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Experimental study on strength properties of metakaolin and GGBS based

geopolymer concrete

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 VOL. 11, NO. 21, NOVEMBER 2016 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
©2006-2016 Asian Research Publishing Network (ARPN). All rights reserved.

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EXPERIMENTAL STUDY ON STRENGTH PROPERTIES

OF METAKAOLIN AND GGBS BASED GEOPOLYMER
CONCRETE
B. Sarath Chandra Kumar1 and K. Ramesh2
1Department of Civil Engineering, K L University, Guntur, Andhra Pradesh, India
2Department of Civil Engineering, P. V. P. Siddhartha Institute of Technology, Kanuru, Vijayawada, Andhra Pradesh, India
E-Mail: [email protected]

ABSTRACT
Energy saving in building technology is among the most critical problems in the world. Thus it is a need to
develop sustainable alternative to conventional concrete utilizing more environmental friendly materials. One of the
possibilities to work out is the massive usage of geopolymer concrete to turn them to useful environmental friendly and
technologically advantages cementitious materials. In the present study metakaolin and Ground Granulated Blast furnace
slag (GGBS) is used to produce geopolymer concrete. Geopolymer concrete is prepared by using alkaline solution of
sodium silicate mixed with sodium hydroxide in the ratio of sodium silicate to sodium hydroxide is 2.5 and the
concentration of sodium hydroxide is 10M is considered in this experimental investigation. The geo polymer concrete
specimens with different proportions of Metakaolin and GGBS were cast and tested for compressive strength, Split
Tensile Strength and Flexural Strength for 3, 7 and 28 days and cured at ambient temperature.

Keywords: geo-polymer, metakaolin, ground granulated blast furnace slag, alkali activator, ambient curing.

1. INTRODUCTION of cement started in the 1960’s and the interest in this

Concrete is the most widely used man made material has considerably increased in recent years.
construction material in civil engineering world. As the Metakaolin has pozzolanic properties bringing positive
demand for concrete as a construction material increased, effects on resulting properties of concrete. Pozzolanic
the world production of cement has greatly increased since properties cause chemical reaction of active components
1990. The global warming is caused by the emission of with calcium hydroxide (portlandite), which is formed as a
greenhouse gases such as CO2 to the atmosphere by product of cement hydration. This reaction leads to
human activities. Among the greenhouse gases, CO2 formation of binding phases of following types: [2]
contributes about 65% to global warming. The cement secondary C-S-H gel, C4AH13, C3AH6, and C2ASH8
industry is responsible for about 6% of all CO2 emissions, thereby increasing strength [2].
because the production of one tonne of Portland cement Davidovits (1988) proposed that an alkaline
emits approximately 0.9 tonne of CO2 into the atmosphere. liquid could be used to react with the silicon (Si) and the
Although the use of Portland cement is still unavoidable aluminium (Al) in a source material of geological origin or
until the anticipated future, many efforts are being made in in by-product materials such as fly ash and rice husk ash to
order to reduce the use of Portland cement in concrete. produce binders. Because the chemical reaction that takes
These efforts include the utilization of supplementary place in this case is a polymerization process, he coined
cementitious materials such as fly ash, silica fume, the term Geopolymer to represent these binders.
granulated blast furnace slag, rice-husk ash and Geopolymer concrete is concrete which does not utilize
Metakaolin, and finding alternative binders to Portland any Portland cement in its production. Geopolymer
cement [1]. concrete is being studied extensively and shows promise
Pozzolanic materials including silica fumes, fly as a substitute to Portland cement concrete. Research is
ash, slag, Rice Husk Ash and Metakaolin have been used shifting from the chemistry domain to engineering
in recent years as cement replacement material for applications and commercial production of geopolymer
developing High strength Concrete with improved concrete.
workability, strength and durability with reduced There are two main constituents of geo polymers,
permeability. Metakaolin, which is a relatively new namely the source materials and the alkaline liquids. The
material in the concrete industry, is effective in increasing source materials for geo polymers based on alumina-
strength, reducing sulphate attack and improving air-void silicate should be rich in silicon (Si) and aluminium (Al).
network. Pozzolanic reactions change the microstructure These could be natural minerals such as kaolinite, clays,
of concrete and chemistry of hydration products by etc. Alternatively, by-product materials such as fly ash,
consuming the released calcium hydroxide (CH) and silica fume, slag, rice-husk ash, red mud, etc could be used
production of additional calcium silicate hydrate (C-S-H), as source materials. The choice of the source materials for
resulting in an increased strength and reduced porosity and making geo polymers depends on factors such as
therefore improved durability. The use of Metakaolin in availability, cost, type of application, and specific demand
High Strength Concrete is discussed in this paper. Use of of the end users. The alkaline liquids are from soluble
Metakaolin in construction industry as partial replacement alkali metals that are usually sodium or potassium based.

