65

CHAPTER-3

MIX DESIGN AND STRENGTH PROPERTIES OF GPC

3.0 IMPORTANCE OF MIX DESIGN

Many parameters are involved in the production of GPC, out of

which alkaline liquid mineral admixtures ratio and superplasticiser are

important. Sulphonated Naphthalene based dispersing agents are

adopted as super plasticizers to obtain better mechanical properties of

GPC. Low calcium flyash gives better results from the point of view of

chemical composition. GGBS is used to fill the voids between flyash and

fine aggregate and this helps in the degree of particle aggregation, nature

and quantity of impurities and basic particle size. Sodium hydroxide and

sodium silicate solutions used as alkaline liquids react with flyash and

GGBS to form the geopolymer gel binding the aggregates to produce GPC.

The final product was cured in steam curing chamber at 60C for 24

hours.

Based on review of literature, Rangans method [18] has been

adopted to produce M60 GPC. TVC mix design has been carried out

using Perumals method [112].

3.1 MATERIALS CHARACTERISTICS

3.1.1 Fly Ash

Fly ash is the alumino silicate source material used for the

synthesis of geopolymeric binder. Class F fly ash shown in fig 3.1

obtained from the silos of Raichur Thermal Power Station, Karnataka

 66

was used for the experimental work. The percentage of fly ash passing

through 45m IS Sieve was found to be 95%. The physical characteristics

are as shown in table 3.1

Fig. 3. 1 - Low calcium Fly Ash (ASTM Class F)

Table 3. 1 - Physical Characteristics of Fly Ash

Properties Values
Specific gravity 2.40
Blaines fineness (m2 / kg) 439

3.1.2 Ground granulated blast furnace slag

Ground Granulated Blast Furnace Slag (GGBS) shown in fig 3.2 is

a byproduct of the steel industry. Blast furnace slag is defined as the

non-metallic product consisting essentially of calcium silicates and other

bases that is developed in a molten condition simultaneously with iron in

a blast furnace. About 10% by mass of binders was replaced with

GGBS.

Fig. 3. 2 - Ground Granulated Blast Furnace Slag (GGBS)

 67

3.1.3 Coarse and Fine Aggregates

The fine aggregate used in the study was river sand and coarse

aggregate are crushed angular granite stone passing 12.5 mm sieve. The

sieve analysis of fine and coarse aggregate are shown in table 3.2 & 3.3

Table 3. 2 - Sieve Analysis Results of Fine Aggregate

Specifications as per IS 383: 1993

Sieve Wt. Cum.
% Wt. [133] for % passing with different
size retained % Wt.
passing zones
(mm) (gms) retained
I II III IV
4.75 001 00.10 99.9 90 - 100 90 - 100 90 - 100 90 100
2.36 023 02.40 97.6 60 - 95 75 - 100 85 - 100 95 100
1.18 129 15.30 84.7 30 - 70 55 - 90 75 - 100 90 100
0.60 328 48.10 51.9 15 - 34 35 - 59 60 - 79 80 100
0.30 406 88.70 11.3 5 - 20 8 - 30 12 - 40 15 50
0.15 094 98.10 01.9 0 - 10 0 - 10 0 - 10 0 15

Table 3. 3 - Sieve Analysis Results of Coarse Aggregate

Sl. Sieve Wt. % Wt. Cum. % Grading limits

% Wt
No Size Retained Retained Wt. as per IS 383:
passing
(mm) Retained 1993 [133]
1 20 0 0 0 100 100
2 12.5 200 4 4 96 90 100
3 10 1280 25.6 29.6 70.4 40 85
4 4.75 3200 64 93.6 6.4 0 10

Coarse and fine aggregate tested conforms to the specifications as

per IS 383: 1970 [110] with fine aggregate belonging to zone II as per the

specifications. The physical characteristics of coarse and fine aggregates

are shown in table 3.4 and 3.5

Table 3. 4 - Physical Characteristics of Coarse Aggregates

Specific Fineness Flakiness Density (kg/m3)

