Emission of carbon dioxide gas has been a source of major concern for the construction industry. To curb this emission, geopolymer concrete has been deemed as a potential alternative in the recent studies. Previous research also indicates that silica and fibers provide strength benefits to ordinary Portland cement concrete OPC. This study was undertaken to recognize the benefits of adding silica and basalt fibers in Class F fly ash based geopolymer concrete and comparing it with OPC concrete. One OPC and four Geopolymer mixtures were prepared. The results show a tremendous potential of using geopolymer concrete in place of OPC concrete with Nano silica proving to be the most advantageous. Nano silica provided 28% increase in compressive strength, 8% increase in resistivity when compared with normal Fly ash based geopolymer concrete. The SEM analysis of geopolymer concrete indicates that nano silica improved the compactness of concrete providing a dense microstructure.

Yes / Demolition and reconstruction of degrading structures alongside with the repetitive repair, maintenance, and renovation applications create significant amounts of construction and demolition waste (CDW), which needs proper tackling. The main emphasis of this study has therefore been placed on the development of concrete mixtures with components (i.e., aggregates and binder) coming entirely from CDW. As the binding phase, powdered CDW-based masonry units, concrete and glass were used collectively as precursors to obtain geopolymer binders, which were then incorporated with CDW-based fine and coarse concrete aggregates. Together with the entirely CDW-based concretes, designs were also proposed for companion mixtures with mainstream precursors (e.g., fly ash and slag) occupying some part of the CDW-based precursor combination. Sodium hydroxide (NaOH), sodium silicate (Na2SiO3) and calcium hydroxide (Ca[OH]2) were used at various concentrations and combinations as the alkaline activators. Several factors that have impact on the compressive strength results of concrete mixtures, such as mainstream precursor replacement rate, al-kaline molar concentrations, aggregate-to-binder ratios and curing conditions, were considered and these were also backed by the micro-structural analyses. Our results showed that through proper optimiza-tion of the design factors, it is possible to manufacture concrete mix-tures entirely out of CDW with compressive strength results able to reach up to 40 MPa under ambient curing. Current research is believed to be very likely to promote more innovative and up-to-date techniques to upcycle CDW, which are mostly downcycled through basic practices of road base/sub-base filling, encouraging further research and increas-ing the awareness in CDW issue. / The full-text of this paper will be released for public view at the end of the publisher embargo on 1 Jul 2024.

