Freeze-thaw durable geopolymer compositions and methods for making same

Patent metadata

Field	Value
Publication number	US-2017166481-A1
Application number	US-201715436360-A
Country	US
Kind code	A1
Filing date	Feb 17, 2017
Priority date	Oct 22, 2015
Publication date	Jun 15, 2017
Grant date	—

Abstract

A freeze-thaw durable, dimensionally stable, geopolymer composition including: cementitious reactive powder including thermally activated aluminosilicate mineral, aluminate cement preferably selected from at least one of calcium sulfoaluminate cement and calcium aluminate cement, and calcium sulfate selected from at least one of calcium sulfate dihydrate, calcium sulfate hemihydrate, and anhydrous calcium sulfate; alkali metal chemical activator; and a freeze-thaw durability component selected from at least one of air-entraining agent, defoaming agent, and surface active organic polymer; wherein the composition has an air content of about 4% to 20% by volume, more preferably about 4% to 12% by volume, and most preferably about 4% to 8% by volume. The compositions are made from a slurry wherein the water/cementitious reactive powder weight ratio is 0.14 to 0.45:1, preferably 0.16 to 0.35:1, and more preferably 0.18 to 0.25:1. Methods for making the compositions are also disclosed.

First claim

1 . A freeze-thaw durable, dimensionally stable, geopolymer composition comprising a mixture of:
cementitious reactive powder comprising:
thermally activated aluminosilicate mineral in an amount of 100 parts by weight,
aluminate cement in an amount of 1 to 100 parts by weight (pbw) per 100 pbw of thermally activated aluminosilicate mineral, and
calcium sulfate in an amount of 2 to 100 parts by weight per 100 pbw of aluminate cement, wherein the calcium sulfate is selected from at least one member of the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, and anhydrous calcium sulfate; and
alkali metal chemical activator in an amount of 1 to 6 weight % based upon the total weight of the cementitious reactive powder, wherein the alkali metal chemical activator is selected from at least one member of the group consisting of an alkali metal salt and an alkali metal base; freeze-thaw durability component in an amount of 0.05 to 21.5 weight % based upon the total weight of the cementitious reactive powder, the freeze-thaw durability component comprising:
air-entraining agent in an amount of 0 to 1 weight % based upon the total weight of the cementitious reactive powder,
defoaming agent in an amount of 0 to 0.5 weight % based upon the total weight of the cementitious reactive powder, and
surface active organic polymer in an amount of 0 to 20 weight % based upon the total weight of the cementitious reactive powder;
wherein at least one member of the group consisting of the air-entraining agent defoaming agent, superplasticizer, and the surface active organic polymer is present, wherein said thermally activated aluminosilicate mineral, said aluminate cement, and said calcium sulfate is at least 70 wt. % of the cementitious reactive powder, wherein the composition after mixing with water and aerating and setting has a freeze-thaw durability performance according to ASTM C666/C666M-15 of a relative dynamic modulus of greater than 80 percent for at least 100 freeze-thaw cycles.

2 . The composition of claim 1 , wherein the thermally activated aluminosilicate mineral comprises at least 75% Class C fly ash, wherein the aluminate cement is selected from at least one member of the group consisting of calcium sulfoaluminate cement and calcium aluminate cement, wherein the alkali metal chemical activator is selected from at least one member of the group consisting of an alkali metal citrate, alkali metal hydroxide and an alkali metal silicate.

3 . The composition of claim 1 , wherein the composition contains at least one feature selected from the group consisting of:
air-entraining agent in an amount of 0.01 to 1 weight % based upon the total weight of the cementitious reactive powder, and surface active organic polymer in an amount of 1 to 20 weight % based upon the total weight of the cementitious reactive powder.

4 . The composition of claim 1 , wherein the composition is made from setting a slurry comprising water, the cementitious reactive powder, the alkali metal chemical activator, and the freeze-thaw durability component, wherein the water/cementitious reactive powder weight ratio of the slurry is 0.16-0.35.

5 . The composition of claim 1 , wherein the composition has an absence of Portland cement.

6 . The composition of claim 1 , wherein the composition comprises lithium carbonate.

7 . The composition of claim 1 , comprising 5 to 60 parts aluminate cement by weight per 100 pbw of thermally activated aluminosilicate mineral, the aluminate cement comprising the calcium sulfoaluminate cement and the calcium aluminate cement, wherein the amount of calcium aluminate cement is about 5 to about 75 parts by weight (pbw) per 100 pbw of total calcium sulfoaluminate cement and calcium aluminate cement, wherein the composition has an absence of Portland cement.