Sl. No.
Gravity Modulus Index Loose Rodded
1 2.65 7.04 28.3% 1373 1535
 68

Table 3. 5 - Physical characteristics of Fine Aggregates

Specific Fineness Flakiness Density (kg/m3)

Sl. No.
Gravity Modulus Index Loose Rodded
1 2.56 2.429 4.1% 1500 1675

3.1.4 Alkaline Liquids

Sodium silicate gel (Na2SiO3) and sodium hydroxide (NaOH)

solutions used for fly ash activation is shown in fig 3.3 Sodium hydroxide

solution of 8, 12 and 14 Molar was prepared by mixing the pellets with

water. The mass of NaOH solids in a solution varied depending on the

concentration of the solution expressed in terms of molar, M. For

instance, NaOH solution with a concentration of 8M consisted of 840 =

320 grams of NaOH solids (in pellet form) per litre of the solution, where

40 is the molecular weight of NaOH. The Sodium silicate and Sodium

hydroxide solution were mixed 24hrs prior to usage.

Fig. 3. 3 - Sodium hydroxide pellets and Sodium silicate solution.

3.1.5 Super plasticizer

Super plasticizers are capable of reducing water contents by about

30 percent. However it is to be noted that full efficiency of super

plasticizer can be got only when it is added to a mix that has as initial

slump of 20 to 30 mm. Addition of super plasticizer to stiff concrete mix

reduces its water reducing efficiency. Depending on the solid content of

 69

the mix, a dosage of 1 to 3 percent by weight is recommended. For the

present investigation, a super plasticizer namely CONPLAST SP 430 has

been used for obtaining workable concrete at low a/m ratio. CONPLAST

SP 430 complies with IS 9103: 1999 [130] and BS: 5075 part 3 and

ASTM C 494, TYPE B as a HR WRA. CONPLAST SP 430 is based on

Sulphonated naphthalene formaldehyde (NSF) condensates with chloride

content.

3.1.6 Water

Potable drinking water was used.

3.2 NORMAL CONCRETE

3.2.1 Cement

The cement used in the study is ordinary Portland cement (53

Grade) conforming to IS 12269: 1987 [131] with the physical

characteristics as shown in table 3.6

Table 3. 6 - Physical Characteristics of Cement

Properties Values
Specific gravity 3.07
Blaines fineness (m2 / kg) 310

3.2.2 Silica fume

Silica fume is a by-product of silicon metal or ferrosilicon alloy

production. 42 kg/m3 of silica fumes was used in M60 concrete.

 70

3.3 GPC MIX DESIGN AND EXPERIMENTAL DATA

3.3.1 Ingredients Required

The range of ingredients for M60 concrete based on Rangans [18]

Is listed below.

Fly ash Low calcium (ASTM Class F)

GGBS 10% of flyash

Ratio of Na2SiO3 Solution to NaOH Solution, by mass 0.4 to 2.5

Molarity of NaOH Soln 8M to 14M.

Alkaline liquid to Binders ratio 0.3 and 0.45.

Aggregates 75 to 80% of mass of concrete

Super plasticizer 2.5 to 3% of flyash and GGBS

GPC mix design based on trial mix design and the following quantities

are arrived for M60 concrete as given in table 3.13

3.4 MIX DESIGN FOR TRADITIONALLY VIBRATED CONCRETE

PROCEDURE

3.4.1 Target Mean Strength

Target mean strength is calculated as follows:

= fck + (t s) with usual IS notations. When adequate data are not

available to establish, the fck value can be determined from the following

table 3.7 given by ACI report 318.

 71

Table 3. 7 - Target Mean Strength when Data are not available

to establish a Standard Deviation
Specified Characteristic Target mean Compressive
Compressive Strength, fck (MPa) Strength, (MPa)
Less than 20.5 fck + 6.9
20.5 34.5 fck + 8.3
More than 34.5 fck + 9.7

3.4.2 Selection of maximum size of coarse aggregate

The maximum size of the coarse aggregate is selected from the

following table 3.8 as given by ACI Report 211.4R.93.

