The last few years have seen spectacular technological progress in the development of geosynthesis and geopolymeric applications.

New state-of-the-art materials designed with the help of geopolymerisation reactions are opening up new applications and procedures, and transforming ideas that have been taken for granted in inorganic and mineral chemistry.

Since the discovery of the geopolymer chemistry by Prof. Joseph Davidovits (see also in the Library the scientific paper IUPAC 1976) this new generation of materials, whether used pure, with fillers or reinforced, is already finding applications in all fields of industry. These applications are to be found in the automotive and aerospace industries, non-ferrous foundries and metallurgy, civil engineering, cements and concretes, ceramics and plastics industries, waste management, art and decoration, retrofit of buildings, etc. One third of the recently updated book Geopolymer Chemistry & Applications is dedicated to geopolymeric applications. You may also go to the Geopolymer Library and download several papers, for example #21 Geopolymer cement review 2013.

Some of the geopolymer applications are still in development whereas others are already industrialized and commercialized. They will be listed in six (6) categories, namely:

Geopolymer Precursor

Geopolymer Resin, paint, binder, grout

Geopolymer cement, concrete, waste management, global warming

Applications with geopolymer cements and concretes are described in the section Geopolymer Cement with special emphasis on the introduction of user-friendly systems. It is striking to notice that Geopolymer cements manufacture emits 80 to 90% less CO₂ (greenhouse effect gas) than Portland Cement. See in GLOBAL WARMING. They are perfect examples of Green Chemistry and Sustainable Development.

For information on Fly Ash-based geopolymer cements go to European Research Project GEOASH. For updated very recent detailed information, read Chapters 12, 24, 25 in Geopolymer Chemistry & Applications; you may also download previous papers in the Library .

Rock-based geopolymer cements are ideal for environmental applications, such as the permanent encapsulation of radioactive and other hazardous wastes, toxic metals, as well as sealants, capping, barriers, and other structures necessary for remedying toxic waste containment sites (see our European Research Project GEOCISTEM and the GEOPOLYTECH process). See also in the Library .

Rock-based geopolymer cements and concretes for building and repairing infrastructure have very high early strength, their setting times can be entirely controlled, and they remain intact for a very long time without the need for repair. See in Davidovits’ book, Geopolymer Chemistry & Applications, the Chapters 9, 10, 24 and 25. The strength of geopolymeric rock-based geopolymer concrete is such that a heavy Boeing or Airbus can land on a runway freshly patched with geopolymeric rock-based geopolymer concrete only four hours after patching has been completed. The discovery of this new cement was awarded with a Gold Ribbon by the American National Association for Science, Technology and Society (NASTS) in 1994 (Library paper #3 NASTS award ).

Geopolymer specialty

Geopolymer ceramic

Several decades ago, ceramicists tried to manufacture ceramic tiles at temperatures lower than 450°C, without firing. Geopolymer science masters the transformation of kaolinite, the major component of ceramic clays, into geopolymers of the poly(sialate) and poly(sialate-siloxo) types. Application of this chemistry yielded several technological breakthroughs pertaining to LTGS, Low-Temperature-Geopolymeric-Setting and geopolymerized modern ceramic processing. See in Chapter 23 of Davidovits’ book Geopolymer Chemistry & Applications .

Geopolymer high-tech/ fiber reinforced composite

Geopolymer composites have three main properties that make them superior to ceramic-matrix composites, plastics, and organic composite materials.

First:
Geopolymers are very easy to make, as they handle easily and do not require high heat.
Second:
Geopolymeric composites have a higher heat tolerance than organic composites. Tests conducted on Geopolymer carbon-composites showed that they will not burn at all, no matter how many times ignition might be attempted.
Third:
The mechanical properties of Geopolymer composites are as good as those of organic composites. In addition, Geopolymers resist all organic solvents (and are only affected by strong hydrochloric acid).

Before the discovery of geopolymerization, these three critical properties had not been incorporated into any one material. More information are available in applications called GEO-COMPOSITE and GEO-STRUCTURE and in Davidovits’ book Geopolymer Chemistry & Applications , Chapter 21.

An Example of the Development of Geopolymeric Composites and Cements That Improves Air Travel Safety and Airport Efficiency*

The Chapters of the book GEOPOLYMER Chemistry & Applications dedicated to these applications are referred to in italic.

A jet is preparing for takeoff from a runway in New York as a crew begins placing a section of geopolymer concrete (Chapters 24, 25) on a Los Angeles runway. The plane is equipped with a fire-resistant geopolymer-encased electronic flight recorder. The jet’s cabin has also been rendered fireproof with sandwich panels of carbon/Geopolymite® composites (Chapter 21) and geopolymer foam insulating boards (Chapter 22). The jet is also equipped with a highly advanced fireproof air filter. Several structural components of the jet, made with an advanced SPF Al superplastic aluminum alloy, have been manufactured at 550°C using compression ceramic tools made of geopolymer materials (Chapter 20).

When the plane is ready to land in Los Angeles, the runway repaired with Pyrament® concrete will be ready for it.

*This fictitious example illustrates possible applications that are or have been manufactured and/or patented by several companies

Prof. Dr. Joseph Davidovits, Nov. 2011

Solid-Phase Synthesis of a Mineral Blockpolymer by Low Temperature Polycondensation

of Alumino-Silicate Polymers: Na-poly(sialate) or Na-PS and Characteristics .

