Dimensionally stable geopolymer composition and method

Patent metadata

Field	Value
Publication number	US-2016214897-A1
Application number	US-201615071424-A
Country	US
Kind code	A1
Filing date	Mar 16, 2016
Priority date	Apr 27, 2012
Publication date	Jul 28, 2016
Grant date	—

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 for bridge decks and overlays, road repair or road patch comprising a reaction product of
a reactive powder comprising:
a thermally activated aluminosilicate mineral;
a calcium sulfoaluminate cement in an amount of 1-100 parts by weight per 100 parts by weight of thermally activated aluminosilicate mineral;
a 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 2 to 100 parts by weight per 100 parts by weight of calcium sulfoaluminate cement; and
a chemical activator selected from the group consisting of an alkali metal salt and an 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 reactive powder, and
at least one member of the group consisting of air entraining agents, defoaming agents, organic rheology control agents, and film-forming polymers; and entrained air; and water.

2 . The composition of claim 1 , comprising the reaction product of about 33 to about 97% by weight of the thermally activated aluminosilicate mineral, about 1 to about 40% by weight of the calcium sulfoaluminate cement, about 1 to about 40% by weight of the calcium sulfate, about 1.0 to about 6.0% by weight of the chemical activator selected from the group consisting of an alkali metal salt and an alkali metal base, and water.

3 . The composition of claim 1 , wherein the chemical activator comprises an alkali metal citrate, and the thermally activated aluminosilicate mineral comprises Class C fly ash.

4 . The composition of claim 1 , comprising a reaction product of amounts of the chemical activator and calcium sulfate relative to the amounts of the thermally activated aluminosilicate mineral and calcium sulfoaluminate cement effective to cause the reaction product to set in a predetermined time after mixing with water.

5 . The composition of claim 1 , 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.

6 . The composition of claim 1 , wherein the composition has 0-0.5 parts by weight organic rheology control agents per 100 parts by weight of the reactive powder.

7 . The composition of claim 6 , wherein the organic rheology control agents comprise biopolymer.

8 . The composition of claim 1 , wherein the composition has 0-20 parts by weight film forming polymer per 100 parts of the reactive powder.

9 . The composition of claim 8 , wherein the composition has 0-0.050 parts by weight defoaming agent per 100 parts of the reactive powder.

10 . The composition of claim 1 wherein the reaction product is formed from water and a thermally activated aluminosilicate mineral comprising about 60% to about 90% by weight thermally activated aluminosilicate mineral and Class C fly ash; about 4% to about 35% by weight calcium sulfoaluminate cement, about 4.0% to about 15% by weight calcium sulfate, and about 1.25 to 4.00% by weight chemical activators.

11 . The composition of claim 1 wherein the reaction product is formed from water; and about 60% to about 85% by weight of a thermally activated mineral comprising Class C fly ash, about 8% to about 30% by weight calcium sulfoaluminate cement, about 4.0% to about 15% by weight calcium sulfate, and about 1.5 to 3.00% by weight chemical activator.

12 . The composition of claim 1 wherein the reaction product is formed from calcium sulfate with an average particle size from about 1 to about 100 microns.

13 . The composition of claim 1 , wherein the reaction product is formed from water; and a thermally activated aluminosilicate mineral; a calcium sulfoaluminate cement; a calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, anhydrous calcium sulfate and mixtures thereof; a chemical activator selected from the group consisting of an alkali metal salt and an alkali metal base or mixtures thereof; and less than about 15% by weight Portland cement.

14 . The composition of claim 1 , wherein the weight ratio of the water to reactive powder is about 0.15 to about 0.4.

15 . A settable mixture for forming an aluminosilicate geopolymer cementitious composition when reacted in water, comprising:
about 33 to about 97% by weight of a thermally activated aluminosilicate mineral; about 1 to about 40% by weight of a calcium sulfoaluminate cement, about 1 to about 40% by weight of a calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, anhydrous calcium sulfate and mixtures thereof; and about 1.0 to about 6.0% by weight of a chemical activator selected from the group consisting of an alkali metal salt and an alkali metal base, and mixtures thereof; at least one member of the group consisting of air entraining agents, defoaming agents, bipolymers, organic rheology control agents, and film-forming polymers; and entrained air.

16 . The aluminosilicate geopolymer composition formed from the reaction of the mixture of claim 15 with water, wherein the weight ratio of the water to reactive powder is about 0.15 to about 0.4.

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

18 . A method of preparing an aluminosilicate geopolymer cementitious composition, comprising:
reacting a thermally activated aluminosilicate mineral, a calcium sulfoaluminate cement, a calcium sulfate selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, anhydrous calcium sulfate, and mixtures thereof, a chemical activator selected from the group consisting of an alkali metal salt and an alkali metal base and mixtures thereof, and water; and at least one member of the group consisting of air entraining agents, defoaming agents, bipolymers, organic rheology control agents, and film-forming polymers; and entrained air.

19 . The method of claim 18 , wherein the aluminosilicate geopolymer cementitious composition comprises the reaction product of:
about 33 to about 97 parts by weight, of the thermally activated aluminosilicate mineral comprising class C fly ash, about 1 to about 40 parts by weight of calcium sulfoaluminate cement, about 1 to about 40 parts by weight of the calcium sulfate, the chemical activator which comprises an alkali metal citrate in an amount equal to about 1.0 to about 6.0% by weight based on total weight of the reactive powder, the entrained air, and the water.

20 . The method of claim 19 , wherein the composition further comprises a filler.

Assignees

• United States Gypsum Co

Inventors

• Dubey Ashish

Classifications

• C04B28/14

  containing calcium sulfate cements {(gypsum-paper plates E04C)} · CPC title

• C04B2111/00482

  Coating or impregnation materials · CPC title

• C04B2111/0075

  for road construction · CPC title

• C04B28/18

  containing mixtures of the silica-lime type · CPC title

• C04B2111/00586

  Roofing materials · CPC title