Development and performance of class F fly ash based geopolymer concretes against sulphuric acid attack

摘要

Geopolymer concretes synthesised from composite class F fly ashes and a mixed alkaline activator were optimised by use of Taguchi orthogonal design method. The optimised mix achieved a compressive strength at the age of 28 days of 70 and 58 MPa after initial curing at 70°C for 12 hours and at 23°C for 24 hours, respectively. The resultant Geopolymer has an amorphous aluminosilicate structure. Efflorescence and the potential risk of alkali-silica reaction for the Geopolymer used in this study are both very low.The research confirmed that the Geopolymer concrete developed in this study is far superior to Portland cement concrete when exposed in a sulphuric acid environment. The standard immersion tests finally selected for this research were in 10% sulphuric acid for 56 days and in 1% sulphuric acid for one year. Geopolymer concrete samples retained their shape without softening though they experienced a mass loss of about 5% and a strength loss of some 30%. Portland cement concrete recorded a mass loss of some 40% in a 10% sulphuric acid for 28 days.The penetration rate of sulphuric acid into the Geopolymer concrete was found to approximately follow Fick’s first law of diffusion and a linear relationship between the neutralisation depth and the square root of immersion time (in day) was established.The degradation processes of Geopolymer concrete in sulphuric acid environments were intensively studied. The first stage involved the preferential liberation of alkali ions. The tetrahedral aluminium in the Si-O-Al configuration was removed and converted to octahedral aluminium. Consequently, the original units of Si(1Al) degraded to a silica polymorph structure in the corroded Geopolymer, which continued to serve a cementitious role. In contrast, in the case of Portland cement concrete, the acid solution dissolved the hydration products of the cement paste. The residual reaction products were found to be soft and have no structural strength. Geopolymers with alkaline activators of mixed sodium hydroxide and sodium silicate did not exhibit any cracking problems. Class F fly ash with low calcium content was found to be suitable for developing a Geopolymer binder able to withstand sulphuric acid attack.