Joseph DAVIDOVITS

INTRODUCTION

The work exposed here comes from an attempt to transfer our knowledge of organic polymers and the technologies associated with it to the yet unknown, or hardly known field of the synthesis and transformation of inorganic polymers, in order to develop new materials and new industrial processes. It is a matter of fact that inorganic materials like glass, ceramics, bricks, concrete, and most natural rocks by far outclass organic polymers with respect to their resistance to high temperature. This study provides an answer to the following question: Could we take mineral materials such as clay, kaolinite, that is to say aluminosilicate polymers, and transform them using the extreme low-temperature polymerisation technology of organic polymers ?”.The answer is : yes, we can. The resulting products have similar characteristics to natural rock‑forming minerals, such as zeolites, feldspathoids and feldspars. These different minerals are usually called silicates or aluminosilicates in the same way as kaolinite, clays, micas, mullite, andalusite, spinel, etc. that is in brief all the minerals whose empirical formula contains Si, AI, O, and any other elements such as H, Na, K, Ca, Mg, etc. For the development of our knowledge and for a better understanding of the mechanism of this new synthesis of inorganic polymers, we felt we had to introduce a more precise terminology.

Click here to see how to download paper nr 20.

Go to Video Kriven (15 minutes long video).

Course director

All the courses will be directed by Professor Joseph Davidovits, the inventor and founder of Geopolymer.

Who should attend?

The courses are for professionals with a solid chemical background (engineer degrees, master degrees) or with equivalent long-term practice.
Some courses (Geopolymer for Newcomers, Geopolymer for Investors, …) are designed for professionals involved for a wide range of development in all applications including managers, finance specialists, R&D, marketing, business decision makers, technology and product development, …

Language is English ( langue française sur demande pour 2 participants ou plus ). Each course is designed for a maximum of 10 participants in order to encourage fruitful discussions between Prof. Joseph Davidovits and the students.

Courses Schedule for 2008-2009

We are providing below the list of the courses for the year 2008 (April-December) and 2009 (January-March).

Geopolymer Course # 1: Geopolymer for Newcomers (3 days)
April 01-03, May 13-15, August 05-08, September 02-04 (in French), October 22-24 (in French), December 09-11, February 10-12, March 10-12

Geopolymer Course # 2: Metakaolin based Geopolymer Ceramics (3 days)
April 08-10, October 21-24, Other dates on demand

Geopolymer Course # 3-4: Low-energy / Low-CO₂ Cement : Slag/rock/fly ash-based Geopolymer (4 days)
April 15-17, other dates on demand,

Geopolymer Course # 5: Quality Controls, Physical and Chemical Properties (3 days)
April 28-30, Other dates on demand

Geopolymer Course # 6: Low-Energy Geopolymer Technology applied to Ceramic Industry (3 days)
May 20-22, September 09-11,

Geopolymer Course # 7: Castable Geopolymer Compounds (molds, prototypes, artifacts) (2 days)
May 27-28, Other dates on demand

Geopolymer Course # 8: Fire Resistant Geopolymer Matrix Composites (2 days)
May 29-30, Other dates on demand 

Geopolymer Course # 9: Geopolymers in Toxic and Radioactive Waste Management (3 days)
June 03-05, September 23-25, Other dates on demand

Geopolymer Course # 10: Geopolymer for Investors (2 days)
May 06-07, Other dates on demand

All courses are organized in learning / teaching sessions that allow to attend several courses in a row. So, you can attend a series of course that belong to the same topics.

Click here for the entire Courses Program

Sessions for 2008-2009

Sessions A to C

Sessions D to F

Sessions G to I

Tuition per one participant:

It includes luncheons, breaks, book and course notes;
4-day course: 1950 Euros; group rate 1800 Euros (+ tax if any)
3-day course: 1650 Euros; group rate 1500 Euros (+ tax if any)
2-day course: 1150 Euros; group rate 1050 Euros (+ tax if any)

Course location

The courses are held at the Geopolymer Institute. Please read the following pages to prepare your stay: Access Map and Prepare your stay

Client Site. You can ask for a short course at your site and at your convenience. 2 persons from the Geopolymer Institute will come (likely Prof. J. Davidovits with another person). You will have to pay for travel expenses, lodging and the tuition for a min. of 4 enrollments. For further information, please contact us.

Text

Each participant will receive for the course the most updated version of the book GEOPOLYMER Chemistry and Applications by J. Davidovits, and additional Technical Papers.

Please, go to the next page for the registration form.

Registration form

Before filling in the registration form, find the date and the course’s title you want to attend, and note its reference on the sessions’ table above. It corresponds to the session and the topic of the course. So, if we change the date (e.g. from one or two days to group several courses in a row), we will not change the reference of the course.
Then, print it, fill it in, and fax or mail it. All information about the payments and general information can be found there.

We are open to any arrangements for groups, especially from overseas, who would like to participate to two or more courses in a row, for example Wednesday-Friday and Monday-Wednesday, with a free weekend time in Paris. Because we accept few participants, we are very flexible. Do not hesitate to contact us.

How to register ?

Download the registration form in PDF format.

First, download the registration form in PDF format to read all information about your tuition and methods of payment. Then, you can either fill in this form, or do it online with the form below.

All the courses will be directed by Professor Joseph Davidovits, the inventor and founder of Geopolymer. They are for professionals with a solid chemical background (engineer degrees, master degrees) or with equivalent long-term practice. Language is English (langue française sur demande pour 2 participants ou plus). Each course is designed for a maximum of 5 participants in order to encourage fruitful discussions between Prof. Joseph Davidovits and the students.

Tuition per one participant: includes luncheons, breaks, book and course notes; + VAT
3-day course: 1650 Euros; group rate 1500 Euros
2-day course: 1150 Euros; group rate 1050 Euros

Venue
Location the Geopolymer Institute place:
Access Map

The texts for the course included in the fee are the new book GEOPOLYMER Chemistry and Applications by J. Davidovits, and additional Technical Papers.