Table 3. 8 - Maximum Size of Coarse Aggregate

Characteristic Comp. Strength,

Maximum aggregate size (mm)
fck (MPa)
Less than 62 20 - 25
Greater than or equal to 62 10 - 12.5

3.4.3 Estimation of free water content

The water content to obtain the desired workability depends upon

the quantity of water and super plasticizer. However, the saturation point

of the super plasticizer is known, and then the water dosage is obtained

from the following table 3.9 If the saturation point is not known, it is

suggested that a water content of 150 liters/m3 shall be taken to start

with.

Table 3. 9 - Determination of the Minimum Water Dosage

Saturation
0.6 0.8 1.0 1.2 1.4
Point (%)
Water (l/m3) 120-125 125-135 135-145 145-155 155-165
 72

3.4.4 Super plasticizer dosage

The super plasticizer dosage is obtained from the dosage at the

saturation point. If the saturation point is not known, it is suggested that

a trial dosage of 1.0% shall be taken to start with.

3.4.5 Estimation of air content

The air content (approximate amount of entrapped air) is obtained

from the table 3.10 as given ACI Report 311.4R.93. However, it is

suggested that an initial estimate of entrapped air content shall be taken

as 1.5% or less, and then adjusting it on the basis of the result obtained

with the trial mix.

Table 3. 10 - Approximate Entrapped Air Content

Nominal maximum size Entrapped air, as percent

of Coarse aggregate (mm) of Volume of concrete
10 2.5
12.5 2.0
20 1.5
25 1.0

3.4.6 Selection of coarse aggregate content

The coarse aggregate content is obtained from the table 3.11 as a

function of the particle shape. If there is any doubt about the shape of

the CA or if its shape is not known, it is suggested that a CA content of

1050 kg/m3 shall be taken to start with. The CA so selected should

satisfy the requirements of grading and other requirements of IS 383:

1970 [110].
 73

Table 3. 11 - Coarse Aggregate Content

CA Particle Elongated
Average Cubic Rounded
shape or Flat
CA Dosage
950-1000 1000-1050 1050-1100 1100-1150
(kg/m3)

3.4.7 Selection of water-binder ratio

The water-binder ratio for the target mean compressive strength is

chosen from fig 3.4, the proposed w/b ratio Vs compressive strength

relationship. The w/b ratio so chosen is checked against the limiting w/c

ratio for the requirements of durability as per table 3.5 of IS 456: 2000

[132] and the lower of the two values is adopted.

Fig. 3. 4 - w/b ratio v/s compressive strength relationship

3.4.8 Calculation of binder contents

The binder or cementitious contents per m3 of concrete is

calculated from the w/b ratio and the quantity of water content per m3 of

concrete. The cement content so calculated is checked against the

minimum cement content for the requirements of durability as per table

3.1.5 and 3.1.6 of IS 456: 2000 [132] and the greater of the two values is

adopted.
 74

3.4.9 Estimation of fine aggregate content

The absolute volume of FA is obtained from the following equation:

Vfa = 1000 - [Vw + (Mc / Sc) + (Msf / Ssf) + (Mca / Sca) + Vsol + Vea]

Where,

Vfa = absolute volume of FA in liters per m3 of concrete

Vw = volume of water (liters) per m3 of concrete

Mc = mass of cement (kg) per m3 of concrete

Sc = specific gravity of cement

Msf, Mca = Total masses of the SF and CA (kg) per m3 of concrete

respectively

Sca, Ssf = specific gravities of saturated surface dry coarse aggregate

and silica fume respectively, and

Vea = Volume of the entrapped air (liters) per m3 of concrete

respectively.

The fine aggregate content per unit volume of concrete is obtained

by multiplying the absolute volume of fine aggregate and the specific

gravity of the fine aggregate.

3.4.10 Moisture Adjustments

The actual quantities of CA, FA and water content are calculated

after allowing necessary corrections for water absorption and free

(surface) moisture content of aggregates. The volume of water included in

the liquid super plasticizer is calculated and subtracted from the initial

mixing water.
 75

3.4.11 Unit Mass of Concrete

The mass of concrete per unit volume was calculated by adding the

masses of the concrete ingredients. Trial mixes were done to obtain

mixes having suitable consistency and workability. The results of the

trials are indicated in table 3.12 for GPC mix 2 was adopted and the final

proportions for M60 is indicated in table 3.13 (GPC and TVC).

