Geopolymer Brick Technology and Manufacturing

Low-carbon concrete incorporating natural aggregates from quarry waste, such as marble or limestone, into a geopolymer binder. The concrete achieves significant CO2 reduction compared to conventional concrete while maintaining comparable compressive strength and fire resistance. The natural aggregates, which include quarry waste from ornamental stone processing, replace traditional sand and gravel in the geopolymer binder, forming a sustainable concrete solution that reduces environmental impact.

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Sustainable composite material comprising a geopolymeric matrix that incorporates and stabilizes various types of carbon materials, including waste plastics. The geopolymeric matrix is formed through an alkaline aqueous solution process, allowing the incorporation of carbon materials while maintaining their stability. This material combines the benefits of geopolymeric composites with the environmental advantages of carbon-based materials, offering a versatile and sustainable solution for various applications.

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A geopolymer composition that maintains high strength and durability through enhanced flow and workability during processing, while maintaining the final composition's performance characteristics. The composition comprises a reactive aluminosilicate geopolymer mixture, an alkali activator, a solvent, and a water-soluble polymer additive containing repeat units derived from methacrylic acid or salts thereof. The polymer additive is specifically designed to provide improved flow characteristics without compromising the material's mechanical properties.

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Inorganic polymer containing silicon, aluminum, calcium, alkali metal hydroxides, and oxygen, which forms a polymer network through a specific reaction mechanism. The polymer exhibits unique properties such as resistance to water, acid, and salt corrosion, suitable for hydrophobic applications. The polymer can be used as a cement-free concrete substitute, adhesive, coating material, and composite material in various applications, including ceramics, concrete, and building materials.

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Low-shrinkage geopolymer mortar with improved curing properties. The mortar contains fly ash, slag, sand, and a specific alkaline activator, with particle sizes optimized for optimal workability and curing performance. The mortar achieves enhanced curing characteristics through controlled water absorption and reduced relative humidity during the curing process, resulting in significantly lower shrinkage compared to conventional geopolymer mortars.

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Geopolymer compositions, methods of making and using geopolymer compositions, coatings prepared from geopolymer compositions, and composite products prepared from geopolymer compositions. The compositions and methods enable the production of fire-resistant, high-performance geopolymer-based materials through a novel combination of alkali metal geopolymer binder and filler systems. The geopolymer binder can be formulated with various fillers to enhance its mechanical properties and thermal resistance. The compositions and methods enable the creation of composite materials with exceptional fire retardancy, stiffness, and thermal insulation properties, making them suitable for applications requiring both fire protection and mechanical performance.

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Cementitious binders for geopolymers that combine Portland cement with two chemically different aluminosilicates to enhance chemical resistance. The binders contain at least two aluminosilicates, Portland cement, calcium sulfate, and aggregates, with the aluminosilicates selected from steelmaking slag and fly ash. The binders exhibit improved resistance to chemical attack compared to using each aluminosilicate alone, particularly against acid attack. The binders can be used in geopolymer applications, including concrete repair, shotcrete, and 3D printing, while the binders can also be used in shotcrete production.

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Geopolymer concrete with waste ceramic powder as an admixture, comprising waste ceramic powder, fly ash, and/or silica fume, and its preparation technology. The geopolymer concrete comprises waste ceramic powder, fly ash, and/or silica fume, and its preparation technology. The geopolymer concrete comprises waste ceramic powder, fly ash, and/or silica fume, and its preparation technology.

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Geopolymer concrete that replaces conventional Portland cement, developed from submerged arc welding slag. The geopolymer is produced through a novel process involving the conversion of slag into a refractory material that reacts with silica and alumina to form a durable, high-performance concrete. This geopolymer concrete exhibits superior mechanical properties, including compressive strength up to 55 MPa at 28 days, compared to conventional Portland cement-based concrete.

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Water-resistant and antibacterial environmental protection slag brick made using a slag-based cementitious material with added waterproofing and antimicrobial agents. The brick composition includes slag powders like blast furnace slag and alkali slag, as well as a waterglass-based binder, PTB emulsion, acid salt, and sodium sulfate. The mixture is pressed and cured to form the bricks. The waterproofing agents enhance the brick's resistance to water ingress, and the PTB emulsion provides antibacterial properties.

