IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 03 | September 2016

ISSN (online): 2349-784X

Evaluation of Mechanical Properties of GeoPolymer Concrete by using Crushed Clay Bricks

as Coarse Aggregates
M. N. Shiva Kumar
Department of Civil Engineering
Bapuji Institute of Engineering & Technology, Davangere-577
005, Karnataka, India

Arpitha. J
Department of Civil Engineering
Bapuji Institute of Engineering & Technology, Davangere-577
005, Karnataka, India

Abstract
Concrete is widely used construction material, in Concrete cement is the main component. Cement produces greenhouse gas
during manufacture so to reduce carbon emission in atmosphere cement is replaced by industrial by-product such as Fly ash.
Geo-polymer concrete (GPC) utilizes fly ash as binding material instead of cement. Utilizing construction waste in concrete and
making the concrete economical is gaining more importance now a day, more researches are going on this. The purpose of this
project is to experimentally investigate the effect of using crushed clay bricks as coarse aggregates in Fly ash based GPC. In
present project Fly ash is used as cementesious material, Sodium hydroxide and sodium silicate solution is used as binding
activators which binds on geopolymerisation and granite aggregates are replaced by 0%,25%,50%,75%,100% crushed clay
bricks as coarse aggregates. Geo-Polymer concrete specimens are cured at 60C temperature for 24 hours. Mechanical properties
such as Compressive strength, Splitting tensile strength Flexural strength are conducted on GPC samples and results are
compared with conventional concrete samples. As bricks are cheap and easily accessible near the place of demolition of old
buildings it reduces cost of construction than stone granite aggregate. Brick aggregates up to 50% can be replaced to get good
result.100% replacement of Brick aggregate has least strength. GPC needs much care because of presence of activator NaOH
which is caustic in nature.
Keywords: Geo-Polymer Concrete, Clay Bricks, Coarse Aggregate, Fly Ash, Alternate Building Material
________________________________________________________________________________________________________
I.

INTRODUCTION

In 1978 Davidovits coined the term Geo-polymer, he proposed that binders are produced by polymerization of alkaline liquid
which contains Silicon (Si) and Aluminum (Al) as base or industrial by-products. The binder can be replaced by industrial byproducts example fly ash, GGBS etc., with binding activator forming new product called Geo-polymer concrete. Geo-polymer
paste is formed by the reaction between silicon and aluminum oxides of low calcium fly ash and alkaline liquid, this paste binds
all the materials and results in Geo polymer concrete. This large quantity of demolished waste created great challenge to disposal
and its effect on environment. The reuse of these materials in construction becomes solution for problem. The bricks from
demolition waste can be reused as coarse aggregates. Brick aggregates have better fire resistance than normal aggregate. It
becomes economical as 75% of volume of concrete is occupied by aggregates. Three basic forms of Geo-polymer are Poly
(sialate), Poly (sialate-siloxo), Poly (sialatedisiloxo), it among the above three forms poly (sialate siloxo) has high mechanical
strength and poly (sialate) has the low strength.
The main advantages of the GPC is stronger in tension, due to high brittleness it resists earth quake loads better than
conventional concrete, but not fully earth quake proof. In Geo-polymer concrete has less heat of hydration. The creep and
shrinkage is also less in geo-polymer concrete. Spalling starts in GPC only after it reaches Two thousand two hundred degree
Fahrenheit. The same time the disadvantages also are transporting the binding material fly ash from far off place to the
construction site. Precaution is must, because of the use of high alkaline sodium hydroxide solutions activator. Practical
application of Steam curing / high temperature curing process is difficult.
II. SCOPE OF THE WORK AND OBJECTIVES OF THE STUDY
Reduce the CO2 emission by cement industries by using the waste materials like fly ash and waste bricks. Using geo-polymer
concrete without the cement as construction material forms GREEN CONCRETE It increases the efficiency of the concrete
and at the same time maintains the quality of product. The main objectives of the study is study of strength characteristics of
conventional concrete and Geo-polymer concrete produced by replacing granite aggregate by crushed brick aggregate on
different percentage (0, 25,50,75,100%). Flay ash is used as course aggregate and make economical and eco-friendly alternative
binding material.

