How to make geopolymer concrete with your own hands at home: technology and scope of application

A special kind of concrete known as geopolymer concrete is created by substituting materials such as fly ash or slag for conventional cement. Due to its superior durability and environmental benefits, it is becoming more and more popular.

Although creating geopolymer concrete at home can seem intimidating, it is completely doable with the correct advice. With just a few materials and tools, you can make a durable, environmentally friendly substitute for regular concrete.

We’ll take you step-by-step through the creation of geopolymer concrete in this post. We’ll also go through some of its many uses so you can see how adaptable this material is for do-it-yourself projects.

Whether you’re a novice or an experienced do-it-yourselfer, this tutorial will help you make your own geopolymer concrete and add a sustainable touch to your projects.

History of creation

Joseph Davidovich, a Frenchman, succeeded in creating concrete using geopolymers in 1978. Observing natural processes taking place in the natural world gave rise to the idea. The French scientist discovered that when certain elements of geological origin come into contact with alkaline environments, they start to polymerize. A number of experiments were conducted with the aim of determining a methodical strategy to guarantee the production of geopolymer. This is the exact name by which the material is known.

As per the inventor, the pyramids of Giza were primarily built using monolithic construction. The composition of the monolithic blocks used to build the pyramids was ascertained by the scientist. Although this theory is under scrutiny, geopolymer concrete’s superior qualities continue to drive its widespread use. Since then, the recipe has changed a little bit. Today’s geopolymer concrete is extremely competitive with traditional concrete compositions while being environmentally safe.

Features of the material and scope of use

Polymer concrete has a structure similar to that of natural stone. This makes the solution suitable for both casting ornamental items and building applications. Because of its excellent strength characteristics, polymer concrete is ideal for architectural applications.

The material’s properties make it suitable for use in the construction of tall buildings. The elements in the mixture support the creation of a comfortable environment within the building. Because of the final material’s structure, it is possible to cut the wall thickness during construction by half or three times without compromising the comfort of the space.

Geopolymer concrete has a high fire resistance, which makes it ideal for use in both residential and commercial construction. It is also used to create sculptures and bas-reliefs, as well as different monuments, because of its enhanced plasticity and quick hardening characteristic.

Advantages

They have numerous benefits when a unique recipe for geopolymer composite materials is prepared.

The enumerable positive attributes are as follows:

• Low shrinkage, which makes it possible to shorten the time required for construction. Finishing can be done immediately after the construction of the walls is completed.
• During the construction process, the dimensions of all products that come into contact with the solution will be preserved.
• High resistance to compression is noted, so geopolymers can be used to build high-rise buildings.
• Can maintain integrity during repeated thawing and freezing.
• Greenhouse gases are released in small quantities.
• Well tolerates the effects of aggressive substances.
• Fire resistance, which even at a temperature of 900 degrees allows polymer concrete to retain its structure and integrity.
• Reduced vapor permeability, the coefficient is close to that of natural stone.
• Can be processed using a hand tool equipped with diamond elements.
• Environmentally friendly, safe for others.
• It is possible to use industrial waste for the production of polymer concrete. This can improve the environmental situation of any area.
• The composition hardens twice as fast as in the case of simple concrete.
• Affordable cost allows customers with a not particularly high income to purchase the material.
• Resistance to corrosion, which can have a destructive effect on simple reinforced concrete.
• It is possible to make geopolymer concrete with your own hands at home.

Polyconcrete is a distinct alternative to regular concrete mortar because of its many advantageous features.

Composition

The composition of the substance known as geopolymer concrete is as follows:

• Ash dust.
• Slag.
• Liquid glass.
• Potassium hydroxide 200.
• Water.

The presence of slag in the concrete mixture gives it strength and durability. However, during shrinkage, the material cracks, which needs to be avoided by taking specific precautions. The same quantity of fly ash is added to the slag to keep it from cracking. Their combined efforts serve to fortify the concrete’s composition and increase its resistance to outside influences.

Fly ash offers enhanced performance characteristics and convenient physical properties. The component has an impact on the final composition’s quality. Its application guarantees the creation of a mixture with qualities on par with Portland cement. The strength of geopolymer concrete is comparable to that of granite.