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Uncalcined geopolymer-based refractory material exhibiting ductile fracture behavior, comprising a matrix of geopolymer obtained by polymerization of a mixture of mineral powder, fly ash, and metakaolin, and silicon carbide (SiC) whiskers embedded in the geopolymer matrix.

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Geopolymer foam compositions comprising two different types of aluminosilicate geopolymer foams, with average pore sizes ranging from 1 μm to 5000 μm. The compositions combine mechanically-foamed and chemically-foamed aluminosilicate geopolymer foams, with the chemically-foamed foams having larger pore sizes. The compositions exhibit enhanced mechanical, thermal, and fire-resistance properties compared to single-pore size foams.

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A multi-functional inorganic polymer adobe that combines the benefits of waste materials with advanced engineering properties. The adobe comprises a polymer matrix derived from waste materials like fly ash, silt, and mud, combined with an alkaline solution. The waste materials are mixed with a controlled amount of mud, which enhances the polymer matrix's porosity and mechanical properties. The resulting material exhibits superior compressive strength, permeability, and energy dissipation characteristics, making it suitable for a wide range of construction applications, including foundation support, building components, and environmental protection systems.

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Geopolymer composition comprising a reaction product of a reaction mixture comprising alkali metal silicate and Portland cement, wherein the composition is prepared by adding the alkali metal silicate to the slurry to initiate a geopolymerization reaction and allowing the paste to harden.

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Geopolymer cements utilizing magnesium oxide as an alkali activator enable the production of fire-resistant wall panels with superior performance characteristics compared to conventional gypsum-based panels. The cements achieve enhanced fire resistance through controlled magnesium oxide activation, which enables improved cement properties without compromising strength. The resulting panels exhibit superior thermal performance, reduced shrinkage, and enhanced environmental benefits. The magnesium oxide-based geopolymer cements can be used in various construction applications, including fire-resistant wall assemblies, shaft-liner assemblies, and structural insulated panels.

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Geopolymer materials made from naturally occurring or byproduct minerals, particularly quartz, that produce amorphous frameworks through non-thermal activation. The geopolymer composition comprises silicon dioxide, aluminum oxide, ferric oxide, and titanium dioxide, with trace amounts of calcium, and is produced without calcination. The material exhibits enhanced compressive strength and thermal insulation properties compared to traditional Portland cement, while achieving significant reductions in energy consumption and environmental impact through its non-thermal activation process.

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Fly ash geopolymer concrete with enhanced durability and performance, utilizing a fly ash-based polymer matrix with specific composition and processing parameters. The concrete combines fly ash with metakaolin, sodium hydroxide, potassium hydroxide, and alkaline activators to form a geopolymer matrix. The formulation includes modified ceramic microsphere particles, polymer fibers, coarse aggregates, fine aggregates, and water glass as an alkaline activator. The microsphere particles are created through a controlled spray drying process, enabling precise control over the ceramic microsphere size and distribution. This microsphere-based approach enhances the concrete's thermal resistance, chloride ion permeability, and mechanical properties, making it suitable for high-performance applications in saline-alkali environments.

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Geopolymer composite with improved thermal insulation properties through enhanced fire retardancy. The composite comprises a geopolymer matrix and an athermanous additive, where the athermanous additive is encapsulated within the geopolymer matrix to prevent radical interactions with flame retardants. This encapsulation enables controlled dispersion of the additive during processing, while maintaining its flame retardant properties. The composite is produced through a combination of geopolymer synthesis and athermanous additive encapsulation, resulting in a material with improved thermal insulation performance compared to conventional flame retardant systems.

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Microsilica improves flowability in geopolymer suspensions by enhancing dispersion and rheological properties. The microsilica, particularly containing zirconium, is added to geopolymer suspensions in combination with cationic polymers. The zirconium-based microsilica facilitates the dispersion of the suspension components, while the cationic polymers enhance the suspension's rheological properties. This additive combination enables improved flowability in geopolymer suspensions, particularly in low-calcium systems, by addressing the unique challenges of these systems.

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A lightweight, safe, and environmentally friendly brick wall material that replaces traditional ceramic tile construction. The material utilizes a novel, energy-efficient manufacturing process that produces a decorative brick-like structure through a controlled, low-temperature sintering process. This process eliminates the need for high-temperature firing, reducing energy consumption and greenhouse gas emissions compared to traditional ceramic tile production. The resulting brick wall offers improved durability, fire resistance, and aesthetic appeal while minimizing environmental impact.

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