To get the list of the courses for the year 2008 (April-December) and registration details go to Courses Schedule

Use of Inorganic Polymer to Improve the Fire Response of Balsa Sandwich Structures
J. Mat. in Civ. Engrg., Volume 18, Issue 3, pp. 390-397 (May/June 2006)
James Giancaspro, M.ASCE; P. N. Balaguru, M.ASCE; and Richard E. Lyon

Abstract
The study presented in this paper deals with the fire performance of balsa sandwich panels made using inorganic Geopolymer resin and high-strength fiber facings. A thin layer of a fire-resistant paste composed of Geopolymer and hollow glass microspheres was applied to the facings to serve as a protective fire barrier and to improve the fire resistance of the sandwich panels. Using 17 sandwich panel specimens, the primary objective of this program was to establish the minimum amount of fireproofing necessary to satisfy the Federal Aviation Administration (FAA) requirements for heat and smoke release. The influence of this fireproofing insulation on the increase in mass of the panels was also evaluated. The system is simple and inexpensive to manufacture, and a 1.8-mm-thick layer of fireproofing satisfies the FAA requirements for both heat release and smoke emission.

The link to the publication

Published at: http://www.azom.com/Details.asp?ArticleID=3171

Abstract:
A geopolymer was prepared by dissolving metakaolinite in a solution of K2SiO3 and KOH and curing at 80°C for 24 h. It was progressively heated from ambient to 1400°C in air and the phase changes were studied by X-ray diffraction analysis, scanning electron microscopy and energy dispersive X-ray spectroscopy. Only an amorphous geopolymer phase was observed on heating up to 800°C. Kalsilite was the major phase at 1000°C and 1250-1400°C. At 1200°C leucite was the major phase formed. At 1400°C there was no sign of significant melting. The open porosity of the material was ~ 38% at 1000°C, which is sufficiently porous for it to be used as a heat insulation material for continuous use at this temperature.

The first report: Report GC 2 is dealing with the long term properties. It has been included in the Technical Paper #17 in the Library, in addition to the previous report GC 1.

The second : Report GC 3 describes the properties of Beams and Columns. It is named Technical Paper #18 in the Library.

Published in The Indian Concrete Journal, April 2014, Vol. 88, Issue 4, pp. 41-48, 50-59.

Professor Vijay Rangan is Australia Mr. Concrete. He presents here a review on the extensive studies conducted on fly ash-based geopolymer concrete. Salient factors that influence the properties of the geopolymer concrete in the fresh and hardened states are identified. Test data of various short-term and long-term properties of the geopolymer concrete are then presented. The paper describes the results of the tests conducted on large-scale reinforced geopolymer concrete members and illustrates the application of the geopolymer concrete in the construction industry. Some recent applications of geopolymer concrete in the precast construction and the economic merits of the geopolymer concrete are also included.

It is the complement of previous Research Reports GC1 and GC2 that covered the development, the mixture proportions, the short-term properties, and the long-term properties of low-calcium fly ash-based geopolymer concrete, see paper #17 .

The study demonstrated that the design provisions contained in the Australian Standard for Concrete Structures AS3600 and the American Concrete Institute Building Code ACI318-02 are applicable to reinforced Fly ash-based geopolymer concrete columns.

Click here to see how you can download paper number 18.

Concrete experts talk today about how to make concrete durable. Many ancient Roman concrete buildings are still in use after more than 2000 years. For these modern concrete experts, the Romans were fortunate builders in that they apparently simply used natural pozzolan deposits, which were found to be suitable for producing a hydraulic mortar. Contrary to this pronouncement, our recent linguistical study and new translation of Latin author Vitruvius’ book De Architectura (1st Century B.C.) states that the magnificent quality of Roman concrete resulted from the extensive use of artificial pozzolanic mortars and concretes. Two artificial pozzolans were intensively manufactured:

1. calcined kaolinitic clay, in Latin testa
2. calcined volcanic stones, in Latin carbunculus

See in #D The synthetic pozzolanic mortar by Vitruvius and #E Searching for Carbunculus .

In addition to these artificial reactive ingredients, the Romans used a natural reactive volcanic sand named harena fossicia wrongly translated as pit sand or simply sand by modern authors. The ingredients testa, carbunculus and harena fossicia were intensively used in Roman buildings. These reactive ingredients must not be confused with the traditional pozzolan whose name originates from the city of Puzzuoli, near Napoli (Mt Vesuvio). According to Vitruvius Book V, 12, the traditional pozzolan was exclusively used for making piers into the sea or foundations for bridges, whereas harena fossicia, carbunculus and testa produced the concrete for buildings on land.

Roman concrete technology was more efficient than traditional building with hewn stone. The Table compares the construction time for the domes of most famous world monuments.

Construction time for dome structures made of concrete and hewn stone

From the digging of ancient Roman ruins, one knows that approximately 95% of the concretes and mortars constituting the Roman buildings consist of a very simple lime cement, which hardened slowly through the precipitating action of carbon dioxide CO₂, from the atmosphere. This is a very weak material that was used essentially in the making of foundations and in buildings for the populace. But for the building of their “ouvrages d’art”, the Roman architects did not hesitate to use more sophisticated and expensive ingredients. These outstanding Roman cements are based on the calcic activation of ceramic aggregates (testa) and alkali rich volcanic tuffs (cretoni, pozzolan) respectively with lime. The excess of unreacted lime recarbonates slowly into Ca-Carbonate. Conventional mineralogical analysis does not provide satisfactory explanation of the hardening mechanism. Yet, owing to the powerful MAS-NMR Spectroscopy investigation of these archaeological cements, one was able to distinguish two geopolymeric archaeological Roman cement analogues, dating to the 2nd. c. AD. See the scientific analysis on these high-performance Roman cements in paper nr 28 of Geopolymere ‘99 Proceedings and in Archaeo-Analogues .

