WO2016030904A1 - A process for geopolymer concrete making with curing at ambient temperature and without using sodium hydroxide - Google Patents
A process for geopolymer concrete making with curing at ambient temperature and without using sodium hydroxide Download PDFInfo
- Publication number
- WO2016030904A1 WO2016030904A1 PCT/IN2014/000543 IN2014000543W WO2016030904A1 WO 2016030904 A1 WO2016030904 A1 WO 2016030904A1 IN 2014000543 W IN2014000543 W IN 2014000543W WO 2016030904 A1 WO2016030904 A1 WO 2016030904A1
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- aluminum oxide
- geopolymer
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00215—Mortar or concrete mixtures defined by their oxide composition
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- the present invention relates to geopolymer based concrete and to methods of , casting geopolymer based concrete to form precast products such as bricks, paver blocks, wall panels, rooftop slabs and the like at room temperature.
- Geopolymers consist of polymer network of silicon and aluminium atoms bonded via oxygen. The reactions of dissolution and polycondensations between an
- aluminosilicate binder and an alkaline silicate are the normal methods of preparation of geopolymers.
- the alkaline silicate may usually contain metal hydroxide and alkali metal silicate.
- Geopolymer concrete will exhibit greater acid ,fire, and heat resistance compared to Ordinary Portland cement. This type of geopolymer concrete will find application in a variety of precast applications .
- Geopolymer concrete gains high early strength rapidly after casting compared to ordinary
- Geopolymerisation process is generally accelerated than at ambient temperatures.
- Geopolymerization process will also be influenced by the alkalinity of activating solution and properties of the calcium sources
- the present invention reveals method of making geopolymer concrete making at ambient temperature without using heat or steam for curing and also not using metal hydroxide in the alkali activator but using Aluminum oxide containing sources and other contents include fly ash, GGBS, sodium silicate, fine and coarse aggregates. 4.DESCRIPTION (Description shall start from next stage.) :
- geopolymer concrete may be used in preparing precast products other consolidated moulded products by using a geopolymer concrete .
- Sodium silicate with The Si0 2 /Na 2 0 mass ratio in the range of 1.8 to 2.4 is used and no metal hydroxide is used but instead Aluminum oxide is used to form the Geopolymer concrete..
- a method of forming a geopolymer concrete forming with curing at room temperature comprising: forming a geopolymer concrete composition comprising sodium silicate, Aluminum oxide source materials with aluminum oxide 0 to 15% and preferably 0.2 to 5 % and most preferably 0.5 to 2.5%. ,Fly ash (Class F), granulated blast furnace slag (GGBS), aggregates and water. GGBS has been found useful in achieving room temperature curing of the geopolymer concrete
- Fine aggregates, aggregates, fly ash, GGBS, Aluminum Oxide, are mixed in the same sequence.
- Required water and sodium silicate are to be mixed separately and added to the above mix and mixed for uniformity.
- the setting times observed maximum to about 120minutes.
- Mixing time required will be about 5 to 8 minutes
- Aluminum oxide source materials have been used without using metal hydroxide in the geopolymer concrete making.
- the source materials can be pure aluminum oxide or bauxite mineral or any other Aluminum oxide containing material with a minimum A1 2 0 3 content of 35%.
- Aluminum oxide has been found to accelerate the setting of the geopolymer concrete even without any sodium hydroxide in the mix.
- the required quantity of active Aluminum oxide content in the geopolymer mix has been found to be 0 to 15% , preferably 0.2 to 5% and more preferably 0.5 to 2.5%
- Granulated blast furnace slag in the mix has been found to set the geopolymer mix without the need for heating chambers or steam curing for all the products tried including bricks, paver blocks, wall panels with the geopolymer concrete described in this invention, and GGBS used will be 5 to 45% by weight, preferably 10 to 30% and more preferably 15 to 18%.
- Class F fly ash has been found to be suitable for the geopolymer concrete.
- Example 1 The following composition has been is used to cast bricks, blocks, pavers, wall panels.