Thesis (MEng) -- Stellenbosch University, 2014. / ENGLISH ABSTRACT: Geopolymer concrete is an alternative construction material that has comparable mechanical properties to that of ordinary Portland cement concrete, consisting of an aluminosilicate and an alkali solution. Fly ash based geopolymer concrete hardens through a process called geopolymerisation. This hardening process requires heat activation of temperatures above ambient. Thus, fly ash based geopolymer concrete will be an inadequate construction material for in-situ casting, as heat curing will be uneconomical. The study investigated fly ash/slag based geopolymer concrete. When slag is added to the matrix, curing at ambient temperatures is possible due to calcium silicate hydrates that form in conjunction with the geopolymeric gel. The main goal of the study is to obtain a better understanding of the mechanical properties of geopolymer concrete, cured at ambient temperatures. A significant number of mix variations were carried out to investigate the influence that the various parameters, present in the matrix, have on the compressive strength of fly ash/slag based geopolymer concrete. Promising results were found, as strengths as high as 72 MPa were obtained. The sodium hydroxide solution, the slag content and the amount of additional water in the matrix had the biggest influence on the compressive strength of the fly ash/slag based geopolymer concrete. The modulus of the elasticity of fly ash/slag based geopolymer concrete did not yield promising results as the majority of the specimens, regardless of the compressive strength, yielded a stiffness of less than 20 GPa. This is problematic from a structural point of view as this will result in large deflections of elements. The sodium hydroxide solution had the most significant influence on the elastic modulus of the geopolymer concrete. Steel and polypropylene fibres were added to a high- and low strength geopolymer concrete matrix to investigate the ductility improvement. The limit of proportionality mainly depended on the compressive strength of the geopolymer concrete, while the amount of fibres increased the energy absorption of the concrete. A similar strength OPC concrete mix was compared to the low strength geopolymer concrete and it was found that the OPC concrete specimen yielded slightly better flexural behaviour. Fibre pull-out tests were also conducted to investigate the fibre-matrix interface. From the knowledge gained during this study, it can be concluded that the use of fly ash/slag based geopolymer concrete, as an alternative binder material, is still some time away as there are many complications that need to be dealt with, especially the low modulus of elasticity. However, fly ash/slag based geopolymer concrete does have potential if these complications can be addressed. / AFRIKAANSE OPSOMMING: Geopolimeerbeton is ‘n alternatiewe konstruksiemateriaal wat vergelykbare meganiese eienskappe met beton waar OPC die binder is, en wat bestaan uit ‘n aluminosilikaat en ‘n alkaliese oplossing. Vliegas-gebaseerde geopolimeerbeton verhard tydens ‘n proses wat geopolimerisasie genoem word. Hierdie verhardingsproses benodig hitte-aktivering van temperature hoër as dié van die onmiddellike omgewing. Gevolglik sal vliegas-gebaseerde geopolimeerbeton ‘n ontoereikende konstruksiemateriaal vir in situ gietvorming wees, aangesien hitte-nabehandeling onekonomies sal wees. Die studie het vliegas/slagmentgebaseerde geopolimeerbeton ondersoek. Wanneer slagment by die bindmiddel gevoeg word, is nabehandeling by omliggende temperature moontlik as gevolg van kalsiumsilikaathidroksiede wat in verbinding met die geopolimeriese jel vorm. Die hoofdoel van die studie was om ‘n beter begrip te kry van die meganiese eienskappe van geopolimeerbeton, wat nabehandeling by omliggende temperature ontvang het. ‘n Aansienlike aantal meng variasies is uitgevoer om die invloed te ondersoek wat die verskeie parameters, aanwesig in die bindmiddel, op die druksterkte van die vliegas/slagmentgebaseerde geopolimeerbeton het. Belowende resultate is verkry en sterktes van tot so hoog as 72 MPa is opgelewer. Daar is gevind dat die sodiumhidroksiedoplossing, die slagmentinhoud en die hoeveelheid water in die bindmiddel die grootste invloed op die druksterkte van die vliegas/slagmentgebaseerde geopolimeerbeton gehad het. Die styfheid van die vliegas/slagmentgebaseerde geopolimeerbeton het nie belowende resultate opgelewer nie. Die meeste van die monsters, ongeag die druksterkte, het ‘n styfheid van minder as 20 GPa opgelewer. Vanuit ‘n strukturele oogpunt is dit problematies, omdat groot defleksies in elemente sal voorkom. Die sodiumhidroksiedoplossing het die grootste invloed op die styfheid van die vliegas/slagmentgebaseerde geopolimeerbeton gehad. Staal en polipropileenvesels is by ‘n hoë en lae sterke geopolimeer beton gevoeg om die buigbaarheid te ondersoek. Die die maksimum buigbaarheid het hoofsaaklik afgehang van die beton se druksterkte terwyl die hoeveelheid vesels die beton se energie-opname verhoog het. ‘n OPC beton mengsel van soortgelyke sterkte is vergelyk met die lae sterkte geopolimeerbeton en daar is gevind dat die OPC beton ietwat beter buigbaarheid opgelewer het. Veseluittrektoetse is uitgevoer om die veselbindmiddel se skeidingsvlak te ondersoek. Daar kan tot die gevolgtrekking gekom word dat, alhoewel belowende resultate verkry is, daar steeds sommige aspekte is wat ondersoek en verbeter moet word, in besonder die styfheid, voordat geopolimeerbeton as ‘n alternatiewe bindmiddel kan optree. Volgens die kennis opgedoen tydens hierdie studie, kan dit afgelei word dat die gebruik van vliegas/slagmentgebaseerde geopolimeerbeton, as 'n alternatiewe bindmiddel, nog 'n geruime tyd weg is, as gevolg van baie komplikasies wat gehandel moet word, veral die lae elastisiteitsmodulus. Tog het vliegas/slagmentgebaseerde geopolimeerbeton potensiaal as hierdie komplikasies verbeter kan word.