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Evaluation of Mechanical Properties of Geo-Polymer Concrete by using Crushed Clay Bricks as Coarse Aggregates
(IJSTE/ Volume 3 / Issue 03 / 015)

III. MATERIALS AND METHODS

Materials used for Conventional Concrete
Cement
Cement is the binding material which binds all the ingredients in concrete. It is important component in concrete.
Lumps should not present in cement.
For the present study Dalmia cement of 43 grade which is conforming to IS: 8112-1976 was used.
Fine Aggregate
For the present work naturally available river sand is used. The fine aggregate confirming to zone-I was used for the
present work. Aggregates were saturated surface dry. Physical Characteristics of the fine aggregate is given Table 1
Coarse Aggregate
Aggregates (Coarse aggregate + Fine aggregate) conforming to IS 383-1970, procured from a single quarry in single
transport was used for entire work for manufacture of conventional concrete and geo-polymer concrete. 20mm down size is
used for entire work. Physical Characteristics of the coarse aggregate is given Table 1.
Super Plasticizer
Conplast SP430 agrees is a high range water decreasing admixture. Conplast SP430 is in light of Sulphonated Napthalene
Polymers and is supplied as cocoa fluid immediately dispersible in water and exceptionally defined to surrender high water
decrease to 25% with no loss of workability, Specific gravity is 1.22. It was procured from Davanagere local market.1% of
Super plasticizer by the weight of cement is added to concrete while mixing.
Water
It is the main ingredient in concrete for mixing and curing and it is also necessary for process of hydration. So, water used
should be free from dust, dissolved salts and impurities. Potable tap water conforming to IS456:2000 was used in the
present work.

IV. EXPERIMENTAL METHODS

Mixing, Casting and Curing of Conventional Concrete
The conventional concrete was mixed for the grade M40. After the mixing is done, samples are casted by giving proper
compaction in three layers. In the present study, 150mmX150mmX150mm size cubes, 100mmX100mmX500mm sized beams
and 150mm dia, 300mm height cylinders were casted. For 5 Mix proportions 9 cubes, 6 beams and 6 cylinders for each mix
proportions were casted. After casting specimens were de-moulded after 24 hours, after de-moulding, samples were immersed in
water for curing, and curing was done for 3, 7, 28 days. The water and super plasticizer density were used in Mix M40 is 173
kg/m3 and 3.94 kg/m3 respectively. The other materials density is given in Table 1.
Table 1
Physical Characteristics of Materials used in the study
Materials
Cement
Fine Aggregate Coarse Aggregate
Specific Gravity
3.13
2.72
2.66
Bulk density
1.61gm/cc
1.527 gm/cc
Fineness modulus
7 min
2.1
7.5
Initial Setting time 35 minutes
Final setting time 250 minutes
Impact test
11.56%
Density
394kg/m3
684.46 kg/m3
1189.9 kg/m3

Geo-Polymer Concrete (GPC)

