1.

Introduction
Cement is most popularly used as a binder material in concrete. The cement manufacturing
industry has a large contribution to rising level of carbon dioxide emissions in the environment.
Therefore, it is the time requirement to develop an eco-friendly and economic binder material
that can totally replace cement as a binder in mortar and concrete. In context of this, materials
prepared by geopolymerization process can be effectively used as binders, instead of cement
binder in mortar and concrete. Geopolymerization is a process that can transform alumina and
silica rich waste materials into valuable building/binding materials, having the same properties as
of cement-based construction materials.

The term “geopolymer” was first investigated by a French Professor Davidov its in 1978 to
represent a broad range of materials which are members of the inorganic polymer’s family.

The mortar prepared with geopolymerization process is known as geopolymer mortar.

Geopolymer mortar is developed by alkali activating alumina and silica rich waste materials such
as fly ash, rice husk ash, GGBS etc. for this research select fly ash. with high alkaline solution
that results in three-dimensional polymeric chain and ring structure consisting of Si‒O‒Al‒O
bonds. This 3D molecular chain results in conversion of the waste material into binding material
[3. According to the survey, the total fly ash (waste material from electricity generated thermal
plant) production in the world is about 780 million tons per year out of which 75,000 tons of fly
ash is produced in Ethiopia, whereas utilization of this waste material ids only about 17–20%.
The utilization of fly ash as source material in geopolymer mortar and concrete not only helps in
the reduction of disposing problem of fly ash but also eliminates the adverse impact causes to the
environment during cement production by totally replacing cement as a binding material in
mortar and concrete.

Fly ash based geopolymer mortar is prepared by activating fly ash with alkaline solutions.
Sodium based alkaline activators are most commonly used as alkaline activators.

The present study provides the experimental data on the variation in compressive strength of fly
ash based geopolymer mortar with the incorporation of sodium silicate along with different
molarities of sodium hydroxide and different temperature.
2.Problem of statement
The major problem that must be issued is the challenge of global warming and climate changes
due to carbon dioxide (CO2) greenhouse gases and increment of CO2 concentration. Industrial
sector such as, cements (OPC) production has a big challenge to maintain high quality of life
while ensuring low energy consumptions and CO2 emissions. To control this there is need to
provide an alternative use of fly ash by substituting them to natural fine aggregates in the form
fly ash based Geopolymer. Fly ash based Geopolymer which is very good at its durability as
compared to the OPC can also solve the energy intensiveness and price of OPC.

3. Objectives

3.1 General objective

 Studying the effect of curing temperature and alkalinity on geopolymer mortar

3.2 Specific objective

 To design concrete mix containing fly ash with varying curing temperature and molarity
of activation solution.
 To develop a concrete with high mechanical property.
 To identify the setting time of Geopolymer paste.
 To design a small-scale fly ash based Geopolymer mortar/bricks.

4. Scope of study
The research utilized low calcium fly ash as the base material for making geopolymer concrete.
The fly ash was obtained from only one source, because the main focus of this study was
the short-term behavior and the engineering properties of fly ash-based geopolymer concrete.
As far as possible, the technology and the equipment currently used to manufacture OPC
concrete were also used to make the geopolymer concrete. The concrete properties studied
included the compressive and flexural strength test, density, water absorption, durability (%
NaCl), and FTIR and XRF test.
6. Significance of study
Fly ash is industrial waste that lies idle in dumpsites causing hazardous effects to the
environment and human health. Because of the availability of them, they are low cost materials.
Therefore, they can be used in economizing the cost of projects. Other than economy, it also
saves environmental cost of cement since the use of cement leads to production of high amount
of carbon dioxide that causes greenhouse effect. Thus, this study will provide approach of
reducing the cost associated with construction process as well as saving environment.

6. Literature review
6.1 Introduction

Geopolymers are a relatively new class of construction materials that do not require calcium-
silicate-hydrate gel but utilize the polycondensation of silica and alumina precursors to achieve a
superior strength level.

Geopolymers are normally synthesized by mixing source materials having alumino-silicate and
the alkaline solutions. Source materials used are kaolinite, clays, zeolite, fly ash, silica fume,
slag, POFA, rice-husk ash, red mud, etc. The most common alkaline liquid used in
geopolymerization is a combination of NaOH/KOH and sodium silicate. When any of the above
source materials (for example fly ash (FA) in solid form) are mixed with alkali solutions of
appropriate concentration and sodium silicate, geopolymers are formed.