Civil infrastructures, especially works related to water storage (cisterns, aqueducts) required a high-performance material and a special technology. The technology of this first Roman cement analogue was known under the generic technical term of Opus Signinum obtained by blending crushed and sieved ceramic, in Latin testa, with lime. According to the Roman author Plinius (Natural History, Book 35, 165), this technology was recognized as: ”… one of the most spectacular inventions of mankind …” The ingredient testa is a special ceramic powder from calcined kaolinitic clay (alumino-silicate oxide) and therefore identical to the MK-750 (or kandoxi) ingredient in modern geopolymeric cements. We performed 29 Si and 27 Al NMR Spectroscopy on Opus Signinum samples, dating to the 2nd Century A.D. There spectra are identical to those of modern GEOCISTEM Geopolymeric cements.

The second Roman cement analogue involved the use of an artificial pozzolan named in Latin Carbunculus. Analysis were carried out on samples from Ostia, 2nd-3rd Century A.D.

See the scientific analysis on Roman cements in Archaeo-Analogues .

Geopolymer insure thermal protection of industrial buildings and facilities up to 1200°C. Hüls AG (Dynamit Nobel) and its licensees, including Willig, have invented the TROLIT-WILLIT material known as the “mineral plastic” involved in the manufacture of:

• Expanded foam
• Monolithic compound
• Composite

Sources: Annual reports. In the recently updated book GEOPOLYMER Chemistry & Applications these geopolymeric applications are outlined in Chapter 22.

Geopolymer composite material for structural or protective applications, temperature range 300°C to 1000°C.

These peculiar materials are now tested and used for their outstanding properties.

During the Grand Prix season 1994 and 1995, Benetton-Renault Formula 1 Sport Car designed a unique thermal shield made out of carbon/geopolymer composite. It helped Michael Schumacher to win twice the world championship and offered to his technical team to become World Champion of car builders during these two years. Still today, most Formula 1 teams are using geopolymer composite materials. A geopolymer-composite exhaust pipe system has been developed by Porsche. Source: Porsche PCT Patent, 2004.

The Federal Aviation Administration (F.A.A.), Rutgers State University, U.S.A., and other Institutions have initiated an evaluation program for these new composite materials. These materials would contribute to be the standard in fire protection for the aeronautic industry. In the recently updated book Geopolymer Chemistry & Applications the fire and heat resistant composite applications are thoroughly outlined in Chapter 21. You may also go to the Geopolymer Library and download several papers.

The First Non-flammable fabric laminate for Aircraft cabin and cargo interiors, geopolymer Composite was introduced on November 18, 1998, in Atlantic City, NJ, USA, at the International Aircraft Fire and Cabin Safety Research Conference sponsored by the Federal Aviation Administration.

For other Fireproof, Fire Resistant Applications (ship, ferry), see also in GEOPOLY-THERM .

The Federal Aviation Administration (F.A.A.), USA, has recently initiated a research program to develop low-cost, environmentally-friendly, fire resistant matrix materials for use in aircraft composites and cabin interior applications. The flammability requirement for new materials is that they withstand a 50 kW/m² incident heat flux characteristic of a fully developed aviation fuel fire penetrating a cabin opening, without propagating the fire into the cabin compartment. The goal of the program is to eliminate cabin fire as cause of death in aircraft accidents. However, voluntary adoption of the new materials technology by aircraft and cabin manufacturers requires that it be cost effective to install and use, so it is expected that these new aircraft materials will be broadly applicable in transportation and infrastructure where a high degree of intrinsic fine resistance is needed at low to moderate cost. To this end the F.A.A. is evaluating a new, low-cost, inorganic geopolymer matrix derived from the naturally occurring geological materials- silica and alumina. At irradiance levels of 50 kW/m² typical of the heat flux in a well developed fire, glass- or carbon-reinforced polyester, vinylester, epoxy, bismaleinide, cyanate ester, polyimide. phenolic, and engineering thermoplastic laminates ignited readily and released appreciable heat and smoke, while carbon-fiber reinforced geopolymer composites did not ignite, burn, or release any smoke even after extended heat esposure.

In the recently updated book Geopolymer Chemistry & Applications the fire and heat resistant composite applications are thoroughly outlined in Chapter 21. You may also go to the Geopolymer Library and download several papers..

Excerpt from the technical press
Performance Materials,
February 5, 1996, page 5.

As Hot as You Like It

Mechanical Properties are Looking Good for French Inorganic Polymer that Doesn’t Burn.

Fire safety is a concern often voiced by those who are skeptical about the use of composite materials in the infrastructure. These fears may be put to rest by a revolutionary European matrix material that doesn’t burn at all (PM, July 31, 1995). “Fire is going to be the limiting criterion in a lot of infrastructure applications C says Rich Lyon of the Federal Aviation Administration (FAA) Tech Center in Atlantic City. But his ICCI ‘96 presentation about the new family of inorganic polymer composites was almost anticlimactic. “It’s a fairly boring story because there is no fire response,” Lyon said in Tucson.

FAA Is Interested, Too

The inorganic polymeric materials are cheap, at about $2-3 a pound. They cure at low temperatures.
And now there is evidence that the new material family, trade named Geopolymer (or, more precisely, Géopolymère), boasts mechanical properties comparable to those of organic-matrix composites. FAA-supported testing was conducted at Rutgers University in New Jersey.
“The initial results are very encouraging: Prof. P (Bala) Balaguru of Rutgers said at the Tucson infrastructure meeting. Carbon-matrix composites made with the Geopolymer matrix demonstrated a strength of approximately 327 MPa (about 225 ksi), he said, quite comparable to organic composites. “The same thing is true for flex and shear;’ Balaguru said. The Rutgers test coupons were made using 3K, polyacrylonitrile-based carbon fiber that was manually impregnated and vacuum-bagged for curing in an 80°C (176°F) heated press. The samples were post-cured in an 80°C oven for 24 hours.
Experimenters have thus far made samples only via hand layup, and have been able to achieve fiber loadings of only 50 % (the Rutgers tests were conducted on 45-percent material). At least 60 % is expected when fabrication processes are refined, says the FAA’s Lyon. Problems with voids are also expected to be solved when better fabrication techniques are applied.
“These materials are in their infancy) FAA Lyon says. Geopolymer inventor Joseph Davidovits spent much of his career as a textile chemist and began pursuing inorganic polymers in part, he says, behind a tragedy in France in which the deaths by fire of more than 100 young night club patrons were attributed to fast-burning polyester curtains. Davidovits cites three key Geopolymer attributes his company says “make them superior to ceramics, plastics, and organic composite materials:” (Performance Materials, February 5, 1996).