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The most common alkaline liquid used in geo Table-2. Chemical Properties of Metakaolin.
polymerization is a combination of sodium hydroxide
(NaOH) or potassium hydroxide (KOH) and sodium Al2O3 >39.0 %
silicate or potassium silicate. [3] Fe2O3 <0.8%

2. METAKAOLIN 3. GGBS
General the raw material in the manufacture of Ground granulated blast furnace slag (GGBS) is a
Metakaoline is kaolin clay. Kaolin is a fine, white, clay byproduct of the manufacturing of iron in a blast furnace
mineral that has been traditionally used in the manufacture where iron ore, limestone and coke are heated up to
of porcelain. Kaolins are classifications of clay minerals, 1500◦C.When these materials melt in the blast furnace,
which like all clays, are phyllosilicates, i.e. a layer silicate two products are produced i.e molten iron, and molten
mineral. The Meta prefix in the term is used to denote slag. The molten slag is lighter and floats on the top of the
change. In case of Metakaolin, the change that is taking molten iron. The molten slag comprises mostly silicates
place is dehydroxylization, brought on by the application and alumina from the original iron ore, combined with
of heat over a defined period of time. Dehydroxylation is a some oxides from the limestone. The process of
reaction of decomposition of kaolinite crystals to a granulating the slag involves cooling the molten slag
partially disordered structure. The results of isothermal through high pressure water jets. This rapidly quenches the
firing shows that the dehydroxylation begins at 4200C. [4] slag and forms granular particles generally not larger than
At about 100 - 2000C clay minerals lose most of their 5mm in diameter. The rapid cooling prevents the
adsorbed water. The temperature at which kaolite loses formation of larger crystals, and the resulting granular
water by dehydroxilization is in the range 500-8000C. This material comprises some 95% non-crystalline calcium-
thermal actvation of a mineral is also referred to as aluminosilicates. The granulated slag is further processed
calcining. Beyond the temperature of dehydroxylization, by drying and then ground to a very fine powder, which is
kaolinite retains two dimensional order in the crystal GGBS (ground granulated blast furnace slag) cement it is
structure and the product is termed Metakaolin. another excellent cementitious material. [4]
Metakaolin is neither the by-product of an industrial Wainwright and Ait-Aider (1995) examined the
process nor is it entirely natural. It is derived from influence of the composition of OPC and the addition of
naturally occurring mineral and is manufactured specially up to 70% GGBS on the bleed characteristics of concrete
for cementing applications. Metakaolin is produced under and conclude that the partial replacement of OPC with
carefully controlled conditions to refine its colour, remove 40% and 70% of GGBS. GGBS led to increases in the
inert impurities, and tailor particle size such, a much high bleeding of the concretes, like fly ash, also GGBS can
degree of purity and pozzolanic reactivity can be obtained. improve many mechanical and durability properties of
Metakaolin is white, amorphous, highly reactive concrete and it generates less heat of hydration. [5]
aluminium silicate pozzolan forming stabile hydrates after Babu and Kumar (2000) determined the
mixing with lime stone in water and providing mortar with cementitious efficiency of GGBS in concrete at various
hydraulic properties. Heating up of clay with kaolinite replacement percentages (10-80%) through the efficiency
Al2O3.2SiO2.2H2O as the basic mineral component to the concept by establishing the variation of strength to water-
temperature of 500 - 600°C causes loss of structural water to-cementitious materials ratio relations of the GGBS
with the result of deformation of crystalline structure of concretes from the normal concretes at the age of 28 days.
kaolinite and formation of an unhydrated reactive form - The 28-day compressive strength of concretes containing
so-called metakaolinite. The chemical equations GGBS up to 30% replacement were all slightly above that
describing this process is [2] of normal concretes, and at all other percentages, the
relationships were below that of normal concretes. It was
Table-1. Physical properties of Metakaolin. also observed that the variations due to the different
Colour Pink / Off-white percentages of slag replacement were smaller than the
corresponding variations in the case of fly ash. The result
Pozzolan Reactivity mg Ca showed that the slag concretes based on overall efficiency
900
(OH)2 / gm factor (k), will need an increase of 8.6% for 50%
Average Particle size 1.4 micron replacement and 19.5% for 65% replacement in the total
Brightness (ISO) 75 ± 2 cementitious materials for achieving strength equivalent to
that of normal concrete at 28 days. [6 - 7]
Bulk Density (Gms / Ltr) 320 to 370
Specific Gravity 2.5