8 . The composition of claim 1 , comprising the air entraining agent and the surface active organic polymer,
wherein the surface active organic polymer comprises at least one member of the group consisting of biopolymers, organic rheology control agents, film forming redispersible polymers, and film forming polymer of film forming polymer dispersions, wherein the biopolymer is selected from at least one member of the group consisting of Succinoglycans, diutan gum, guar gum, wellan gum, xanthan gums galactomannan gums, glucomannan gums, guar gum, locust bean gum, cara gum, hydroxyethyl guar, hydroxypropyl guar, cellulose, hydroxypropyl cellulose, hydroxymethyl cellulose, and hydroxyethyl cellulose, wherein the at least one organic rheology control agent comprises at least one acrylic-based polymer selected from the group consisting of alkali-swellable (or soluble) emulsions (ASE's), hydrophobically modified alkali-swellable emulsions (HASE's), and hydrophobically modified, ethoxylated urethane resins (HEUR's), wherein the film forming redispersible polymer is selected from the group consisting of (meth)acrylic polymers, styrene polymers, styrene-butadiene rubber polymers, vinyl polymers, polyesters, polyurethanes, polyamides, chlorinated polyolefins, and mixtures or copolymers thereof, wherein said film forming polymer has a glass transition temperature (Tg) of from −40° to 70° C., and wherein the film forming polymer of the film forming polymer dispersions is selected from the group consisting of (meth)acrylic polymers, styrene polymers, styrene-butadiene rubber polymers, vinyl polymers, polyesters, polyurethanes, polyamides, chlorinated polyolefins, and mixtures or copolymers thereof, wherein said film forming polymer has a glass transition temperature (Tg) of from −40° to 70° C.

9 . The composition of claim 1 , comprising the defoaming agent, wherein the defoaming agent is selected from at least one member of the group consisting of polyethylene oxides, polyetheramine, polyethylene glycol, polypropylene glycol, alkoxylates, polyalkoxylate, fatty alcohol alkoxylates, hydrophobic esters, tributyl phosphate, alkyl polyacrylates, silanes, silicones, polysiloxanes, polyether siloxanes, acetylenic diols, tetramethyl decynediol, secondary alcohol ethoxylates, silicone oil, hydrophobic silica, oils (mineral oil, vegetable oil, white oil), waxes (paraffin waxes, ester waxes, fatty alcohol waxes), amides, fatty acids, and polyether fatty acids.

10 . The composition of claim 1 , comprising
0 to 5 parts by weight fine aggregate per 1 part total weight of the cementitious reactive powder; 0 to 5.5 parts by weight coarse aggregate per 1 part total weight of the cementitious reactive powder; wherein there is 1 to 8 parts by weight total fine and coarse aggregate per 1 part total weight of the cementitious reactive powder, wherein the aluminate cement comprises calcium sulfoaluminate cement and calcium aluminate cement.

11 . The composition of claim 10 , comprising, 25 to 40 parts said aluminate cement by weight per 100 pbw of thermally activated aluminosilicate mineral, the aluminate cement comprising the calcium sulfoaluminate cement and the calcium aluminate cement, wherein the amount of the calcium aluminate cement is about 30-50 parts by weight (pbw) per 100 pbw of total calcium sulfoaluminate cement and calcium aluminate cement, wherein the composition has an absence of Portland cement;
the air entraining agent, the defoamer, a superplasticizer comprising polycarboxylate polyether, wherein the superplasticizer in an amount of 5 wt. % or less based upon the total weight of the cementitious reactive powder; in the amount of 0 to 20 weight % based upon the total weight of the cementitious reactive powder greater than 0 to at most 5 parts by weight fine aggregate per 1 part total weight of the cementitious reactive po

Assignees

• United States Gypsum Co

Inventors

• Dubey Ashish
• CHITHIRAPUTHIRAN Sundararaman

Classifications

• C04B28/006 Primary

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

• C04B2111/0075

  for road construction · CPC title

• C04B12/005

  Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates · CPC title

• C04B7/32

  Aluminous cements · CPC title

• Y02P40/10

  Production of cement, e.g. improving or optimising the production methods; Cement grinding · CPC title