*COMPARATIVE STUDY OF PORTLAND CEMENT CONCRETE AND GEOPOLYMER

FLY ASH CONCRETE

A Thesis Outline Submitted to

the faculty of Department of
Civil Engineering
College of Engineering and Information Technology
Cavite State University
Indang, Cavite

In partial fulfillment
of the requirement for the degree of
Bachelor of Science in Civil Engineering

RONALD JOSHUA B. PANALIGAN

MARK JASPER O. VILLANUEVA
December 2019
COMPARATIVE STUDY OF PORTLAND CEMENT CONCRETE AND GEOPOLYMER
FLY ASH CONCRETE

Ronald Joshua B. Panaligan

Mark Jasper O. Villanueva

______________________________________________________________________

An undergraduate design project manuscript submitted to the faculty of Department of Civil

Engineering, College of Engineering and Information Technology, Cavite State University,
Indang, Cavite in partial fulfillment of the requirements for the degree of Bachelor of Science in
Civil Engineering with Contribution No. ________. Prepared under the supervision of Engr. Cene
M. Bago.
______________________________________________________________________

INTRODUCTION

Concrete is the world’s most versatile, durable and reliable construction material.

Next to water, concrete is the most used material, which required large quantities of

Portland Cement. Ordinary Portland Cement production is the second only to the

automobile as the major generator of carbon di oxide, which polluted the atmosphere. In

addition to that large amount energy was also consumed for the cement production.

Portland cement and fly ash can both be key ingredients in concrete mixes. Although

concrete is sometimes use interchangeable with cement, concrete is actually a mixture

of a base with larger aggregate materials. The aggregates are typically different types of

stone, but the base is most often Portland cement, a mixture of clays, metallic elements

and minerals like calcium and silica. While Portland cement can have fly ash in it, fly ash

concrete is typically made with a base of full fly ash instead of any Portland cement.

Fly ash is a fine powder that is a byproduct of burning pulverized coal in electric

generation power plants. Fly ash is a pozzolan, a substance containing aluminous and
siliceous material that forms cement in the presence of water. When mixed with lime and

water, fly ash forms a compound similar to Portland cement. This makes fly ash suitable

as a prime material in blended cement, mosaic tiles, and hollow blocks, among other

building materials. When used in concrete mixes, fly ash improves the strength and

segregation of the concrete and makes it easier to pump.

The Cement production generated carbon dioxide, which pollutes the

atmosphere. The Thermal Industry produces a waste called fly ash which is simply

dumped on the earth, occupies larges areas. The waste water from the Chemical

Industries is discharged into the ground which contaminates ground water. By producing

Geopolymer Concrete all the above-mentioned issues shall be solved by rearranging

them.

Waste Fly Ash from Thermal Industry + Waste water from Chemical Refineries =

Geopolymer concrete. Since Geopolymer concrete does not use any cement, the

production of cement shall be reduced and hence the pollution of atmosphere by the

emission of carbon di oxide shall also be minimized.

Therefore, the study of the potential of making geopolymer binder is expected to

be one solution to lessen the release of Carbon Dioxide in the process of producing

conventional Portland cement in order to be more easily accepted and applied by the

public.

Statement of the Problem

The primary problem of the study is to determine, compare and investigate the

different advantages and disadvantages of using Fly Ash Geopolymer Concrete in terms

of its mechanical properties specifically its compressive strength and its economic

impact compared to Conventional Portland Cement Concrete.

Objectives of the Study

The main objective of the study is to compare the compressive strength and the

slump test result of Fly Ash Geopolymer Concrete with conventional Portland Cement

Concrete.

Specifically, it aims to:

1. identify the differences between the compressive strength and the slump test

result of Portland Cement Concrete and Fly Ash Geopolymer Concrete.

2. know the advantages and disadvantages of using Geopolymer concrete.

Significance of the Study

Next to water, concrete is the most used material, which required large quantities

of Portland Cement. Ordinary Portland Cement production is the second only to the

automobile as the major generator of carbon dioxide, which polluted the atmosphere. In

addition to that, large amount energy was also consumed for the cement production.

Hence, it is inevitable to find an alternative material to the existing most expensive, most

resource consuming Portland Cement. The Thermal Industry produces a waste called fly

ash which is simply dumped on the earth, occupies larges areas. The waste water from

the Chemical Industries is discharged into the ground which contaminates ground water.

By producing Geopolymer Concrete all the above-mentioned issues shall be solved by

rearranging them.

Scope and Limitation

The main focus of the study is to produce a concrete which does not use

Portland Cement as a binder. The focal point will be on the technical evaluation and

analysis of the properties of geopolymer concrete. Class F fly ash from coal which is

activated using chemicals such as sodium hydroxide and sodium silicate will be used.

The following tests will be conducted: Slump Test, Compressive Strength Test and Unit

Weight Test.
Time and Place of the Study

The study will be conducted at Cavite State University - Indang Cavite from

December 2019 to May 2020.

