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Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -1-
30 Years of Successes and Failures
in Geopolymer Applications.
Market Trends and Potential Breakthroughs.
Prof. Dr. Joseph Davidovits
Geopolymer Institute
02100 Saint-Quentin, France
www.geopolymer.org
Summary:
The presentation included 30 slides describing following geopolymer applications developed
since 1972 in France, Europe and USA. The Geopolymer chemistry concept was invented in
1979 with the creation of a non-for profit scientific organization, the Institut de Recherche sur les
Géopolymères (Geopolymer Institute).
1. Fire resistant wood panels
2. Insulated panels and walls,
3. Decorative stone artifacts,
4. Foamed (expanded) geopolymer panels for thermal insulation,
5. Low-tech building materials,
6. Energy low ceramic tiles,
7. Refractory items,
8. Thermal shock refractory,
9. Aluminum foundry application,
10. Geopolymer cement and concrete,
11. Fire resistant and fire proof composite for infrastructures repair and strengthening,
12. Fireproof high-tech applications, aircraft interior, automobile,
13. High-tech resin systems.
The applications are based on 30 patents filed and issued in several countries. Several patents are
now in the public domain, but others are still valid. The applications show genuine geopolymer
products having brilliantly withstood 25 years of use and that are continuously commercialized.
INTRODUCTION
When, 38 years ago, I received the 1964 annual award from the French Textile Chemical Society
(ACIT) for works performed on linear organic polymers, I did not imagine that the major part of
my scientific career would be conducted outside of the field of organic chemistry. Until 1972, I
had been involved in researches dealing with organic binders for foundries, synthetic textile
fibers, natural and synthetic leather, collagen, and organic membranes.
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -2-
In the aftermath of various catastrophic fires in France between 1970-73, which involved
common organic plastic, research on nonflammable and noncombustible plastic materials
became my objective. I founded a private research company in 1972, which is today called
CORDI-GÉOPOLYMÈRE. In my pursuit to develop new inorganic polymer materials, I was
struck by the fact that simple hydrothermal conditions govern the synthesis of some organic
plastics and also heat-resistant mineral feldspathoids and zeolites. The scientific and patent
literature indicated that, the geochemistry that yields the synthesis of zeolites and molecular
sieves had not been investigated for producing mineral binders and mineral polymers. I
proceeded to develop amorphous to semi-crystalline three-dimensional silico-aluminate
materials, which I call «géopolymères» geopolymers (mineral polymers resulting from
geochemistry or geosynthesis).
The quest for low-temperature reactive minerals
In 1972, the ceramicist team J.P. Latapie and M. Davidovics confirmed that water-resistant
ceramic tiles could be fabricated at temperatures lower than 450°C, i.e. without firing. One
component of clay, kaolinite, reacted with caustic soda at 150°C. I learned that the industrial
applications of this kaolinite reaction with alkali began in the ceramic industry with Olsen in
1934 and was, later on, reinvented in 1970 by the Russian team Berg & al., but without any
successful industrial implementation.
The aluminosilicate kaolinite reacts with NaOH at 100°C-150°C and polycondenses into
hydrated sodalite (a tectoaluminosilicate), or hydrosodalite.
Si2O5,Al2(OH)4 + NaOH ⇒ Na(-Si-O-Al-O)n
kaolinite hydrosodalite
In 1969, Besson, Caillère and Hénin at the French Museum of Natural History, Paris, carried out
the synthesis of hydrosodalite from various phyllosilicates (kaolinite, montmorillonite,
halloysite) at 100°C in concentrated NaOH solution. I developed a technology based on this
geosynthesis, which has been disclosed in various patents issued an granted.
Fire-resistant wood-chipboards (1973-1976)
The first applications were building products (developed with J.J. Legrand), such as fire-resistant
chip-board panels, comprised of a wooden core faced with two SILIFACE Q nanocomposite
coatings, in which the entire panel was manufactured in a one-step process (US Patents 3,950,47;
4,028,454). An unusual feature was observed to characterize the manufacturing process: for the
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -3-
first time, the hardening of organic material (wood chips and organic resin) occurred
simultaneously with the setting of the mineral silico-aluminate (Na-Poly(sialate)/quartz
nanocomposite), when applying the same thermosetting parameters as for organic resin (see Fig.
1).
Figure 1 : Manufacture of fire-resistant wood-chipboards faced with geopolymer (Na-
Poly(sialate)
Figure 2 : Pilot and industrial equipments : heated press
Figure 3 : Geopolymer-chipboard
The thermosetting parameters applied on the industrial equipments (Fig. 2) were:
- temperature: 130°C to 200°C
- applied hydraulic pressure: higher than the saturated vapor pressure of water, for the
selected temperature, i.e. 1 to 3 MPa.
The setting time is relatively short. In the absence of any pervious device, i.e. when degassing is
not working, the polycondensation into hydrosodalite occurs very rapidly in a time as short as
15-20 seconds per millimeter thickness, at 180°C and 40kg/cm2 hydraulic pressure. Yet, due to
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -4-
the high internal pressure of water and the danger of explosion, it is recommended to wait until
the item has cooled down to room temperature, before opening the mold.
The fire-resistant chipboard panels were developed in 1972-1976 (Fig. 3). The Industry Partners
were the French companies A.G.S. and Saint-Gobain and the client was the French Government,
for the building of high schools and universities. A decision to build a pilot plant was made but
then in 1976 there has been a change in building policy and a Political decision to stop the
implementation. The project was abandoned.
Ceramic applications (1977-1978)
Very interesting results were obtained with a natural kaolinite/quartz blend supplied by the
French company A.G.S. (Argiles & Minéraux). In this natural blend, the quartz crystals are
surrounded with kaolinite micelles. One obtains the sequenced poly(sialate) (Na-PS)
nanocomposite called SILIFACE Q:
-(Na-PS)-(SiO2)n-(Na-PS)-(SiO2)n-
By replacing quartz with synthetic cordierite, (Si5AlO18)Al3Mg2, melting point 1.460°C, one
obtains a nanocomposite called SILIFACE COR70, which has an exceptional temperature
stability and very low thermal expansion. The comparative values for ceramics, metals and
SILIFACE COR 70 in Table 2, are interesting:
Table 2: Mean linear thermal expansion between 20°C-700°C
Fe 0.96% Steatite 0.80%
Iridium 0.50% Mulite 0.40%
Mo 0.45% Cermet 0.70%
Tn 0.37% SILIFACE COR 70 0,13%
Silicium nitrid 0.25%
Figure 4 : Electrical fuses made with geopolymer SILIFACE COR 70
This unique geopolymer was tested for the manufacture of electrical fuses for the French
company LEGRAND in1977-1978 (Fig. 4). The mechanical properties, thermal properties,
molding at 120 deg.C, post-treatment at 450 deg.C, were excellent. Yet, water absorption (0.3%)
was not good enough, and the project abandoned.