Materials used to prepare the GPC fly ash was collected form Ballary Thermal Power Plant which is situated in Kudthini village.
Characteristics of the fly ash were measured. Clay bricks are crushed which forms aggregates these aggregates are known as
Brick aggregates. Waste clay bricks are collected from different places are and are crushed manually by hammer to 20mm down
size to which produced angular aggregates. Physical properties are tabulated as below. Bricks are used in saturated surface dry
(SSD) condition to avoid absorption of water during mixing. The sodium hydroxides with purity of 97% are available in the form
of flakes and pallets. Calculated amount of Sodium hydroxide flakes are taken and made to dissolve in 1 liter of distilled water to
make solution. Concentration of NaOH solution varies from 8M to16M. For present work flakes are used. It is procured from the
Davangere local market. Sodium silicate solution is used in this study has SiO2 = 29.4%, Na2O = 14.7%, and water = 55.9%, is
used in the present work and it is procured from local market of Mangalore. Finally conducted Fundamental Parameters of the
mix design is given below.
Combined aggregates weight is 77%, which comprises of coarse aggregate at 70%, fine aggregate at 30%.
Concentration of NaOH solution is 16M. Ratio of Na 2CO3 solution and NaOH solution is kept 2.5 based on the
previous work results.
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Evaluation of Mechanical Properties of Geo-Polymer Concrete by using Crushed Clay Bricks as Coarse Aggregates
(IJSTE/ Volume 3 / Issue 03 / 015)

The ratio between alkaline liquid and fly ash is kept 0.4. Oven curing is done by maintaining temperature 60c for about 24
hrs. Assuming the density of GPC as 2400kg/m3.
V. RESULTS AND DISCUSSION
Mixed Design for GPC

Prepared using combined aggregates weight is 77%, which comprises of coarse aggregate at 70%, fine aggregate at 30%.
Concentration of NaOH solution is 16M. Ratio of Na 2CO3 solution and NaOH solution is kept 2.5 based on the previous work
results. The ratio between alkaline liquid and fly ash is kept 0.4. Oven curing is done by maintaining temperature 60c for about
24 hrs. Assuming the density of GPC as 2400kg/m3. The details of the mix design are given in Table 2. Total different
composition of five mixes were prepared and are Compressive strength test, Splitting tensile strength test and Flexural strength
test were conducted.
Table 2
Mix Design for GPC
Materials
GPS Design
Combined aggregate
1848kg/m3
Coarse aggregates
1293.6 kg/m3
Fine aggregates
554.4 kg/m3
Fly ash and alkaline liquid
552 kg/m3
Alkaline liquid to fly ash ratio
0.4
Mass of Fly ash
394.28 kg/m3
Density
2400kg/m3
Mass of alkaline liquid
157.72 kg/m3
sodium hydroxide to sodium silicate Ratio 112.72 kg/m3
Table 3
Mix Proportions for GPC
Constituents
Density (kg/m3)
Fly Ash
394.28
Fine aggregates
554.4
Coarse aggregate
1293.6
Sodium Hydroxide solution
45
Na2CO3 solution
112.72
Super plasticizer
6
Extra water
23.65
Table 4
Quantity of materials required for Geo-polymer concrete for different mix
Constituents
Mix1
Mix2
Mix3
Mix4
Mix5
Fly Ash
394.28 394.28 394.28 394.28 394.28
Fine aggregates
554.4
554.4
554.4
554.4
554.4
Coarse aggregate
1293.6 970.2
646.8
323.4
Brick aggregate
323.4
646.8
970.2 1293.6
Sodium Hydroxide solution 112.72 112.72 112.72 112.72 112.72
Na2CO3 solution
23.65
23.65
23.65
23.65
23.65
Super plasticizer
6
6
6
6
6
Extra water
23.65
23.65
23.65
23.65
23.65

Mixing

Fig. 1: Pouring activator solution to dry mix, mixing and Curing

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Evaluation of Mechanical Properties of Geo-Polymer Concrete by using Crushed Clay Bricks as Coarse Aggregates
(IJSTE/ Volume 3 / Issue 03 / 015)

