Alkali Activated Fuel Ash and Slag Mixes:Optimization Study from Mortars to Concrete Building Blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (PFA) from a UK power plant, ground granulated blast furnace slag (GGBS) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several PFA and GGBS combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of PFA/GGBS and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from PFA/GGBS combinations.

Alkali activated fuel ash and slag mixes:optimization study from paste to concrete building blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (pfa) from a UK power plant, ground granulated blast furnace slag (ggbs) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several pfa and ggbs combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of pfa/ggbs and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from pfa/ggbs combinations.

Engineering properties of alkali-activated natural pozzolan concrete

The development of alkali-activated binders with superior engineering properties and longer durability has emerged as an alternative to ordinary portland cement (OPC). It is possible to use alkali-activated natural pozzolans to prepare environmentally friendly geopolymer cement leading to the concept of sustainable development. This paper presents a summary of an experimental work that was conducted to determine mechanical strength, modulus of elasticity, ultrasonic pulse velocity, and shrinkage of different concrete mixtures prepared with alkali-activated Iranian natural pozzolans—namely Taftan andesite and Shahindej dacite, both with and without calcining. Test data were used for Taftan pozzolan to identify the effects of water-binder ratios (w/b) and curing conditions on the properties of the geopolymer concrete, whereas the influence of material composition was studied by activating Shahindej pozzolan both in the natural and calcined states. The results show that alkali-activated natural pozzolan (AANP) concretes develop moderate-to-high mechanical strength with a high modulus of elasticity and a shrinkage much lower than with OPC.

Oxygen and Chloride Permeability of Alkali-Activated Natural Pozzolan Concrete

One of the important factors in the use of portland cement concrete is its durability, and most of the situations where durability is lacking have been identifi ed and strategies to manage durability have been implemented. Geopolymer concrete, made from an alkali-activated natural pozzolan (AANP), provides an important opportunity for the reduction of carbon dioxide (CO2) emissions associated with the manufacture of concrete but has a limited history of durability studies. Until its different properties are well understood there is no desire to adopt this new technology of unknown provenance by the concrete industry. This paper presents an experimental study of oxygen and chloride permeability of AANP concrete prepared by activating Taftan andesite and Shahindej dacite (Iranian natural pozzolans), with and without calcining, and the correlations between these properties and compressive strength. The results show that compared to ordinary portland cement (OPC) concrete, AANP concrete has lower oxygen permeability at later ages; but it shows moderate to high chloride ion penetrability.

Alkali-Activated Natural Pozzolan Concrete as New Construction Material

In the near future, geopolymers or alkali-activated cementitious materials will be used as new high-performance construction materials of low environmental impact with a reasonable cost. This material is a good candidate to partially replace ordinary portland cement (OPC) in concrete as a major construction material that plays an outstanding role in the construction industry of different structures. Geopolymer materials are inorganic polymers based on alumina and silica units; they are synthesized from a wide range of dehydroxylated alumina-silicate powders condensed with alkaline silicate in a highly alkaline environment. Geopolymeric materials can be produced from a wide range of alumina-silica, including natural products--such as natural pozzolan and metakaolin--or coproducts--such as fly ash (coal and lignite), oil fuel ash, blast furnace or steel slag, and silica fume--and provide a route toward sustainable development. Using lesser amounts of calcium-based raw materials, lower manufacturing temperature, and lower amounts of fuel result in reduced carbon emissions for geopolymer cement manufacture up to 22 to 72% in comparison with portland cement. A study has been done by the authors to investigate the intrinsic nature of different types of Iranian natural pozzolans to determine the activators and methods that could be used to produce a geopolymer concrete based on alkali-activated natural pozzolan (AANP) and optimize mixture design. The mechanical behavior and durability of these types of geopolymer concrete were investigated and compared with normal OPC concrete mixtures cast by the authors and also reported in the literature. This paper summarizes the main conclusions of the research regarding pozzolanic activity, activator properties, engineering and durability properties, applications and evaluation of carbon footprint, and cost for AANP concrete.

Factors influencing the compressive strengths of fly ash based geopolymers

Several factors affecting the reactivity of pulverised fuel ash (pfa) as a precursor for geopolymer concrete have been investigated. These include physical and chemical properties of various pfa sources, inclusion of ground granulated blast furnace slag (ggbs), chemical activator dosages and curing temperature. Alkali-activated pfa was found to require elevated curing temperatures and high alkali concentrations. A mixture of sodium hydroxide and sodium silicate was used and this was shown to result in high strengths, as high as 70 MPa at 28-days. The presence of silicates in solution was found to be a key factor. Detailed physical and chemical characterisation was carried out on thirteen pfa sources from the UK. The most important factor affecting the reactivity was found to be the particle size of pfa. The loss on ignition (LOI) and the amorphous content are also important parameters that need to be considered for the selection of pfa for use in geopolymer concrete. The partial replacement of pfa by ground granulated blast furnace slag (ggbs) was found to be beneficial in not only avoiding the need for elevated curing temperatures but also in improving compressive strengths. Microstructural characterisation with scanning electron microscope (SEM) coupled with energy dispersive X-ray spectroscopy (EDS) was performed on pfa/ggbs pastes. The reaction product of pfa and ggbs in these binary systems was calcium aluminium silicate hydrate gel (C-A-S-H) with inclusion of Na in the structure.

Sulfate Resistance of Alkali Activated Pozzolans

The consequence of sulfate attack on geopolymer concrete, made from an alkali activated natural pozzolan (AANP) has been studied in this paper. Changes in the compressive strength, expansion and capillary water absorption of specimens have been investigated combined with phases determination by means of X-ray diffraction. At the end of present investigation which was to evaluate the performance of natural alumina silica based geopolymer concrete in sodium and magnesium sulfate solution, the loss of compressive strength and percentage of expansion of AANP concrete was recorded up to 19.4% and 0.074, respectively.

Load Testing of Floor Slabs in a Full-Scale Reinforced Concrete Building

A series of short and long term service load tests were undertaken on the sixth floor of the full-scale, seven storey, reinforced concrete building at the Large Building Test Facility of the Building Research Establishment at Cardington. By using internally strain gauged reinforcing bars cast into an internal and external floor bay during the construction process it was possible to gain a detailed record of slab strains resulting from the application of several arrangements of test loads. Short term tests were conducted in December 1998 and long term monitoring then ensued until April 2001. This paper describes the test programmes and presents results to indicate slab behaviour for the various loading regimes.

Arching action in high strength concrete slabs

The corrosion of reinforcement in bridge deck slabs has been the cause of major deterioration and high costs in repair and maintenance.This problem could be overcome by reducing the amount of reinforcement and/or altering the location.This is possible because, in addition to the strength provided by the reinforcement, bridge deck slabs have an inherent strength due to the in-plane arching forces set up as a result of restraint provided by the slab boundary conditions. This is known as arching action or Compressive Membrane Action (CMA). It has been recognised for some time that laterally restrained slabs exhibit strengths far in excess of those predicted by most design codes but the phenomenon has not been recognised by the majority of bridge design engineers. This paper presents the results of laboratory tests on fifteen reinforced concrete slab strips typical of a bridge deck slab and compares them to predicted strengths using the current codes and CMA theory. The tests showed that the strength of laterally restrained slabs is sensitive to both the degree of external lateral restraint and the concrete compressive strength.The tests particularly highlighted the benefits in strength obtained from very high strength concrete slabs. The theory extends the existing knowledge of CMA in slabs with concrete compressive strengths up to 100 N/mm[2] and promotes more economical and durable bridge deck construction by utilising the benefits of high strength concrete.