The First Non-flammable fabric laminate for Aircraft cabin and cargo interiors, Géopolymère Composite was introduced on November 18, 1998, in Atlantic City, NJ, USA, at the International Aircraft Fire and Cabin Safety Research Conference sponsored by the Federal Aviation Administration. More details in Press Release (see page 3)

Predicted time to flashover in ISO 9705 corner/room fire test with various structural composites as wall materials

Press Release, November 20, 1998
The First Non-Flammable Material for Aircraft Cabin Safety presented at FAA.

Fire Safety Meeting in Atlantic City, New Jersey, USA

The First Non-flammable fabric laminate for Aircraft cabin and cargo interiors, Géopolymère Composite was introduced on November 18, 1998, in Atlantic City, NJ, USA, at the International Aircraft Fire and Cabin Safety Research Conference sponsored by the Federal Aviation Administration.

Current aircraft design utilizes several tons of combustible plastics for cabin interior components that includes the passenger compartment, cockpit and cargo compartments. This is a fire load comparable to the equivalent weight of aviation fuel. The recent introduction of fly-by-wire control system as well as the increase of electronics components on an aircraft (such as flat panel displays for TV, telephones and computers) represents a new, higher risk of electrical fires and the potentially tragic consequences of uncontained in-flight fires. The FAA is working to eliminate cabin fire as a cause of death in aircraft accidents. In the unusual event of an aircraft accident, there are only seconds for passengers to escape before toxic fumes and fire fill the cabin compartment.

The FAA flammability requirement for new materials is that they must withstand the 50-kw/m² incident heat flux characteristic of a fully developed aviation fuel fire that penetrates the cabin skin. The material must prevent propagation of the fire into the cabin compartment. The first material to withstand this arduous test is Géopolymère Composite developed by Professor Joseph Davidovits of the Geopolymer Institute in France. Géopolymère Composite is described as an inorganic polymer (a silico-aluminate polysialate polymer) derived from the naturally non-flammable occurring geological materials silica and alumina, hence the name Geopolymer or Géopolymère in French.

Since January 1994, the Federal Aviation Administration has conducted a research and evaluation program on carbon fiber reinforced Géopolymère Composite. Tests were carried out at the FAA Fire Research Section, FAA Technical Center, Atlantic City, NJ and at the Department of Civil Engineering, Rutgers, The State University of New Jersey, in collaboration with Prof. Davidovits’ French company, CORDI-Géopolymère SA, Saint-Quentin, France. The FAA experiments indicate that even after exposure to a severe fire environment (more than 1,500°F during several hours), the carbon fiber reinforced Géopolymère Composite retained 63 % of its original flexural strength of 245 Mpa (approximately 169 ksi). In comparison, all materials presently used in an aircraft, including aluminum sheets and parts, organic based laminate composites and plastics, actually burn and are destroyed when submitted to the same severe fire environment.
Aircraft operators and manufacturers are sensitive to cost and cost-effectiveness. Aircraft operators estimate that each pound of weight on a commercial aircraft costs between $100 to $300 in operating expenses over the service life of the aircraft. Consequently, fire safe materials for use in aircraft must be extremely lightweight. With its low density of 1.85, carbon fiber reinforced Géopolymère Composite is lighter than aluminum (density 2.70) and structural steel (density 7.86).

Infrastructure in the United States such as bridges are degrading due to the corrosion of steel-reinforced concrete by salty water and deicing compounds. A relatively new and little known repair method for concrete and brick structures, consists of externally bonding flexible sheets of fiber composites. Another application for continuous fiber composites in infrastructure, already well underway in Japan (with organic matrix) is the wrapping of concrete columns to reinforce new construction and damaged bridges and buildings in earthquake and hurricane prone areas. In this application, particularly for beams, interior building columns, flammability is a serious concern. The flammability of organic polymer matrix, fiber-reinforced composites also limits the use of these materials in offshore oil platforms, military vehicles and public transportation where fire endurance and fire hazard are important design considerations.

This susceptibility to fire currently limits the use of polymer composites in infrastructure precluding any useful advantage in specific strength/ stiffness and corrosion resistance compared to steel or concrete. Carbon-fiber reinforced geopolymer composites did not ignite, burn, or release any smoke even after extended heat flux.The geopolymer matrix carbon fiber composite retains sixty-three percent of its original 245 MPa flexural strength after a simulated large fire.

For further information download the paper #2 Reinforced concrete beams with Geopolymer-Carbon composite .

Sticks Better, Too

Not Only Does the Material Not Burn, But It Adheres Better than Epoxy to Concrete.

Experiments by researchers at Rutgers University indicate that a new European composite material dubbed Geopolymer not only does not burn, but adheres better to concrete more effectively and reliably than organic materials, paving the way for use in strengthening both new concrete structures and enhancing old ones.

Fabrics Fail First

“Geopolymer provides excellent adhesion both to concrete surface and in the interlaminar planes of fabrics;’ states Prof. Bala Balaguru of Rutgers University. Geopolymer composites were affixed to concrete beams, and “all three beams failed by tearing of fabrics;’ Balaguru reports. “This is significant because … the most common failure pattern reported in the literature is the failure by delamination of fabrics at the interface of concrete and fabrics;’ says the report. “Hence it can be stated that Geopolymer provides as good or better adhesion in comparison with organic polymers”.

At least part of the Rutgers research is funded by the Federal Aviation Administration, which is interested in Geopolymer for aircraft interiors. “Tests conducted on Geopolymer carbon-composites showed that they will not burn at all, no matter how many times ignition might be attempted;’ developers say.