Low Temperature Geopolymeric Setting of ceramic, L.T.G.S. (1977-1982)
Low Temperature Geopolymeric Setting (L.T.G.S.) takes place at drying temperatures (50°C to
250°C), in alkaline conditions, through an oligosialate precursor (-Si-O-Al-O-) (Na) in
concentrations from 2 to 6% by weight of the ceramic paste. The kaolinite in clays is
transformed by LTGS into a three dimensional compound of the poly(sialate) Na-PS sodalite
type, stable to water and possessing high mechanical strength (French Patents 2,490,626;
2,528,822) (Fig.5).
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -5-
Figure 5: Brick made with L.T.G.S. on kaolinitic soils. Mechanical compressive strength in Mpa
for untreated and geopolymerised kaolinitic earth (with 3% by weight equivalent Na2O). Setting
temperature ranges between 20°C and 1000°C.
L.T.G.S. may dramatically enhance and modernize the traditional ceramic industry. Once
geopolymerised into Na-polysialate (Na-PS) or K-polysialate (K-PS), at 125-250°C, ceramic
bodies may be ultra rapidly fired at 1000°C-1200°C, to produce high quality ceramics
(European Patent 0,101,714) (Fig. 6).
Figure 6: Fabrication of ceramic tile; energy consumption in kcal/kg of tile for current, rapid
and geopolymerized methods (Geopoly- A, B) and firing at 1000°C-1200°C.
MAM-MADE ROCK GEOSYNTHESIS
The Geopolymer Terminology
We showed that naturally occurring alumino-silicates, such as kaolinite, are transformed at low-
temperature, in an astonishingly short time, into tridimensional tecto-aluminosilicates. The
thermosetting method is very similar that used for the polycondensation of organic resins. The
process yields nanocomposites that are actually man-made rocks. This geosynthesis is manifest
in nature itself in great abundance. At least 55% of the volume of the Earth's crust is composed
of siloxo-sialates and sialates, with pure silica or quartz at only 12%. The geosynthesis is based
on the ability of the aluminum ion (6-fold or 4-fold coordination) to induce crystallographical
and chemical changes in a silica backbone.
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -6-
This basic innovation, the low-temperature transformation from kaolinite into hydrosodalite,
demonstrated the tremendous latent potential of this new mineral reaction. This potential was
neglected by the mainstream ceramics industry, by virtue of the infamous NIH principle (not
invented here). It also failed to have any impact on other branches of industry because it was
classified as an inexpensive clay product and listed under the heading of construction materials.
As such, it did not have the «cachet» of developments in the «advanced» or so-called high-tech
industries.
To define the importance of this chemistry, in 1976 I established a new terminology that served
to properly classify mineral polymers.
Terminology
In 1979, I created and applied the term «geopolymer».
For the chemical designation of geopolymers based on silico-aluminates, poly(sialate) was
suggested. Sialate is an abbreviation for silicon-oxo-aluminate. Polysialates are chain and ring
polymers with Si4+
and Al3+
in IV-fold coordination with oxygen and range from amorphous to
semi-crystalline. The amorphous to semi-crystalline three dimensional silico-aluminate
structures were christened «geopolymers» of the types:
Si:Al>3 Sialate link
Geopolymeric Binders (1979-1995)
The new terminology was the key to the successful development of new materials. For the user,
geopolymers are polymers and, therefore, by analogy with the organic polymers derived from
oil, they are transformed, undergo polycondensation, and set rapidly at low temperature, within
few minutes. But they are, in addition, GEO-polymers, i.e. inorganic, hard, stable at temperature
up to 1250°C and non-inflammable. This gave a tremendous boost to creativity and
innovation.(Fig. 7).
Liquid binders, which are the inorganic countertype of organic resins, were developed by the
Geopolymere group (with Michel Davidovics and Nicolas Davidovits), GEOPOLYMITE®
binders (US Patents 4,349,386; 4,472,199; 4,888,311; 5,342,595; 5,352,427) and by Neuschäffer
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -7-
& al., Randel & al., at the licensed German Company Dynamit Nobel (later Hüls Troisdorf AG,
now sublicensed to Willig GmbH, binders TROLIT® and WILLIT®). The field of application
developed since 1979 includes aeronautical engineering, the nuclear sector, the reproduction of
«objets d’art», thermal insulation of buildings, furnace insulation (Fig. 8), mechanical
engineering, molding, stamping, foundry work, metal casting, etc.. and it even includes
archaeological research.
Figure 7 : decorative items made of (K)-Poly(sialate-siloxo) geopolymer binder.
Figure 8 : foamed geopolymer (Na,K)-Poly(sialate-siloxo) resin.
Since 1986, the French aeronautic company Dassault Aviation has used geopolymer mold and
tooling in the development of the Rafale fighter plane (Fig. 9)
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -8-
Figure 9 : the French fighter plane Rafale. Courtesy: Dassault Aviation
In addition, we made for Northtrop Aviation a geopolymer composite tooling prototype (self-
heated carbon/SiC/Geopolymite composite) used in the fabrication of carbon/APC2 composite
designed for a new US Airforce bomber. More than a hundred tooling and items has been
delivered for aeronautic applications (Airbus) and SPF Aluminum processing.
The Invention of
Geopolymer High-Strength Cement (1983)
(K-Ca) (Si-O-Al-O-Si-O-) Poly(sialate-siloxo) cement
In early 1983, Chairman, Mr. James Stewart, and Mr. W. Kirkpatrick, of Lone Star Industries
Inc. (then America's leading cement manufacturer), were traveling in Europe and learned about
my new geopolymeric binders. Lone Star Industries and Shell Oil Company had just announced
the formation of the QUAZITE Corporation to develop, produce, and market a new class of
materials that were expected to have a wide-ranging impact on construction, architectural, and
engineering applications. QUAZITE materials were made from mineral aggregates combined
with polymers and monomers. In other words, QUAZITE was an «organic polymer concrete.»
Shell Oil supplied the chemical expertise in organic polymers for QUAZITE, while Lone Star
supplied the mineral aggregates. By enlisting my new inorganic geopolymers, Lone Star took the
opportunity to challenge Shell Oil's chemical expertise. In August 1983, with James Sawyer as
Head of Lone Star's research laboratory in Houston, Texas, we started to develop early high-
strength geopolymeric binders and cements based on both geopolymeric and hydraulic cement
chemistries. Within one month, Lone Star Industries Inc. formed the development company,
PYRAMENT, which was exclusively dedicated to the implementation of this new class of
cement. Few months later, Lone Star separated from the Shell Oil deal.
