Process for Producing a Geopolymer Concrete And/or Mortar

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This invention discloses a process for producing geopolymer concrete and mortar using an activator solution (containing water-soluble alkali metal silicate and an inorganic base), at least one reactive aluminosilicate binder, and at least one aggregate. The process enables the use of unconventional sands (including desert sand) and industrial by-products as aggregates, and requires curing at moderate temperatures (20°C to 100°C). The resulting geopolymer concrete or mortar achieves high compressive strength and improved chemical and thermal resistance compared to traditional cement-based products.

Use CasesContent extracted from patent full text and abstract with AI.

• Construction of buildings and infrastructure using low-carbon geopolymer concrete or mortar instead of Portland cement-based materials.
• Manufacturing of precast blocks, bricks, panels, or tiles from geopolymer compositions.
• Utilization of desert sand or industrial waste products in concrete production where standard construction sand is scarce or expensive.
• Rapid repair of structures due to the fast-setting property of geopolymer materials.
• Applications requiring high chemical, acid, or thermal resistance, such as sewer pipes, chemical containment, or fire-resistant materials.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces carbon dioxide emissions compared to traditional cement production, supporting sustainable construction.
• Enables the use of otherwise unsuitable sand (e.g., desert sand) or local/industrial materials, reducing the demand for high-quality, scarce construction sand.
• High early and long-term compressive strength, comparable to or better than standard concrete.
• Enhanced durability, including resistance to fire, temperature extremes, and most acids (except hydrofluoric acid).
• Offers fast setting and curing, allowing quicker project turnarounds.
• Potential for lower cost by substituting expensive or scarce raw materials with abundant alternatives.
• Can be manufactured as a dry-mix kit for transportation and on-site mixing, improving logistics and convenience.

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Inventors & Applicants

Patent Abstract

The invention relates to a process for producing a geopolymer concrete and/or mortar from an activator composition, at least one binder and at least one aggregate, comprising at least the steps of: a) providing an activator composition A comprising at least one water-soluble alkali metal silicate and at least one inorganic base, b) mixing the composition A with at least one binder and at least one aggregate to afford a composition C, c) curing the composition C at a temperature of 20°C to 100°C to afford a geopolymer concrete and/or mortar, wherein the at least one alkali metal silicate is selected from sodium waterglass and/or potassium waterglass and/or lithium waterglass and wherein the at least one inorganic base is selected from metal hydroxides and wherein the at least one binder comprises at least one reactive aluminosilicatic component and wherein the composition C produced in step b) has a molar Si:Al ratio in the range from 1:1 to 30:1, preferably in the range from 1:1 to 6:1, and a molar Na:Al ratio in the range from 0.5:1 to 1.5:1, preferably in the range from 0.7:1 to 1:1.