NaOH-activated ground fly ash geopolymer cured at ambient temperature

NaOH-activated ground fly ash geopolymers, cured at room temperature, were studied in this paper. Ground fly ash (GFA), with a median particle size of 10.5 μm, was used as source material. NaOH concentrations of 4.5-16.5 M (M) were used as an alkali activator. Compressive strength tests and microstructure observations using SEM, EDX, XRD and FTIR were performed. Results indicated that GFA gave higher strength geopolymer paste compared to original fly ash. Ground fly ash could be used as a source material for making geopolymers cured at room temperature. An increase in NaOH concentration from 4.5 to 14.0 M increased the strength of GFA geopolymer pastes. Microstructure studies indicated that NaOH concentrations of 12.0-14.0 M created new crystalline products of sodium aluminosilicate. The compressive strengths at 28 days of 20.0-23.0 MPa were obtained with the NaOH concentrations of 9.5-14.0 M. Increasing the NaOH concentration beyond this point resulted in a decrease in the strength of the paste due to early precipitation of aluminosilicate products.     

Effect of nano-silica on the chemical durability and mechanical performance of fly ash based geopolymer concrete

In this study, the effect of nano silica on the short term severe durability performance of fly ash based geopolymer concrete (GPC) specimens was investigated. Four types of GPC were produced with two types of low calcium fly ashes (FAI and FAII) with and without nano silica, and ordinary Portland cement concrete (OPC) concrete was also cast for reference. For the geopolymerization process, the alkaline activator has selected a mixture of sodium silicate solution (Na₂SiO₃) and sodium hydroxide solution (NaOH) with a ratio (Na₂SiO₃/ NaOH) of 2.5. Main objectives of the study were to investigate the effect of usability or replaceability of nano silica-based low calcium fly ash based geopolymer concretes instead of OPC concrete in structural applications and make a contribution to standardization process of the fly ash based geopolymer concrete. To achieve the goals, four types of geopolymer and OPC concretes were subjected to sulfuric acid (H₂SO₄), magnesium sulfate (MgSO₄) and seawater (NaCl) solutions with concentrations of 5%, 5%, and 3.5%, respectively. Visual appearances and weight changes of the concretes under chemical environments were utilized for durability aspects. Compressive, splitting tensile and flexural strength tests were also performed on specimens to evaluate the mechanical performance under chemical environments. Results indicated that FAGPC concretes showed superior performance than OPC concrete under chemical attacks due to low calcium content. Amongst the chemical environments, sulfuric acid (H₂SO₄) was found to be the most dangerous environment for all concrete types. In addition, nano silica (NS) addition to FAGPC specimens improved both durability and residual mechanical strength due to the lower porosity and more dense structure. The FAIIGPC specimens including nano silica showed the superior mechanical performance under chemical environment.     

The evolution of strength and crystalline phases for alkali-activated ground blast furnace slag and fly ash-based geopolymers

The increase in strength and evolution of crystalline phases in inorganic polymer cement, made by the alkali activation of slag, Class C and Class F fly ashes, was followed using compressive strength test and synchrotron X-ray diffraction. In order to increase the crystallinity of the product the reactions were carried out at 80 °C. We found that hydrotalcite formed in both the alkali-activated slag cements and the fly ash-based geopolymers. Hydroxycancrinite, one member of the ABC-6 family of zeolites, was found only in the fly ash geopolymers. Assuming that the predominantly amorphous geopolymer formed under ambient conditions relates to the crystalline phases found when the mixture is cured at high temperature, we propose that the structure of this zeolitic precursor formed in Na-based high alkaline environment can be regarded as a disordered form of the basic building unit of the ABC-6 group of zeolites which includes poly-types such as hydroxycancrinite, hydroxysodalite and chabazite-Na.     