It was discovered that the addition of ground blast furnace slag, which is a latent hydraulic
cementitious product, to the poly(sialate) type of geopolymer, accelerates the setting time and
significantly improves compressive and flexural strength. The first Davidovits/Sawyer patent
was filed in Feb. 22, 1984, and titled «Early High-Strength Mineral Polymer» (US Patent). The
corresponding European Patent, filed in 1985, is titled «Early High-Strength Concrete
Composition» and these patents disclose our preliminary finding from the research carried out in
August-September of 1983. Geopolymer cements are acid-resistant cementitious materials with
zeolitic properties, developed for the long-term containment of hazardous and toxic wastes (US
Patents 4,859,367; 5,349,118). Geopolymerization involves the chemical reaction of alumino-
silicate oxides (Al3+ in IV-V fold coordination), with alkali and calcium polysilicates, yielding
polymeric Si-O-Al bonds, for instance:
2(Si2O5,Al2O2)+K2(H3SiO4)2+Ca(H2SiO4)2 ⇒ (K2O,CaO)(8SiO2,2Al2O3,nH2O)
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -9-
Tailored aluminosilicate geopolymeric cement comprises following major compounds, namely:
- specific alumino-silicates of the kaolinitic clay species, calcined at 750°C;
- alkali-disilicates (Na2,K2)(H2SiO4)2
- calcium disilicates Ca(H2SiO4)2 produced by the alkali-reaction with blast furnace slag
Unlike conventional Portland cement, geopolymeric cements do not rely on lime and are not
dissolved by acidic solutions. Portland based cements (plain and slag blended) are destroyed in
acidic environment. Calcium aluminate cement is expensive to produce, and does not behave
satisfactorily, having 30 to 60% of weight loss (destruction). Geopolymeric cements, Potassium-
Poly(sialate-siloxo) type, Geopolymite®, remain stable with a loss in the 5-8 % range. This acid-
resistant cement hardens rapidly at room temperature and provides compressive strength in the
range of 20 MPa, after only 4 hours at 20°C, when tested in accordance with the standards
applied to hydraulic binder mortars (Fig. 10). The final 28-day compressive strength is in the
range of 70-100 MPa.
Figure 10 : High-early strength of (K,Ca)-Poly(sialate-siloxo) cement
James Sawyer's team (Richard Heitzmann & colleagues) adapted the geopolymeric cement
formulations for use in the production of precast and prestressed concrete (heat cured
PYRAMENT), while also developing ultra-rapid high ultimate strength cement (ambient
temperature cured PYRAMENT) (Fig. 11). The latter enables pavement to be placed so that
heavy traffic can traverse in four hours.
Figure 11 : Use of PYRAMENT in USA as pavement repair material
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -10-
PYRAMENT® cements, Portland blended cements :
As early as 1981, I had utilized Portland cement as a room temperature setting admixture for a
geopolymer foam compound (French Patent 2,512,806). At Lone Star, Richard Heitzmann and
James Sawyer likewise blended Portland cement with geopolymer. Their purpose was to take
advantage of the good properties of geopolymeric cement along with the low manufacturing cost
of Portland cement. The resulting PYRAMENT® Blended Cement (PBC) is very close to alkali-
activated pozzolanic cement (US Patent 4,842,649)[26]. PYRAMENT PBC cement comprises
80% ordinary Portland cement and 20% of geopolymeric raw materials, that is, calcium silicate
and alumino-silicates alkali-activated with potassium carbonate and retarded with citric acid.
PYRAMENT PBC is recognized in the construction industry for its ability to gain very high
early strength quite rapidly.
The Pyrament® blended-cement is the ideal material for repairing runways made of concrete,
industrial pavements, and highway roads. In the case of a runway, a 4-6 hours hardening is
enough to allow the landing of an Airbus or a Boeing. The geopolymeric cement reaches a
compression strength of 20 Mpa after 4 hours, whereas plain concrete gets to this strength after
several days. The Pyrament® blended cement is recognized in the construction industry for its
ability to gain very high early strength quite rapidly. As of fall 1993, PYRAMENT concrete was
listed for over 50 industrial facilities in the USA, 57 military installations in the USA, and 7 in
other countries, and for nonmilitary airports. In 1994 the US Army Corps of Engineers released a
well-documented study on the properties of PYRAMENT Blended Cements based concretes,
which are performing better than had ever been expected for high-quality concretes
(Performance of Concretes Proportioned with Pyrament Blended Cement, by Tony B. Husbands,
Philip. G. Malone, Lilian D. Wakeley, US Army Corps of Engineers, Final Report CPAR-SL-
94-2, April 1994).
Fireproof Geopolymer Fiber reinforced composites (1987-2000)
Giving Survivors More Time to Escape
Figure 12 : A Carbon-Epoxy aerospace composite (left) is burning while a
Carbon-Géopolymère Composite ™ (right) still resists a 1200°C fire.
When a plane crash-lands and catches fire, half the people who survive the impact may not get
out in time. That is because the plastics in the cabin -- the seat cushions, carpeting, walls and
luggage bins -- are combustible. And when they burn, they give off flammable gases that, in two
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -11-
minutes, can explode into a fireball. The U.S. Federal Aviation Administration (F.A.A.), wants
to give passengers more time to escape. In 1994 the F.A.A. initiated a cooperative research
program to develop low-cost, environmentally friendly, fire resistant matrix materials for aircraft
composites and cabin interior applications. The GÉOPOLYMÈRE Composite has been selected
by F.A.A. as the best candidate for this program (Fig. 13).
Aviation applications (1994-2000)
Aircraft cabin materials targeted for GÉOPOLYMÈRE Composite include cargo liners, ceiling,
floor panels, partitions and sidewalls, stowage bins, wire insulation, yielding 2500-3000 kg.
There is an increase demand for fire-resistant containers
Figure 13 : Time to flashover (minutes) for various organic resins
compared to geopolymer resin.
Civil and military ships/submarines
A significant technical issue, which limits composite use on board Naval ships and submarines,
is the combustible nature, and hence, the fire, smoke, and toxicity of organic matrix based
composite materials. The main conclusion from the extensive fire testing conducted by U.S.
NAVY is that unprotected composite systems cannot meet the stringent fire requirements
specified for interior spaces. Military vessels must perform their mission even when damaged,
and must survive the fire for sufficient period of time to carry out rescue missions. The effects of
fires aboard vessels have been demonstrated as a result of collision between ships and ferries
during peacetime, and by experiences of the British Navy in the Falkland Islands and the
American Navy in the Persian Gulf.
Automotive applications
During the Grand Prix season 1994 and 1995, the Benetton Formula 1 team designed a unique
thermal shield made out of GÉOPOLYMÈRE Composite. All the parts were around the exhaust
area, with special parts replacing titanium. They brilliantly withstood the severe vibration and
heat (over 700 deg. C) seen on a Formula One car. It helped the team to become World
Champion of car builders and pilots during these two years. Still today, most Formula 1 teams
are using geopolymer composite materials.
In 1999, All American Racers (Dan Gurney's team) has introduced a more sophisticated design
on an American C.A.R.T. car (former Indy-Cart) recognizable with its unique design and
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -12-
distinctive note of the exhaust system going through the molded Carbon Géopolymère
Composite body (Eagle 1999) (Fig. 14).
Figure 14 : The Eagle 1999 from All American Racers.
The experience gained on racing cars for exhaust parts could be transferred and applied for the
mass production of regular automobile parts (corrosion resistant exhaust pipes and the like) as
well as heat shields.