This research studies the green geopolymer incorporated with phase change material (PCM) for energy saving in buildings. First class F fly ash (FA) based-geopolymer binder was studied. In order to improve the mechanical properties, low calcium slag (SG) was added to the FA to produce geopolymer. The effect of different factors including SG content (at different relative amounts FA/SG = 0/100, 25/75, 50/50, 75/25 and 100/0), NaOH solution at different concentrations (7.5, 10 and 15 M), various curing times (1, 2, 4, 7, 14 and 28 days) and curing temperatures (25 (ambient), 45, 60, 75 and 90°C) was investigated. The unit weight and uniaxial compressive strength (UCS) of the geopolymer specimens were measured. Scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDX) and X-ray diffraction (XRD) were also performed to characterize the microstructure and phase composition of the geopolymer specimens. The results show that the incorporation of SG not only improves the strength of the geopolymer specimens but also decreases the initial water content and thus the NaOH consumption at the same NaOH concentration required for geopolymer production. In addition, the inclusion of SG increases the unit weight of the geopolymer specimens, simply because SG has a much greater specific gravity than FA. The results also show that the strength of the FA/SG-based geopolymer develops rapidly within only 2 days and no obvious gain of the strength after 7 days. The optimum curing temperature (the curing temperature at which the maximum UCS is obtained) at a FA/SG ratio of 50/50 is around 75°C. Second, FA-based geopolymer concrete was synthesized and the effect of different factors including sodium silicate to sodium hydroxide (SS/SH) ratio, aggregate shape, water to fly ash (W/FA) ratio, curing time, water exposure and PCM inclusion on the compressive strength of the geopolymer concrete specimens cured at different ambient temperatures was studied. The results show that the UCS of the specimens increases with higher SS/SH and W/FA ratios up to a certain level and then starts to decrease at higher ratios. The results also indicate that a major portion of the strength of the specimens cured at ambient temperatures develops within the first four weeks. In addition the strength of the FA-based geopolymer concrete is slightly decreased with water exposure and PCM incorporation. Third, the mechanical and thermal properties of geopolymer mortar synthesized with FA and different amount of PCM were studied and the effect of incorporated PCM on the unit weight and UCS of geopolymer mortar was evaluated. SEM imaging was performed to identify the change of micro structure of the geopolymer mortar after incorporation of PCM. The thermal properties of the geopolymer mortar containing different amount of PCM were also characterized using differential scanning calorimetry (DSC) analysis. In addition model tests were performed using small cubicles built with geopolymer mortar slabs containing different amount of PCM to evaluate the effectiveness of geopolymer mortar wall with incorporated PCM in controlling the heat flow and internal temperature. The results indicate that both the unit weight and UCS of the geopolymer mortar decrease slightly after PCM is incorporated, mainly due to the small unit weight and low strength and stiffness of the PCM, respectively. However, the compressive strength of geopolymer mortar containing up to 20% PCM is still sufficiently high for applications in buildings. The results also show that the incorporation of PCM leads to substantial increase of heat capacity and decrease of thermal conductivity of the geopolymer mortar and is very effective in decreasing the temperature inside the cubicles. Finally, a numerical study on the thermal performance of geopolymer with incorporated PCM was carried out. In order to simulate the heat transfer through geopolymer containing PCM, a simplified method was first presented. The influence of phase transition was linked to the energy balance equation through variable specific heat capacity of the PCM-geopolymer. The thermal properties of the geopolymer containing PCM for the numerical analysis were determined using DSC and guarded heat flow (GHF) tests. The simplified method was validated based on the good agreement between the numerical and experimental results. With the validated model, the effect of various factors including the specific heat capacity, thermal conductivity and wall thickness on the thermal performance of PCM-geopolymer walls was studied. Then a modified numerical method was proposed for simulating the whole thermal transfer processes and the simulation results were used to conduct the economic evaluation of PCM-geopolymer walls for energy savings in buildings.

Concrete is the most common building material in the world and its use has been increasing during the last century as the need for construction projects has escalated. Traditionally, concrete uses Ordinary Portland Cement (OPC) as binder, water as the activator of cement and aggregate. Finding an appropriate replacement for traditional concrete is a desirable solution to obviate the environmental problems caused by cement production. The use of fly ash as a partial replacement for Portland cement is a method to maintain the properties of concrete and reduce the need for cement. Fly ash is a by-product from coal-fired power plants and is abundantly available. The percentage of cement replacement can be varied according to application and mix design. One of the potential materials to substitute for conventional concrete is geopolymer concrete (introduced by Davidovits in 1979). Geopolymer concrete is an inorganic alumino-silicate polymer synthesized from predominantly silicon, aluminum and byproduct materials such as fly ash. Geopolymer properties have been investigated for several years and it is still a major area of interest among researchers and industry partners as it does not contain cement and uses fly ash and alkali liquids as binders to produce a paste to consolidate aggregates. Furthermore, the aggregate comprises a substantial portion of concrete. Including coarse and fine aggregates it is normally obtained from natural sources. Fine aggregate in Australia is usually mined from sand quarries. As the demand for concrete production increases, more natural sand is needed. The need for fine aggregate should be addressed in an environmentally friendly manner, considering the diminishing sources of natural sand. Red sand is a by-product generated from the manufacture of alumina from bauxite by the Bayer process. / Previous studies on properties of red sand have shown that it has the potential to be used in concrete as a fine aggregate. While the use of red sand in traditional concrete has been investigated by some researchers, no research has been reported regarding the use of this by-product in manufacturing geopolymer concrete. This research looks into the replacement of natural sand fine aggregates with red sand in geopolymer concrete. Initially, an extensive series of mixtures was prepared and tested. The objective of the research was to identify the salient parameters affecting the properties of geopolymer concrete when natural sand is replaced by red sand. At the next stage, attempts were made to enhance the mechanical and durability features of red sand geopolymer concrete. The final stage consisted of testing red sand geopolymer concrete to find out the various properties of this novel construction material.