- Sodium silicate used is with solids 45% and Si0 2 /Na 2 0 weight ratio as 2.00.
- Fly ash used is class F grade.
- Aluminum oxide used is pure Aluminum oxide industrial grade . Water added given does not include water in the sodium silicate. Has a maximum setting time of 2hours. The precast products can be demoulded after 2hours.
- Example 2 All the ingredients in example 1 are the same except Aluminum oxide. Bauxite mineral with Aluminum oxide content of 49% was used. The composition is given in table 2. Table 2.
- the present invention applicable and useful to the precast geopolymer concrete industry for casting various products including pavers, blocks, wall panels, beams, columns and the like.
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- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Engineering & Computer Science (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Environmental & Geological Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
A method of forming geopolymer precast product comprising: forming a geopolymer concrete composition comprising an alkali metal silicate component, Aluminum oxide containing source materials, granulated blast furnace slag, fly ash (grade F), fine and course aggregates, water; and casting the geopolymer concrete into a mold and subjecting the molded concrete to consolidation using a suitable vibration table with curing at at room temperature.
Description
3. PREAMBLE TO THE DESCRIPTION: COMPLETE
Technical Field; The present invention relates to geopolymer based concrete and to methods of , casting geopolymer based concrete to form precast products such as bricks, paver blocks, wall panels, rooftop slabs and the like at room temperature.
Background Art; Geopolymers consist of polymer network of silicon and aluminium atoms bonded via oxygen.. The reactions of dissolution and polycondensations between an
aluminosilicate binder and an alkaline silicate are the normal methods of preparation of geopolymers. The alkaline silicate may usually contain metal hydroxide and alkali metal silicate.
Geopolymer concrete will exhibit greater acid ,fire, and heat resistance compared to Ordinary Portland cement. This type of geopolymer concrete will find application in a variety of precast applications .
Normally heat curing or steam curing of the geopolymer concrete at higher temperatures and using metal hydroxide based the alkali activator
Geopolymer concrete gains high early strength rapidly after casting compared to ordinary
Portland cement as recognized by Davidovits et al in US pat No: 4,509,985 .
At higher temperatures the geopolyemerisation process is generally accelerated than at ambient temperatures. Geopolymerization process will also be influenced by the alkalinity of activating solution and properties of the calcium sources
Sarker, Prabir and Nath, Pradip in their paper titled . "Geopolymer concrete for ambient curing condition". (Presented at Australian Structural Engineering Conference 2012 (ASEC 2012) , Jul 11 - 13 2012. Perth , Western Australia.) studied the production of geopolymer concrete at ambient curing temperatures using low-calcium fly ash, granulated blast furnace slag (GGBS), alkaline activator and others- Occupational Health and Safety hazards are possible if liquid alkali activators are used and also possible environmental hazards if they leak while handling. Thus for safe production of Geopolymer concrete there is a need for a safe activator without using sodium hydroxide.
So far only one solid activator without using Sodium hydroxide and involving sodium carbonate was reported in WO2014075134 Al.
The present invention reveals method of making geopolymer concrete making at ambient temperature without using heat or steam for curing and also not using metal hydroxide in the alkali activator but using Aluminum oxide containing sources and other contents include fly ash, GGBS, sodium silicate, fine and coarse aggregates.
4.DESCRIPTION (Description shall start from next stage.) :
Disclosure of Invention:
We have now found that geopolymer concrete may be used in preparing precast products other consolidated moulded products by using a geopolymer concrete . . Sodium silicate with The Si02/Na20 mass ratio in the range of 1.8 to 2.4 is used and no metal hydroxide is used but instead Aluminum oxide is used to form the Geopolymer concrete..