Infrastructure and building applications
F.A.A. is aware that the adoption of the new GÉOPOLYMÈRE Composite 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 fire resistance is needed at low to moderate cost
and mass production. To this end the F.A.A. had funded the evaluation program carried out at
Rutgers, The State University of New Jersey (the GEO-STRUCTURE program) based on the
GÉOPOLYMÈRE technology.
A relatively new and very attractive repair method for concrete, brick and stone structures
consists of externally bonding flexible sheets of fiber composites (Fig. 15 and 16). Another
application for continuous fiber composites in infrastructure, already well underway in Japan and
USA 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
exposed interior building columns, flammability is a serious concern. Fire safety is a concern
often voiced by those who are skeptical about the use of composite materials in the infrastructure
and building industry.
Figure 15 : Concrete beam (3 meters long) with Geopolymer Carbon composite layers applied
on its bottom surface, before testing
In Europe, the market targets on the retrofit of valuable Cultural Heritage buildings where fire
safety is the major concern.
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -13-
Figure 16 : Load vs Deflection for concrete beams with 0, 2, 3, 5 layers of Geopolymer Carbon
composite.
Successful applications 
The following Figure 17 summarizes the successful applications carried out since 1979 with
geopolymers of different types.
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -14-
Figure 17 : Geopolymer types involved in successful applications.
PATENTS REFERENCES :
The majority of the patents (with very few exception such as the PYRAMENT patents) were
first filed in France at the Paris Patent Office (INPI). The list provides the title of the patent
translated into English, the publication number, the date of filing and the names of the inventors.
Process for the fabrication of sintered panels and panels resulting from the application of this process. FR
2.204.999, FR 2.246.382 , 02/11/1972, 09/10/1973, Joseph Davidovits.
Process for the fabrication of caustic soda NaOH in powder. FR 2.259.056, 29/01/1974 ; Joseph
Davidovits, Jean-Jacques Legrand
Process for agglomerating compressible mineral substances under the form of powder, particles or fibres.
FR 2.324.427, FR 2.346.121, 11/01/1974, 03/06/1975 , Joseph Davidovits, Jean-Jacques Legrand.
Process for the fabrication of molded refractory items and products resulting from the process. FR
2.314.158, 09/06/1975 , Joseph Davidovits, Jacques Laveau.
Fabrication process of light panels for insulation and high compressive strength, and products resulting
from the process. FR 2.366.233, 03/06/1975 , Joseph Davidovits, Jean-Jacques Legrand, Jacques
Laveau.
Process for the fabrication of synthetic feldpathoids., FR 2.341.522, 20/02/1976 , CORDI-Géopolymère,
Joseph Davidovits, Jacques Laveau, Alfred Emberger.
Process for the fabrication of ceramics and products resulting from the process. FR 2.358.371,
12/07/1976 , Joseph Davidovits.
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -15-
Mineral Polymers and methods of making them. FR 2.424.227, FR 2.489.290, 04/09/1979, 03/09/1980,
Joseph Davidovits
Synthetic mineral polymer compound of the silicoaluminates family and preparation process. FR
2.489.291, 03/09/1980, Joseph Davidovits.
Process for the fabrication of building materials made with kaolinitic, lateritic, ferralitic soils and
products resulting from the process. FR 2.490.626, 23/09/1980 , Joseph Davidovits
Foamed mineral silico-aluminates products based on K-Poly(sialate) and/or (Na,K)-Poly(sialate-siloxo). FR 2.512.805,
17/09/1981, Joseph Davidovits, Jean-Jacques Legrand
Method for the makingoffoamed alkaline silico-aluminate mineral materials. FR 2.515.806,17/09/1981,Joseph Davidovits ,
NicolasDavidovits
Thermalinsulation(passivecooling)forbuildings.FR2.512.808,17/09/1981,JosephDavidovits
Method for manufacturing decorated, enamalled ceramics by monfiring, with geopolymer silico-aluminates. FR 2.523.118,
08/03/1982,JosephDavidovits,MichelDavidovics
Method for manufacturing floor and wallstonetiles with geopolymers.FR 2.528.818,22/08/1982,Joseph Davidovits, Claude
Boutterin
Method for manufacturing building materials with lateritic soils and clays. FR 2.528.822, 22/08/1982, Joseph Davidovits,
ClaudeBoutterin
Earlyhigh-strengthmineralpolymer.US4.509.985,22/02/1984,JosephDavidovits,JamesL.Sawyer
Ceramic-Ceramic composite material and production method. FR 2.604.994, 14/10/1986, Nicolas Davidovits , Michel
Davidovics,JosephDavidovits
Method for eliminating the alkali-aggregate reaction in concretes and cement thereby obtained. FR 2.657.867, 05/02/1990,
JosephDavidovits
Geopolymeric fluoro-alumino-silicate binder and process for obtaining it. FR 2.659.320, 07/03/1990, Joseph Davidovits ,
MichelDavidovics,NicolasDavidoviits
Fire-proof géopolymeric panels for thermal protection and process for obtaining them. FR
2.659.963, 20/03/1990, Joseph Davidovits , Michel Davidovics, Nicolas Davidovits
Method for obtainingan earlyhigh-strengthgeopolymeric matrice forthen impregnationofcomposite materials and products
obtainedthereof.FR2.666.328,04/09/1990,JosephDavidovits,MichelDavidovics,NicolasDavidovits
Process for obtaining a geopolymeric alumino-silicate and products thus obtained. FR 2.671.344, 03/01/1991, Joseph
Davidovits,MichelDavidovics,NicolasDavidovits
Alkaline aluminosilicate geopolymeric matrix for composite materials with fibre reinforcement and method for obtaining
same.EP 0. 815.064, 15/03/1995, JosephDavidovits,MichelDavidovics,NicolasDavidovits
Method for bonding fiber reinforcement on concrete and steel structures and resultant products. FR
2.756.840,06/12/1996,JosephDavidovits
BIBLIOGRAPHICAL REFERENCES
complete and detailed lists of scientific papers are to be found in following references (all listed
in the Library at <www.geopolymer.org>) :
The Proceedings of Géopolymère '99, 2nd International Conference on geopolymers, Editors J. and R.
Davidovits, C. James, Geopolymer Institute 1999, 32 articles.
Fire-resistant Aluminosilicate Composites, Lyon, R, Balaguru, P.N., Foden A, Sorathia U., Davidovics,
M. and Davidovits, J, FIRE AND MATERIALS, Vol. 21, PP. 67-73 (1997)
Geopolymers: Man-Made Rock Geosynthesis and the Resulting Development of Very Early High
Strength Cement, Davidovits, J, JOURNAL OF MATERIALS EDUCATION, PP. 91-137, Vol. 16,
N°2&3 (1994)
Geopolymers: inorganic polymeric new materials, Davidovits J, J. THERM. ANAL.
(JTHEA9,03684466); 91; VOL.37 (8); PP.1633-56 (1991)
Geopolymer: ultrahigh-temperature tooling material for the manufacture of advanced composites,
Davidovits J; Davidovics M, 36th SAMPE Symp. (ISSEEG,08910138); 91; VOL.36 (2); PP.1939-49
(1991)
The Proceedings of Geopolymer ’88, European Conference on Soft Mineralurgy, Davidovits J. and
Orlinski J. eds., Geopolymer Institute an Université de Technologie, Compiègne, France, Vol. 1-2,
1988.
Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -16-

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30 years in geopolymer applications

  • 1. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -1- 30 Years of Successes and Failures in Geopolymer Applications. Market Trends and Potential Breakthroughs. Prof. Dr. Joseph Davidovits Geopolymer Institute 02100 Saint-Quentin, France www.geopolymer.org Summary: The presentation included 30 slides describing following geopolymer applications developed since 1972 in France, Europe and USA. The Geopolymer chemistry concept was invented in 1979 with the creation of a non-for profit scientific organization, the Institut de Recherche sur les Géopolymères (Geopolymer Institute). 1. Fire resistant wood panels 2. Insulated panels and walls, 3. Decorative stone artifacts, 4. Foamed (expanded) geopolymer panels for thermal insulation, 5. Low-tech building materials, 6. Energy low ceramic tiles, 7. Refractory items, 8. Thermal shock refractory, 9. Aluminum foundry application, 10. Geopolymer cement and concrete, 11. Fire resistant and fire proof composite for infrastructures repair and strengthening, 12. Fireproof high-tech applications, aircraft interior, automobile, 13. High-tech resin systems. The applications are based on 30 patents filed and issued in several countries. Several patents are now in the public domain, but others are still valid. The applications show genuine geopolymer products having brilliantly withstood 25 years of use and that are continuously commercialized. INTRODUCTION When, 38 years ago, I received the 1964 annual award from the French Textile Chemical Society (ACIT) for works performed on linear organic polymers, I did not imagine that the major part of my scientific career would be conducted outside of the field of organic chemistry. Until 1972, I had been involved in researches dealing with organic binders for foundries, synthetic textile fibers, natural and synthetic leather, collagen, and organic membranes.
  • 2. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -2- In the aftermath of various catastrophic fires in France between 1970-73, which involved common organic plastic, research on nonflammable and noncombustible plastic materials became my objective. I founded a private research company in 1972, which is today called CORDI-GÉOPOLYMÈRE. In my pursuit to develop new inorganic polymer materials, I was struck by the fact that simple hydrothermal conditions govern the synthesis of some organic plastics and also heat-resistant mineral feldspathoids and zeolites. The scientific and patent literature indicated that, the geochemistry that yields the synthesis of zeolites and molecular sieves had not been investigated for producing mineral binders and mineral polymers. I proceeded to develop amorphous to semi-crystalline three-dimensional silico-aluminate materials, which I call «géopolymères» geopolymers (mineral polymers resulting from geochemistry or geosynthesis). The quest for low-temperature reactive minerals In 1972, the ceramicist team J.P. Latapie and M. Davidovics confirmed that water-resistant ceramic tiles could be fabricated at temperatures lower than 450°C, i.e. without firing. One component of clay, kaolinite, reacted with caustic soda at 150°C. I learned that the industrial applications of this kaolinite reaction with alkali began in the ceramic industry with Olsen in 1934 and was, later on, reinvented in 1970 by the Russian team Berg & al., but without any successful industrial implementation. The aluminosilicate kaolinite reacts with NaOH at 100°C-150°C and polycondenses into hydrated sodalite (a tectoaluminosilicate), or hydrosodalite. Si2O5,Al2(OH)4 + NaOH ⇒ Na(-Si-O-Al-O)n kaolinite hydrosodalite In 1969, Besson, Caillère and Hénin at the French Museum of Natural History, Paris, carried out the synthesis of hydrosodalite from various phyllosilicates (kaolinite, montmorillonite, halloysite) at 100°C in concentrated NaOH solution. I developed a technology based on this geosynthesis, which has been disclosed in various patents issued an granted. Fire-resistant wood-chipboards (1973-1976) The first applications were building products (developed with J.J. Legrand), such as fire-resistant chip-board panels, comprised of a wooden core faced with two SILIFACE Q nanocomposite coatings, in which the entire panel was manufactured in a one-step process (US Patents 3,950,47; 4,028,454). An unusual feature was observed to characterize the manufacturing process: for the
  • 3. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -3- first time, the hardening of organic material (wood chips and organic resin) occurred simultaneously with the setting of the mineral silico-aluminate (Na-Poly(sialate)/quartz nanocomposite), when applying the same thermosetting parameters as for organic resin (see Fig. 1). Figure 1 : Manufacture of fire-resistant wood-chipboards faced with geopolymer (Na- Poly(sialate) Figure 2 : Pilot and industrial equipments : heated press Figure 3 : Geopolymer-chipboard The thermosetting parameters applied on the industrial equipments (Fig. 2) were: - temperature: 130°C to 200°C - applied hydraulic pressure: higher than the saturated vapor pressure of water, for the selected temperature, i.e. 1 to 3 MPa. The setting time is relatively short. In the absence of any pervious device, i.e. when degassing is not working, the polycondensation into hydrosodalite occurs very rapidly in a time as short as 15-20 seconds per millimeter thickness, at 180°C and 40kg/cm2 hydraulic pressure. Yet, due to
  • 4. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -4- the high internal pressure of water and the danger of explosion, it is recommended to wait until the item has cooled down to room temperature, before opening the mold. The fire-resistant chipboard panels were developed in 1972-1976 (Fig. 3). The Industry Partners were the French companies A.G.S. and Saint-Gobain and the client was the French Government, for the building of high schools and universities. A decision to build a pilot plant was made but then in 1976 there has been a change in building policy and a Political decision to stop the implementation. The project was abandoned. Ceramic applications (1977-1978) Very interesting results were obtained with a natural kaolinite/quartz blend supplied by the French company A.G.S. (Argiles & Minéraux). In this natural blend, the quartz crystals are surrounded with kaolinite micelles. One obtains the sequenced poly(sialate) (Na-PS) nanocomposite called SILIFACE Q: -(Na-PS)-(SiO2)n-(Na-PS)-(SiO2)n- By replacing quartz with synthetic cordierite, (Si5AlO18)Al3Mg2, melting point 1.460°C, one obtains a nanocomposite called SILIFACE COR70, which has an exceptional temperature stability and very low thermal expansion. The comparative values for ceramics, metals and SILIFACE COR 70 in Table 2, are interesting: Table 2: Mean linear thermal expansion between 20°C-700°C Fe 0.96% Steatite 0.80% Iridium 0.50% Mulite 0.40% Mo 0.45% Cermet 0.70% Tn 0.37% SILIFACE COR 70 0,13% Silicium nitrid 0.25% Figure 4 : Electrical fuses made with geopolymer SILIFACE COR 70 This unique geopolymer was tested for the manufacture of electrical fuses for the French company LEGRAND in1977-1978 (Fig. 4). The mechanical properties, thermal properties, molding at 120 deg.C, post-treatment at 450 deg.C, were excellent. Yet, water absorption (0.3%) was not good enough, and the project abandoned. Low Temperature Geopolymeric Setting of ceramic, L.T.G.S. (1977-1982) Low Temperature Geopolymeric Setting (L.T.G.S.) takes place at drying temperatures (50°C to 250°C), in alkaline conditions, through an oligosialate precursor (-Si-O-Al-O-) (Na) in concentrations from 2 to 6% by weight of the ceramic paste. The kaolinite in clays is transformed by LTGS into a three dimensional compound of the poly(sialate) Na-PS sodalite type, stable to water and possessing high mechanical strength (French Patents 2,490,626; 2,528,822) (Fig.5).