Definition of Terms

Aggregate. It is a granular material, such as sand, gravel, crushed stone,

crushed hydraulic-cement concrete, or iron blast-furnace slag, used with a hydraulic

cementing medium to produce either concrete or mortar.

Cement. It is an adhesive or glue, which when set binds particles of fine

aggregate together to produce mortar.

Cementitious Materials. Any of various building materials which may be mixed

with a liquid, such as water, to form cement base substance, and to which an aggregate

may be added; includes cements, limes, and mortar

Compressive strength. It is the capacity of a material or structure to withstand

loads tending to reduce size, as opposed to tensile strength, which withstands loads

tending to elongate.

Concrete. It is a mixture of Portland cement or any other hydraulic cement, fine

aggregate, coarse aggregate, and water, with or without admixtures.

Geopolymer Concrete. a type of concrete that is made by reacting aluminate

and silicate bearing materials with a caustic activator. Commonly, waste materials such

as fly ash or slag from iron and metal production are used, which helps lead to a cleaner

environment.

Sand. It is a naturally occurring granular material composed of finely

divided rock and mineral particles. It is defined by size, being finer than gravel and

coarser than silt.
 Silica. It is also known as Silicon dioxide (SiO2) and usually present in cement to

the extent of about 30 percent.

 METHODOLOGY

Conceptual Framework

Alkaline Activating Collection of Materials Alkaline Solution mixed

Solution to be Used with water and Fly Ash
Clean Water Geopolymerization Geopolymer Concrete
Fine Aggregates Producing of Specimen
Coarse Aggregates Curing (7, 14, 28)
Testing of Samples
Statistical Analysis
Flow Chart
INPUT PROCESS OUTPUT

GATHERING PREPARATION OF
SLUMP TEST
OF MATERIALS SPECIMEN

MOLDING OF CURING COMPRESSIVE

CONCRETE (7, 14, 28) STRENGTH TEST

STATISTICAL
ANALYSIS
Data gathering

The data needed in this study were generated from the following:

1. Engineering books for general information about aggregates, cement, sand,

related topics;

2. Compilation of student thesis for information in proportioning, mixing and

testing of concrete; and

3. Internet for most recent findings that were related to the study, particularly

about the properties of coal fly ash.

Materials and apparatus

The following materials that will be used in making concrete sample are fly

ash, sodium hydroxide and sodium silicate, water, gravel, and sand.

The following materials that will be used for determining the unit weight of

coconut shell ash are metal volumetric measure, tamping rod, steel, 5/8 inches in

diameter, 24 inches long and balance and weights

The following materials that will be used for slump test are mixing board,

slump mold, metal ruler or meter stick, tamping rod, pointing trowel and container

The following material and equipment that will be used to determine the

compressive strength of the concrete sample are compression cylindrical mold, 6

inches in diameter, 12 inches in height, capping materials and facilities, curing

materials and facilities, pointing trowel, shovel container for mixing sample and

universal testing machine

Making geopolymer cement

For the development of fly ash based geopolymer concrete mix design

method, detailed investigations will be carried out and following parameters were

selected on the basis of workability and compressive strength. In the investigation,

sodium based alkaline activators will be used. The combination of sodium hydroxide

and sodium silicate will be used for the activation of fly ash based geopolymer

concrete.
 Wet mixing method will be used in mixing the fly ash and the activators. A

mixture with 70% fly ash and 30% activators. Activators is composed of 30% Sodium

Hydroxide (12M) and 70% Sodium Silicate will be combined. All proportions will be

based on mass.

Mixing concrete

Correct proportioning of the ingredients to produce concrete also provides a

balance between the requirements of economy, workability, strength, durability and

appearance.

The right proportioning of all the ingredients for concrete is the most difficult

manufacturing step to control, although it is one of the most important aspects in

producing high quality economical concrete.

In this study, the researchers will be conducting 3 sample specimens per

curing days of geopolymer-based concrete with the same proportion and will be

placed in three cylindrical molds.

Procedure for Mixing Concrete

1. The working surface will be cleaned off. The materials will be also assured to

be clean.

2. Materials such as fly ash, sand and gravel will be carefully weighed according

to their respective amount.

3. Sodium Hydroxide Flakes will be prepared.

4. 12 M Sodium Hydroxide will be mixed with distilled water.

5. A mixture with 30% Sodium Hydroxide solution and 70% Sodium Silicate

solution will be produced as the binder.

6. Fly ash and alkaline activators will be mixed according to its specified

proportion to produce geopolymer cement.

7. Sand will be placed on the mixing surface together with geopolymer, mixing

them to achieve evenly distributed particles of each material.

8. With a shovel, a crater was made in the center of the heap.

 9. Gravel was poured around the heap during the mixture by mixing to be evenly

and properly mixed together.

10. With a shovel, another crater was formed in the top of the heap.

11. As water was then added, a shovel was moved from the sides of the heap

into the central crater and turn part of the heap to distribute the water

throughout the mixture.

