Description:Field of the Invention
Present invention relates to a method of Investigating the Impact of Particle Packing Density on Geopolymer Concrete Performance and Sustainability using Life Cycle Assessment. Present invention further relates to a Multi-Pronged Approach with Particle Packing Density and Life Cycle Assessment.
Background of the Invention:
Despite of the research projects that have been reported in the past, the field of Development of Geopolymer Mortar Based on Particle Packing Density (PPD) still needs extensive and methodical research. There is a lack of research on how the packing density affects the properties of geopolymer concrete. Even though aggregates constitute major volume in geopolymer concrete, only limited study related to this parameter has been reported. So, the present study is focused on the impact of PPD on the mechanical and durability properties of Geopolymer concrete.
In the reference the author Nikhil Kumar et al., 2023 develop Specific gravity, consistency, initial and final setting times of Type-I and Type-II limes were analyzed. Particle Size Distribution Analysis: Modified Toufar Model (MTM) and J.D. Dewar (JDD) Models were used to determine proper gradation of sand. In their invention, it said that the average flow values for Type-I and Type-II Lime fly ash-based mortars were obtained as 7.1 cm and 10.4 cm for MTM particle packing sand. From the study, it can be concluded that using Type-I lime fly ash-based mortar and MTM particle packing theory, repair mortars with reasonably good strength can be achieved.
In the reference the author Cheah Chee ban et al., 2016 mention Durability properties namely water absorption, vacuum porosity and capillary absorption X-ray diffraction (XRD) and X-ray fluorescence (XRF). It said that Prolonged water curing resulted in inferior durability performance for all HCWA-PFA Geopolymer mortars.
In the reference the author Priyadharshini Perumal et al., 2022 said that Distribution modulus to be chosen based on the mix composition for maximum packing density. A record high strength of 145 MPa is achieved with ternary blend with slag, silica fume and phyllite dust. Addition of silica fume resulted in cross-linked C-A-S-H and N-A-S-(H) formation.
In the reference the author Niyazuddir, Umesh et al., 2023 describe that Higher GGBS content, binder content, and sodium hydroxide solution molarity improve strength and durability of geopolymer concrete. In the current study, a particle packing approach was used to examine the impact of the packing density of blended aggregate on standard and high-strength geopolymer concrete. GPC mix with Particle packing theory (PPT) significantly improved the compressive strength, and durability, and showed better workability compared to the GPC mix without PPT.
EP3052453B1 discloses construction materials comprising a binder containing fly ashes, ground granulated blast furnace slag and pozzolanas, an activator and aggregates, having self-placing properties and exhibiting excellent workability retention.
CN116378449A discloses a method for reinforcing a T-shaped beam by using recycled geopolymer mortar. Comprises T-shaped beams, FPR grids, an interfacial agent and regenerated polymer mortar. According to the invention, an FRP grid is stuck to a concrete beam web by using an interface agent, and polymer mortar is sprayed on the surface of the FRP grid to form a web reinforcing system. Compared with the prior art, the method fully utilizes the characteristics of simple construction, high strength, high-temperature resistance, good durability, early coagulation, contribution to crack self-healing and the like of the FRP grid, can effectively repair the T-shaped beam web cracks caused by factors such as load, environment and the like, improves the bending bearing capacity and shearing bearing capacity of the T-shaped beam, delays crack development, and increases the durability of the T-shaped beam.
CN113800829A discloses an early-strength type ultrahigh-ductility geopolymer concrete material which comprises the following components in parts by weight: 345-370 parts of alkali activator, 85-95 parts of water, 150-300 parts of micro silicon powder, 120-170 parts of fly ash, 510-700 parts of slag powder, 880-910 parts of river sand, 15-35 parts of calcium carbonate whisker, 10-20 parts of nano calcium carbonate, 15-25 parts of polyethylene chopped fiber, 0.1-0.2 part of defoaming agent and 0.15-0.25 part of aminosilane. According to the invention, a multi-scale reinforcing system consisting of polyethylene fibers, calcium carbonate whiskers and micro-nano calcium carbonate is constructed, so that the compressive strength and ductility of concrete are improved; the early strength characteristic is realized by adjusting the proportion of the slag powder, the fly ash and the micro silicon powder; meanwhile, the introduction of amino silane improves the dispersibility of calcium carbonate whiskers, micro-nano calcium carbonate and micro silicon powder, so that the geopolymer concrete achieves early strength and ultrahigh ductility.