  • 5. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -5- Figure 5: Brick made with L.T.G.S. on kaolinitic soils. Mechanical compressive strength in Mpa for untreated and geopolymerised kaolinitic earth (with 3% by weight equivalent Na2O). Setting temperature ranges between 20°C and 1000°C. L.T.G.S. may dramatically enhance and modernize the traditional ceramic industry. Once geopolymerised into Na-polysialate (Na-PS) or K-polysialate (K-PS), at 125-250°C, ceramic bodies may be ultra rapidly fired at 1000°C-1200°C, to produce high quality ceramics (European Patent 0,101,714) (Fig. 6). Figure 6: Fabrication of ceramic tile; energy consumption in kcal/kg of tile for current, rapid and geopolymerized methods (Geopoly- A, B) and firing at 1000°C-1200°C. MAM-MADE ROCK GEOSYNTHESIS The Geopolymer Terminology We showed that naturally occurring alumino-silicates, such as kaolinite, are transformed at low- temperature, in an astonishingly short time, into tridimensional tecto-aluminosilicates. The thermosetting method is very similar that used for the polycondensation of organic resins. The process yields nanocomposites that are actually man-made rocks. This geosynthesis is manifest in nature itself in great abundance. At least 55% of the volume of the Earth's crust is composed of siloxo-sialates and sialates, with pure silica or quartz at only 12%. The geosynthesis is based on the ability of the aluminum ion (6-fold or 4-fold coordination) to induce crystallographical and chemical changes in a silica backbone.
  • 6. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -6- This basic innovation, the low-temperature transformation from kaolinite into hydrosodalite, demonstrated the tremendous latent potential of this new mineral reaction. This potential was neglected by the mainstream ceramics industry, by virtue of the infamous NIH principle (not invented here). It also failed to have any impact on other branches of industry because it was classified as an inexpensive clay product and listed under the heading of construction materials. As such, it did not have the «cachet» of developments in the «advanced» or so-called high-tech industries. To define the importance of this chemistry, in 1976 I established a new terminology that served to properly classify mineral polymers. Terminology In 1979, I created and applied the term «geopolymer». For the chemical designation of geopolymers based on silico-aluminates, poly(sialate) was suggested. Sialate is an abbreviation for silicon-oxo-aluminate. Polysialates are chain and ring polymers with Si4+ and Al3+ in IV-fold coordination with oxygen and range from amorphous to semi-crystalline. The amorphous to semi-crystalline three dimensional silico-aluminate structures were christened «geopolymers» of the types: Si:Al>3 Sialate link Geopolymeric Binders (1979-1995) The new terminology was the key to the successful development of new materials. For the user, geopolymers are polymers and, therefore, by analogy with the organic polymers derived from oil, they are transformed, undergo polycondensation, and set rapidly at low temperature, within few minutes. But they are, in addition, GEO-polymers, i.e. inorganic, hard, stable at temperature up to 1250°C and non-inflammable. This gave a tremendous boost to creativity and innovation.(Fig. 7). Liquid binders, which are the inorganic countertype of organic resins, were developed by the Geopolymere group (with Michel Davidovics and Nicolas Davidovits), GEOPOLYMITE® binders (US Patents 4,349,386; 4,472,199; 4,888,311; 5,342,595; 5,352,427) and by Neuschäffer
  • 7. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -7- & al., Randel & al., at the licensed German Company Dynamit Nobel (later Hüls Troisdorf AG, now sublicensed to Willig GmbH, binders TROLIT® and WILLIT®). The field of application developed since 1979 includes aeronautical engineering, the nuclear sector, the reproduction of «objets d’art», thermal insulation of buildings, furnace insulation (Fig. 8), mechanical engineering, molding, stamping, foundry work, metal casting, etc.. and it even includes archaeological research. Figure 7 : decorative items made of (K)-Poly(sialate-siloxo) geopolymer binder. Figure 8 : foamed geopolymer (Na,K)-Poly(sialate-siloxo) resin. Since 1986, the French aeronautic company Dassault Aviation has used geopolymer mold and tooling in the development of the Rafale fighter plane (Fig. 9)
  • 8. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -8- Figure 9 : the French fighter plane Rafale. Courtesy: Dassault Aviation In addition, we made for Northtrop Aviation a geopolymer composite tooling prototype (self- heated carbon/SiC/Geopolymite composite) used in the fabrication of carbon/APC2 composite designed for a new US Airforce bomber. More than a hundred tooling and items has been delivered for aeronautic applications (Airbus) and SPF Aluminum processing. The Invention of Geopolymer High-Strength Cement (1983) (K-Ca) (Si-O-Al-O-Si-O-) Poly(sialate-siloxo) cement In early 1983, Chairman, Mr. James Stewart, and Mr. W. Kirkpatrick, of Lone Star Industries Inc. (then America's leading cement manufacturer), were traveling in Europe and learned about my new geopolymeric binders. Lone Star Industries and Shell Oil Company had just announced the formation of the QUAZITE Corporation to develop, produce, and market a new class of materials that were expected to have a wide-ranging impact on construction, architectural, and engineering applications. QUAZITE materials were made from mineral aggregates combined with polymers and monomers. In other words, QUAZITE was an «organic polymer concrete.» Shell Oil supplied the chemical expertise in organic polymers for QUAZITE, while Lone Star supplied the mineral aggregates. By enlisting my new inorganic geopolymers, Lone Star took the opportunity to challenge Shell Oil's chemical expertise. In August 1983, with James Sawyer as Head of Lone Star's research laboratory in Houston, Texas, we started to develop early high- strength geopolymeric binders and cements based on both geopolymeric and hydraulic cement chemistries. Within one month, Lone Star Industries Inc. formed the development company, PYRAMENT, which was exclusively dedicated to the implementation of this new class of cement. Few months later, Lone Star separated from the Shell Oil deal. It was discovered that the addition of ground blast furnace slag, which is a latent hydraulic cementitious product, to the poly(sialate) type of geopolymer, accelerates the setting time and significantly improves compressive and flexural strength. The first Davidovits/Sawyer patent was filed in Feb. 22, 1984, and titled «Early High-Strength Mineral Polymer» (US Patent). The corresponding European Patent, filed in 1985, is titled «Early High-Strength Concrete Composition» and these patents disclose our preliminary finding from the research carried out in August-September of 1983. Geopolymer cements are acid-resistant cementitious materials with zeolitic properties, developed for the long-term containment of hazardous and toxic wastes (US Patents 4,859,367; 5,349,118). Geopolymerization involves the chemical reaction of alumino- silicate oxides (Al3+ in IV-V fold coordination), with alkali and calcium polysilicates, yielding polymeric Si-O-Al bonds, for instance: 2(Si2O5,Al2O2)+K2(H3SiO4)2+Ca(H2SiO4)2 ⇒ (K2O,CaO)(8SiO2,2Al2O3,nH2O)
