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INTRODUCTION
Geopolymer concrete was first introduced into VicRoads as part of trial applications in 2009, namely, the
in-situ construction of landscape retaining walls at a bridge site [1, 2, 3, 4, 5], the manufacture and
installation of 180 precast footway panels across a bridge and construction of a significant length of
footpath. Following satisfactory monitoring of the performance of these applications geopolymer concrete
was defined and incorporated into the standard VicRoads specification Section 703 General Paving
Works in 2010 [6] as an equivalent product to Portland cement concrete. This was followed by the
construction of approximately 2 km in length of footpath and bicycle path, kerb and channel, maintenance
strip for wire rope safety barriers and guard rail, a shared user path, other general paving works and nofines geopolymer concrete on major projects, achieving significant reductions in CO 2 emissions.
A 450 metre long structural reinforced geopolymer concrete retaining wall which doubles as a raised
planter bed to improve soil conditions for tree planting was constructed on the M80 Western Ring Road
[7]. This project is the first full scale structural application for VicRoads (since the original trial structural
applications of the landscape retaining walls and footway panels) and considered to be the first major insitu construction on a major infrastructure project in Australia.
This work was followed by the review of steel reinforced geopolymer concrete pipes manufactured by a
major pipe manufacturer, including the associated test data which demonstrated compliance with the
requirements of AS 4058 and standard VicRoads specification Section 701 Underground stormwater
drains [8].
As a result of the above work four standard VicRoads specifications have been amended to incorporate
provisions for the use of geopolymer concrete as follows:
Section 703 General Concrete Paving, geopolymer concrete defined and specified for use in kerb
and channel, joint user paths, footpaths, driveways and other surfacing, as an equivalent product to
conventional concrete for strength grades 20 MPa to 32 MPa
Section 701- Underground stormwater drains, geopolymer concrete for use in the manufacture of
Steel Reinforced Concrete Pipes as an equivalent product to conventional concrete pipes
Section 705 - Drainage Pits, geopolymer concrete for use in the construction of both precast and
in-situ drainage pits [9]
Section 711 - Wire Rope Safety Barriers, geopolymer concrete for use in the construction of anchor
blocks, post footings, maintenance strips and other associated concrete works [10].
At this stage use of geopolymer concrete in lower risk structural applications with respect to the
requirements of Section 610 Structural Concrete [11] may be considered on a job by job basis.
SALMON STREET BRIDGE OVER THE WEST GATE FREEWAYPRECAST GEOPOLYMER CONCRETE PANELS
A total of 180 precast footway units based on a required equivalence to a concrete grade of VR470/55 as
set out in Section 610 were manufactured and installed at the Salmon Street Bridge in 2009 [12] (Fig. 1).
The full scale production and installation of the 180 units was completed within the same timeframe as
achieved by conventional type concrete.
Figure 1: Geopolymer concrete footway panels and footpath on Salmon Street Bridge.
The in-service performance of the precast footway geopolymer panels has been visually monitored for
over 5 years since installation. In general the precast geopolymer panels are performing satisfactorily with
the surface finish looking good. The concrete colour as expected has changed to a light grey colour
(resembling an off-white colour) given the fact that the slag component within the concrete mix would
change colour from green following mixing and placement as a result of exposure to the environment. Its
off-white colour is blending more with the rest of the bridge and its surrounding environment.
However, out of a total of 180 units some eight of them were characterised by minor cracking of less than
0.15 mm. It is considered that this cracking would have been there since manufacture and installation
rather than in-service. Previous monitoring over the past five years identified the same cracking with no
noticeable change or increase in the length or width of cracking detected. Structurally the precast
footway geopolymer panels are considered to be performing very satisfactory without an evidence of
distress.
Figure 2: Finished painted geopolymer concrete wall and installed reference electrodes.
Figure 3: Half-cell potentials of retaining walls of western abutment of Swan Street Bridge.
Figure 5: No-fines geopolymer concrete used as a granular back fill filter material.
Figure 6: Landscape retaining geopolymer structural concrete wall and footway deck planks.
High compaction
Following the satisfactory testing and assessment and review of actual products, geopolymer concrete
pipes have been introduced into Section 701 as equivalent products to conventional cement based pipes.
