Geopolymers as Sustainable Surface Concrete Repair Materials

221 Pages·2022·17.278 MB·English

by  Ghasan Fahim Huseien, Abdul Rahman Mohd Sam, Mahmood Md. Tahir

Geopolymers as
Sustainable Surface
Concrete Repair Materials
The progressive deterioration of concrete surface structures is a major concern in
construction engineering that requires precise repairing. While a number of repair
materials have been developed, geopolymer mortars have been identified as poten-
tially superior and environmentally friendly high-performance construction mate-
rials, as they are synthesized by selectively combining waste materials containing
alumina and silica compounds which are further activated by a strong alkaline solu-
tion. Geopolymers as Sustainable Surface Concrete Repair Materials offers readers
insights into the synthesis, properties, benefits and applications of geopolymer-based
materials for concrete repair.
• Discusses manufacturing and design methods of geopolymer-based
materials
• Assesses mechanical strength and durability of geopolymer-based materials
under different aggressive environmental conditions
• Characterizes the microstructure of these materials using XRD, SEM,
EDX, TGA, DTG and FTIR measurements
• Describes application of geopolymer-based materials as surface repair
materials
• Compares environmental and cost benefits against those of traditional OPC
and commercial repair materials
This book is written for researchers and professional engineers working with con-
crete materials, including civil and materials engineers.
Emerging Materials and Technologies
Series Editor
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and Applications
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Geopolymers as Sustainable Surface Concrete Repair Materials
Ghasan Fahim Huseien, Abdul Rahman Mohd Sam, and Mahmood Md. Tahir
Nanomaterials in Manufacturing Processes
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For more information about this series, please visit: https://www.routledge.com/
Emerging-Materials-and-Technologies/book-series/CRCEMT
Geopolymers as
Sustainable Surface
Concrete Repair Materials
Ghasan Fahim Huseien, Abdul Rahman Mohd Sam,
and Mahmood Md. Tahir
First edition published 2023
by CRC Press
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ISBN: 978-1-032-00299-6 (hbk)
ISBN: 978-1-032-00305-4 (pbk)
ISBN: 978-1-003-17361-8 (ebk)
DOI: 10.1201/9781003173618
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Contents
Preface.......................................................................................................................ix
About the Authors .....................................................................................................xi
Chapter 1 Concrete Durability and Surface Deterioration ...................................1
1.1 Introduction ...............................................................................1
1.2 Concrete Durability ...................................................................2
1.3 Concrete Surface Deteriorations ...............................................3
1.4 Causes of Concrete Degradation ...............................................3
1.5 Existing Surface Repair Materials ............................................4
1.6 Waste Materials–Based High-Performance Geopolymers........6
1.7 Summary ...................................................................................7
References ............................................................................................7
Chapter 2 Geopolymer as Emerging Repair Materials .......................................11
2.1 Introduction .............................................................................11
2.2 Geopolymer Mortar .................................................................13
2.3 Geopolymer Mortar as Repair Materials ................................15
2.4 Geopolymer Performance........................................................16
2.5 Durability and Sustainability ..................................................20
2.6 Economic Feasibility ...............................................................21
2.7 Environment Suitability and Safety Features ..........................22
2.8 Merits and Demerits of Geopolymer as Repair Material ........23
2.9 Summary .................................................................................23
References ..........................................................................................24
Chapter 3 Manufacturing Geopolymer: Materials and Mix Design ..................31
3.1 Introduction .............................................................................31
3.2 Fly Ash-Based Geopolymer Binder ........................................32
3.2.1 Effect of FA on Workability and Strength
Properties ...................................................................32
3.2.2 Effect of FA on Durability of Geopolymer ................33
3.3 Palm Oil Fuel Ash ...................................................................33
3.3.1 Effect of POFA on Workability and Strength
Properties ...................................................................34
3.3.2 Effect of POFA on Durability of Geopolymer ...........35
3.4 Ground Blast Furnace Slag ......................................................35
3.4.1 Effect of GBFS on Workability and Strength
Properties ...................................................................35
3.4.2 Effect of GBFS on Durability of Geopolymer ...........36
v
vi Contents
