Geopolymer mortar and method
View Patent ↗A geopolymer mortar formed by mixing about 35% to about 45% by weight pozzolanic material, about 35% to about 45% by weight silicon oxide source, about 15% to about 20% by weight alkaline activator solution, and about 0.3% to about 2.5% by weight copper ion source. The pozzolanic material may be fly ash and the silicon oxide source may be sand. The alkaline activator solution may be a sodium hydroxide solution containing sodium silicate. The geopolymer mortar may have a viscosity in the range of about 25,000 to about 50,000 centipoise. The geopolymer mortar may be formed by further mixing one or more additives, such as surfactants, thermal spheres, anti-sagging agents, adhesion primers, or fibers. The geopolymer mortar may be applied as a protective coating on a surface of a structure.
1. A composition of matter formed by the mixing of the components comprising:
(a) about 35% to about 45% by weight fly ash;
(b) about 35% to about 45% by weight sand;
(c) about 15% to about 20% by weight alkaline activator solution;
(d) about 0.3% to about 2.5% by weight copper ion source; and
(e) about 0% to about 2.2% by weight fibers.
2. The composition of matter according to claim 1 , wherein the fly ash is predominantly class C or class F fly ash.
3. The composition of matter according to claim 2 , wherein a combined SiO 2 and Al 2 O 3 content of the fly ash is at least 50% by weight, a SiO 2 :Al 2 O 3 ratio is about 1.5 to about 3, and a CaO content of the fly ash is about 1% to about 2.5% by weight.
4. The composition of matter according to claim 1 , wherein the activator solution comprises a 10 M to 12.5 M NaOH solution including sodium silicate with a SiO 2 /Na 2 O weight ratio of about 3.1 to about 3.3 and a sodium silicate to sodium hydroxide weight ratio of about 1.3 to about 1.7.
5. The composition of matter according to claim 1 , wherein the viscosity of the composition is about 25,000 to about 50,000 centipoise (cP).
6. The composition of matter according to claim 5 , wherein the composition further comprises an anti-sagging agent and has a flowability as per ASTM C1437 of about 80% to about 100%.
7. The composition of matter according to claim 1 , wherein the copper ion source is at least one of CuSO 4 , Cu 2 O, Cu(NO 3 ) 2 , and Cu(NO 3 ) 2 .3H 2 O.
8. The composition of matter according to claim 1 , wherein the copper ion source is at least one of Cu 2 S, CuS, CuCO 3 .Cu(OH) 2 , and Cu(OH) 2 .
9. The composition of matter according to claim 1 , further comprising about 0.1% to about 0.2% by weight surfactant.
10. The composition of matter according to claim 9 , wherein the surfactant comprises a vinsol resin surfactant.