The effect of ionic contaminants on the early-age properties of alkali-activated fly ash-based cements

Alkali-activated fly ash-based cements are concrete binders that utilise fly ash as their major solid raw material. The solid particles are activated using concentrated silicate and hydroxide solution to produce high-strength products. Due to the highly alkaline nature of the solution, precipitation of the reactive species, both from the solids and from the solution, proceeds at a very fast rate. This renders short setting times, which can be advantageous or disadvantageous depending on the practical situation. The present work examines the effects of inorganic salt addition towards the setting and rheological characteristics of the early pastes. Compressive strength, Fourier transform infrared spectroscopy (FTIR) and X-ray diffractograms were collected to examine the hardened products. It was found that calcium (Ca) and magnesium (Mg) salts shortened the setting time by providing heterogeneous nucleation centers in the initial paste solution. Potassium salts retarded setting only to the cements, which used less sodium silicate in the initial solution for activation. Managed ionic contamination can be used to increase the product early strength. However, its long-term effects still need to be identified.     

Durability of geopolymer materials in sodium and magnesium sulfate solutions

This paper presents an investigation into the durability of geopolymer materials manufactured using class F fly ash and alkaline activators when exposed to a sulfate environment. Three tests were used to determine resistance of geopolymer materials. The tests involved immersions for a period of 5 months into 5% solutions of sodium sulfate and magnesium sulfate, and a solution of 5% sodium sulfate+5% magnesium sulfate. The evolution of weight, compressive strength, products of degradation and microstructural changes were studied.In the sodium sulfate solution, significant fluctuations of strength occurred with strength reduction 18% in the 8FASS material prepared with sodium silicate and 65% in the 8FAK material prepared with a mixture of sodium hydroxide and potassium hydroxide as activators, while 4% strength increase was measured in the 8FA specimens activated by sodium hydroxide. In the magnesium sulfate solution, 12% and 35% strength increase was measured in the 8FA and 8FAK specimens, respectively; and 24% strength decline was measured in the 8FASS samples. The most significant deterioration was observed in the sodium sulfate solution and it appeared to be connected to migration of alkalies into solution. In the magnesium sulfate solution, migration of alkalies into the solution and diffusion of magnesium and calcium to the subsurface areas was observed in the specimens prepared using sodium silicate and a mixture of sodium and potassium hydroxides as activators. The least strength changes were found in the solution of 5% sodium sulfate+5% magnesium sulfate. The material prepared using sodium hydroxide had the best performance, which was attributed to its stable cross-linked aluminosilicate polymer structure.     

Geopolymeric materials prepared using Class F fly ash and elevated temperature curing

This paper reports the results of the study of the influence of elevated temperature curing on phase composition, microstructure and strength development in geopolymer materials prepared using Class F fly ash and sodium silicate and sodium hydroxide solutions. In particular, the effect of storage at room temperature before the application of heat on strength development and phase composition was studied. X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and SEM were utilised in this study.Long precuring at room temperature before application of heat was beneficial for strength development in all studied materials, as strength comparable to 1 month of curing at elevated temperature can develop in this case only after 24 h of heat curing. The main product of reaction in the geopolymeric materials was amorphous alkali aluminosilicate gel. However, in the case of sodium hydroxide activator in addition to it, traces of chabazite, Linde Type A, Na-P1 (gismondine) zeolites and hydroxysodalite were also present. The type of zeolite present and composition of aluminosilicate gel were dependent on the curing history.     

Effect of elevated temperatures on geopolymer paste, mortar and concrete

Geopolymers are generally believed to provide good fire resistance due to their ceramic-like properties. Previous experimental studies on geopolymer under elevated temperatures have mainly focused on metakaolin-based geopolymers. This paper presents the results of a study on the effect of elevated temperature on geopolymer paste, mortar and concrete made using fly ash as a precursor. The geopolymer was synthesized with sodium silicate and potassium hydroxide solutions. Various experimental parameters have been examined such as specimen sizing, aggregate sizing, aggregate type and superplasticizer type. The study identifies specimen size and aggregate size as the two main factors that govern geopolymer behavior at elevated temperatures (800 °C). Aggregate sizes larger than 10 mm resulted in good strength performances in both ambient and elevated temperatures. Strength loss in geopolymer concrete at elevated temperatures is attributed to the thermal mismatch between the geopolymer matrix and the aggregates.     