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Table-3. Physical properties of GGBS.

Parameter GGBS IS : 12089 – 1987
CaO 37.34% ---
Al2O3 14.42% ---
Fe2O3 1.11% ---
SiO2 37.73% ---
MgO 8.71% Max. 17%
MnO 0.02% Max. 5.5%
Sulphide Sulphur 0.39% Max. 2%
Loss of Ignition 1.41% ---
Insoluble Residue 1.59% Max. 5%
Glass Content (%) 92% Min. 85%

4. COARSE AGGREGATE will produce concrete of satisfactory workability. These

Coarse aggregate are a broad category particulate aggregates are bound together by the cement and fine
inert materials used in construction. Hard stones are aggregate in the presence of water to form concrete.
crushed to the required size and are used as coarse Coarse aggregates of sizes 12mm and 20mm and fine
aggregate. The material that is retained on as IS sieve of aggregate taken from a local supplier are used in the
size 4.75 is called coarse aggregate. Aggregate of present study and the properties as shown in Table-4.
essentially the same nominal maximum size and grading

Table-4. Physical properties of course aggregate.

20 mm 12 mm
Sieve size Requirement as
(mm) Requirement as Percentage
per IS: 383- Percentage passing
per IS:383-1970 passing
1970
80.00 ---- ---- ---- ----
63.00 ---- ---- ---- ----
40.00 100 % 100 % ---- ----
20.00 85 – 100 % 94.60 % ---- ----
16.00 ---- ---- 100 % 100 %
12.50 ---- ---- 85 -100 % 93.4 %
10.00 0 – 20 % 14.30 % 0 – 45 % 39.23 %
4.75 0 – 05 % 2.85 % 0 – 10 % 6%
2.36 ---- ---- ---- ----
Specific gravity 2.82 - 2.79
Water Absorption % 0.40 - 0.48
Aggregate Impact Value 12 % - 13 %
3
Bulk Density (kg/m ) 1660 - 1655
Flakiness 14 % - 15 %
Elongation 15 % - 16 %

5. FINE AGGREGATE not contain any appreciable amount of clay balls and
Fine aggregate should consist of natural sand or harmful impurities such as alkalis, salts, coal, decayed
crushed stone sand. It should be hard, durable and clean vegetation etc. The silt contents should not exceed 4%.
and be free from organic matter etc. fine aggregate should

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Table-5. Physical Properties of Fine Aggregate.

