GEOPOLYMER CONCRETE A SUSTAINABLE ALTERNATIVE TO TRADITIONAL CONCRETE

SYNOPSIS

ABSTRACT
The global construction industry is one of the largest contributors to greenhouse gas emissions, primarily due to
the production of Portland cement, a key component of traditional concrete. Geopolymer concrete (GPC)
emerges as a sustainable alternative, offering significant environmental and performance benefits. This
innovative material is produced using industrial byproducts such as fly ash, slag, and silica fume, which are
activated with alkaline solutions to create a binder, eliminating the need for cement.
Geopolymer concrete exhibits superior properties, including high compressive strength, excellent durability,
and resistance to chemical attacks and thermal degradation. Additionally, the production of GPC results in a
substantial reduction in carbon emissions, energy consumption, and reliance on natural resources compared to
conventional concrete. Despite its advantages, challenges such as scalability, variability of raw materials, and
lack of standardized guidelines hinder its widespread adoption.
This paper explores the composition, properties, and environmental benefits of geopolymer concrete,
highlighting its potential to revolutionize sustainable construction practices. By addressing the current barriers
and leveraging advancements in material science, geopolymer concrete can pave the way for eco-friendly
infrastructure development in the face of growing environmental concerns
Chapter 1:INTRODUCTION

Industrialization leads to the generation and release of undesirable pollutants into the environment. In order to
have control over rapid industrialization there is a need to select alternate environmentally friendly construction
materials, to reduce the emission of greenhouse gases into the atmosphere. Recently, there has been increased
attention towards the safer disposal of industrial by-products such as GGBS and FA. Hence, this can be used in
the construction industry which forms a very significant segment of the nation’s economy; utilization of these
industrial by-products in this sector may become an important route for large-scale disposal of these industrial
wastes. Fly ash and ground granulated blast furnace slag are the major waste of various thermal plants, which
should be disposed of properly. Fly ash and GGBFS boast significant levels of silica and alumina. This can
form a binder when it comes in contact with an alkaline solution. Foundry sand serves as a top-grade silica
material essential for crafting molds in metal casting procedures. Usually, it comprises silica, clay, and diverse
enhancements to enhance its characteristics. Natural sand is used as fine aggregate in conventional concrete and
it is replaced by foundry sand. The combination of sodium hydroxide and sodium silicate solutions served to
activate the pozzolanic material, enabling it to function as a binding agent in the geo-polymerization process.
Geopolymer concrete has its origins in the 20th century, emerging as scientists sought alternatives to traditional
Portland cement-based concrete. A significant breakthrough came in the 1950s when French materials scientist
Joseph Davidovits introduced the concept of geopolymers. He found that certain aluminosilicate materials, like
fly ash and metakaolin, could be activated with an alkaline solution to form a binder akin to cement. This
innovative discovery led to the coining of the term "geopolymer." For any type of concrete structure, cement is
the key ingredient, which is highly affecting the environment. The production of ordinary Portland cement
results in significant emissions of carbon dioxide (CO2), contributing to atmospheric pollution.
The very main objective of this study is to make concrete more environment friendly by using different types of
wastes produced largely in industries. B. Vijaya Rangan et al. [1] The chemical reaction of Geopolymer
concrete doesn't involve water; instead, water is expelled during curing and subsequent drying. This sets it apart
from Portland cement, where hydration reactions with water produce primary hydration products like calcium
silicate hydrate and calcium hydroxide. This distinction significantly influences the mechanical and chemical
properties of geopolymer concrete, rendering it more resistant to heat, water ingress, alkali-aggregate reactivity
and other types of chemical attack. Geopolymer concrete (GPC) exhibits superior physical, chemical and
mechanical characteristics compared to ordinary Portland cement (OPC) concrete. In recent years geopolymers
have emerged as novel materials having unique and highly desirable chemical and mechanical properties. The
discovery of geopolymers is a breakthrough, which provides a cleaner and environmentally friendlier
alternative to OPC. The technology of geopolymerisation is gaining commercial interest because it has been
demonstrated that, in certain cases, the properties of geopolymeric materials are superior to existing
cementitious systems. Brief details of the works carried out are indicated below • Slump cone test carried out
for determining workability of fresh concrete • Compressive strength test is carried out on cubes • Rebound
hammer test is also carried out to check the strength of slab without destructing. • Crack development
observation is documented in comparison between Geopolymer concrete and conventional concrete using M-
sand.
Chapter 2 : THEORETICAL BACKGROUND