First Fly ash, fine aggregates, Granite and Brick aggregates were mixed in dry condition for about 3-4 minutes until uniform
colour is obtained. After dry mixing, measured amount of liquid alkaline solution that is combined sodium hydroxide and
sodium silicate solution is added ,then super plasticizer with extra water if needed was added. Mixing continued for again 3-4
minutes. Colour of freshly prepared geopolymer concrete was greenish grey and appearance was shiny and also mix was
cohesive. The pouring activator solution to dry mix is given in Figure 1.
Casting and Curing
After proper mixing the ingredients of concrete, then the concrete is made to fall inside the moulds in three layers and compacted
by compacting rod by giving 25 blows for each layer. The casted specimens were covered with HDPE (High Density
Polyethelene) sheet to minimize the water evaporation and kept in rest period for 24hrs at room temperature. After rest
period the specimens were then kept in the oven and curing is done at 60c for 1 day, when curing is over cured samples were
removed and are allowed to leave in room temperature till they are tested at 7,28 days.
The results obtained from tests conducted are discussed and tabulated. The tests which are conducted for different mix are
Compressive strength test, Splitting tensile strength test and Flexural strength test. The tests results are given in Table 5.
Table 5
Strength results for M40 mix
Sl No.

Strength

1.
2.
3.

Compressive strength (N/mm2)

Splitting tensile Strength (N/mm2)
Flexure strength (N/mm2)

7 Days
22.23
2.18
4.32

22.65
2.45
4.21

28 Days
22.85
3.56
4.44

44.22
4.14
5.35

45.10
4.23
5.42

43.78
3.95
5.37

Average
7 days 28 days
22.91
44.36
2.73
4.10
4.32
5.38

VI. DISCUSSION
For the same mix, strength of Geopolymer concrete is 1.5 times more than conventional concrete. GPC needs more care to
prepare activator solution and preparation consumes much time. Replacement of Brick aggregates upto 50% produced almost
same result of GPC with 100% granite aggregate. As water absorption is more for brick aggregate soaking of brick aggregates
for 3 min before mixing is necessary. As the percentage of replacement of brick aggregates increases compressive strength,
splitting tensile and flexural strength decreases. Comparison of, GPC with 50% brick aggregates and conventional concrete
strength results shows that brick aggregates is a good alternative for coarse aggregates. Different test results were expressed in
Figure 2, 3 and 4.

Sl. No.

Mix

1.
2.
3.
4.
5.

100% GA
75% GA + 25% BA
50% GA + 50% BA
25%GA + 75% BA
100% BA

Table 6
Strength results for GPC
Compressive strength (N/mm2) Splitting tensile Strength (N/mm2)
7 days
28 Days
7 days
28 Days
30.14
45.52
2.65
4.2
31.20
38.24
1.52
3.3
28.20
36.33
1.62
3.5
26.30
33.65
1.58
2.24
25.00
28.22
1.65
2.05

Flexure strength (N/mm2)

7 days
28 Days
4.20
6.50
3.90
6.00
2.55
5.23
2.60
3.66
2.04
3.06

Note: GA-Granite Aggregate, BA-Brick aggregate

Fig. 2: Compressive strength for GPC

Fig. 3: Compressive strength for GPC

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Evaluation of Mechanical Properties of Geo-Polymer Concrete by using Crushed Clay Bricks as Coarse Aggregates
(IJSTE/ Volume 3 / Issue 03 / 015)

Fig. 4: Flexural strength for GPC

VII. CONCLUSION
Based on the results the following conclusion was drawn.
The geopolymer concrete has more compressive strength than conventional concrete.
The strength of GPC with brick aggregates is less than GPC with granite aggregate.
100% replacement of granite aggregates by brick aggregates forms light weight concrete.
Even though the strength of GPC with brick aggregate is less but it is not less than conventional concrete. Brick aggregate
can be replaced by coarse aggregate.
GPC can be used to produce pervious concrete which drains off rainwater quickly.
Brick aggregates up to 50% replacement gives good result.
GPC needs much care because of presence of activator NaOH which is caustic in nature.
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Geopolymer Concrete
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[3] Kolli Ramujee and M. Potharaju,entitled, Development of Low Calcium Flyash Based Geopolymer Concrete
[4] Neville, A.M., (1995). Properties of Concrete, 4th ed., Pittman, London.
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