Percentage passing Percentage passing
I.S. Sieve (mm)
through I.S. Sieve I.S. Sieve as per IS 383
10 100 100
4.75 99.6 90-100
Fineness modulus = 2.2
2.36 99 75-100 Specific Gravity = 2.50
1.18 92.6 55-90 Bulk Density =1625 Kg/m3
Bulking of Sand = 23%
600 micron 48.6 35-50 Silt Content = 0.25 %
300 micron 8.2 8-30
150 micron 2 0-10
Zone II

6. SODIUM HYDROXIDE SOLUTION 8. CASTING PROCEDURE

The most common alkaline activator used in Generally the fine aggregate, coarse aggregate
geopolymerisation is a combination of sodium hydroxide and fly ash are weighed to the required quantities and then
(NaOH) or potassium hydroxide (KOH) and sodium they are mixed in dry condition foe 2-3 minutes and then
silicate or potassium silicate [3]. The type and the alkaline solutions prepared(combination of sodium
concentration of alkali solution affect the dissolution of fly hydroxide and sodium silicate) are to be taken to required
ash. Leaching of Al3+ and Si4+ ions are generally high quantity is added to the dry mix. This mixing is done for
with sodium hydroxide solution compared to potassium 5-7 minutes in the mixer for proper bonding of all the
hydroxide solution. materials. After the mixing is done the mix is filled in the
Therefore, alkali concentration is a significant cube moulds of size 150mm x 150mm 150 mm in 3 layers
factor in controlling the leaching of alumina and silica with equal compacting an the these cubes are kept on a
from fly ash particles, subsequent geo polymerization and vibrating table so that no voids are formed.
mechanical properties of hardened geopolymer. Duchesne
et al (2010) confirmed that in presence of NaOH in the 9. EXPERIMENTAL PROGRAM
activating solution the reaction proceeds more rapidly and
the gel is less smooth. The gel composition analysed in the 9.1 Mix design of geopolymer concrete
sample activated with the mixture of sodium silicate and In the design of geopolymer concrete (GPC mix),
NaOH is enriched in Na and Al [8]. coarse and fine aggregates together were taken as 75% of
entire mixture by mass. This value is similar to that used
7. SODIUM SILICATE SOLUTION in OPC concrete in which it will be in the range of 75% to
Palomo et al (1999) concluded that the type of 80% of the entire mixture by mass. Fine aggregate was
activator plays an important role in the polymerization taken as 30.8% of the total aggregates. From the past
process. Reactions occur at a high rate when the alkaline literatures it is clear that the average density of
activator contains soluble silicate, either sodium or Cementitious materials based geopolymer concrete is
potassium silicate, compared to the use of only alkaline similar to that of OPC concrete (2400kg/m3). Knowing the
hydroxides. A study conducted by Xu and Van Deventer density of concrete, the combined mass of alkaline liquid
(2000) showed that the addition of sodium silicate solution and Cementitious materials can be arrived. By assuming
to the sodium hydroxide solution as the alkaline activator the ratios of alkaline liquid to Cementitious materials as
enhanced the reaction between the source material and the 0.45, mass of metakaolin and mass of alkaline liquid was
solution. Tempest et al (2009) state that the sodium found out. To obtain mass of sodium hydroxide and
silicate activator dissolves rapidly and begins to bond fly sodium silicate solutions, the ratio of sodium silicate
ash particles. Open porosity can be observed and is rapidly solution to sodium hydroxide solution was fixed as 2.5.
filled with gel as soon as the liquid phase is able to reach Extra water (other than the water used for the preparation
the ash particles. The liquid phase is important as a fluid of alkaline solutions) used respectively to achieve
transport medium permitting the activator to reach and workable concrete. The mix proportion for geopolymer
react with the fly ash particles [9-10]. concrete is given after several trial mixes in Table-6 and
the different combinations of GGBS and Metakaolin
investigated are given in Table-7.

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Table-6. Mix proportions.

