Dimensionally stable geopolymer composition and method

Patent metadata

Field	Value
Publication number	US-10392307-B2
Application number	US-201715452054-A
Country	US
Kind code	B2
Filing date	Mar 7, 2017
Priority date	Apr 27, 2012
Publication date	Aug 27, 2019
Grant date	Aug 27, 2019

Abstract

A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar, patching materials for road repairs and other repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium sulfoaluminate cement, a calcium sulfate and a chemical activator with water.

First claim

What is claimed is:

1. An aluminosilicate geopolymer cementitious composition comprising a reaction product of:
a cementitious reactive powder comprising:
33 to 81.6% by weight a thermally activated aluminosilicate mineral comprising Class C fly ash;
4.65 to 43% by weight calcium sulfoaluminate cement, wherein the calcium sulfoaluminate cement in an amount of 10-100 parts by weight per 100 parts by weight of thermally activated aluminosilicate mineral; and
4.35 to 40% by weight calcium sulfate, wherein the calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, anhydrous calcium sulfate and mixtures thereof, the calcium sulfate in an amount of up to 100 parts by weight per 100 parts by weight of calcium sulfoaluminate cement; and

a chemical activator selected from the group consisting of alkali metal salt, alkali metal base and mixtures thereof in an amount equal to about 1.0 to about 6.0% by weight based on total weight of the cementitious reactive powder, and
at least one of the group consisting of superplasticizers, air entraining agents, defoaming agents, organic rheology control agents, and film-forming polymers; and water,
wherein the calcium sulfate has an average particle size from about 1 to about 100 microns.

2. The composition of claims 1 ,
33 to 76.9% by weight Class C fly ash,
8.7 to 43% by weight of the calcium sulfoaluminate cement,
6.1 to 40% by weight of the calcium sulfate;
wherein the chemical activator is selected from the group consisting of alkali metal citrate, alkali metal silicate, alkali metal hydroxide, and mixtures thereof.

3. The composition of claim 1 , wherein the chemical activator is present in an amount equal to about 1.25 to 4.00% by weight based on total weight of the cementitious reactive powder, wherein the chemical activator is selected from at least one member of the group consisting of alkali metal citrate and alkali metal silicate.

4. The composition of claim 1 , comprising the superplasticizer, wherein the chemical activator comprises alkali metal hydroxide.

5. The composition of claim 1 , comprising the air entraining agent, wherein the air entraining agent is in an amount of about 0.01 to about 1 wt. % of the weight of the aluminosilicate geopolymer cementitious composition and the calcium sulfoaluminate cement in an amount of 15-100 parts by weight per 100 parts by weight of the thermally activated aluminosilicate mineral.

6. The composition of claim 1 , wherein the calcium sulfate comprises calcium sulfate hemihydrate.

7. The composition of claim 1 , wherein the calcium sulfate comprises calcium sulfate dihydrate.

8. The composition of claim 1 , wherein the calcium sulfate comprises anhydrous calcium sulfate.

9. The composition of claim 1 , wherein the cementitious reactive powder comprises:
41 to 67% by weight Class C fly ash,
8.7 to 15.9% by weight calcium sulfoaluminate cement, and
47.7 to 36% by weight calcium sulfate;
wherein the chemical activator is selected from at least one of the group consisting of sodium citrate, potassium citrate, and sodium hydroxide.

10. The composition of claim 1 , wherein the cementitious reactive powder comprises 15.4 to 43% by weight calcium sulfoaluminate cement.

11. The composition of claim 1 , wherein the reaction product is formed from
the water; and
the cementitious reactive powder comprising
60% to 81.6% by weight Class C fly ash,
8% to 30% by weight calcium sulfoaluminate cement, and
4.35 to 26.2% by weight the calcium sulfate, and

the chemical activator in an amount equal to about 1.5 to 4.0% by weight based on total weight of the cementitious reactive powder.

12. The composition of claim 1 , wherein the composition has an absence of Portland cement and the cementitious reactive powder comprises 8.7 to 43% by weight calcium sulfoaluminate cement.

13. The composition of claim 1 , wherein the cementitious reactive powder comprises less than about 15% by weight Portland cement.

14. The composition of claim 1 , wherein the weight ratio of the water to cementitious reactive powder is about 0.15 to about 0.4, wherein the cementitious reactive powder comprises less than 5 wt. % Portland cement.

15. The composition of claim 1 forming a repair material for traffic bearing surfaces.

16. A method of preparing an aluminosilicate geopolymer cementitious composition of claim 1 , comprising:
reacting a mixture of
a cementitious reactive powder comprising:
33 to 81.6% by weight thermally activated aluminosilicate mineral comprising Class C fly ash,
4.65 to 43% by weight calcium sulfoaluminate cement, wherein the calcium sulfoaluminate cement in an amount of 10-100 parts by weight per 100 parts by weight of thermally activated aluminosilicate mineral, and
4.35 to 40% by weight calcium sulfate, wherein the calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, anhydrous calcium sulfate, and mixtures thereof, the calcium sulfate in an amount of up to 100 parts by weight per 100 parts by weight of calcium sulfoaluminate cement;

a chemical activator selected from a member of the group consisting of alkali metal salt, alkali metal base and mixtures thereof in an amount equal to about 1.0 to about 6.0% by weight based on total weight of the cementitious reactive powder;
water; and
at least one of the group consisting of superplasticizers, air entraining agents, defoaming agents, bipolymers, organic rheology control agents, and film-forming polymers;
wherein the calcium sulfate has an average particle size from about 1 to about 100 microns.

17. The method of claim 16 , wherein the cementitious reactive powder comprises:
33 to 76.9% by weight class C fly ash, and
8.7 to 43% by weight of calcium sulfoaluminate cement,
6.1 to 40% by weight of the calcium sulfate, and
wherein the chemical activator is selected from the group consisting of alkali metal citrate, alkali metal silicate, and alkali metal hydroxide and mixtures thereof,
wherein the mixture comprises the superplasticizer.

18. The method of claim 17 , wherein the cementitious reactive powder comprises:
41 to 67% by weight said Class C fly ash,
8.7 to 43% by weight said calcium sulfoaluminate cement, and
7.7 to 36 by weight said calcium sulfate,
wherein the amount of chemical activator equals about 2 to about 5.0% by weight of the cementitious reactive powder.

19. A settable mixture for forming an aluminosilicate geopolymer cementitious composition when reacted in water, comprising:
a cementitious reactive powder comprising:
33 to 81.6% by weight of a thermally activated aluminosilicate mineral comprising Class C fly ash;
4.65 to 43% by weight of a calcium sulfoaluminate cement,
4.35 to 40% by weight of a calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hem ihydrate, anhydrous calcium sulfate and mixtures thereof; and
about 1.0 to about 6.0% by weight, based on weight of cementitious reactive powder, of a chemical activator selected from the group consisting of alkali metal salt, alkali metal base, and mixtures thereof; and
at least one of the group consisting of superplasticizers, air entraining agents, defoaming agents, bipolymers, organic rheology control agents, and film-forming polymers;
wherein the calcium sulfate has an average particle size from about 1 to about 100 microns.

20. The alum inosiilcate geopolymer composition formed from the reaction of the mixture

Assignees

• United States Gypsum Co

Inventors

• Dubey Ashish

Classifications

• C04B28/006 Primary

  containing mineral polymers, e.g. geopolymers of the Davidovits type · CPC title

• C04B22/0093

  Aluminates · CPC title

• C04B2111/0075

  for road construction · CPC title

• C04B2111/0012

  Thixotropic mixtures · CPC title

• C04B2111/00586

  Roofing materials · CPC title