Other results

Beam prior to start of testing Geopolymer-Carbon unidirectional fabric (2,3,5 layers) at the bottom surface of the beam

Summary of test Results

Technical Data Sheet for Geopolymeric cement type (Potassium, Calcium) – Poly(sialate-siloxo) / (K,Ca) – (Si-O-Al-O-Si-O-), Si:Al=2:1

Further details in Davidovits’ book, GEOPOLYMER Chemistry & Applications, Part III, Properties, Chapters 15 to 18, GEOCISTEM , GLOBAL WARMING, and also previous papers in the Geopolymer Library.

Tested on standard sand mortar prisms:

• setting: 10 hours at -20°C to 7-60 minutes at +20°C.
• shrinkage during setting: <0,05%, not measurable.
• compressive strength (uniaxial): > 90 MPa at 28 days (for high early strength formulation, 20 MPa after 4 hours).
• flexural strength: 10-15 MPa at 28 days (for high early strength 10 MPa after 24 hours).
• Young Modulus: > 2 GPa.
• freeze-thaw: mass loss < 0,1% (ASTM 4842), strength loss < 5% after 180 cycles.
• wet-dry: mass loss < 0,1% (ASTM 4843).
• pH: crushed and powdered, 11-11,5 after 5 minutes in deionized water (compared to Portland cement: 12 to 12,5, and granite: 11).
• leaching in water, after 180 days: K₂O < 0,015%.
• water absorption: < 3%, not related to permeability.
• hydraulic permeability: 10-10 m/s.
• Sulfuric acid, 10%: mass loss 0,1% per day.
• chlorhydric acid 5%: mass loss 1% per day.
• KOH 50%: mass loss 0,02% per day.
• ammoniac solution: no mass loss.
• sulfate solution: shrinkage 0,02% at 28 days.
• alkali-aggregate reaction: no expansion after 250 days, -0,01% (compared to Portland Cement with 1% Na₂O, +1,5%).
• linear expansion: < 5.10-6/K.
• heat conductivity: 0,2 to 0,4 W/Km.
• specific heat: 0,7 to 1,0 kJ/kg.
• electrical conductivity: strongly dependent on humidity.
• thermal stability:
  • mass loss < 5% up to 1000°C.
  • strength loss < 20% at 600°C, < 60% at 1000°C

Other values:

• D.T.A.: endothermic at 250°C (zeolitic water).
• MAS-NMR spectroscopy:
  • 29Si: SiQ₄, major resonance at -94,5 ± 3ppm.
  • 27Al: AlQ(4Si), major narrow resonance at 55 ± 3ppm.
• Energy consumption: SEC for cement 1230-1310 MJ/tonne (compared to Portland clinker 3500 MJ/tonne).
• CO₂ emission during manufacture: 0,180 t/tonne of cement (compared to Portland clinker 1,0 t/tonne).

Prof. Joseph Davidovits presents the road map for the next couple of years on geopolymer science innovation and research, at the 2^nd International Congress on Ceramics, Verona, Italy, July 4th, 2008.

There is a great need for innovation and therefore further research must be carried out. We have listed below the topics that deserve further involvement in the field of chemistry, physical-chemistry, materials science, and others. These needs are outlined in Davidovits’ book Geopolymer Chemistry & Applications, generally at the end of the chapter dedicated to the topic, and are given in the list.

We hope that this initiative will minimize the number of scientific papers and conference communications that are simply re-inventing the wheel, i.e. replicate studies and research already performed by others, sometimes several decades ago, and outlined in the reference book Geopolymer Chemistry & Applications.

The GeopolymerCamp is the opportunity to prepare the new edition of the book Geopolymer Chemistry & Applications. Indeed, the Geopolymer Institute wishes to publish every year a new revised edition with the most up to date information. During this session, participants will propose subjects or issues that are worthwhile to be edited or added, and the assembly will discuss about it. Prepare your arguments if you want to see your last research, data, applications be added to this reference book.

Research topics:

Chapter 2: Polymeric character of geopolymers: geopolymeric micelle
“Further research is needed to provide scientific tools for the determination of several physical parameters such as overall dimension and molecular weight.”

Let physicochemical research institutions confirm covalent bonding system. Determine the molecular weight of the geopolymer micelle, a nanosized particulate detected by W. Kriven in 2003.

Chapter 5: Poly(siloxonate), soluble silicate (waterglass)
“The standard industrial silicates are mixtures of several silicate species (…) Any changes in the industrial fabrication parameters will strongly affect the nominal mixture composition and the geopolymeric properties of the soluble silicates obtained with these glasses (…) Nevertheless, researchers in geopolymer science should always keep in mind these data when developing tailored industrial geopolymer applications (…) Further research on this important topic will probably provide additional 3-D structures connected with the solid rings and polygons disclosed in Figure 5.9. (…) Further research is needed on this crucial technology.”

Let modify and master the manufacture process in order to get uniformity and quality control on the molecular sizes of Na-poly(siloxonate), K-poly(siloxonate) (soluble silicate).

Chapter 8: Metakaolin MK-750-based geopolymer
“In general, (Na,K)–poly(sialate-siloxo) is not made of single polymeric macromolecules but consists of a mixture, a solid solution, of at least two well defined geopolymers with different Si:Al ratios. The standardized methods of investigation, like ²⁹Si and ²⁷Al NMR spectroscopy, are not sophisticated enough for the detection and separation of these different macromolecules. Future research is necessary. (…) The identification of Al-O-Al bonding in geopolymers has been confirmed by ¹⁷O MAS-NMR spectroscopy as the one displayed in Figure 8.24… The effect seems to diminish with the increase of the Si:Al ratio, when oligo-siloxonate molecules, Q₀ , Q₁ and Q₂ types are added to the geopolymeric reactant mixture. Further research is needed.”

