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Faculty of Materials Science and Chemistry, China University of Geosciences, Wuhan 430074, China
Engineering Research Center of Nano-Geomaterials of Ministry of Education, China University of Geosciences, Wuhan 430074, China
c
Zhejiang Research Institute, China University of Geosciences, Hangzhou 311305, China
d
Center of Materials Research and Analysis, Wuhan University of Technology, Wuhan 430070, China
b
a r t i c l e
i n f o
Article history:
Received 28 November 2014
Revised 5 March 2015
Accepted 7 March 2015
Available online 9 March 2015
Keywords:
Geopolymer
Fly ash
Metakaolin
Durability
OPC
a b s t r a c t
This study aims to investigate durability and microstructure of uidized bed y ash and metakaolin based
geopolymer exposed to elevated temperatures and acid attack. Geopolymer specimens were prepared by
combination of y ash and metakaolin activated by sodium silicate and sodium hydroxide solutions and
were cured in microwave radiation environment plus a heat curing period. Compressive strength and
several key durability parameters for geopolymer and ordinary Portland cement (OPC) were assessed
and compared. Microstructure formation and development was characterized in terms of morphology
and pore structure as well as simulation.
The experimental results reveal a dense microstructure of geopolymer compared to OPC. In terms of
resistance to the acidic solution and elevated temperatures, geopolymer is superior to OPC as indicated
by the relatively lower strength loss and lower mass change. Compressive strength shows a dramatic
drop in OPC while geopolymer shows a strength increase after 400 C. The mass loss curves of geopolymer are similar to OPC, but it shows relatively lower mass loss compared to OPC. The result of saturated
water absorption after 28 days curing indicates less water absorption in geopolymer before and after
thermal and acid exposure. Durability of geopolymer is demonstrated by monitoring the pore structure.
Crown Copyright 2015 Published by Elsevier Ltd. All rights reserved.
1. Introduction
Cement production is associated with the emission of considerable amount of greenhouse gas [1]. The amount of carbon dioxide
released in the manufacture of cement is about one ton for one ton
cement clinker. Therefore, it is considered vital to search for alternative low CO2 emission binders for concrete in order to reduce its
carbon footprint and the development of alternative binders utilizing industrial by-products is one of existing strategies.
Geopolymer is such an emerging alternative binder, which is
prepared using by-product materials such as y ash (by-product
of coal combustion in thermal power plants with an average size
of less than 20 lm and low bulk density (0.540.86 g/cm3), high
surface area (300500 m2/kg) and light texture with spherical in
shape and consist of solid spheres, cenospheres, irregular-shaped
debris and porous unburnt carbon), blast furnace slag (produced
when iron ore is reduced by coke at about 13501550 C in a blast
Corresponding author at: Faculty of Materials Science and Chemistry, China
University of Geosciences, Wuhan 430074, China.
E-mail address: dp19851128@sina.com (P. Duan).
http://dx.doi.org/10.1016/j.matdes.2015.03.009
0261-3069/Crown Copyright 2015 Published by Elsevier Ltd. All rights reserved.
126
127
Cement
Fly ash
Metakaolin
a
SiO2
Al2O3
Fe2O3
MgO
CaO
Na2O
K2O
MnO
TiO2
LOIa
21.35
29.47
53.32
7.67
51.72
42.09
3.31
2.25
2.33
3.08
0.15
0.21
62.60
5.21
0.09
0.35
0.05
0.49
0.39
0.35
0.64
0.05
0.03
0.02
0.25
1.83
0.63
0.95
8.58
0.08
LOI: mass loss of dried sample after calcined between 1000 and 1100 C.
materials mentioned above was listed in Table 1 and their micrographs were shown in Figs. 1 and 2, respectively. Alkali activator
was a combination of sodium silicate and sodium hydroxide
(99.2% NaOH) in analytical reagent degree. The liquid portions in
the mixture were 10 M sodium hydroxide (NaOH) and sodium
silicate (Na2SiO3) with 14.51% Na2O, 33.39% SiO2, and 48.53% H2O.
Portland cement (CEM I 42.5) (relative density 3100 kg/m3,
specic surface area 369.6 m2/kg) was used as binder and was
compared to geopolymer. The properties of cement were shown
in Table 2.