Effect of partial replacement of geopolymer binder materials on the fresh and mechanical properties: A review

The growth of demand for concrete raises concerns about the consumption of natural resources and ordinary Portland cement. Geopolymer composites show promise as a sustainable alternative for conventional cement concrete. Considering the wide range of potential geopolymer composites applications (including suitability for transportation infrastructure, underwater applications, repair and rehabilitation of structures as well as recent developments in 3D printing), the desired fresh and mechanical properties of the geopolymer composite may vary between applications: for example, rapid setting can be a merit for certain applications and a demerit for others. Therefore, the desired fresh and mechanical properties (e.g., workability, setting time, compressive strength, etc.) can be controlled for a given geopolymer source material through its partial substitution by natural or by-product materials. Recognizing the critical role of various replacement materials in enhancing the potential applications of geopolymer composites, the present review was undertaken to quantify and understand the effect of partial replacement by fly ash, metakaolin, kaolin, red mud, slag, ordinary Portland cement, and silica fume on the setting time, workability, compressive strength and flexural strength of various source materials addressed in the literature. The review also provides insights into research gaps in the field to promote future research.     

Optimization of coal fly ash-based porous geopolymer synthesis and application for zinc removal from water

Coal fly ash-based porous geopolymer (CFAPG) is a potential adsorbent for heavy metal-contaminated water remediation and can also mitigate the accumulation of coal fly ash from thermal power plants. Production parameters influence the physicochemical properties (e.g., adsorption capacity) of CFAPG. Ten potential factors involved in the CFAPG production process were examined using a Plackett-Burman design (PBD) and then an orthogonal experimental design (OED). The results show the alkali activator modulus (MS), alkali-ash mass ratio (AA), foaming agent-ash mass ratio (FAR), and sodium dodecyl sulfate-ash mass ratio (SDSA) were the most important factors influencing the Zn adsorption capacity of CFAPG. Ternary plots confirm the interaction between these four factors, with the role of FAR being easily masked by other factors and MS being the least influenced by other factors. Furthermore, Zn adsorption on the CFAPG created with optimal parameters was best described by the Bi_Langmuir model, indicating two different sorption site classes on the surface of CFAPG with a total maximum Zn adsorption capacity of 13.42 mg g^?1. These results provide key parameters for the production of geopolymers as heavy metal adsorbents.     

Modeling the hydration of concrete incorporating fly ash or slag

Granulated slag from metal industries and fly ash from the combustion of coal are industrial by-products that have been widely used as mineral admixtures in normal and high strength concrete. Due to the reaction between calcium hydroxide and fly ash or slag, the hydration of concrete containing fly ash or slag is much more complex compared with that of Portland cement. In this paper, the production of calcium hydroxide in cement hydration and its consumption in the reaction of mineral admixtures is considered in order to develop a numerical model that simulates the hydration of concrete containing fly ash or slag. The heat evolution rates of fly ash- or slag-blended concrete is determined by the contribution of both cement hydration and the reaction of the mineral admixtures. The proposed model is verified through experimental data on concrete with different water-to-cement ratios and mineral admixture substitution ratios.     

Enhanced mechanical properties of wood ash and fly ash as supplementary cementitious materials

The incorporation of fly ash (FA) and wood ash (WA) in concrete as supplementary cementitious materials (SCM) was studied. The chemical composition of ordinary Portland cement, FA and WA was determined according to ASTM C-114. SEM and optical microscopy were used for the analysis of concrete. Setting time, compressive strength, water absorption and acid resistance of the concrete with different percentages of SCM ranging from 0 to 60% were evaluated. The results obtained showed that setting time and rate of water absorption increased with the increase in percentage of SCM. After 7 and 28 days, the compressive strength of concrete with 20% FA as SCM was higher than that with substitution with 20% WA. Resistance of concrete against sulphate attack increased with an increase in the percentage of FA. It was found that incorporating more than 20% WA resulted in a decrease in sulphate attack resistance.     

An experimental study on strength development of concrete containing fly ash and optimum usage of fly ash in concrete