Materials Cementitious Fine Coarse Sodium Sodium
used materials aggregate aggregate Hydroxide silicate
Quantity of
materials in 414 660 1136 53 133
kg/m3

Table-7. Combinations of GGBS and Metakaolin. inner surfaces of the cast iron mould. Concrete was poured
into the moulds and compacted thoroughly using a
Mix ID Metkaolin GGBS tamping rod. The top surface was finished using a trowel.
M1 100% 0% The GPC specimens were removed from the mould after
1or 2 days based on setting of specimens. The specimens
M2 90% 10% were left at room temperature till the day of testing.
M3 80% 20% Compressive strength test was conducted using a 3000kN
M4 70% 30% Compression testing machine. The test was conducted as
per the relevant Indian standard specifications.
M5 60% 40%
M6 50% 50% 10. RESULTS AND DISCUSSIONS
M7 40% 60% 10.1 Compressive strength
M8 30% 70% The compressive strength of Metakaolin based
geopolymer concrete at the age of 3 days 7 days and 28
M9 20% 80%
days are presented in the Figure-1.
M10 10% 90%
M11 0% 100% Table-8. Compressive strength.

Mix Compressive strength N/mm2

9.2 Preparation of geopolymer concrete ID 3 days 7days 28 days
To prepare 10 molarity concentration of sodium
hydroxide solution, 400 grams (molarity x molecular M1 53.62 54.64 61.03
weight) of sodium hydroxide flakes was dissolved in M2 51.3 53.91 56.71
distilled water and makeup to one litre. The sodium
hydroxide solution thus prepared is mixed with sodium M3 44.91 46.94 50.28
silicate solution one day before mixing the concrete to get M4 42.14 44.32 48.13
the desired alkaline solution. The solids constituents of the
GPCC mix i.e. kaolinite clay, GGBS and the aggregates M5 34.20 35.72 39.29
were dry mixed in the mixer for about three minutes. After M6 31.23 34.12 35.23
dry mixing, alkaline solution was added to the dry mix and
M7 33.67 35.61 38.34
wet mixing was done for 4 minutes. Finally extra water
was added to achieve workable GPCC mix. M8 41.23 43.75 47.35
In this experimental work a total of 297 numbers M9 43.65 45.07 49.94
of Geopolymer concrete specimens were cast with various
mix ratios as shown in Figure-1. The specimens are of 150 M10 50.32 52.32 55.5
mm side. Before casting machine oil was smeared on the M11 52.12 53.8 60.03

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Compressive Strength
70

60

50
Strength Mpa

40
3 Days
30 7 Days
28 Days
20

10

0
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11
Mix Proportions

Figure-1. Compressive strength.

Compressive strength test on cubes is the most 10.2 Split tensile strength
common test conducted on hardened concrete because it is Split Tensile Strength of concrete cylinders
an easy test to perform and most of the desirable 150mm diameter and 300mm long were tested as per the
properties of concrete are comparatively related to its procedure explained in IS 5816.
compressive strength. The compression test was carried
out on cubical specimen of size 150mm in a compression Table-9. Split tensile strength.
testing machine of capacity 3000 kN [2]. The strength is
determined at 3, 7 and 28 days of casting. Split tensile strength N/mm2
The compressive strength of GGBS based Mix 3 days 7 days 28 days
kaolinite clay geopolymer concrete at the age of 28 days is
presented in Figure-1. At 3 days, the mix proportion M6 M1 6.22 6.53 6.73
has the lowest compressive strength of 31.23 N/mm2 and M2 5.26 5.87 5.81
the mix proportion of M1 gave the highest compressive M3 4.21 4.65 4.71
strength of 53.62 N/mm2 at 3 days. At 7 days, the mix
proportion M1 gives the highest compressive strength of M4 3.92 3.98 4.23
54.64 N/mm2 and the mix proportion M6 gives the lowest M5 3.70 3.81 4.14
compressive strength of 34.12 N/mm2. At 28 days, M1
cube specimens attained a compressive strength of 61.03 M6 3.12 3.72 3.9
N/mm2 and the mix proportion M6 gives the lowest M7 3.60 3.71 4.10
compressive strength of 35.23 N/mm2. It is seen from the
M8 3.71 3.79 4.20
results that when the percentage of GGBS and Matakaolin
is increased the compressive strength of the geopolymer M9 4.19 4.50 4.61
concrete. Though addition of GGBS and Matakaolin, M10 5.19 5.77 5.72
increases the compressive strength in geopolymer
concrete, GGBS and Matakaolin based geopolymer M11 6.12 6.37 6.65
concrete shows the high compressive strength.