Accordingly we provide a method of forming a geopolymer concrete forming with curing at room temperature comprising: forming a geopolymer concrete composition comprising sodium silicate, Aluminum oxide source materials with aluminum oxide 0 to 15% and preferably 0.2 to 5 % and most preferably 0.5 to 2.5%. ,Fly ash (Class F), granulated blast furnace slag (GGBS), aggregates and water. GGBS has been found useful in achieving room temperature curing of the geopolymer concrete
The mixing sequence followed is described below: Fine aggregates, aggregates, fly ash, GGBS, Aluminum Oxide, are mixed in the same sequence. Required water and sodium silicate are to be mixed separately and added to the above mix and mixed for uniformity. The setting times observed maximum to about 120minutes. Mixing time required will be about 5 to 8 minutes
Best Mode(s) for Carrying out the Invention:
In this method Aluminum oxide source materials have been used without using metal hydroxide in the geopolymer concrete making. The source materials can be pure aluminum oxide or bauxite mineral or any other Aluminum oxide containing material with a minimum A1203 content of 35%. Aluminum oxide has been found to accelerate the setting of the geopolymer concrete even without any sodium hydroxide in the mix. The required quantity of active Aluminum oxide content in the geopolymer mix has been found to be 0 to 15% , preferably 0.2 to 5% and more preferably 0.5 to 2.5%
Granulated blast furnace slag in the mix has been found to set the geopolymer mix without the
need for heating chambers or steam curing for all the products tried including bricks, paver blocks, wall panels with the geopolymer concrete described in this invention, and GGBS used will be 5 to 45% by weight, preferably 10 to 30% and more preferably 15 to 18%.
Class F fly ash has been found to be suitable for the geopolymer concrete. In this invention normally fly ash by weight 5 to 40%, preferably 8 to 30% and more preferably 10 to 15%has been found to be suitable in all the geopolymer concrete products tried.
Sodium silicate with solids minimum of 44% and Si02/Na20 ratio as 1.8 to 2.4 preferably 1.9 to 2.2 and more preferably 2.0 has been found to be suitable.
The following examples describe in detail as to how the process in the invention is carried out.
Example 1 : The following composition has been is used to cast bricks, blocks, pavers, wall panels. Sodium silicate used is with solids 45% and Si02/Na20 weight ratio as 2.00. Fly ash used is class F grade. Aluminum oxide used is pure Aluminum oxide industrial grade . Water added given does not include water in the sodium silicate. Has a maximum setting time of 2hours. The precast products can be demoulded after 2hours.
Table 1
Example 2: All the ingredients in example 1 are the same except Aluminum oxide. Bauxite mineral with Aluminum oxide content of 49% was used. The composition is given in table 2.
Table 2.
The compressive strengths observed for 15cm geopolymer cubes cast at room temperature with the composition given in example 2 are given in Table 3 below.
Table3
Industrial Applicability: The present invention applicable and useful to the precast geopolymer concrete industry for casting various products including pavers, blocks, wall panels, beams, columns and the like.
Claims
1. A method of forming geopolymer precast product comprising: forming a geopolymer concrete composition comprising an alkali metal silicate component, Aluminum oxide containing source materials, granulated blast furnace slag, fly ash (grade F) , fine and course aggregates , water; and casting the geopolymer concrete into a mold and subjecting the molded concrete to consolidation using a suitable vibration table.