3.5 Ceramic Wastes .......................................................................37
3.5.1 Effect of Ceramic Wastes on Workability and
Strength Properties .....................................................37
3.5.2 Effect of Ceramic Waste on Durability of
Geopolymer ................................................................38
3.6 Alkaline Activator Solutions ...................................................38
3.6.1 Workability and Strength Performance ......................39
3.6.2 Effect of Solution on Durability of
Geopolymer ................................................................41
3.7 Characteristics of Various Geopolymers .................................42
3.8 Geopolymer Mix Design .........................................................42
3.9 Summary .................................................................................44
References ..........................................................................................44
Chapter 4 Factors Effect on the Manufacturing of Geopolymer ........................51
4.1 Introduction .............................................................................51
4.2 Fresh Properties of Geopolymer .............................................52
4.3 Compressive Strength ..............................................................54
4.3.1 Effect of Calcium Content ..........................................54
4.3.2 Effect of Alkaline Solution Characterization .............56
4.3.3 Effect of Aggregate-to-Binder Ratio ..........................58
4.3.4 Effect H O:Na O Ratio...............................................58
2 2
4.3.5 SiO :Na O Ratio Effect ..............................................59
2 2
4.4 Bond Strength ..........................................................................59
4.4.1 Effect Calcium Content ..............................................59
4.4.2 Effect of Alkaline Activator Solution ........................61
4.4.3 Effect of Silicate-to-Aluminium Ratio .......................62
4.4.4 Effect of Solid-to-Liquid Ratio ..................................62
4.4.5 Effect of Curing Humidity .........................................63
4.4.6 Effect of SiO :K O Ratio ............................................63
2 2
4.4.7 Bond Strength at Elevated Temperatures ...................64
4.5 Flexural Strength .....................................................................64
4.6 Drying Shrinkage ....................................................................65
4.7 Abrasion–Erosion Resistance ..................................................67
4.8 Microstructures .......................................................................68
4.9 Failure Mode and Interface Zone ............................................71
4.10 Summary .................................................................................72
References ..........................................................................................73
Chapter 5 Performance Criteria of Geopolymer as Repair Materials ................77
5.1 Introduction .............................................................................77
5.2 Geopolymer Binder .................................................................78
5.3 Geopolymer Mix Design .........................................................81
5.4 Workability Performance ........................................................83
Contents vii
5.5 Compressive Strength Performance ........................................87
5.6 Splitting Tensile Strength ........................................................89
5.7 Flexural Strength .....................................................................90
5.8 Bond Strength Performance ....................................................91
5.9 Summary .................................................................................92
References ..........................................................................................93
Chapter 6 Compatibility of Geopolymer for Concrete Surface Repair ..............97
6.1 Introduction .............................................................................97
6.2 Geopolymer Preparation .........................................................99
6.3 Workability of Fresh GPMs ...................................................102
6.4 Strength Performance ............................................................104
6.5 Slant Shear Bonding Strength ...............................................110
6.6 Thermal Expansion Coefficient .............................................111
6.7 Third-Point Loading Flexural ...............................................113
6.8 Bending Stress .......................................................................116
6.9 Summary ...............................................................................117
References ........................................................................................118
Chapter 7 Effects of Aggressive Environments on Geopolymer
Performance as Repair Materials .....................................................123
7.1 Introduction ...........................................................................123
7.2 Geopolymer Ternary Blended ...............................................125
7.3 Procedures of Geopolymer Tests ...........................................129
7.4 Compressive Strength Performance ......................................130
7.5 Bond Strength of Geopolymer ...............................................132