Chapter 9: Calcium-based geopolymer
“There is production of two geopolymers: hydrated gehlenite and (Na,K)–poly(sialate-siloxo), and in addition calcium di-siloxonate hydrate (CSH cement type). Further research is needed on this very interesting topic of ancient Roman technology. (…) We could also assume that, in the hydrated state, our geopolymeric structures are more flexible than the rigid anhydrous chains. Their molecular arrangement might comply with the replacement of K⁺ with Ca⁺⁺. Further research is needed to clarify this important issue.”

Chapter 10: Rock-based geopolymer
“The extrapolation from the solid solution structures set forth in Chapter 9 would probably focus on the Ca-siloxonate-hydrate, and its resonance at -78 ppm for Q₁ structure in the ²⁹Si spectrum of Figure 10.5. However, in addition to the dimer Ca-di-siloxonate hydrate molecule, one could get higher oligomers: trimer, tetramer, pentamer, hexamer, with cyclic structures similar to those depicted for soluble silicates in Figure 5.13 of Chapter 5 as well as in Figure 2.8 of Chapter 2. Further research is needed.”

Chapter 11: Silica-based geopolymer
“The geopolymer composite has a high potential for fire-heat resistant coatings as well as corrosion resistant paint for steel. With tailored ceramic fillers one obtains heat stable materials with remarkable heat resistance. Further research is needed. (…) These results highlight the need for caution during the use and disposal of these manufactured nanomaterials to prevent unintended environmental impacts, as well as the importance of further research on tailored formulations aimed at preventing any risk.”

Chapter 12: Fly ash-based geopolymer
“Overall, the geopolymer matrix gives a Si:Al molar ratio ranging from 1.56–2.14 corresponding to a poly(sialate-siloxo) with inclusions of siloxonate-hydrate molecules consisting of higher oligomers: trimer, tetramer, pentamer, hexamer, with cyclic structures similar to those depicted for soluble silicates in Figure 5.13 of Chapter 5 as well as in Figure 2.8 of Chapter 2. Further research is needed. (…) Gasifier slag consists of four main components: silica, alumina, iron oxide and calcium oxide, mainly added as a flux in the gasification process. The gasifier slag composition is similar to that of iron blast-furnace slag (Sullivan and Hill, 2001). In other words, a possible shortage of iron blast-furnace slag would be easily compensated by the production of gasifier slag, opening new perspectives for the industrial implementation of geopolymers issuing from coal combustion in electrical power plants. Further research is needed.”

Chapter 13: Phosphate-based geopolymer
“Several laboratories are working on the inclusion of PO₄ units into sialate and sialate-siloxo sequences. Data have not been published, so far. Further research is needed on these materials that show promising potential applications.”

Chapter 14: Organic-mineral geopolymer
“Further research is needed in order to take advantage of the chemical compatibility of poly-organo-siloxane and mineral geopolymers. (…) Further research is needed on the geopolymerization mechanism in acid medium. (…) The previous examples show the potentiality of organo-mineral geopolymer compounds. Further research is needed.”

Chapter 17: Long-term durability
“As for technological applications of geopolymeric materials in waste management, any risk assessment must contain input from geological and geochemical analogues. The problem is the very low amount of available data on this topic. Further research is needed.

Chapter 21: Geopolymer-fiber composites
“In this Chapter, the best results involved the use of carbon or SiC fibers that are more expensive than E-glass. Future research will therefore take advantage of the geopolymeric systems outlined in Chapter 13 with phosphate based acidic matrix. This chemistry is not as aggressive to E-glass as the alkali driven poly(sialate) medium.”

The introduction of composites on a large scale in aircraft manufacture by Boeing and Airbus highlights the demand for fire- as well as heat-resistant geopolymer matrices.

Chapter 23: Geopolymer in ceramic processing
Introduce and develop LTGS for the production of low-cost building materials in developing countries with user-friendly geopolymeric ingredients.

Chapter 24: The manufacture of geopolymer cements
“We have learned in Chapter 19 that these dry mixes based on dry NaOH/KOH are corrosive in nature and may not be used (see in section 19.2, The need for user-friendly systems ). Research and development should therefore focus on innovative solutions involving the manufacture of ready to use, user-friendly, geopolymeric precursors. (…) Further research and development is needed on this very important technology.”

The major obstacle to the mass application of geopolymer cements comes from the chemical industry that is unable to manufacture the estimated 250-300 millions tonnes / year of alkali-silicates poly(siloxonates) needed for mass production of geopolymer cements, world-wide (presently ca. 15 millions tonnes / year). One must invent new methods of manufacture for poly(siloxonate) glasses, from geological raw-materials rich in K₂O and Na₂O, as in the European Research project GEOCISTEM (Brite-Euram 1994-1997).

Chapter 25: Geopolymer concrete
“When one adds together the properties described in this Chapter 25, and the chemical and physical parameters of geopolymer cements outlined in previous chapters, it becomes evident that geopolymer concrete is better than Portland cement concrete. Yet, further research is needed to apply and generalize to all geopolymer concrete types the results obtained by B.V. Rangan and his team.”

From 2001, we have conducted some important research on the development, manufacture, behaviour, and applications of Low-Calcium Fly Ash-Based Geopolymer Concrete. This concrete uses no Portland cement; instead, we use the low-calcium fly ash from a local coal burning power station as a source material to make the binder necessary to manufacture concrete. Concrete usage around the globe is second only to water. An important ingredient in the conventional concrete is the Portland cement. The production of one ton of cement emits approximately one ton of carbon dioxide to the atmosphere. Moreover, cement production is not only highly energy-intensive, next to steel and aluminium, but also consumes significant amount of natural resources. In order to meet infrastructure developments, the usage of concrete is on the increase. Do we build additional cement plants to meet this increase in demand for concrete, or find alternative binders to make concrete?