2.2. Test procedure
Geopolymer specimens were synthesized by alkaline-activation
of combination of uidized bed y ash and metakaolin with mass
ratios of 1.0 in alkali silicate solutions (MR = 1.6, MR means
modulus of alkaline activator). The liquid/solid (L/S) mass ratio
was kept constant and equaled to 0.4 (the liquid consists of water
in alkaline solutions and the extra water, the solid materials consists
of y ash, metakaolin or a combination of them), which depended
on an acceptable workability for each paste sample. Fresh geopolymer pastes and cement paste were cast in triplet steel cubes molds
with size of 40 40 40 mm3 and 20 20 20 mm3, respectively,
and vibrated to remove entrained air bubbles. The molds were then
sealed with polyethylene lm and set into a standard curing box in
microwave radiation environment for 5 min. After initial curing at
40 C for 1 day, the samples were released from the molds and were
subjected to further curing at 40 C for acquired ages.
128
Table 2
The properties of cement.
Compressive
strength (MPa)
Flexural
strength (MPa)
3 days
28 days
3 days
28 days
27.3
47.5
6.3
8.7
Final
setting
time (min)
132
187
129
80
70
60
50
40
30
Portland cement
20
Geopolymer
10
0
20
100
200
300
400
500
600
700
800
900 1000
Temperature (C)
Fig. 4. Compressive strength of geopolymer and OPC pastes at 28 days of curing at
various temperatures.
130
OPC
OPC
Geo
Geo
OPC
OPC
Geo
Geo
Fig. 6. Dimension evolution of OPC and geopolymer after the thermal exposure.
According to previous published paper [87], the drying shrinkage of cement paste may be due to a higher volume of mesopores,
which causes a higher capillary stress by the water meniscus
developed in the capillary pores of the paste, resulting in a higher
level of drying shrinkage [88].
3.5. Mass loss at elevated temperatures
The mass losses of the OPC and geopolymer samples due to
elevated temperature were determined from the mass change
before and after heat exposure. The average values of mass loss
after exposure to different temperatures have been plotted in
Fig. 8. An increasing trend of the mass loss in OPC up to 600 C
can be observed. However, the exact values of the mass loss in
the OPC could not be determined after 600 C because of spalling
attributed to the Ca(OH)2 decomposition that occurs at this temperature. The geopolymer specimen shows similar mass loss curves
as OPC before 500 C but with relatively lower mass loss. It can be
seen from Fig. 8 that most of the mass loss takes place at around
500 C for geopolymer. The rate of mass loss reduces and become
stable in geopolymer after this temperature while OPC continues
at a similar rate until 600 C. The mass loss of the geopolymer specimens at 1000 C is 3.39% in total compared to that at ambient
temperature.
3.6. Electron microscopy after thermal exposure
The morphological changes of OPC and geopolymer during the
thermal exposure were illustrated in the micrographs of Fig. 9.
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
Portland cement
1.0
Geopolymer
0.5
0.0
0
200
400
600
800
1000
Temperature (C)
Fig. 7. Thermal shrinkage of Portland cement and geopolymer paste with elevated
temperatures.
Fig. 8. Changes in mass loss of the OPC and geopolymer at elevated temperatures.
OPC 20C
OPC 100C
OPC 200 C
OPC 400 C
GEO 20 C
GEO 100 C
GEO 200 C
GEO 400 C
OPC 600 C
GEO 600 C
131
132
Fig. 11. Compressiver strength evolution of the geopolymer and OPC specimens
exposed to sulfuric acid (2%) plus hydrochloric acid (2%) solutions.
Fig. 10. Photographs of geopolymer and OPC before and after the acid exposures: (a) geopolymer before acid exposures; (b) geopolymer after acid exposures; (c) OPC before
acid exposures; (d) OPC after acid exposures.
133
Fig. 12. Mass change of geopolymer and cement samples in water absorption test.
Fig. 14. Change of mass in water absorption test of geopolymer and cement
samples after acid exposure.
0.09
(a)
0.08
Cement paste
0.07
Metakaolin
Geopolymer
0.06
Fly ash
Geopolymer
0.05
0.04
0.03
0.02
Fig. 13. Change of mass in water absorption test of geopolymer and cement
samples after thermal exposure.