Introduction to Geopolymer Concrete

Geopolymer concrete (GPC) is an innovative construction material that has gained attention as a sustainable
alternative to traditional Portland cement concrete. Traditional concrete is known for its high environmental
footprint, as the production of cement contributes significantly to global CO₂ emissions (approximately 8%).
Geopolymer concrete addresses these challenges by using industrial by-products, such as fly ash or slag, as
binding materials, significantly reducing reliance on cement.
What is Geopolymer Concrete?
Geopolymer concrete is a type of inorganic polymer formed by the reaction of an aluminosilicate material with
an alkaline activator. The primary raw materials for GPC include:
1. Aluminosilicate sources: Industrial by-products like fly ash, slag, or metakaolin.
2. Alkaline activators: Sodium hydroxide (NaOH) and sodium silicate (Na₂SiO₃) solutions.
The chemical process, known as geopolymerization, involves:
1. Dissolution of aluminosilicates in an alkaline medium.
2. Formation of oligomers through condensation.
3. Polymerization into a stable three-dimensional aluminosilicate network.
Key Properties of Geopolymer Concrete
1. High Strength and Durability: GPC exhibits excellent compressive strength, comparable or superior
to traditional concrete, and high resistance to aggressive environments, including chemicals and high
temperatures.
2. Eco-Friendliness: By replacing cement with industrial by-products, GPC reduces CO₂ emissions by
up to 80%, contributing to a lower carbon footprint.
3. Thermal Resistance: GPC can withstand high temperatures, making it suitable for fire-resistant
construction applications.
4. Low Shrinkage: The low water content in the mix reduces shrinkage and cracking.
Advantages over Traditional Concrete
1. Sustainability: Traditional concrete requires energy-intensive clinker production, while GPC uses
industrial waste, diverting it from landfills.
2. Waste Utilization: Fly ash and slag, common by-products of power plants and steel manufacturing,
are effectively reused.
3. Energy Efficiency: GPC production often involves ambient or low-temperature curing, reducing
energy consumption.
4. Improved Lifespan: The enhanced durability of GPC reduces the need for repairs and maintenance,
lowering lifecycle costs.
Challenges in Implementation
1. Raw Material Availability: Dependence on specific industrial by-products may limit scalability.
2. Standardization: The absence of globally accepted standards for GPC hinders its widespread
adoption.
3. Curing Requirements: Some geopolymer systems require heat curing, complicating on-site
applications.
4. Cost: Initial costs can be higher due to the price of alkaline activators.
Applications of Geopolymer Concrete
1. Infrastructure Projects: Bridges, highways, and precast elements where high durability is critical.
2. Industrial Floors: High-strength and chemical-resistant flooring.
3. Fire-Resistant Structures: Construction in areas prone to high temperatures.
4. Sustainable Construction: Eco-friendly buildings seeking green certifications.
Chapter 3: LITERATURE REVIEW

In 1988, Davidovits [2] proposed that binders could be produced by a polymeric reaction of alkaline liquids
with silicon and aluminium in source materials of the geological origin or byproducts materials such as fly ash
and husk ash. He termed these binders as geopolymer. Palomo et al. [3] concluded that the type of alkaline
liquid plays an important role in the polymerization process. Reactions occur at a high rate when the alkaline
liquid contains soluble silicate, either sodium or potassium silicate, compared to the use of only alkaline
hydroxides

. Zongjin Li et al. [4] introduced a sustainable composite called geopolymer. The geopolymer is a type of
amorphous alumino-silicate product. Geopolymer can be synthesized by polycondensation reaction of
geopolymeric precursor and alkali polysilicates. It is shown that compared to Portland cement, geopolymers are
energy efficient and environment friendly. Thus, it is a sustainable cementitious material. The investigation
shows that these two materials have superior properties compared to the Portland cement, such as high early
strength, excellent volume stability, better durability, good fire resistance, and easy manufacturing process.