Table 3. 12 Trial Mixes (GPC)

Mass, kg/m3
Mix1, Mix2, Mix3, Mix4,
Materials
Al/Fa=0.3 Al/Fa=0.35 Al/Fa=0.4 Al/Fa=0.45
Coarse aggregates 1295 1295 1295 1295
Fine sand 555 555 555 555
Fly ash 382 366 355 342
GGBS 42 40 39 38
Na2SiO3 solution 90 103 112 122
NaOH solution 36 41 44 48
Super plasticizer 3% 3% 3% 3%
Extra water 3% 3% 3% 3%
Table 3. 13 Mix proportion for M60 concretes

Materials GPC TVC

Cement kg/m3 - 375
Fly ash kg/m3 366 -
GGBS kg/m3 40 -
Silica fume kg/m3 - 42
Coarse aggregate kg/m3 1295 1050
Fine aggregate kg/m3 555 716
NaOH solution (8M) kg/m3 41 -
Na2SiO3 solution kg/m3 103 -
Water l/m3 16.24 150
Super plasticizer (%) 3 2.5
The present investigation shows that high strength GPC mix

proportioning can be done on similar guide lines given by Rangans

method. Further investigations are to be carried out to validate the

 76

author investigation for generality of the Rangans method for all grades

of geopolymer concrete.

3.5 PRODUCTION METHODOLOGY

3.5.1 Introduction

Fly ash-based geopolymer concrete using low calcium (ASTM Class

F) requires trial and error process was used. The focus of the study is to

identify the salient parameters that influence the mix proportions and

the properties of GPC. The current practice used in the manufacture and

testing of TVC was followed.

In order to simplify the development process compressive strength

is selected as the benchmark parameter. This is not unusual because

compressive strength has an intrinsic importance in the structural

design of concrete structures.

3.5.2. Materials for GPC and TVC

The material for GPC and TVC described in article 3.1

3.6 SPECIMEN PREPARATION

Six cubical moulds of size 100mm, six cylindrical moulds of size

100200mm and six prisms of size 7575450mm were used to prepare

specimen of GPC and TVC.

3.7 MIXING

3.7.1 Geopolymer Concrete

Fly ash, GGBS and aggregates were mixed dry in the 100 kg

capacity pan mixer for 3 minutes. The alkaline solution that was
 77

prepared one day prior with super plasticizer and extra water were added

into the blend and mixed for 4 minutes.

3.7.2 Test on Fresh Concrete

The fresh fly ash-based geopolymer concrete was light in colour

and shiny in appearance (fig 3.5). The mixtures were usually cohesive.

The workability of both geopolymer and traditionally vibrated concrete

were measured by means of the conventional slump test.

Fig. 3. 5 - Slump test on fresh concrete to assess the workability

3.7.3 Casting

The fresh concrete was then cast into standard cylindrical moulds,

cubes and prisms, which was compacted using vibrating table are shown

in figs 3.6 to 3.8

Fig. 3. 6 - Concrete being poured to a tray

Fig. 3. 7 - Moulds on vibrating table

 78

Fig. 3. 8 - Concrete in moulds after compaction

3.7.4 Curing

After demoulding GPC specimens were then transferred to a steam

curing chamber, having a temperature of 60C inside the chamber for 24

hours. A boiler was used to produce the steam, which was let in to the

chamber (fig 3.9). At the end of the curing regime, the specimens were

allowed to cool in air, kept in open till the day of testing.

TVC specimens were demoulded after 24 hours and cured in water

pond till the day of testing.