7.6 Effect of Sulphuric Acid Attack ............................................134
7.7 Geopolymer Resistance to Sulphate Attacks .........................138
7.8 Effect of Elevated Temperatures ...........................................141
7.9 Summary ...............................................................................143
References ........................................................................................145
Chapter 8 Performance Evaluation of Geopolymer as Repair Materials
Under Freeze–Thaw Cycles ..............................................................149
8.1 Introduction ...........................................................................149
8.2 Mix Design ............................................................................151
8.3 Porosity ..................................................................................152
8.4 Surface Abrasion Resistance .................................................154
8.5 Freezing–Thawing Cycle Resistance .....................................155
8.6 Drying Shrinkage ..................................................................160
8.7 Wet–Dry Cycle Resistance ....................................................161
8.8 Summary ...............................................................................163
References ........................................................................................164
viii Contents
Chapter 9 Methods of Evaluating the Geopolymer Efficiency as
Alternative Concrete Surface Repair Materials Compared to
Commercials Products .....................................................................167
9.1 Introduction ...........................................................................167
9.2 Causes of Concrete Surface Degradation ..............................169
9.3 Commercial Repair Materials ...............................................170
9.3.1 Cement- Based Materials ..........................................171
9.3.2 Polymer- Modified Cement- Based Materials ............172
9.3.3 Epoxy-B ased Materials ............................................172
9.4 Selection of Repair Materials ................................................173
9.5 Development of Geopolymer as Repair Materials ................173
9.6 Efficiency Evaluation of Geopolymer as Repair Materials ...175
9.7 Summary ...............................................................................176
References ........................................................................................178
Chapter 10 Sustainability of Geopolymer as Repair Materials ..........................179
10.1 Introduction ...........................................................................179
10.2 Geopolymer Preparation .......................................................181
10.3 Strength Performance ............................................................183
10.4 Life Cycle Assessment ...........................................................187
10.5 Modified LCA with Respect to CS and Durability ...............193
10.6 ANN for Estimating CO Emission and EE ..........................195
2
10.6.1 Rationale ...................................................................195
10.6.2 Cuckoo Optimization Algorithm .............................195
10.6.3 Generation of Training and Testing Data Sets .........196
10.6.4 Model Predictions and Results .................................199
10.7 Summary ...............................................................................202
References ........................................................................................203
Index ......................................................................................................................207
Preface
Geopolymers as Sustainable Surface Concrete Repair Materials is the first edi-
tion of the book comprising 10 chapters under the series Emerging Materials and
Technologies. Each of these chapters discusses one of the applications of geopoly-
mer binder as a surface concrete repair material in the concrete industry. Utilization
of geopolymers as repair materials in the concrete industry not only improves the
engineering properties but it was also found to help reduce landfill and environment
problems and achieve the sustainability goals.
The first chapter deals with the general introduction on concrete durability, dete-
rioration cases and performance in aggressive environments. Industrial and agricul-
ture waste–based geopolymer binder and the effect of chemical, physical and mineral
raw materials on geopolymerization process are widely discussed in Chapter 2. In
Chapter 3, we review the factors’ effect on geopolymer mix design such as alka-
line activator solution molarity and modulus, binder and filler contents, water-to-
binder ratio and curing regime. The performance criteria, compatibility between
geopolymer and concrete substrate, resistance to sulphuric acid and sulphate attacks,
and wet–dry and thaw–freeze cycles are presented in Chapters 4–8. Topics regard-
ing environmental and sustainable benefits and future utilization are presented in
Chapters 9 and 10.
The utilization of waste-based geopolymer binders in sustainable surface con-
crete repair materials production and construction industry whose growth knows no
boundaries has been studied. Mounting evidence of worldwide interest suffices the
need to produce a collective anthology of a wide variety of sustainable repair materi-
als for current and future applications.
Ghasan Fahim Huseien
Abdul Rahman Mohd Sam
Mahmood Md. Tahir
ix