By using industrial by-products, Geopolymer concrete significantly reduces CO2 emissions marking a sustainable construction leap with less environmental harm. The particle packing density theory boosts concrete mix workability and strength, leading to more durable structures and better material efficiency. Over their lifespan, steering the industry toward sustainable material choices, life cycle assessment emphasizes assessing materials' environmental impacts. Machine learning in mix design optimizes concrete properties prediction, achieving desired strength and durability with resource conservation.
Geopolymer concrete is revolutionizing construction with its focus on sustainability and performance. It utilizes industrial waste products instead of traditional cement, significantly reducing CO2 emissions – a major win for the environment. Particle packing theory optimizes the mix design, making the concrete easier to work with while achieving superior strength. This translates to more durable structures and less wasted material. Life cycle assessment, which considers a material's environmental impact throughout its lifespan, highlights the advantage of geopolymer concrete. It promotes sustainable choices for the construction industry. Secondly, by optimizing the mix design, it allows for precise prediction of the concrete's strength and durability, ensuring the desired outcome while conserving resources. Geopolymer concrete represents a significant leap towards a greener future for construction. It offers a combination of environmental responsibility, improved performance, and efficient resource utilization.
Summary of the Invention:
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope.
The main objective of the invention is to evaluate effect of particle packing density on various Geopolymer mortars with varying precursor, Normality and Temperature, also with modified curing conditions. To conduct durability and micro-structure development of Geopolymer mortar mixes with respect to Maximum particle packing density. The theory is design to perform life cycle assessment analysis for developing sustainable geopolymer concrete mix. And to optimizes compressive strength of geopolymer mortar using machine learning techniques.
In the present invention, Scientific theories are used to determine the ideal size distribution of raw materials for a dense and strong concrete mix. The maximum size of fine aggregate particles is limited to 1.2mm. The concentration (molarity) of the activating solution is varied (4, 8, 10, 12) to find the optimal level for desired concrete properties. The casted concrete can be cured in an oven at elevated temperature or at ambient temperature (and potentially exposed to sunlight) depending on the desired outcome. After curing, the concrete specimens are tested according to relevant standards from ASTM International (ASTM) or the Indian Standards (IS) to ensure they meet the required specifications.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
Figure 1: Geopolymer Concrete Mix Design with Particle Packing and Curing Conditions
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
Detailed description of the Invention
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Geopolymer technology has garnered significant interest in the academic and industrial communities due to its potential to address several Sustainable Development Goals (SDGs), particularly those related to environmental sustainability, climate change mitigation, and sustainable industrial processes.
In terms of publication sources, the journals Construction and Building Materials and Journal of Cleaner Production are the top preferred for geopolymer publications. In terms of keyword co-occurrence, the most used keywords are geopolymers, inorganic polymer, and geopolymer. Regarding countries’ contribution, the highest number of publications was from China, India, Australia, and the United States of America. Globally, OPC production is projected to reach 6000 million tonnes by 2060, surpassing the current 4000 million tones annually, prompting exploration of alternatives such as fly ash, GGBS, and geopolymer concrete, which offer lower carbon footprints and enhanced mechanical properties (Niyazuddin and Umesh, 2023). GPC strength enhancement (C-A-S-H, N-A-S-H) relies on various factors such as precussor type and its dosage (Swathi and Vidjeapriya, 2023), molarity activity (Shilar et al., 2022) and temperature (Albidah et al., 2022).
Geopolymer concrete is emerging as a promising alternative to traditional Portland cement concrete due to its potential for significant environmental benefits. Unlike traditional concrete, geopolymer concrete utilizes industrial byproducts as precursors, leading to a substantial reduction in CO2 emissions during production. However, the performance of geopolymer concrete is highly dependent on various factors such as the type of precursor material used, curing temperature, and the ratios of sodium (Na) to aluminum (Al) and silicon (Si) to aluminum in the activating solution. Previous research on geopolymer concrete has primarily focused on these factors. Recognizing a gap in the existing knowledge, this study delves into the application of Particle Packing Density (PPD) theory in optimizing geopolymer concrete mixes. By considering PPD, researchers aim to achieve a denser packing of particles within the concrete, potentially leading to improved workability, strength, and durability. This research also incorporates Life Cycle Assessment (LCA) to evaluate the environmental impact of geopolymer concrete throughout its entire lifespan, further strengthening the argument for its sustainability.