Table 1: Proof and Ultimate Load
Pipe Type
First
crack
kN/m
Proof
Load
kN/m
Geopolymer Pipes
65
85
AS/NZS4058
Min. Proof
Requirement
kN/m
Ultimate
Load
kN/m
125
30 - 50
Conventional Pipes
55
AS/NZS4058
Minimum Ultimate
Requirement
kN/m
45 - 80
80
120
Average
Absorption %
AS/NZS4058
Max Allowable %
VPV
%
Geopolymer
5.5 5.8
15.0 15.5
15
rounded down
Conventional
5.0 5.5
11.5 12.5
15
rounded down
As a result of the acceptable test results a range of diameters and classes ranging from 375 mm to 750
mm of geopolymer concrete pipes were subsequently supplied and installed at the Princess Highway
Duplication at Winchelsea in south western Victoria (Fig. 8), in accordance with the requirements of
Section 701. The VicRoads acceptance of geopolymer pipes has also resulted in other installations
including drainage works in Harley Street, City of Greater Bendigo and Bendigo Airport in Victoria.
Figure 10: Building constructed with precast geopolymer concrete and general paving.
Geopolymer concrete has been introduced into Section 703 on the basis that Portland cement concrete
and geopolymer binder concrete are equivalent products. This was the first specification with geopolymer
concrete provisions. In order to facilitate the compliant use of this type of concrete a number of
definitions relating to the material components have been introduced as follows:
Alkaline Component: Combinations of alkali and alkali earth containing salts, minerals and glasses
Cementitious Material: Portland cement or a mixture of Portland cement with one or more of Fly
Ash, Ground Granulated Blast Furnace Slag (GGBF Slag), or Amorphous Silica complying with the
requirements of AS 3582.1, AS 3582.2 and AS 3582.3 respectively
Geopolymer Binder: Binder containing greater than 80% Fly Ash, Ground Granulated Blast Furnace
Slag (GGBF Slag) or Amorphous Silica complying with the requirements of AS 3582.1, AS 3582.2
and AS 3582.3 respectively, metakaolin and up to 20% alkaline components
Geopolymer Concrete: Concrete which comprises geopolymer binder, aggregates, water and
admixtures.
The minimum compressive strength requirements for each grade of geopolymer binder concrete are
consistent with normal class Portland cement concrete and they cover 20 MPa, 25 MPa and 32 MPa.
The general construction requirements including the placing, compaction, finishing, curing and sampling
and testing of geopolymer concrete is the same as conventional concrete. However, due to the greater
susceptibility of geopolymer concrete to unsatisfactory practices compared to conventional concrete, the
general manufacturing and delivery practices for geopolymer concrete as stated in Section 703 are more
in line with the more stringent requirements of Section 610.
Precast Reinforced Concrete Pipes: pipes manufactured from Portland cement-based concrete or
geopolymer binder-based concrete as specified in Section 703. In the context of the manufacture of
reinforced concrete pipes, Portland cement concrete and geopolymer binder concrete are equivalent
products.
Geopolymer binder-based precast reinforced concrete pipes are required to comply with the requirements
of AS 4058 and Section 701, except that the concrete used must comply with the requirements of
Section 703 for geopolymer concrete with compressive strengths appropriate to the nominated load class
performance requirements as stated in AS 4058.
Drainage pits reinforced with steel reinforcement minimum concrete grade VR330/32
Precast drainage pits using fibre reinforcement minimum concrete grade VR450/50.
Concrete mix designs must be registered in accordance with the requirements of Section 610, and reregistered on an annual basis, unless mix components change prior to the expiry of registration.
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Shayan, Xu and Andrews-Phaedonos conclude that the implication of this finding is that correct amounts
of sodium silicate activator should be used in geopolymer concrete formulations such that free alkali is not
available to cause AAR in the presence of reactive aggregate. Also, compatible superplasticisers should
be used for better workability and to reduce the amount of water in the mix, which would result in
acceptable values of VPV.
SUMMARY
A significant amount of chemical and technical research has taken place into geopolymer concrete both
locally and overseas, as part of a desire to take advantage of its sustainability credentials including low
embodied carbon. It is considered that the initial VicRoads trials some five years ago of both lower risk
structural and general paving applications have served as the major impetus for significant progress in
the commercialisation of geopolymer concrete both in Victoria and other parts of Australia. As a result of
this initial work geopolymer concrete has been used in other lower risk structural applications such as
retaining walls, precast reinforced soil panels, precast building panels, concrete pipes, precast reinforced
concrete beams, footings and slabs, footpaths, joint user paths, kerb and channel, no-fines concrete and
other general paving applications.
This progress has been greatly aided by the provision for geopolymer concrete as an equivalent product
to conventional concrete in the VicRoads standard specification Section 703 for general concrete paving
in 2010, followed by its introduction into Section 701 for reinforced concrete pipes, Section 705 for
drainage pits and Section 711 for concrete works associated with wire rope safety barriers. In addition,
use of geopolymer concrete in lower risk structural applications may be considered on a job by job basis
with respect to the requirements of Section 610 for structural concrete.