6.2 Flay Ash

Fly ash (FA) is the most used and suitable waste material in geopolymerization due to the huge
amount produced worldwide, estimated to be around 780 million tons annually and the great
workability. Fly ash is a byproduct from burning pulverized coal in electric power generating
plants. During combustion, mineral impurities in the coal (clay, feldspar, quartz, and shale) fuse
in suspension and float out of the combustion chamber with the exhaust gases. As the fused
material rises, it cools and solidifies into spherical glassy particles called fly ash.

Fly ash is collected from the exhaust gases by electrostatic precipitators or bag filters. The fine
powder does resemble Portland cement, but it is chemically different.
The major constituents of most of the fly ashes are Silica (Si2O), alumina (Al2O3), ferric oxide
(FeO) and calcium oxide (CaO). The other minor constituent of the fly ash is MgO, NaO, KO,
SO, MnO, TiO and unburnt carbon.

Two types of fly ash are commonly used in concrete: - Class C and Class F.

1. Class C (Calcareous) fly ash: active constituents are calcium alumino-silicate glass, free
lime (CaO), anhydrate (CaSO), tricalcium aluminate and rarely, calcium silicate. They
are often high-calcium fly ashes with carbon content less than 2%. They are produced
from burning sub-bituminous or lignite coals.
2. Class F (Siliceous) Fly ash: characteristically contains a large part of silicate glass of high
silica content and crystalline phases of low reactivity mullite, magnetite and quartz. The
active constituents of class F fly ash is siliceous or alumino-silicate glass. They are
generally low-calcium fly ashes with carbon contents less than 5% but sometimes as high
as 10%. They are produced from bituminous or anthracite coals.

Performance properties between Class C and F ashes vary depending on the chemical and
physical properties of the ash and how the ash interacts with cement in the concrete. Many Class
C ashes when exposed to water will react and become hard just like cement, but not Class F
ashes. Most, if not all, Class F ashes will only react with the byproducts formed when cement
reacts with water. We have selected Class F fly ashes for our final year project.

7. materials and methods

1. Materials

For this investigation, deferent types of materials, equipment’s and chemicals will have used.

Some of the material are, a low calcium processed fly ash as a source material and locally
available river sand as filler material. The laboratory grade sodium hydroxide and sodium silicate
solution will have used as alkaline activators. And finally, salt solution will be used for material
testing.

Some of the equipment’s that we are going to use includes mold, mortar mixer, bucket, towel,
brush, oven etc.
2. methods

The experiment design method to be used is full factorial method which involves two factors
with three levels and one replica. Those are molarity of sodium hydroxide with concentrations of
8 M, 12 M and 14 M and different Curing temperatures of room temp (25 0 C), 45 0 C and 75 0 C.
Therefore, the numbers of experiment that are required to be performed are 9.

Fly ash will be purchased from locally available power plant and will be crushed to a size <80
µm. Analytical grade sodium hydroxide (NaOH) will be mixed with water to have a molarity of
8M, 12M and 14M to see the effect of molarity on the mechanical properties. The NaOH
solution will be mixed with the Sodium Silicate with a ratio of 1:1 to make activating solution.
Fly ash to activating solution ratio of 1:1 will be prepared. Sand is added 3 times the amount of
fly ash. Then it will be mixed for 2min properly and placed in a mold of size 4x4x16 cm and will
be tapped to ensure proper molding. The sample will be allowed to cure for limited time at
testing temperatures and demolded. Then it will be ready for strength tests.

3. properties of the material (geopolymer mortar) to tested.

Compressive Strength

Compressive strength of geopolymer mortars and concretes is an important property. The

strength change in FA geopolymer concrete is due to shape, size distribution, calcium content
and high amorphous microstructure of raw material. This property of the geopolymer must be
tested.

Flexural and Splitting Tensile Strength

Normally, a fly ash-based geopolymer has low tensile strength. It also has low fracture
toughness. Because of these properties, fly ash-based geopolymers suffer from brittle failure.
Test for this property of geopolymer will also be performed.

Durability

Durability of geopolymers (resistance to chloride, sulfate, acid, freeze-thaw, thermal and

efflorescence) depends on the microstructure and the movement of ions within the structure.
Geopolymer made by NaOH is found to be more crystalline and hence more stable, whereas
geopolymers made with the sodium silicate activator is amorphous and less stable in acidic
medium. Active sites present on the surface of aluminosilicate gel are also responsible for
chemical stability.

Setting time

Setting is a process in which geopolymer pastes using a vicar apparatus. There are two types of

setting time i.e. initial and final setting times. The initial setting time indicates the time at which

the paste begins to stiffen considerably and can no longer be molded; while the final setting time

indicates the time at which the paste has hardened to the point at which it can sustain some load.

Like normal consistency these tests are also used for quality control.