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Freeze-thaw durable geopolymer compositions and methods for making same

a geopolymer composition and freeze-thaw technology, applied in the direction of climate sustainability, solid waste management, construction, etc., can solve the problems of expansion and cracking, scaling, concrete collapse, etc., and achieve freeze-thaw durability behavior, good dimensional stability, and sufficient workable time

Active Publication Date: 2017-04-27
UNITED STATES GYPSUM CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0005]The present invention provides rapid-setting, dimensionally stable geopolymer compositions having excellent freeze-thaw durability behavior. The improved properties are provided with good dimensional stability, sufficient workable time, and high early age and later age compressive strengths.
[0039]As used herein, early age strength of the composition is characterized by measuring the compressive strength after 1 to 24 hours of curing. In many applications, relatively higher early age compressive strength can be an advantage for a cementitious material because it can withstand higher stresses without excessive deformation. Achieving high early strength also increases the factor of safety relating to handling and use of manufactured products. Further, due to the achievement of high early strength, many materials and structures can be opened to traffic and allowed to support non-structural and structural loads at an early age. Typically, chemical reactions providing strength development in such compositions will continue for extended periods after the final setting time has been reached.

Problems solved by technology

Successive freeze-thaw cycles will then eventually cause expansion and cracking, scaling, and / or crumbling of the concrete.

Method used

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  • Freeze-thaw durable geopolymer compositions and methods for making same
  • Freeze-thaw durable geopolymer compositions and methods for making same
  • Freeze-thaw durable geopolymer compositions and methods for making same

Examples

Experimental program
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Effect test

example 2

aw Durability Performance of Geopolymer Compositions of the Invention

[0340]TABLE 2.1 shows the raw material composition of the mixture composition investigated. This example investigated freeze-thaw durability performance of three different compositions employing three different types of calcium sulfates. Mix 1 employed calcium sulfate dihydrate (USG TERRA ALBA), Mix 2 employed calcium sulfate hemihydrate (USG HYDROCAL C-BASE), and Mix 3 employed anhydrous calcium sulfate (anhydrite—USG SNOW WHITE FILLER). The material was mixed using a high shear mixer—PERLS hand held ME 140 mixer operated manually at a RPM of 490. The mixing was performed for 4 minutes. The sand used in this example was Sand A Unimin GRANUSIL 5030.

TABLE 2.1Compositions investigated in Example 2Raw MaterialMix 1Mix 2Mix 3Fly Ash Class C (grams)103451034510345Calcium Sulfoaluminate Cement206920692069(grams)Calcium Aluminate Cement103410341034(grams)Calcium Sulfate Dihydrate1552——(grams)Calcium Sulfate Hemihydrate—15...

example 3

aw Durability Performance—Influence of Different Levels of Calcium Aluminate Cement with Calcium Sulfate Hemihydrate

[0352]TABLE 3.1 shows the raw material composition of the inventive mixture compositions investigated in this example.

[0353]The high shear mixer used in this example was PERLS hand held ME 140 mixer operated manually at a RPM of 490. The mixing was performed for 4 minutes.

TABLE 3.1Compositions investigated in Example 3Raw MaterialMix 1Mix 2Fly Ash Class C (grams)103459836Calcium Sulfoaluminate Cement (grams)20691967Calcium Aluminate Cement (grams)10341475Calcium Sulfate Hemihydrate (grams)15521721Total Cementitious Materials (grams)1500015000Sand A (grams)1725017250Potassium Citrate (grams)300300Superplasticizer (grams)7575Rheology Modifier (grams)1.51.5Defoamer (grams)3030Lithium Carbonate (grams)7575Polymer (grams)750750Water (grams)33003300Water / Cementitious Materials Wt. Ratio0.22:10.22:1Sand A / Cementitious Materials Wt. Ratio1.15:11.15:1Calcium sulfoaluminate ceme...

example 4

aw Durability Performance—Influence of Water to Cementitious Materials Ratio

[0360]This example investigated the influence of water-cementitious materials ratio on the freeze-thaw durability performance of the geopolymeric formulations investigated. TABLE 4.1 shows the raw material composition of the mixture compositions investigated. The high shear mixer used in this example was PERLS hand held ME 140 mixer operated manually at a RPM of 490. The mixing was performed for 4 minutes.

TABLE 4.1Compositions investigated in Example 4Raw MaterialMix 1Mix 2Mix 3Fly Ash Class C (grams)103451034510345Calcium Sulfoaluminate Cement (grams)206920692069Calcium Aluminate Cement (grams)103410341034Calcium Sulfate Hemihydrate (grams)776776776Anhydrous Calcium Sulfate (grams)776776776Total Cementitious Materials (grams)150001500015000Sand A (grams)172501725017250Potassium Citrate (grams)300300300Superplasticizer (grams)757575Rheology Modifier (grams)1.51.51.5Defoamer (grams)303030Lithium Carbonate (gr...

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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.

Description

FIELD OF THE INVENTION[0001]The present invention provides rapid-setting, dimensionally stable geopolymer compositions having excellent freeze-thaw durability behavior and method for making these compositions. The improved properties are provided with sufficient workable time, and high early age and later age compressive strengths.BACKGROUND OF THE INVENTION[0002]US 20130284069 A1 Dubey Ashish, discloses Geopolymer compositions comprising reaction product of thermally activated aluminosilicate mineral / calcium aluminate cement / calcium sulfate such as anhydrous calcium sulfate / chemical activator such as alkali metal salt / water. It discloses the compositions may contain air-entraining agents or foaming agents. It also discloses using the composition for panels, road patch, traffic bearing surfaces, and pavements. It discloses some embodiments of its invention can be used with different fillers and additives including foaming agents and air entraining agents for adding air in specific p...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C04B28/00C04B28/14C04B28/06E01C7/14C04B24/04C04B24/34E01C23/10E01C7/36C04B24/26C04B18/08
CPCC04B28/006C04B24/2676C04B28/14C04B28/06C04B28/065C04B2103/0066C04B24/045C04B24/34E01C23/10E01C7/36E01C7/142C04B18/08E01C7/147C04B2111/0075C04B2111/29E01C7/351E01C7/356E01C7/358Y02P40/10Y02W30/91C04B7/32C04B12/04C04B2103/304C04B2103/50C04B38/10C04B22/142C04B24/06C04B12/005C04B2111/60C04B2111/72C04B2103/32C04B2103/40
Inventor DUBEY, ASHISHCHITHIRAPUTHIRAN, SUNDARARAMAN
Owner UNITED STATES GYPSUM CO
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