The invention relates to geopolymer compositions, geopolymers and methods for their production and use. The geopolymers may be used as aggregates, and those aggregates may be used in concrete manufacture. The geopolymer composition comprises fly ash or a fly ash substitute, an aluminium phyllosilicate, an alkaline component and water, wherein the water is present at an amount of about 6% to about 10% by weight of the composition. The geopolymers are made by forming a geopolymer composition as described above, compacting the mixture by applying pressure of about 50 to about 90 kg/cm.sup.2, and curing the compacted mixture to form the geopolymer.

The invention is directed to compositions and methods for the manufacture of pigmented solids structures for which can be used for construction and/or decoration. Manufacturing comprises fixing one or more pigments to an aggregate material such as crushed rock, stone or sand. The pigmented aggregate is incubated with urease or urease producing microorganisms, an amount of a nitrogen source such as urea, and an amount of calcium source such as calcium chloride forming calcite bridges between particles of aggregate. The resulting solid has a hardness and colorfastness for most any construction material. Using selected aggregate and pigment, the process also provides for the manufacture of simulated-stone materials such as clay or granite bricks or blocks, marble counter-tops, and more. The invention is also directed to composition containing microorganisms and pigment as kits that can be added to most any aggregate materials.

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.

The present invention relates to the manufacture of aggregates from mine tailings, and to the use of said aggregates, pellets and/or fine aggregates in engineering applications as fillers, bases and sub-bases or in concrete mixtures.

A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar, patching materials for road repairs and other repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium sulfoaluminate cement, a calcium sulfate and a chemical activator with water.

Disclosed herein are cementitious compositions comprising a non-aqueous fluid and an alkali-activated material. The non-aqueous fluid can include a natural oil, a synthetically derived oil, one or more surfactants, or a combination thereof. In some embodiments, the non-aqueous fluid can include an oil based mud, a synthetic based mud, or a mixture thereof. The alkali-activated material in the cementitious composition can be derived from an aluminosilicate material and an alkaline activator. In some embodiments, the aluminosilicate material includes fly ash. The alkaline activator can be selected from an alkali-hydroxide, an alkali-silicate, an alkali carbonate, an alkali bicarbonate, an alkali sulfate, and a mixture thereof. Wellbore servicing composition, such as compositions to reduce lost circulation of drilling fluids or cement a casing into the borehole, comprising the cementitious compositions are also disclosed. Methods for preparing and using the cementitious compositions are also disclosed.

Binder for the additive production of manufactured items, in particular made of conglomerate, adapted to be distributed on a layer of inert granular material in order to form a rigid matrix incorporating the granules of the inert granular material. The binder according to the invention is a substantially inorganic binder with geopolymer base. Another object of the invention is a process for the additive production of manufactured items by means of the use of the aforesaid binder and the use of geopolymers as binders in the additive production of manufactured items.

A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar and repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium aluminate cement, a calcium sulfate and a chemical activator with water.

A method of controlling the setting time of a geopolymer by coating aluminosilicate particles with nanoparticles to slow the geopolymerization reaction. The coating effectiveness of the nanoparticles may be enhanced by pretreating the aluminosilicate particles with a layer-by-layer assembly of polyelectrolytes. A geopolymer is formed by mixing about 39% to about 66% by weight aluminosilicate source, about 0% to about 40% by weight sand, about 19% to about 33% by weight of alkali activator solution, and about 1% to about 4% nanoparticles.

A geopolymer brick fabrication system comprising a mixer (100) having a tank (101) which comprises a closeable bottom outlet (102) and an inner surface coated with saturated polyester resin that is resistant against corrosive geopolymeric material for receiving the geopolymer raw material to be mixed by shaft (103) driven by a spindle motor (104) a molding section (200) to receive the mixed geopolymer raw material through a slanted conveyer (105) upon opening of the closeable outlet (102) for shaping the mixture under pressure inside a mold (201) to obtain a geopolymer brick and a curing section (300) having a moving platform (301) across a curing chamber (302) to simultaneously cure and transport the brick thereon.