Alkali and aluminum silicates combine to form a solid monolith that resembles real stone. It can be cast to create a variety of shaped products that are used as decorations. Experiments are being conducted to develop the recipe for geopolymer concrete, as it is not yet fully developed. There are numerous composition variations that can be made into functional mixtures.

In order to make geopolymer concrete at home, common materials like fly ash, metakaolin, or slag are combined with alkaline solutions like sodium hydroxide and sodium silicate. This results in a long-lasting, environmentally friendly substitute for traditional concrete that can be used for anything from garden paths to do-it-yourself furniture.

Recipe

A tried-and-true recipe should serve as your guide when choosing the components. Construction industry experts are always trying to make it better. Proportions are not set in stone; rather, they are determined by the attributes and intended use of each component. However, there are also tried-and-true recipes that you can use to make geopolymer concrete at home using your hands.

The parts that are utilized in non-industrial settings will be identical. However, they are used in smaller amounts to make a mixture that is sufficient to carry out the required tasks. This is a basic recipe that can be used to make 20 kg of polyconcrete:

• Potassium hydroxide – 1.8 kg.
• Liquid glass – 4.0 kg.
• Ash – 6.6 kg.
• Slag – 6.6 kg.
• Water – 11 l.

This is a tried-and-true recipe that is frequently made at home.

How to do it yourself

The ingredients mentioned in the recipes are readily available at retail networks and are reasonably priced. However, it should be remembered that polymerization-produced concrete is more expensive than Portland cement mixtures. Tetraborate decahydrate is added to the recipe as a supplement because the composition sets quickly. Latex, PVA, and resins on water can be added.

What is needed for work

In order to get geoconcrete at home, get ready:

• Container for mixing the solution, taking into account that during preparation it releases a certain amount of heat.
• Scales for preparing the desired proportion of each of the components.
• Electric drill with a mixing attachment.
• Wooden spatula.
• A container for molding concrete, which in size and configuration corresponds to the product obtained by casting.
• Protective gloves and other products to prevent the harmful effects of alkali on the skin and mucous membranes.

It is important to prepare the components as quickly as possible. Working with the mixture while maintaining low air humidity is advised. Granules of colorless potassium hydroxide spread when the relative humidity is a little higher. Before making the mixture, they are opened right away.

It is important to remember that the aggressive composition of concrete can cause severe burns if it comes into contact with skin or mucous membranes. It is essential to wear gloves and safety glasses when working. Working with liquid glass requires caution as well because it has a crystallized structure and is hygroscopic.

Preparation technology

The technology behind geopolymer concrete was developed with consideration for the individual properties of its constituent parts. The removal of slag and ash is another guarantee of the manufacturing process. Waste that results from burning solid fuel is called fly ash, and it can make up up to 75% of the mixture’s composition. Although this material has a questionable environmental reputation, when used with concrete, it becomes stronger and more durable.

Using a power tool with a nozzle, the components are mixed in a concrete mixer or a designated container.

The following order is followed when laying components:

• Pouring water.
• Filling slag, fly ash in the required amount.
• Thorough mixing until homogeneous.
• Adding polymers.
• Mixing until ready.

It is best to pour into molds in a dry area. A film is created during solution mixing, and when it comes into contact with water, it swells. After the solution is poured into the molds, precautions should be taken to keep it dry to avoid this kind of reaction.

The process of creating geopolymer concrete at home is useful and satisfying. You can make a strong and green substitute for conventional concrete by combining common materials like fly ash, sodium hydroxide, and water.

The procedure is simple. To achieve the desired consistency, make sure you thoroughly mix the ingredients in the correct proportions. Fill the molds with the mixture, then let it cure. Those who enjoy do-it-yourself projects can complete this with simple tools and equipment.

Geopolymer concrete is perfect for a range of uses. Paving stones, garden pathways, and even modest building projects work well with it. Because of its durability and strength, it can be used for both functional and decorative purposes.

You can take advantage of the advantages of geopolymer concrete by following the instructions provided. When compared to conventional concrete, it’s a greener choice with a lower carbon footprint. It also presents a special chance to investigate cutting-edge building materials at home.

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