This paper presents a laboratory study on the strength development of concrete containing fly ash and optimum use of fly ash in concrete. Fly ash was added according to the partial replacement method in mixtures. A total of 28 mixtures with different mix designs were prepared. 4 of them were prepared as control mixtures with 250, 300, 350, and 400 kg/m³ cement content in order to calculate the Bolomey and Feret coefficients (K_B, K_F). Four groups of mixtures were prepared, each group containing six mix designs and using the cement content of one of the control mixture as the base for the mix design. In each group 20% of the cement content of the control mixture was removed, resulting in starting mixtures with 200, 240, 280, and 320 kg/m³ cement content. Fly ash in the amount of approximately 15%, 25%, 33%, 42%, 50%, and 58% of the rest of the cement content was added as partial cement replacement. All specimens were moist cured for 28 and 180 days before compressive strength testing. The efficiency and the maximum content of fly ash that gives the maximum compressive strength were obtained by using Bolomey and Feret strength equations. Hence, the maximum amount of usable fly ash amount with the optimum efficiency was determined.This study showed that strength increases with increasing amount of fly ash up to an optimum value, beyond which strength starts to decrease with further addition of fly ash. The optimum value of fly ash for the four test groups is about 40% of cement. Fly ash/cement ratio is an important factor determining the efficiency of fly ash.     

Development of fly ash and iron ore tailing based porous geopolymer for removal of Cu(II) from wastewater

This work aims to verify the feasibility of utilizing iron ore tailing (IOT) in porous geopolymer and intends to broaden the application of porous geopolymer in heavy metal removal aspect. Porous geopolymer was prepared using fly ash as resource material, which was partially replaced by IOT at level of 30%, by weight, with H₂O₂ as foaming agent and removal efficiency, adsorption affecting factors, adsorption isotherms and thermodynamics of Cu²⁺ by the developed porous geopolymer were investigated.The experimental results uncover that the porous amorphous geopolymer was successful synthesized with total porosity of 74.6%. The transformation of fly ash and IOT into foaming geopolymer leads to the formation of porous structure encouraging Cu²⁺ sorption. Batch sorption tests were carried out and geopolymer dosage, Cu²⁺ initial concentration, pH, contact time and temperature were the main concern. Both Langmuir and Freundlich models could explain the adsorption of Cu²⁺ on the porous geopolymer due to the high fitting coefficients. The uptake capacity reaches the highest value of 113.41 mg/g at 40 °C with pH value of 6.0. The thermodynamic parameters ΔHº, ΔSº and ΔGº suggests the spontaneous nature of Cu²⁺ adsorption on porous geopolymer and the endothermic behavior of sorption process.     

Dynamic mechanical properties of carbon fiber reinforced geopolymer concrete at different ages

In order to improve the strength and toughness of geopolymer concrete (GC) at different ages under impact load, using slag and fly ash as cementitious materials, NaOH and sodium silicate as alkaline activators, carbon fiber as reinforcement, carbon fiber reinforced geopolymer concrete (CFRGC) was prepared. The dynamic compression test of CFRGC was carried out by Φ 100 mm SHPB test system. The effects of age (3 d, 7 d, 28 d) and fiber content on the dynamic mechanical properties of CFRGC were studied, and the strengthening and toughening effects of carbon fiber on GC were analyzed. In addition, the strengthening and toughening effects of carbon fiber on GC and ordinary Portland cement based concrete (PC) were compared and analyzed. The results show that the performance indicators of CFRGC at different ages have strain rate effect under impact load, and the dynamic compressive strength and specific energy absorption of CFRGC increase approximately linearly with the strain rate. With the increase of age, the dynamic compressive strength and specific energy absorption of CFRGC increase, and the strain rate sensitivity of dynamic compressive strength and specific energy absorption also increases. With the increase of carbon fiber content, the dynamic compressive strength and specific energy absorption of CFRGC increase first and then decrease, and the strain rate sensitivity of dynamic compressive strength and specific energy absorption also increase first and then decrease. When the carbon fiber content is 0.2%, the dynamic mechanical properties of CFRGC are the best, and the strain rate sensitivity of performance indicators is the strongest. Carbon fiber has strengthening and toughening effects on GC and PC. When the fiber content is 0.2%, carbon fiber has the best strengthening and toughening effects on GC and PC. The strengthening and toughening effects of carbon fiber on GC is better than that of PC. Compared with 28 d, carbon fiber has better strengthening and toughening effects on GC at the ages of 3 d and 7 d.     

Comparative performance of geopolymers made with metakaolin and fly ash after exposure to elevated temperatures

This paper presents the results of a study on the effect of elevated temperatures on geopolymers manufactured using metakaolin and fly ash of various mixture proportions. Both types of geopolymers (metakaolin and fly ash) were synthesized with sodium silicate and potassium hydroxide solutions.

