Optimization of local modified metakaolin-based geopolymer concrete by Taguchi method

Geopolymer in recent concrete (GP) has gained significant attention due to its sustainability and environmental friendliness. Local metakaolin-based geopolymer is weaker than geopolymers made from other materials due to its low Si/Al ratio. A consistent mixture design is also lacking because geopolymers are affected by many variables. This study presents a method to find the optimal geopolymer mixture based on locally modified metakaolin as a source of aluminates and silicates using the Taguchi method. Metakaolin was modified using different contents of materials rich in silica, such as silica fume (SF), or materials rich in calcium, such as calcium oxide (CaO) of 5, 10, and 15%. The inclusion of 5% SF, 10% CaO, and a combination of 5% SF and 5% CaO as substitutes for metakaolin increases the compressive strength by 16.8, 6.9, and 22.8%, respectively, compared to the reference mixture without any modifications. In other words, adding 5% SF and CaO increased the molar ratio of SiO2/Al2O3 (R) from 1.782 to 1.914, resulting in the highest compressive strength of 53.3 MPa after 7 days of sun curing. To obtain the optimal mixture that achieves the highest compressive strength, the impact of three main variables, including the concentration of sodium hydroxide (SH), alkali solution-to-binder (Al/B) ratio, and sodium silicate-to-sodium hydroxide (SS/SH) ratio, must be considered using Taguchi method. A total of nine mixtures were investigated. It was found that 13 M of SH, 0.65 Al/B, and 2.5 SS/SH give a high compressive strength of 58.6 MPa at 7 days. Also, it was found that the concentration of SH plays a more important role in increasing the compressive strength than the alkali-to-binder ratio and SS/SH ratio. The scanning electron microscopy images show that the 5% weight replacement of metakaolin by silica and CaO could source fewer and smaller pores and reduce the microcracks' width.