0.00
1
10
100
1000
10000
100000
1000000
(b)
0.16
Cement paste
0.14
dV/dlogD (mL/g)
0.01
Metakaolin
Geopolymer
Fly ash
Geopolymer
0.12
0.10
0.08
0.06
0.04
0.02
0.00
1
10
100
1000
10000
100000
1000000
134
Fig. 16. The porosity and pore size distribution of geopolymer and OPC paste after
thermal exposure.
Fig. 17. The porosity and pore size distribution of geopolymer and OPC paste after
acid exposure.
The comparison among metakaolin geopolymer, y ash geopolymer and OPC paste shows that the total porosity (cumulative intrusion volume) (Fig. 15(a)) is decreasing for geopolymer pastes, and
y ash geopolymer shows a signicant change. The differential
curves of pore size distribution are almost identical between
different samples. The critical pore diameters, dened as the peaks
in the differential curves (Fig. 15(b)), giving the rate of mercury
intrusion per change in pressure (differential curves) [92], do not
show a signicant change. However, the total pore volume in OPC
is higher than that in geopolymer. It is evident that exposure of
cement to acidic solutions shifts the pore size peak to a higher value
and also leads to the development of a macropore system with pore
size exceeding 100 nm.
Unlike cement pastes which hydrate with time, the strength of
the geopolymer samples remain high after exposure to sulfuric acid
(2%) plus hydrochloric acid (2%) solutions. Geopolymer possesses a
relatively lower strength loss when compared to conventional
cement paste. This is also conrmed by MIP tests with almost identical results, which show the total porosities of the OPC samples are
signicantly higher than the porosities of the y ash and metakaolin
based geopolymer. This is also extremely true for metakaolin and y
ash geopolymer samples and OPC paste exposed to high temperature
(Fig. 16) and acid (Fig. 17). Geopolymer has a relatively lower
strength loss when compared to conventional cement paste after
thermal exposure and acid exposure. This is also conrmed by MIP
test, which shows the total porosities of the OPC samples are signicantly higher than the porosities of the y ash and metakaolin
based geopolymer. Additionally, major difference between OPC and
geopolymer can be observed due to marked strength loss of OPC after
thermal exposure and acid exposure (see Figs. 4, 5 and 11).
Based on the pore structure results by MIP, the total porosity
(cumulative intrusion volume) is lower for geopolymer pastes
compared to OPC, which means that geopolymer possesses denser
microstructure. It indicates that geopolymer could withstand outside medium ingress including water and acid, which relates to
better permeability resistance, and the result of MIP is consistent
with the water absorption and acid exposure test. It can be
concluded that alkali activated condition is optimum for better
pore structure modication.
3.11. Formation of microstructure and simulation
MIP tests have been veried from the formation of microstructure aspect, which was simulated with a numerical model. For the
simulation of the reaction processes and of the formation of the
microstructure in cement and geopolymer systems, the numerical
model HYMOSTRUC was developed [93].
In this model, the degree of hydration was simulated as a function of the particle size distribution, the chemical composition of
geopolymer materials, the water/solid ratio and the reaction temperature. In a computer digitized format of HYMOSTRUC [93], the
raw solid particles were modelled as digitized spheres randomly
distributed in a three-dimensional body and the hydrating
geopolymer grains were simulated as growing spheres.
In this model, the geopolymer particles are modelled as spheres
of different diameters. Metakaolin and y ash are not regular
spheres, and this may be the limitation of this simulation model.
However, the hydration proceeded at the particle/water interface
and the hydration products formed around the original particles
in this model are true when geopolymerization occurs.
The microstructure formation and development in geopolymer
is schematically presented in Fig. 18, which can be described via
simplied mechanisms, geopolymer samples show a homogenous
microstructure with reaction products evenly distributed in the
matrix. Some large cavities form and are seemed as isolated by
aluminosilicate gels.
135
The original initial geopolymer particles (Fig. 18(a)) are randomly distributed in a three-dimensional body. Some hydration products form at 1 h (Fig. 18(b)), 2 h (Fig. 18(c)) and 3 h (Fig. 18(d)),
136
Acknowledgements
This work was supported by the Fundamental Research Funds
for the Central Universities (CUGL150806), China University of
Geosciences, Wuhan, Public Service Project of the Chinese
Ministry of Land and Resources (201311024) and the National
Natural Science Foundation of China (NNSF-51202172).
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