requirements of the member
3. Select precursor ratio i.e. GGBS/Fly Ash Ratio based on the compressive strength
requirements
a. 0.4 for Comp strength>25 MPa,
b. 0.3 for Comp strength<25MPa and greater than 15MPa.
c. 0.2 for Comp Strength <15 MPa.
4. Select total Quantity of Precursor including flyash and GGBS. Calculate the quantities of Fly
ash and GGBS. The binder may be selected initially based on MSA
a. 400 kg for MSA = 20mm
b. 500 kg for MSA = 6 mm
5. Select AAS/Binder Ratio
a. The ideal ratio shall be 0.40 to 0.45
6. Select Molarity of NAOH solution. As a guide line, the Molarity may be taken as 8 M/10 M
for GPC<25MPa and 10M/12M for GPC>25 MPa
7. Calculate the quantum of solids and water content in AAS solution
8. Select Total water content for Geopolymer Concrete, As a guide line, 180 lit/cum shall be
taken initially in view of water absorption of aggregates and workability
9. Calculate Free water required (Total water required – Water content in AAS)
10. Calculate the total paste weight/Volume including free water content
11. Calculate the quantities of aggregates after deducting the paste volume from Unit weight of
the GPC (2400 kg/cum)
12. Calculate the quantities of Fine aggregates and Coarse aggregates.
13. With the Constituents fixed, start a trail mix
14. Calculate the workability, in terms of slump test after 10 min of pouring the concrete on
hard surface. It shall be 100 mm. Determine the workability 5 min there after again and the
slump shall be 80 mm. The reduction in slump indicates that the polymer reaction kicked off.
15. If workability requirements is not met, Goto step 8 and repeat the trail
16. After meeting the workability requirements, Cubes may be casted
17. Check for 7 days strength. The strength shall be a minimum of 80% of the target strength. If
not meeting the requirements, Goto step 6 and repeat the same.

Miller machine shall be used during the trail mix.

Davidovits, J. (1999). “Chemistry of geopolymeric systems, terminology”, '99 Geopolymer
International Conference Proceeding, France.

Fernández-Jiménez, A.M. and Palomo, A. (2005). “Composition and microstructure of alkali activated
fly ash binder: Effect of the activator”, Cement and Concrete Research, 35, 1984 – 1992.

Fernández-Jiménez, A.M., Palomo, A. and López-Hombrados, C. (2006). “Engineering Properties of

AlkaliActivated Fly Ash Concrete”, ACI Materials Journal, Title no. 103-M12, Technical paper.

García-Lodeiro, I., Palomo, A. and Fernández-Jiménez, A. (2007). “Alkali–aggregate reaction in

activated fly ash systems” Cement and Concrete Research, 37, 175–183.

xHardjito, D. and Rangan, B.V. (2005). “Development and properties of low-calcium fly ash-based
geopolymer concrete”, Curtin University of Technology, Perth, Australia.

IEA. (2007). “Tracking Industrial Energy Efficiency and CO2 Emissions”, International Energy Agency,
Paris, France.

Lloyd, N.A. and Rangan, B.V. (2010). “Geopolymer concrete with fly ash”, Second International
Conference on Sustainable Construction Materials and Technologies, Italy.

Palomo, A., Grutzeck, M.W. and Blanco, M.T. (1999). “Alkali-activated fly ashes-A cement for the
future”, Cement and Concrete Research, 29, 1323–1329.

Rangan, B.V., Hardjito, D., Wallah, S. E. and Sumajouw, D. M. J. (2005). “Studies on fly ash-based
geopolymer concrete”, Geopolymer, Green Chemistry and Sustainable Development Solutions, 133-
138.

Rangan, B.V. (2008a). “Low-calcium, fly-ash-based geopolymer concrete”, Concrete construction

engineering handbook, Chapter 26,

Taylor & Francis. Rangan, B.V. (2008b). “Design and manufacture of flyash-based geopolymer
concrete”, Concrete in Australia, 34(2), 37-43.

Worrell, E., Price, L., Martin, N., Hendriks, C. and Meida, L.O. (2001). “Carbon dioxide emissions from
the global cement industry” Annual Review of Energy and the Environment, 26, 303-329.

Pavithra, P., Srinivasula Reddy, M., Dinakar, P., Hanumantha Rao, B., Satpathy, B. K., & Mohanty, A.
N. (2016). A mix design procedure for geopolymer concrete with fly ash. Journal of Cleaner
Production, 133, 117–125.

Chaitanya Srikrishna Thunuguntla and Tippabhotla Durga Gunneswara Rao, “Mix Design Procedure
for Alkali-Activated Slag Concrete Using Particle Packing Theory J. Mater. Civ. Eng., 2018, 30(6):
0899-1561.

Mallikarjuna Rao, G., & Gunneswara Rao, T. D. (2018). A quantitative method of approach in
designing the mix proportions of fly ash and GGBS-based geopolymer concrete. Australian Journal of
Civil Engineering, 16(1), 53–63.

Talha Junaid, M., Kayali, O., Khennane, A., & Black, J. (2015). A mix design procedure for low calcium
alkali activated fly ash-based concretes. Construction and Building Materials, 79, 301–310.

Ali Rafeet, Raffaele Vinai, Marios Soutsos, Wei Sha, “Guidelines for mix proportioning of fly
ash/GGBS based alkali activated Concretes”, Construction and Building Materials 147 (2017) 130–
142