  • 9. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -9- Tailored aluminosilicate geopolymeric cement comprises following major compounds, namely: - specific alumino-silicates of the kaolinitic clay species, calcined at 750°C; - alkali-disilicates (Na2,K2)(H2SiO4)2 - calcium disilicates Ca(H2SiO4)2 produced by the alkali-reaction with blast furnace slag Unlike conventional Portland cement, geopolymeric cements do not rely on lime and are not dissolved by acidic solutions. Portland based cements (plain and slag blended) are destroyed in acidic environment. Calcium aluminate cement is expensive to produce, and does not behave satisfactorily, having 30 to 60% of weight loss (destruction). Geopolymeric cements, Potassium- Poly(sialate-siloxo) type, Geopolymite®, remain stable with a loss in the 5-8 % range. This acid- resistant cement hardens rapidly at room temperature and provides compressive strength in the range of 20 MPa, after only 4 hours at 20°C, when tested in accordance with the standards applied to hydraulic binder mortars (Fig. 10). The final 28-day compressive strength is in the range of 70-100 MPa. Figure 10 : High-early strength of (K,Ca)-Poly(sialate-siloxo) cement James Sawyer's team (Richard Heitzmann & colleagues) adapted the geopolymeric cement formulations for use in the production of precast and prestressed concrete (heat cured PYRAMENT), while also developing ultra-rapid high ultimate strength cement (ambient temperature cured PYRAMENT) (Fig. 11). The latter enables pavement to be placed so that heavy traffic can traverse in four hours. Figure 11 : Use of PYRAMENT in USA as pavement repair material
  • 10. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -10- PYRAMENT® cements, Portland blended cements : As early as 1981, I had utilized Portland cement as a room temperature setting admixture for a geopolymer foam compound (French Patent 2,512,806). At Lone Star, Richard Heitzmann and James Sawyer likewise blended Portland cement with geopolymer. Their purpose was to take advantage of the good properties of geopolymeric cement along with the low manufacturing cost of Portland cement. The resulting PYRAMENT® Blended Cement (PBC) is very close to alkali- activated pozzolanic cement (US Patent 4,842,649)[26]. PYRAMENT PBC cement comprises 80% ordinary Portland cement and 20% of geopolymeric raw materials, that is, calcium silicate and alumino-silicates alkali-activated with potassium carbonate and retarded with citric acid. PYRAMENT PBC is recognized in the construction industry for its ability to gain very high early strength quite rapidly. The Pyrament® blended-cement is the ideal material for repairing runways made of concrete, industrial pavements, and highway roads. In the case of a runway, a 4-6 hours hardening is enough to allow the landing of an Airbus or a Boeing. The geopolymeric cement reaches a compression strength of 20 Mpa after 4 hours, whereas plain concrete gets to this strength after several days. The Pyrament® blended cement is recognized in the construction industry for its ability to gain very high early strength quite rapidly. As of fall 1993, PYRAMENT concrete was listed for over 50 industrial facilities in the USA, 57 military installations in the USA, and 7 in other countries, and for nonmilitary airports. In 1994 the US Army Corps of Engineers released a well-documented study on the properties of PYRAMENT Blended Cements based concretes, which are performing better than had ever been expected for high-quality concretes (Performance of Concretes Proportioned with Pyrament Blended Cement, by Tony B. Husbands, Philip. G. Malone, Lilian D. Wakeley, US Army Corps of Engineers, Final Report CPAR-SL- 94-2, April 1994). Fireproof Geopolymer Fiber reinforced composites (1987-2000) Giving Survivors More Time to Escape Figure 12 : A Carbon-Epoxy aerospace composite (left) is burning while a Carbon-Géopolymère Composite ™ (right) still resists a 1200°C fire. When a plane crash-lands and catches fire, half the people who survive the impact may not get out in time. That is because the plastics in the cabin -- the seat cushions, carpeting, walls and luggage bins -- are combustible. And when they burn, they give off flammable gases that, in two
  • 11. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -11- minutes, can explode into a fireball. The U.S. Federal Aviation Administration (F.A.A.), wants to give passengers more time to escape. In 1994 the F.A.A. initiated a cooperative research program to develop low-cost, environmentally friendly, fire resistant matrix materials for aircraft composites and cabin interior applications. The GÉOPOLYMÈRE Composite has been selected by F.A.A. as the best candidate for this program (Fig. 13). Aviation applications (1994-2000) Aircraft cabin materials targeted for GÉOPOLYMÈRE Composite include cargo liners, ceiling, floor panels, partitions and sidewalls, stowage bins, wire insulation, yielding 2500-3000 kg. There is an increase demand for fire-resistant containers Figure 13 : Time to flashover (minutes) for various organic resins compared to geopolymer resin. Civil and military ships/submarines A significant technical issue, which limits composite use on board Naval ships and submarines, is the combustible nature, and hence, the fire, smoke, and toxicity of organic matrix based composite materials. The main conclusion from the extensive fire testing conducted by U.S. NAVY is that unprotected composite systems cannot meet the stringent fire requirements specified for interior spaces. Military vessels must perform their mission even when damaged, and must survive the fire for sufficient period of time to carry out rescue missions. The effects of fires aboard vessels have been demonstrated as a result of collision between ships and ferries during peacetime, and by experiences of the British Navy in the Falkland Islands and the American Navy in the Persian Gulf. Automotive applications During the Grand Prix season 1994 and 1995, the Benetton Formula 1 team designed a unique thermal shield made out of GÉOPOLYMÈRE Composite. All the parts were around the exhaust area, with special parts replacing titanium. They brilliantly withstood the severe vibration and heat (over 700 deg. C) seen on a Formula One car. It helped the team to become World Champion of car builders and pilots during these two years. Still today, most Formula 1 teams are using geopolymer composite materials. In 1999, All American Racers (Dan Gurney's team) has introduced a more sophisticated design on an American C.A.R.T. car (former Indy-Cart) recognizable with its unique design and
  • 12. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -12- distinctive note of the exhaust system going through the molded Carbon Géopolymère Composite body (Eagle 1999) (Fig. 14). Figure 14 : The Eagle 1999 from All American Racers. The experience gained on racing cars for exhaust parts could be transferred and applied for the mass production of regular automobile parts (corrosion resistant exhaust pipes and the like) as well as heat shields. Infrastructure and building applications F.A.A. is aware that the adoption of the new GÉOPOLYMÈRE Composite 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 fire resistance is needed at low to moderate cost and mass production. To this end the F.A.A. had funded the evaluation program carried out at Rutgers, The State University of New Jersey (the GEO-STRUCTURE program) based on the GÉOPOLYMÈRE technology. A relatively new and very attractive repair method for concrete, brick and stone structures consists of externally bonding flexible sheets of fiber composites (Fig. 15 and 16). Another application for continuous fiber composites in infrastructure, already well underway in Japan and USA 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 exposed interior building columns, flammability is a serious concern. Fire safety is a concern often voiced by those who are skeptical about the use of composite materials in the infrastructure and building industry. Figure 15 : Concrete beam (3 meters long) with Geopolymer Carbon composite layers applied on its bottom surface, before testing In Europe, the market targets on the retrofit of valuable Cultural Heritage buildings where fire safety is the major concern.