As a result of these geopolymer concrete specification initiatives another Victorian state owned
enterprise, VicTrack Access, has allowed the use of 32 MPa geopolymer concrete for the construction of
protection post and marker post footings in their specification TS-SP-013 Issue 3G with reference to
Section 703.
It is considered that the definition and provision of geopolymer concrete in VicRoads standard
specifications serves to overcome the barriers created by the unfamiliarity of this new material and the
entrenched use of conventional concrete over the decades. It further provides the confidence and
pathway required by designers, contractors and asset owners and managers to specify and use low
carbon geopolymer concrete.
ACKNOWLEDGEMENT
The author wishes to thank VicRoads for permission to publish this paper. The views expressed in this
paper are those of the author and do not necessarily reflect the views of VicRoads.
REFERENCES
1. Andrews-Phaedonos, F. 2011. Geopolymer green concrete: reducing the carbon footprint. The
VicRoads experience. 8th Austroads Bridge Conference, Sydney, NSW, Australia, October 2011.
2. Andrews-Phaedonos, A. (2012), Reducing the carbon footprint The VicRoads experience,
Concrete in Australia, Vol.38, No.1, pp.40-48.
3. Shayan, A, Xu, A & Andrews-Phaedonos, F. (2013), Field application of geopolymer concrete: a
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measure towards reducing carbon dioxide emission 26 Biennial Conference, Concrete Institute of
Australia, October, Gold Coast, Australia.
4. Shayan, A, Xu, A & Andrews-Phaedonos, F. (2014), Investigation of a geopolymer concrete used in
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retaining walls of a bridge, 36 ICMA Conference, Milan, Italy.
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5. Shayan, A and Xu, A, ARRB Group (2014), Monitoring Measurements of geopolymer concrete,
Swan Street Bridge 2013- 2014, Contract Report No. 007919
6. VicRoads Standard Specification (2013), Section 703 General concrete paving.
7. Structural reinforced concrete landscape retaining wall M80 Western Ring Road, Sunshine Ave to
Furlong Road (2013), VicRoads Intranet and Exchange.
8. VicRoads Standard Specification (2013), Section 701 Underground stormwater drains.
9. VicRoads Standard Specification (2013), Section 705 Drainage pits.
10. VicRoads Standard Specification (2013), Section 711 Wire Rope Safety Barrier.
11. VicRoads Standard Specification (2013), Section 610 Structural Concrete.
12. Andrews-Phaedonos, F. "Monitoring of Salmon Street Bridge Precast Geopolymer Concrete Footway
Panels", VicRoads Internal Report, 2013
13. Andrews-Phaedonos, F. Shayan, A, Xu, A. (2013), Use of Corrosion Monitoring Sensors to Monitor
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the In-Situ Performance and Intervention needs in Reinforced Concrete Structures 26 Biennial
Conference, Concrete Institute of Australia, October, Gold Coast, Australia.
14. Communication with RCPA Pty Ltd.
15. Communication with Zeobond Pty Ltd.
16. Communication with ACM Pty Ltd.
17. Aldred, J & Day, J. (2012), Is geopolymer concrete a suitable alternative to traditional concrete?,
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37 Conference on Our World in Concrete & Structures, August, Singapore
18. Wallah, S.E. (2010) Creep Behaviour of Fly Ash-Based Geopolymer Concrete/Civil Engineering
Dimension (CED), Vol. 12, No. 2, September, pp. 7378.
AUTHOR BIOGRAPHY
Fred Andrews-Phaedonos is the Principal Engineer-Concrete Technology at VicRoads and is a Past
President of the Concrete Institute of Australia. He is also the Chairman of the Australian Technical
Infrastructure Committee (ATIC). He has worked for VicRoads for 37 years, mainly in the bridge and
concrete related areas. He has been a technical specialist for many years in the areas of concrete
technology, concrete durability, precast, repair, rehabilitation and protection of concrete structures and
Lead Auditor in all aspects of construction. He has a great interest in emerging and innovation
technologies. He is an active member of several Standards Australia, AUSTROADS, ACI and FIB
technical committees and has been involved in the organising of international conferences. He served as
Chairman of the Technical Committee for the Concrete Institute of Australia Conference, Concrete
2005.He is the author and co-author of many published papers.
Copyright Licence Agreement
The Author allows ARRB Group Ltd to publish the work/s submitted for the 9th Austroads Bridge Conference, granting ARRB the
non-exclusive right to:
publish the work in printed format
publish the work in electronic format
publish the work online.
The Author retains the right to use their work, illustrations (line art, photographs, figures, plates) and research data in their own
future works
The Author warrants that they are entitled to deal with the Intellectual Property Rights in the works submitted, including clearing all
third party intellectual property rights and obtaining formal permission from their respective institutions or employers before
submission, where necessary.
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