ORIGIN OF TERM ‘GEOPOLYMER’

The term ‘‘geopolymers’’ was first introduced to the chemical world by Davidovits in the mid 1970’s
(Davidovits, 1993), and in so doing a new field of research and technology was created. He explained that
“geosynthesis” is the science of manufacturing artificial rock at a temperature below 100°C (Davidovits, 1993)
in order to obtain natural characteristics (hardness, longevity and heat stability). Geopolymers were thus
viewed as mineral polymers resulting from geochemistry or geosynthesis.
The mechanism of geopolymerisation is reported to be consisting of dissolution, transportation or orientation,
and polycondensation (Xu & van Deventer 2000), and takes place through an exothermic process (Palomo,
Grutzeck & Blanco 1999; Davidovits 1999). “ANALYSIS OF PROPERTIES OF GEOPOLYMER
CONCRETE USING FOUNDRY WASTE AND M-SAND” SVERI’s College of Engineering, Pandharpur.
Page 5

BACKGROUND OF GEOPOLYMER
Djwantoro Hardjito et al [5] investigated geopolymer as the binder, instead of cement paste and the geo-
polymeric binding action was achieved by hydroxide-silicate based chemicals as an initiators or catalysts for
polymeric reaction to produce concrete. The manufacture of geopolymer concrete was carried out using the
usual concrete technology methods. As in the Portland cement concrete, the aggregates occupied the largest
volume, i.e. about 75-80 % by mass, in geopolymer concrete. The silicon and the aluminium in the fly ash were
activated by a combination of sodium hydroxide and sodium silicate. It was observed that several authors have
used the term ‘alkali activated slag’ to describe their work on development of binding material from blast
furnace slag powder (BFSP).

Palomo et al [6] suggested that pozzolans such as blast furnace slag might be activated using alkaline liquids to
form a binder and hence totally replace the use of OPC in concrete. In this scheme, the main contents to be
activated are silicon and calcium in the blast furnace slag. The main binders produced is C-S-H gel, as the
result of the hydration process.

Rafat Siddiquea et al. [7] reported the results of an experimental investigation, which is to be carried out to
evaluate the mechanical properties of concrete mixtures. In this study fine aggregate i.e. regular sand was
partially replaced with used-foundry sand. Fine aggregates were replaced by weight with three percentages
(10%, 20%, and 30%) of used-foundry sand. Different tests were performed for the properties of fresh concrete.
Different test on hard concrete, Compressive strength, splitting-tensile strength, flexural strength, and modulus
of elasticity were performed for 28, 56, 91, and 365 days. These test results show a slight increase in the
strength properties of plain concrete by including used-foundry sand as a partial replacement of fine aggregate.
It can be effectively used in making good quality concrete and construction materials
CHAPTER 4 :METHODOLGY
Geopolymer concrete is made of fly ash as a cement-free alternative. The fly ash is the binder, while the
alkaline solution is the activator. Both combine to produce alumino-silicate gel through geopolymerization. The
sodium hydroxide and sodium silicate alkaline fly ash were utilized in our study. Most notably, there is no
mention of Portland cement in geopolymer concrete. Therefore, their agent is dramatically different and
involves fly ash – an industrial by-product high in silicon and aluminum. Instead of utilizing Portland cement
as a base, geopolymer concrete’s chemicals react with fly ash, which is full of Silica and Alumina. These
alternative components are combined with a highly alkaline fluid, usually composed of sodium silicate and
sodium hydroxide solution, to create the geopolymeric agent.The study derives from the development of
Geopolymer resins and binders that are non-flammable and non-combustible. The immense research on
geopolymer concrete indicates it as an eco-friendly substitute for ordinary cement concrete. The focus of
research has transitioned from the realm of chemistry to engineering applications and the commercial
production of Geopolymer

FUNDAMENTAL FORMS • Poly (sialate), which has [-Si-O-Al-O-] as the repeating unit. • Poly ( sialate-
siloxo ), which has [-Si-O-Al-O-Si-O-] as the repeating unit. • Poly ( sialate-disiloxo ), which has [-Si-O-Al-O-
Si-O-Si-O] as the repeating unit, Here sialate is an abbreviation of Silicon-Oxo-aluminate. Geopolymer
concrete is a type of concrete that uses geopolymer binders instead of traditional Portland cement. Geopolymer
binders are typically formed by the chemical reaction of aluminosilicate materials with alkaline activators.
There are several fundamental forms or types of geopolymer concrete, which differ based on their composition
and properties. Here are the main forms:
a. Class F Fly Ash-Based Geopolymer Concrete
b. Class C Fly Ash-Based Geopolymer Concrete
c. Slag-Based Geopolymer Concrete
d. Metakaolin-Based Geopolymer Concrete
e. Natural Pozzolan-Based Geopolymer Concrete