The strength of the fly ash-based geopolymer increased after exposure to elevated temperatures (800 °C). However, the strength of the corresponding metakaolin-based geopolymer decreased after similar exposure. Both types of geopolymers were subjected to thermogravimetric, scanning electron microscopy and mercury intrusion porosimetry tests. The paper concludes that the fly ash-based geopolymers have large numbers of small pores which facilitate the escape of moisture when heated, thus causing minimal damage to the geopolymer matrix. On the other hand, metakaolin geopolymers do not possess such pore distribution structures. The strength increase in fly ash geopolymers is also partly attributed to the sintering reactions of un-reacted fly ash particles.     

适用于预拌混凝土的粉煤灰水泥的研制

在去年笔者提出的水泥厂发展混凝土掺和料产业的思路基础上,通过试验研究和经济成本分析,进一步探讨了水泥厂以生产、推广使用粉煤灰水泥的模式发展混凝土掺和料产业的技术经济可行性,并在此基础上研制开发了适用于预拌混凝土的专用粉煤灰水泥。     

粉煤灰对混凝土拌合物泵送性能的影响

介绍了粉煤灰对掺有M17塑化剂的混凝土拌合物泵送性能和混凝土强度的影响，通过扫描电镜对粉煤灰颗粒形貌进行了观察，初步探讨了粉煤灰的作用机理。试验说明在接有M17塑化剂的泵送混凝土中加入粉煤灰，可增加坍落度，降低泌水率，泵逆性能可得到改善。     

Electrochemical studies on the corrosion performance of steel embedded in activated fly ash blended concrete

The use of fly ash to replace a portion of cement has resulted significant savings in the cost of cement production. Fly ash blended cement concretes require a longer curing time and their early strength is low when compared to ordinary Portland cement (OPC) concrete. By adopting various activation techniques such as physical, thermal and chemical methods, hydration of fly ash blended cement concrete was accelerated and thereby improved the corrosion-resistance of concrete. Concrete specimens prepared with 10-40% of activated fly ash replacement were evaluated for their open circuit potential measurements, weight loss measurements, impedance measurements, linear polarization measurements, water absorption test, rapid chloride ion penetration test and scanning electron microscopy (SEM) test and the results were compared with those for OPC concrete without fly ash. All the studies confirmed that up to a critical level of 20-30% replacement; activated fly ash cement improved the corrosion-resistance properties of concrete. It was also confirmed that the chemical activation of fly ash yielded better results than the other methods of activation investigated in this study.     

Analysis of mechanism on water-reducing effect of fine ground slag, high-calcium fly ash, and low-calcium fly ash

The addition of ultrafine powder (UFP) to concrete can improve the fluidity of concrete, showing a water-reducing effect. The aim of this article was to analyze the water-reducing mechanism of UFP both experimentally and theoretically. Three UFPs—fine ground slag, high-calcium fly ash, and low-calcium fly ash—were chosen for the study. The contrastive experiments were done to investigate the fluidity of mortars with 30%, 45%, 60%, and 75% equivalent cement replaced by fine ground slag, high-calcium fly ash, and low-calcium fly ash, respectively. The results showed the physical and chemical characteristic of the powders, such as their grain morphology, glass phase activities, densities, specific areas, and their grain cumulating conditions, can strongly affect their water-reducing effect.     

Use of ground coarse fly ash as a replacement of condensed silica fume in producing high-strength concrete

This paper presents a method of improving coarse fly ash in order to replace condensed silica fume in making high-strength concrete. The coarse fly ash, having the average median diameter about 90-100 μm, yields a very low pozzolanic reaction and should not be used in concrete. In order to improve its quality, the coarse fly ash was ground until the average particle size was reduced to 3.8 μm. Then, it was used to replace Portland cement type I by weights of 0%, 15%, 25%, 35%, and 50% to produce high-strength concrete. It was found that concrete containing the ground coarse fly ash (FAG) replacement between 15% and 50% can produce high-strength concrete and 25% cement replacement gave the highest compressive strength. In addition, the concrete containing FAG of 15-35% as cement replacement exhibited equal or higher compressive strengths after 60 days than those of condensed silica fume concretes. The results, therefore, suggest that the FAG with high fineness is suitable to use to replace condensed silica fume in producing high-strength concrete.