  • 13. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -13- Figure 16 : Load vs Deflection for concrete beams with 0, 2, 3, 5 layers of Geopolymer Carbon composite. Successful applications  The following Figure 17 summarizes the successful applications carried out since 1979 with geopolymers of different types.
  • 14. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -14- Figure 17 : Geopolymer types involved in successful applications. PATENTS REFERENCES : The majority of the patents (with very few exception such as the PYRAMENT patents) were first filed in France at the Paris Patent Office (INPI). The list provides the title of the patent translated into English, the publication number, the date of filing and the names of the inventors. Process for the fabrication of sintered panels and panels resulting from the application of this process. FR 2.204.999, FR 2.246.382 , 02/11/1972, 09/10/1973, Joseph Davidovits. Process for the fabrication of caustic soda NaOH in powder. FR 2.259.056, 29/01/1974 ; Joseph Davidovits, Jean-Jacques Legrand Process for agglomerating compressible mineral substances under the form of powder, particles or fibres. FR 2.324.427, FR 2.346.121, 11/01/1974, 03/06/1975 , Joseph Davidovits, Jean-Jacques Legrand. Process for the fabrication of molded refractory items and products resulting from the process. FR 2.314.158, 09/06/1975 , Joseph Davidovits, Jacques Laveau. Fabrication process of light panels for insulation and high compressive strength, and products resulting from the process. FR 2.366.233, 03/06/1975 , Joseph Davidovits, Jean-Jacques Legrand, Jacques Laveau. Process for the fabrication of synthetic feldpathoids., FR 2.341.522, 20/02/1976 , CORDI-Géopolymère, Joseph Davidovits, Jacques Laveau, Alfred Emberger. Process for the fabrication of ceramics and products resulting from the process. FR 2.358.371, 12/07/1976 , Joseph Davidovits.
  • 15. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -15- Mineral Polymers and methods of making them. FR 2.424.227, FR 2.489.290, 04/09/1979, 03/09/1980, Joseph Davidovits Synthetic mineral polymer compound of the silicoaluminates family and preparation process. FR 2.489.291, 03/09/1980, Joseph Davidovits. Process for the fabrication of building materials made with kaolinitic, lateritic, ferralitic soils and products resulting from the process. FR 2.490.626, 23/09/1980 , Joseph Davidovits Foamed mineral silico-aluminates products based on K-Poly(sialate) and/or (Na,K)-Poly(sialate-siloxo). FR 2.512.805, 17/09/1981, Joseph Davidovits, Jean-Jacques Legrand Method for the makingoffoamed alkaline silico-aluminate mineral materials. FR 2.515.806,17/09/1981,Joseph Davidovits , NicolasDavidovits Thermalinsulation(passivecooling)forbuildings.FR2.512.808,17/09/1981,JosephDavidovits Method for manufacturing decorated, enamalled ceramics by monfiring, with geopolymer silico-aluminates. FR 2.523.118, 08/03/1982,JosephDavidovits,MichelDavidovics Method for manufacturing floor and wallstonetiles with geopolymers.FR 2.528.818,22/08/1982,Joseph Davidovits, Claude Boutterin Method for manufacturing building materials with lateritic soils and clays. FR 2.528.822, 22/08/1982, Joseph Davidovits, ClaudeBoutterin Earlyhigh-strengthmineralpolymer.US4.509.985,22/02/1984,JosephDavidovits,JamesL.Sawyer Ceramic-Ceramic composite material and production method. FR 2.604.994, 14/10/1986, Nicolas Davidovits , Michel Davidovics,JosephDavidovits Method for eliminating the alkali-aggregate reaction in concretes and cement thereby obtained. FR 2.657.867, 05/02/1990, JosephDavidovits Geopolymeric fluoro-alumino-silicate binder and process for obtaining it. FR 2.659.320, 07/03/1990, Joseph Davidovits , MichelDavidovics,NicolasDavidoviits Fire-proof géopolymeric panels for thermal protection and process for obtaining them. FR 2.659.963, 20/03/1990, Joseph Davidovits , Michel Davidovics, Nicolas Davidovits Method for obtainingan earlyhigh-strengthgeopolymeric matrice forthen impregnationofcomposite materials and products obtainedthereof.FR2.666.328,04/09/1990,JosephDavidovits,MichelDavidovics,NicolasDavidovits Process for obtaining a geopolymeric alumino-silicate and products thus obtained. FR 2.671.344, 03/01/1991, Joseph Davidovits,MichelDavidovics,NicolasDavidovits Alkaline aluminosilicate geopolymeric matrix for composite materials with fibre reinforcement and method for obtaining same.EP 0. 815.064, 15/03/1995, JosephDavidovits,MichelDavidovics,NicolasDavidovits Method for bonding fiber reinforcement on concrete and steel structures and resultant products. FR 2.756.840,06/12/1996,JosephDavidovits BIBLIOGRAPHICAL REFERENCES complete and detailed lists of scientific papers are to be found in following references (all listed in the Library at <www.geopolymer.org>) : The Proceedings of Géopolymère '99, 2nd International Conference on geopolymers, Editors J. and R. Davidovits, C. James, Geopolymer Institute 1999, 32 articles. Fire-resistant Aluminosilicate Composites, Lyon, R, Balaguru, P.N., Foden A, Sorathia U., Davidovics, M. and Davidovits, J, FIRE AND MATERIALS, Vol. 21, PP. 67-73 (1997) Geopolymers: Man-Made Rock Geosynthesis and the Resulting Development of Very Early High Strength Cement, Davidovits, J, JOURNAL OF MATERIALS EDUCATION, PP. 91-137, Vol. 16, N°2&3 (1994) Geopolymers: inorganic polymeric new materials, Davidovits J, J. THERM. ANAL. (JTHEA9,03684466); 91; VOL.37 (8); PP.1633-56 (1991) Geopolymer: ultrahigh-temperature tooling material for the manufacture of advanced composites, Davidovits J; Davidovics M, 36th SAMPE Symp. (ISSEEG,08910138); 91; VOL.36 (2); PP.1939-49 (1991) The Proceedings of Geopolymer ’88, European Conference on Soft Mineralurgy, Davidovits J. and Orlinski J. eds., Geopolymer Institute an Université de Technologie, Compiègne, France, Vol. 1-2, 1988.
  • 16. Geopolymer 2002 Conference, October 28-29, 2002, Melbourne, Australia, -16-