Fig. 3. 9 - Steam Boiler with curing chamber

 79

3.8 STRENGTH STUDIES

3.8.1 Compressive Strength

The GPC and TVC specimens were tested for 7, 14 and 28 days

compressive strength as per IS 516: 1959 [127]. The specimens were

cleaned and weight of each specimen were recorded. After which the

specimen was kept in compression testing machine and loaded till fail as

shown in fig 3.10

Fig. 3. 10 - Specimens before and after compression testing

3.8.2 Split Tensile Strength

The GPC and TVC cylindrical specimens were tested for 28 days

split tensile strength as per IS 5816: 1999 [128] using compression

testing machine. The test consists of applying compressive line loads

along the opposite generators of a concrete cylinder placed with its axis

horizontal between the plattens as shown in fig 3.11 The magnitude of

the tensile stress is given by 2P/DL, where P is the applied load causing

splitting of the specimen, where D and L are the diameter and length of

the cylinder respectively.

 80

Fig. 3. 11 - Specimens before and after split tensile testing

3.8.3 Flexure

The GPC and TVC specimens were tested for 28 days flexure

strength with the modulus of rupture is determined by testing test

specimens of 7575450mm prism as shown in fig 3.12 The modulus of

rupture is determined from the equation fr = M/Z. where M is the

bending moment causing the flexure failure and Z is the sectional

modulus.

Fig. 3. 12 - Specimen before and after flexural testing

3.9 COMPARISON OF STRENGTH PROPERTIES - GPC AND TVC

3.9.1 Compressive strength

For M60 grade concrete the compressive strength results of both

GPC and TVC are tabulated in the table 3.14

 81

Table 3. 14 - Compressive strengths for GPC and TVC

Days GPC (MPa) TVC (MPa)

7 72 26
14 81 59
28 88 85

3.9.2 Split tensile strength

For M60 grade concrete the split tensile strength results of both

GPC and TVC are tabulated in the tables 3.15 & 3.16

Table 3. 15 - Split tensile strength values GPC

Tensile load (kN) Splitting tensile strength (MPa)

120 3.82
120 3.82
80 2.55
120 3.82
120 3.82
110 3.50
Average 3.55

Table 3. 16 - Split tensile strength values TVC

Tensile load (kN) Splitting tensile strength (MPa)

150 4.77
140 4.46
130 4.14
140 4.46
150 4.77
140 4.46
Average 4.51

3.9.3 Flexural strength

For M60 grade concrete the flexural strength results of both GPC and

TVC are tabulated in the tables 3.17 & 3.18 according to IS 456 [132].
 82

Table 3. 17 - Flexural strength values for GPC

Mix no DG reading P (N) f = Pl/bD2 .

1 20 6033.21 6.435 6.566

2 23 6938.19 7.401 6.566
3 22 6636.53 7.078 6.566
4 18 5429.89 5.791 6.566
5 24 7239.85 7.722 6.566
6 19 5731.55 6.113 6.566
Average 6.757 MPa 6.566 MPa

Table 3. 18 - Flexural strength values for TVC

Mix no DG reading P (N) f = Pl/bD2 .

1 20 6033.21 6.435 6.454

2 23 6334.87 6.757 6.454
3 22 6636.53 7.078 6.454
4 18 6334.87 6.757 6.454
5 24 6033.21 6.435 6.454
6 19 6636.53 7.078 6.454
Average 6.757 MPa 6.454 MPa

3.10 CONCLUSIONS OF STRENGTH PROPERTIES OF M60 GPC AND

TVC

3.10.1 Compressive strength

GPC is around 62% more than OPC in 7 days but at 28 days the

strength difference between GPC and TVC is only 5%. Hence GPC

is attaining early strength but the improvement of strength after

7days is less.

3.10.2 Split Tensile Strength

Tensile strength of GPC is 20% less than TVC.

Rapid development of tensile strength is achieved.

 83

It is true that geopolymer concrete which performs better in

compressive strength should have performed in a better way also in split

tensile strength as available in the literature. More tests are required to

throw light on this so that split tensile strength can be correlated with

the corresponding compressive strength.

3.10.3 Flexural strength

There is no much variation in experimental and theoretical values

of flexural stress.

There was no much difference found in Flexural stresses of GPC

and TVC.