The use of Portland cement in concrete construction is under critical review due to high amount of carbon dioxide gas released to the atmosphere during the production of cement. In recent years, attempts to increase the utilization of fly ash to partially replace the use of Portland cement in concrete are gathering momentum. Most of this by-product material is currently dumped in landfills, creating a threat to the environment. Geopolymer concrete is a ‘new’ material that does not need the presence of Portland cement as a binder. Instead, the source of materials such as fly ash, that are rich in Silicon (Si) and Aluminium (Al), are activated by alkaline liquids to produce the binder. Hence concrete with no Portland cement. This thesis reports the details of development of the process of making fly ash-based geopolymer concrete. Due to the lack of knowledge and know-how of making of fly ashbased geopolymer concrete in the published literature, this study adopted a rigorous trial and error process to develop the technology of making, and to identify the salient parameters affecting the properties of fresh and hardened concrete. As far as possible, the technology that is currently in use to manufacture and testing of ordinary Portland cement concrete were used. Fly ash was chosen as the basic material to be activated by the geopolimerization process to be the concrete binder, to totally replace the use of Portland cement. The binder is the only difference to the ordinary Portland cement concrete. To activate the Silicon and Aluminium content in fly ash, a combination of sodium hydroxide solution and sodium silicate solution was used. Manufacturing process comprising material preparation, mixing, placing, compaction and curing is reported in the thesis. / Napthalene-based superplasticiser was found to be ii useful to improve the workability of fresh fly ash-based geopolymer concrete, as well as the addition of extra water. The main parameters affecting the compressive strength of hardened fly ash-based geopolymer concrete are the curing temperature and curing time, the molar H2O-to-Na2O ratio, and mixing time. Fresh fly ash-based geopolymer concrete has been able to remain workable up to at least 120 minutes without any sign of setting and without any degradation in the compressive strength. Providing a rest period for fresh concrete after casting before the start of curing up to five days increased the compressive strength of hardened concrete. The elastic properties of hardened fly ash-based geopolymer concrete, i,e. the modulus of elasticity, the Poisson’s ratio, and the indirect tensile strength, are similar to those of ordinary Portland cement concrete. The stress-strain relations of fly ash-based geopolymer concrete fit well with the expression developed for ordinary Portland cement concrete.

One technology that makes concrete without cement and does not have the associated carbon footprint is geopolymer concrete. This technology utilizes waste fly ash from power stations and mixes it with activating chemicals to form a binder with similar or better properties than cement. Not only does this technology directly reduce carbon emissions by replacing cement it also utilizes the waste bi-product from power stations and prevents it from going to landfill. Concrete is composed of coarse aggregates, sand and cementitious paste. It seemed possible to make geopolymer concrete from 100% waste. The aggregates would come from recycled concrete and hard brittle bottom ash from power stations, the sand would come from foundries and the fly ash binder would also come from the same power station as the bottom ash. All of these materials are waste and would all be dumped in landfill. Where would one find all these waste materials in one place? The industrial suburb of Kwinana outside Perth is home to a large number of industries producing all these wastes. To find products that have a specification that these materials would suit was a material with a relatively low specification, one such specification is the concrete masonry units’ specification. For this to be adopted the mix design would then have to be altered to a drier type mix without any slump. As recycling facilities do not make a range of products it was decided to crush the aggregates in the laboratory specifically for this research and to blend all the waste materials. Numerous combinations were blended, analysed and assessed to establish which blends would best suit the aims and scope of this research. Eventually three blends were selected that encompassed all the waste products. / To find the right mix design proved challenging as these masonry products generally require a mix to have zero slump. It was decided to test across all the known and analysed water to geopolymer solids ratios for each of the mixes and establish the best mix based on compressive strength, workability and slump A known mix design based on research into low calcium Class F geopolymer concrete, developed at Curtin University using natural aggregates, was applied to these selected recycled waste mix designs. The benefit was to be able to compare the results of this research to a known result. Flash setting, an unknown phenomenon in geopolymer concrete, did occur in the low water mixes, but in spite of this, geopolymer concrete was successfully manufactured. The compressive strengths were substantially lower than those of the design mix and more research is required in this regard, however an indirect relationship was observed between the amount of bottom ash and the compressive strength. The high degree of LOI (loss of ignition) in both ashes, porosity of recycled aggregates, angularity, degree of fineness of the fines and flash setting are all possible factors influencing the properties of the geopolymer concrete. More research is recommended in a number of these areas to be able to understand and develop this technology further in order to make this a practical and robust technology in the quest to find solutions to our warming planet and our changing climate.