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Split Tensile Strength

8
7
Strength Mpa 6
5
4 3 Days
3 7 Days
2 28 Days
1
0
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11
Mix Proportions

Figure-2. Split tensile strength.

The values of split tensile strength of cylindrical Table-10. Flexural strength.

specimens subjected to ambient curing conditions. It is
seen that control specimen M1 have higher split tensile Flexural strength N/mm2
strength. Also, the split tensile strength decreases with Mix 3 days 7 days 28 days
increase in Metakaoline.
With reference to the Table-8 and Figure-2, at 3 M1 3.2 3.41 3.54
days, the mix proportion M6 has the lowest split tensile M2 1.96 2.57 2.81
strength of 3.12 N/mm2 and the mix proportion of M1 M3 1.63 1.67 1.71
gave the highest split tensile strength of 6.11 N/mm2 at 3
days. At 7 days, the mix proportion M1 gives the highest M4 1.11 1.58 1.75
split tensile strength of 6.53 N/mm2 and the mix M5 0.85 0.9 1.2
proportion M6 gives the lowest split tensile strength of
3.72 N/mm2. At 28 days, M1 cube specimens attained a M6 0.75 0.822 0.87
split tensile strength of 6.73 N/mm2 and the mix M7 0.80 0.90 1.0
proportion M6 gives the lowest split tensile strength of 3.9
M8 1.3 1.1 1.2
N/mm2. It is seen from the results that when the
percentage of GGBS and Matakaoline is increased the M9 1.52 1.56 1.61
split tensile strength of the geopolymer concrete. Though M10 1.86 2.46 2.71
addition of GGBS and Matakaoline, increases the split
tensile in geopolymer concrete, GGBS and Matakaoline M11 3.0 3.31 3.43
based geopolymer concrete shows the high split tensile
strength.

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Flexural Strength
4
3.5
Strength Mpa 3
2.5
2 3 Days
1.5 7 Days
1 28 Days
0.5
0
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11
Mix Proportions

Figure-3. Flexural strength.

With reference to the Table-9 and Figure-3, at 3 e) The improvement in 7 Days compressive strength
days, the mix proportion M6 has the Lowest Flexural over 3days is in the range of 5% to 9% over 3 days
strength of 0.75 N/mm2 and the mix proportion of M1 and it is 12% to 15 % for 28 Days.
gave the highest Flexural strength of 3.2 N/mm2 at 3 days. f) The % improvement in strength of 7 Days is 9.25%
At 7 days, the mix proportion M1 gives the highest for the mix M6.
Flexural strength of 3.41 N/mm2 and the mix proportion g) Then increase in strength of GPC between 7days and
M6 gives the lowest Flexural strength of 0.822 N/mm2. At 28days appeared to be high when compared with
28 days, M1 cube specimens attained a Flexural strength 3days and 7days.It shows that even after 7days
of 3.54 N/mm2 and the mix proportion M6 gives the geopolymer reaction is taking place but at a higher
lowest Flexural strength of 0.87 N/mm2. It is seen from the rate.
results that when the percentage of GGBS and h) Based on the test results, the following three
Matakaoline is increased the Flexural strength of the combinations of source material are recommended for
geopolymer concrete. Though addition of GGBS and making geopolymer concrete used in structural
Matakaoline, increases the Flexural strength in applications
geopolymer concrete, GGBS and Matakaoline based  100% GGBS
geopolymer concrete shows the high Flexural strength.  70% GGBS – 30% Metakaoline
 50% Metakaoline - 50% GGBS
11. CONCLUSIONS
The conclusions based on the limited ACKNOWLEDGEMENTS
observations from the present investigation on properties The authors wish to gratefully acknowledge the
of fresh and hardened metakaolin and GGBS based support of KaoMin Industries regarding Metakaolin
concrete are: supply. The help of the concrete laboratory staff of K L
University is gratefully acknowledged.
a) Workability of geopolymer concrete decreased as the
metakaolin content increases with GGBS. But REFERENCES
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