In present invention, the systematic methodology addresses a critical gap in current knowledge and aims to develop geopolymer concrete with enhanced mechanical and durability properties using the innovative approach of PPD theory. In modern concrete mix design, maximization of packing density by adjusting the grading of the aggregates and cementitious materials using PPD theory is done to enhance the mechanical and durability properties (Wong and kwan, 2005). In this context, very limited research has been done in the particle packing aspects of geopolymer concrete (Umesh 2023; Luo et al., 2023). This study aims to integrate PPD (Andreasen packing model) with mechanical and durability properties of GPC by varying precursor dosage and molarity.
Previous research on geopolymer concrete has not extensively explored the influence of PPD on its properties. Aggregates, which make up a significant portion of geopolymer concrete, haven't been given due consideration in optimizing PPD. The present invention aims to bridge this knowledge gap by investigating the effects of PPD on the mechanical and durability of geopolymer concrete.
Figure 1 discloses a block diagram of a method for geopolymer concrete production, the steps involved in the process are as follows:
Step 1: Material sourcing and processing: This involves selecting and preparing the raw materials for the geopolymer concrete, such as industrial byproducts, binders, and aggregates.
Step 2: Varying precursors, RSM based DOE for mix proportion, Varying curing period and temperature: This refers to optimizing the mix design of the geopolymer concrete. RSM (Response Surface Methodology) and DOE (Design of Experiments) are techniques used to identify the optimal combination of precursors (raw materials), ratios, curing conditions (time and temperature) to achieve the desired properties of the concrete.
Step 3: Optimization using ML: This step involves using machine learning algorithms to analyze the data from the casting and testing phase and optimize the mix design for future production runs.
Further, the figure also shows other parameters:
Gradation using Particle Packing Theory and MA theory: This refers to applying scientific theories to optimize the gradation (particle size distribution) of the raw materials in the concrete mix to achieve a dense packing and improve the workability and strength of the concrete.
Molarity variation (4,8,10,12): This likely refers to experimenting with different concentrations of a solution (possibly an activating solution) to determine its impact on the properties of the geopolymer concrete.
Maximum FA size kept 1.2 mm: This specifies the upper limit for the size of the fine aggregate (FA) particles used in the mix.
Curing in Oven and ambient/sunlight: This indicates that the casted concrete can be cured in an oven or at ambient temperature and/or sunlight, depending on the desired properties.
Testing as per ASTM/IS standards: This refers to testing the cured concrete specimens according to relevant standards set by ASTM International (ASTM) or the Indian Standards (IS).

Advantages of the Invention:
Denser Packing: By applying Particle Packing Density (PPD) theory, the invention achieves a denser packing of particles in the concrete mix. This leads to:
• Enhanced Workability: Denser packing allows for easier handling and pouring of the concrete.
• Increased Strength: A denser structure translates to stronger concrete, improving its ability to withstand loads.
• Boosted Durability: Denser packing can also lead to improved resistance to cracking and wear, making the concrete more durable.
This invention takes sustainability a step further by incorporating LCA. LCA evaluates the environmental impact of the concrete throughout its entire lifespan, from material sourcing to disposal. This provides a more comprehensive picture of the concrete's sustainability compared to traditional options.
The invention utilizes data from the casting and testing phase to further refine the mix design. This allows for continuous improvement and ensures the concrete meets the desired performance and sustainability goals.
These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope. , Claims:1. A method of Optimizing Geopolymer Concrete Performance through Particle Packing Density and Life Cycle Assessment comprising the steps of:
sourcing and processing Material which involves selecting and preparing the raw materials for the geopolymer concrete, such as industrial by-products, binders, and aggregates;
Varying precursors, RSM based DOE for mix proportion, Varying curing period and temperature to optimizing the mix design of the geopolymer concrete.
Optimization using Machine Learning (ML) which involves using ML algorithms to analyze the data from the casting and testing phase and optimize the mix design for future production runs;
Wherein RSM (Response Surface Methodology) and DOE (Design of Experiments) are techniques used to identify the optimal combination of precursors (raw materials), ratios, curing conditions (time and temperature) to achieve the desired properties of the concrete.
2. The method as claimed in claim 1, wherein Molarity variation (4,8,10,12) refers to experimenting with different concentrations of a solution to determine its impact on the properties of the geopolymer concrete.
3. The method as claimed in claim 1, wherein Maximum FA size is kept 1.2 mm which specifies the upper limit for the size of the fine aggregate (FA) particles used in the mix.
4. The method as claimed in claim 1, wherein the casted concrete is cured in an oven or at ambient temperature and/or sunlight, depending on the desired properties.