The invention is directed to a fly ash containing construction material having improved strength and water resistance. The fly ash containing material includes fly ash, an alkali solution comprising sodium hydroxide, and water. The invention further provides a geopolymerization method of forming a fly ash containing material.

The invention is directed to a fly ash containing construction material having improved strength and water resistance. The fly ash containing material includes fly ash, an alkali solution comprising sodium hydroxide, and water. The invention further provides a geopolymerization method of forming a fly ash containing material.

The invention relates to methods for manufacturing an inorganic polymer object from a precursor wherein the precursor consists of one or more or comprises one or more selected from the group consisting of gibbsite-containing bauxite, gibbsite containing residue of the Bayer process, thermally processed gibbsite-containing bauxite, and thermally processed gibbsite-containing residue of the Bayer process, the method comprising the steps of alkaline-activating said precursor, mixing the precursor, shaping the mixed precursor and hydrothermally curing the shaped precursor at a temperature between 70° C. and 350° C.

The invention relates to methods for manufacturing an inorganic polymer object from a precursor wherein the precursor consists of one or more or comprises one or more selected from the group consisting of gibbsite-containing bauxite, gibbsite containing residue of the Bayer process, thermally processed gibbsite-containing bauxite, and thermally processed gibbsite-containing residue of the Bayer process, the method comprising the steps of alkaline-activating said precursor, mixing the precursor, shaping the mixed precursor and hydrothermally curing the shaped precursor at a temperature between 70° C. and 350° C.

A composite product comprising a metakaolin-based mineral polymer. The composite product has a number of applications including use as a fire resistant material, use as a thermally insulating material and use as an impact resistance material. Methods of preparing a composite product according to the present invention and a kit of parts for preparing the composite product are also disclosed.

A composite product comprising a metakaolin-based mineral polymer. The composite product has a number of applications including use as a fire resistant material, use as a thermally insulating material and use as an impact resistance material. Methods of preparing a composite product according to the present invention and a kit of parts for preparing the composite product are also disclosed.

A geopolymer material made from principal minerals, which comprises SiO.sub.2, Al.sub.2O.sub.3, Fe.sub.2O.sub.3, TiO.sub.2, and optionally trace amounts of calcium. Also disclosed are cementitious material comprised of the geopolymer and concrete made from mixing the geopolymer cementitious material with an alkaline solution. Methods of making the geopolymer composite as well as methods of making the geopolymer concrete are also disclosed.

A system and method for applying a construction material is provided. The method may include mixing blast furnace slag material, geopolymer material, alkali-based powder, and sand at a batching and mixing device to generate a non-Portland cement-based material. The method may also include transporting the non-Portland cement-based material from the mixing device, through a conduit to a nozzle and combining the transported non-Portland cement-based material with liquid at the nozzle to generate a partially liquefied non-Portland cement-based material. The method may further include pneumatically applying the partially liquefied non-Portland cement-based material to a surface.

A method of manufacturing molds and cores suitable for producing fiber composite bodies or cast parts of metal or plastic from a mold base material and a multicomponent binder by 3D printing includes pretreating the particulate mold base material with at least one silicon-organic compound having a polar hydrophilic end and a nonpolar hydrophobic end, forming a layer of the pretreated particulate mold base material, and applying the binder or at least one component of the binder in liquid form to the layer, wherein b. and c. are repeated.

A rapid-setting composition includes fly ash and an activator solution for mixing with the fly ash. The activator solution has a silicate solution including a monovalent hydroxide. The activator solution when mixed with the fly ash produces a composition that has a final set time of no more than about 65 minutes.