2. A method according to claim 1 where the alkali metal silicate is the sodium silicate.
3. A method according to claim 1 where the sodium silicate used has Si02/Na20 mass ratio in the range of 1.80 to 2.40
4. A method according to claim 1 where the sodium silicate used has Si02 Na20 mass ratio of 1.20
5. A method according to claim 1 used in the casting of various geopolymer concrete products including pavers, blocks, bricks, wall panels, beams , columns, furniture and the like
6. A method according to claim 1 where the geopolymer concrete is subjected to vibration for compacting using suitable device i
7. A method according to claim 1 where aluminum oxide source material has a minimum aluminum oxide content not less than 35% by weight
8. A method according to claim 1 where the active aluminum oxide content from the source material used in the mix is in the range of 0.5 to 1.2% by weight
9. A method according to claim 1 where the active aluminum oxide content from the source material used in the mix is in the range of 1.2 to 3.0% by weight
10. A method according to claim 1 where the active aluminum oxide content from the source material used in the mix is in the range of 3 to 15.0% by weight
11. A method according to claim 1 where the granulated blast furnace slag present in the mix is range of 5to 15% by weight
12. A method according to claim 1 where the granulated blast furnace slag present in the mix is range of 15to 18% by weight
13. A method according to claim 1 where the granulated blast furnace slag present in the mix is range of 18 to 45% by weight
14. A method according to claim 1 where the F grade fly ash content in the mix is in the ratio of 5 to 15% by weight
15. A method according to claim 1 where the F grade fly ash content in the mix is in the ratio of 15 to 18% by weight
16. A method according to claim 1 where the F grade fly ash content in the mix is in the ratio of 18 to 45% by weight
17. A method according to claim 1 where the course aggregates content in the mix is in the range of 25 to 45% by weight
18. A method according to claim 1 where the fine aggregates content in the mix is in the range of 15 to 25% by weight
19. A method according to claim 1 where the water content in the mix is in the range of 2 to 10% by weight
20. A method according to claim 1 in which the cast product is cured at ambient temperature
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/IN2014/000543 WO2016030904A1 (en) | 2014-08-25 | 2014-08-25 | A process for geopolymer concrete making with curing at ambient temperature and without using sodium hydroxide |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/IN2014/000543 WO2016030904A1 (en) | 2014-08-25 | 2014-08-25 | A process for geopolymer concrete making with curing at ambient temperature and without using sodium hydroxide |
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| WO2016030904A1 true WO2016030904A1 (en) | 2016-03-03 |
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| Application Number | Title | Priority Date | Filing Date |
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| PCT/IN2014/000543 Ceased WO2016030904A1 (en) | 2014-08-25 | 2014-08-25 | A process for geopolymer concrete making with curing at ambient temperature and without using sodium hydroxide |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110357462A (en) * | 2019-07-29 | 2019-10-22 | 南京工业大学 | Slag-based dry powder geopolymer and preparation method and application thereof |
| US11214520B1 (en) | 2018-10-18 | 2022-01-04 | TRUce Global, Inc. | Mortar for eco-masonry element |
| CN114031317A (en) * | 2021-11-12 | 2022-02-11 | 兰州大学 | Method for preparing blast furnace slag modified siliceous stone powder cementing materials with different properties by controlling water loss rate |
| EP4028371B1 (en) | 2019-09-13 | 2023-09-27 | METTEN Technologies GmbH & Co. KG | Concrete element and method for the production thereof |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070125272A1 (en) * | 2003-11-19 | 2007-06-07 | Rocla Pty Ltd | Geopolymer concrete and method of preparation and casting |
| US20110271876A1 (en) * | 2009-01-09 | 2011-11-10 | Stephen Alter | Geopolymer compositions |
-
2014
- 2014-08-25 WO PCT/IN2014/000543 patent/WO2016030904A1/en not_active Ceased
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070125272A1 (en) * | 2003-11-19 | 2007-06-07 | Rocla Pty Ltd | Geopolymer concrete and method of preparation and casting |
| US20110271876A1 (en) * | 2009-01-09 | 2011-11-10 | Stephen Alter | Geopolymer compositions |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11214520B1 (en) | 2018-10-18 | 2022-01-04 | TRUce Global, Inc. | Mortar for eco-masonry element |
| CN110357462A (en) * | 2019-07-29 | 2019-10-22 | 南京工业大学 | Slag-based dry powder geopolymer and preparation method and application thereof |
| EP4028371B1 (en) | 2019-09-13 | 2023-09-27 | METTEN Technologies GmbH & Co. KG | Concrete element and method for the production thereof |
| CN114031317A (en) * | 2021-11-12 | 2022-02-11 | 兰州大学 | Method for preparing blast furnace slag modified siliceous stone powder cementing materials with different properties by controlling water loss rate |
| CN114031317B (en) * | 2021-11-12 | 2022-10-11 | 兰州大学 | Method for preparing blast furnace slag modified siliceous stone powder cementing materials with different properties by controlling water loss rate |
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