12. Mixing the mixture within a minimum of almost fifteen minutes or even for

much longer period was done to assure that all ingredients were mixed

uniformly.

Slump Test

Slump of concrete was conducted pursuant to ASTM C143 or the standard

test method for slump of hydraulic-cement concrete. The slump test includes the

following procedures:

1. Place the freshly mixed concrete inside the mold in 3 layers. Each layer is

rodded separately by a 6 mm rod 25 times.

2. Level the mold and lift at once.

3. Measure the slump action immediately by getting the difference in height

between the height of the mold and the top of the slumped concrete.

4. If the slump measures 5 cm, it is called 5 cm slump.

The degree of consistency of concrete could be ascertained by referring to Table 1.

Table 1. Recommended slumps for various construction structures

Types of construction Maximum Minimum
cm. cm.
Reinforced foundation wall and footing 13 5

Plain footing, caissons and sub – structure walls 10 2.5

Slab, beam and reinforced walls 15 7.5

Building columns 15 7.5

Pavements 7 5

Heavy mass construction 7 2.5

Source: Building Construction by Max Fajardo

Casting Cylinders

This test was carried out following the procedure of ASTM C31 or the standard

practice for making and curing concrete test specimens in the field. Test cylinders

were casted to verify the specified compressive strength of the mix has been

achieved. The procedures for casting cylinders are:

1. After slump test, mix the concrete thoroughly and place the casting molds on

the concrete floor.

2. Fill the mold to 1/3 full by volume (4-inch depth) and rod the bottom layer with

25 strokes evenly spaced

3. Fill the mold to 2/3 full (8-inch depth) and rod the second layer with 25 strokes

penetrating the top of the second layer.

4. Heap the concrete on the top of the mold and rod the top layer with 25

strokes penetrating the top of the second layer.

5. Tap the sides of the mold lightly to close the voids left by the rod.

6. Strike off the top surface of the concrete using a sawing action with the rod.

Smooth the surface and be sure to mark the cylinders with your mix number,

cylinder number, batch number and date.

7. Carefully move the cylinder to temporary storage.

8. Cover the cylinders with a plastic bag.

9. After 20 to 24 hours remove the mold. Place the concrete in container filled

with water for curing.

Curing of Concrete

Following the standard procedure of ASTM C31 or the standard practice for

making and curing concrete test specimens in the field, concrete cylinders were

cured at 7 days, 14 days and 28 days period. The procedure involves the following:

1. After removing the concrete from the mold, place the concrete inside the

container filled with water.

 2. Cover the surface of the container to avoid evaporation of water.

3. Let the concrete absorb water until the specified days.

4. Be sure that the concrete does not undergo any disturbance.

Compression Test

Cylinders tested for acceptance and quality control are made and cured in

accordance with procedures described for standard-cured specimens in ASTM C 31

standard practice for making and curing concrete test specimens in the field. An

average of 3 consecutive tests shall be done for each mix design. Compression test

involves the following procedures:

1. For a coarse aggregate not more than 5 cm diameter, prepare a cylindrical

specimen 15 cm diameter and 30 cm long.

2. For a coarse aggregate more than 5 cm diameter, prepare a cylindrical

specimen with a diameter 3 times the maximum size of the aggregate and a

height double its diameter.

3. The mold should be made of metal placed on a plane surface preferably 6 to

12 mm plate.

4. Place the fresh concrete inside the mold in 3 separate equal layers rodded

separately with 16 mm rod 25 strokes.

5. Level the surface with trowel and cover with a glass or plane steel.

6. After 4 hours, cover the specimen with a thin layer of cement paste and cover

again with plane metal or glass.

7. After 24 hours, start curing in a moist atmosphere at 21 °centigrade.

8. Test should be done at 7, 14 and 28 days period.

9. Be sure that both ends of the specimen are perfectly leveled.

10. Specimen is placed under a testing machine and a compressive load is

applied until the specimen fails. The load that causes the specimen to fail is

recorded.
 11. The recorded load divided by the cross-sectional area of the cylinder gives

the ultimate compressive unit stress of the sample

Cost Analysis

In this study, crumb rubber is to be used as a partial substitution to fine

aggregate in producing concrete floor tiles. The cost of producing one cubic meter of

crumb rubber against stone cubic meter of commercial sand will be compared. The

costs of producing concrete floor tiles made of crumb rubber to the commercial

concrete floor tiles will also be compared.

Experimental Results

Test results will be presented in tabulated and graphical form to be easily

understood. They will be shown in the appendices.

Statistical Analysis

The experiment will be conducted using the Least Significant Difference

method (LSD) in Statistical Package for Social Sciences (SPSS). SPSS is a widely

used program for statistical analysis in social science. It is also used by market

researchers, health researchers, survey companies, government, education

researchers, marketing organizations, data miners, and others.

Analysis of Variance (ANOVA) will be used to analyze the data collected. The

results will be tabulated and interpreted.