GEO POLYMER CONCRETE
[EIRI/EDPR/4576] J.C.: 2793XL
INTRODUCTION
Geo polymer concrete is an innovative, eco-friendly construction material.
It is used as replacement of cement concrete.
In geo polymer concrete cement is not used as a binding material.
Fly ash, silica-fume, or GGBS, along with alkali solution are used as binders.
IS THERE A WAY TO USE OPC WITHOUT ENVIRONMENTAL IMPACT?
Replacing some limestone with fly ash and blast furnace slag called as blended cement
Using carbon dioxide emission captures and storage (CCS)
Accelerated carbonation where CO2 penetrate concrete reacting with Ca(OH)2 in presence of H2O forming CaCO3
COST ESTIMATION
Plant Capacity 200 m3/Day
Land & Building (4000 sq.mt.) Rs. 1.23 Cr
Plant & Machinery Rs. 60 Lac
Working Capital for 1 Month Rs. 2.55 Cr
Total Capital Investment Rs. 4.50 Cr
Rate of Return 25%
Break Even Point 54%
CONTENTS
INTRODUCTION
IS THERE A WAY TO USE OPC WITHOUT ENVIRONMENTAL IMPACT?
WHY GEOPOLYMER CONCRETE?
CONSTITUENTS OF GEO POLYMER CONSCRETE
SODIUM HYDROXIDE
POTASSIUM HYDROXIDE
SODIUM SILICATE (WATER GLASS) -AVAILABLE IN GEL FORM
FLY ASH
TABLE1: CHEMICAL COMPOSITION OF FLY ASH
GGBS
TABLE 2-CHEMICAL COMPOSITION OF GGBS
SILICA FUME
TYPES OF GEO POLYMER
SLAG BASED GEO POLYMER
ROCK BASED GEO POLYMER
FLY ASH BASED GEO POLYMER
FERRO-SILICATE BASED GEO POLYMER
ADVANTAGES OF GEO POLYMER CONCRETE
FIG: ADVANTAGES OF GEOPOLYMER CONCRETE
APPLICATIONS OF GEO POLYMER CONCRETE
FORMULATION OF GEOPOLYMER CONCRETE
MANUFACTURING FLY ASH BASED GEO POLYMER CONCRETE
PREPARATION ALKALINE SOLUTION1 FOR GEO POLYMER:
MIXING PROCEDURE FOR GEO POLYMER CONCRETE:
TEST OF FLY ASH BASED GEO POLYMER CONCRETE:
SLUMP TEST:
COMPRESSIVE STRENGTH TEST:
SPLITTING TENSILE STRENGTH TEST:
PROCESSING DETAILS OF GEO POLYMER CONCRETE
ALKALINE ACTIVATOR SOLUTION
MIX DESIGN
FIG: PRODUCTION OF GEOPOLYMER CONCRETE
GEO POLYMERISATION
FIG: CONCEPTUAL MODEL OF GEOPOLYMERISATION
TEST ON GEO POLYMER CONCRETE
CREEP TEST
DRYING SHRINKAGE TEST
MODULUS OF ELASTICITY AND POISSON’S RATIO
PROPERTIES
WORKABILITY
COMPRESSIVE STRENGTH
RESISTANCE AGAINST AGGRESSIVE ENVIRONMENT
BEHAVIOUR OF GEOPOLYMER AT ELEVATED TEMPERATURE
BOND STRENGTH
DIFFERENT PARAMETERS OF GEO POLYMERISATION
FINENESS OF FLY ASH
TEMPERATURE IMPOSED TO ACTIVATOR
MOLARITY
CURING
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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