Yes / Geopolymers have been recognised as a viable replacement to ordinary Portland cement (OPC), providing a cleaner solution since it can significantly reduce greenhouse gas emissions as well as accomplishing effective waste recycling. Construction and demolition waste (CDW) has been recently identified as raw materials for geopolymers due to its availability and high contents of silica and alumina. This paper aimed at reviewing the current state-of-the-art on the geopolymer paste, mortar, and concrete production and their properties, with special attention paid to geopolymers incorporating CDWs. The review covers brief assessment of using CDWs in concrete, the mix design of geopolymer mixtures in addition to identification of the main factors influencing the performance of geopolymer containing CDW. The most recent data related to the mechanical and durability properties of CDW-based geopolymers are presented, while the cost and environmental impacts of using recycled materials in producing geopolymer concretes are also discussed. Geopolymer concretes have a vast range of possible applications, however, there are still several barriers facing commercialisation of geopolymers in construction industry. The review indicated that it is possible to produce geopolymer concretes from CDW-based materials with properties comparable to OPC-based ones; however, the selection of proper material composition should be carefully considered, especially under normal curing conditions.

Yes / The flexural performance of geopolymer concrete (GPC) T-beams reinforced longitudinally with GFRP bars under a four-point static bending test was investigated. Six full-scale simply supported T-beams were cast and tested; one control specimen was made with ordinary Portland cement concrete (OPCC), while the other five beams were made of geopolymer concrete. The G-GPC2 was designed to attain the same theoretical moment capacity as the G-OPCC6 control beam. The main parameters investigated were the reinforcement ratio of ρ_f/ρ_b= 0.75, 1.05, 1.12, 1.34 and 1.34 for G-GPC1, G-GPC2, G-GPC3, G-GPC4, and G-GPC5, respectively, and compressive strength of geopolymer concrete. Based on the results of the experiments, the ultimate strain of GPC did not show the same behaviour as that of OPCC, which affects the mode of failure. The beam capacity and deflection were, respectively, overestimated and underestimated using the ACI 440 2R-17 predictive equations.

Yes / Concrete requires a vast amount of aggregate and cement production. Although there are some efforts in the literature to reduce the amount of Portland cement in the concrete mixture to lessen the greenhouse gas release, a limited number of studies were conducted to investigate the possibility of using this geopolymer mixtures to serve as a structural component. Therefore, this study firstly aimed to produce geopolymer concrete from construction and demolition waste-based precursors, including masonry units (red clay brick, roof tile, hollow brick, etc.) and glass. In addition, recycled aggregates produced from the concrete waste portion of the CDW were used to obtain 100% recycled construction material on the scale of the binder and aggregate phase. Then, this study investigated the possible use of this proposed geopolymer concrete to produce structural components that perform similar to conventional concrete. Therefore, the structural properties of reinforced geopolymer concrete beams produced from the recycled construction demolition wastes were evaluated in this study by conducting laboratory experiments. To this end, bending tests were performed on reinforced conventional concrete beam specimens and reinforced geopolymer concrete beam specimens. The test observations clearly showed that construction demolition waste could be recycled to produce new constructional components, considering its advantage of promoted sustainability. / The authors gratefully acknowledge the European Union’s Horizon 2020 Research and Innovation Programme’s financial assistance under Grant Agreement No: 869336 and Acronym: ICEBERG and the financial assistance of the Scientific and Technical Research Council (TUBITAK) of Turkey and the British Council under Grant no:218M102. This work was also supported by Newton Prize 2020.