In this work, low-calcium (ASTM Class F) fly ash-based geopolymer is used as the binder, instead of Portland or other hydraulic cement paste, to produce concrete. The fly ash-based geopolymer paste binds the loose coarse aggregates, fine aggregates and other un-reacted materials together to form the geopolymer concrete, with or without the presence of admixtures. The manufacture of geopolymer concrete is carried out using the usual concrete technology methods. As in the case of OPC concrete, the aggregates occupy about 75-80 % by mass, in geopolymer concrete. The silicon and the aluminium in the low-calcium (ASTM Class F) fly ash react with an alkaline liquid that is a combination of sodium silicate and sodium hydroxide solutions to form the geopolymer paste that binds the aggregates and other unreacted materials.

This paper contains 2 reports. The first Report GC1 (curtin-flyash-GP-concrete-report.pdf) describes the mixes and the short term properties. The second Report GC2 (curtin_flyash_GC-2.pdf) provides the long term properties. See the conclusions below.

Click here to see how you can download paper number 17.

Based on the test results, the following conclusions are drawn:
1. There is no substantial gain in the compressive strength of heat-cured fly ash- based geopolymer concrete with age.
2. Fly ash-based geopolymer concrete cured in the laboratory ambient conditions gains compressive strength with age.
3. Heat-cured fly ash-based geopolymer concrete undergoes low creep.
4. The creep coefficient, defined as the ratio of creep strain-to-instantaneous strain, after one year for heat-cured geopolymer concrete with compressive strength of 40, 47 and 57 MPa is around 0.6 to 0.7; for geopolymer concrete with compressive strength of 67 MPa this value is around 0.4 to 0.5.
5. The heat-cured fly ash-based geopolymer concrete undergoes very little drying shrinkage in the order of about 100 micro strains after one year. This value is significantly smaller than the range of values of 500 to 800 micro strain for Portland cement concrete.
6. The drying shrinkage strain of ambient-cured specimens is in the order of 1500 microstrains after three months. This value is many folds larger than that of heat- cured specimens, and the most part of that occurs during the first few weeks.
7. The test results demonstrate that heat-cured fly ash-based geopolymer concrete has an excellent resistance to sulfate attack.
8. Exposure to sulfuric acid solution damages the surface of heat-cured geopolymer concrete test specimens and causes a mass loss of about 3% after one year of exposure. The severity of the damage depends on the acid concentration.
9. The sulfuric acid attack also causes degradation in the compressive strength of heat-cured geopolymer concrete; the extent of degradation depends on the concentration of the acid solution and the period of exposure. However, the sulfuric acid resistance of heat-cured geopolymer concrete is significantly better than that of Portland cement concrete as reported in earlier studies.

(1) B.P.S. Engineering GmbH
(2) WISMUT GmbH
(3) Cordi-Géopolymère SA

published in the Géopolymère ‘99 Proceedings, 2nd International Conference on Geopolymers

Sludges containing radionuclides, toxic heavy metals and hydro-carbons can be solidified by geopolymer with excellent long-term structural, chemical and microbial stability, satisfying high standards of contaminant retention. The novel technology gives a monolithic product which can be easily handled, stored and monitored. It requires only simple mixing and moulding technology known from conventional solidification methods.

Extensive laboratory investigation has been carried out to demonstrate the performance of the novel solidification method under adverse stress conditions. In particular, the sludges of a treatment facility for uranium mining effluents and sludges from a settling pond, contaminated organically, radioactively and by heavy metals, have been treated. An optimized two-step technology, known as geopolymer, was successfully adapted to the specific characteristics of these sludges. Moreover, the geopolymer process has been shown to deliver excellent results for radioactive and arsenic-loaded sludges from municipal drinking water purification plants that are sensitive with respect to public risk perception and regulatory policy.

Pilot-scale experiments that show the method’s maturity for industrial use and to provide realistic material and operation cost estimates were done for the uranium mine sludges. Several tons were solidified in WISMUT’s Schlema-Alberoda water treatment plant in 1998. Our results clearly show that geopolymer solidification is a prime candidate to fill cost-efficiently the gap between conventional concrete technology and vitrification methods. Due to the reduced effort to prepare, operate and close the landfill, solidification by geopolymer leads to approximately the same unit cost as by conventional portland cement, but provides in most aspects the performance of vitrification.

The paper is divided into two parts. Part I describes in detail the basic principles of geopolymer and the laboratory investigations carried out to develop a viable solidification technology. After briefly introducing the basic principles of the Geopolytec® process and comparing it to conventional solidification methods, our paper shows promising results that were obtained for the long-term stability and contaminant retention of under several testing procedures. Subsequently, the experience from the pilot-scale experiment in the water treatment facility of WISMUT is presented. It shows that the Geopolytec® process is now mature for industrial application.

Part II is devoted to a pilot-scale experiment in which about 10 tons of radioactive and toxic sludges were solidified by the Geopolytec® process.

Finally, the prospects and market potential for the solidification of sludges by geopolymer are discussed, and an outlook to future activities is given.

Click here to see how you can download paper number 13.

Geopolymers of the Poly(sialate-disiloxo) type (- Si-O-Al-Si-O-Si-O -), very-low viscosity inorganic resins, harden like thermosetting organic resins, but have use-temperature range up to 1000°C (1830°F). High-temperature techniques are no longer necessary to obtain materials which are ceramic-like in their properties. Geopolymers provide faithful reproduction of mold or die surface and allow for precision and fineness. Geopolymer composite-tooling and geopolymer castable-tooling offer direct replication, on-site construction capabilities and very short cure-cycle. They enable product designers and tool makers to envisage the use of ceramic type materials with the same facility as organic polymers. Geopolymer composite and castable tooling have been fabricated and are in use, processing APC-2 thermoplastic materials as well as PMR-15 polyimides.

Click here to see how you can download paper number 9.