1. Geopolymer Concrete for Green Construction Materials
Dr. Erez Allouche
Trenchless Technology Center
Louisiana Tech University
November 5, 2009

2. Summary Statement
Inorganic polymer concrete (geopolymer) is an emerging class of cementitious materials that aimed at utilizing one of the most abundant industrial by-products on earth, fly ash (800,000,000 tons per year), as a substitute for the most widely produced man-made material on earth, Portland cement (2,600,000,000 tons/yr).

3. Research Context and Prior Work
49.6% of the US electrical energy production is fueled by coal (western USA has 250-year supply of recoverable coal)
72 M tones of fly ash are produced; only 38.1% is recycled
The US produce 110 million metric tones of cement, resulting in 90 million metric tones of carbon dioxide.
Cement production contributes 7% of human CO2 emissions
Cement production - energy intensive process (heat raw materials to 2550 F)
Remaining R&D
Technical risk
Remaining milestones
Future enhancements
Need for outside expertise or resources

4. Re-Arranging the Equation
Cement Production
Power Generation
Refinery/Chemical industry

5. Re-Arranging the Equation+

6. Accomplishments to Date
Evaluate the geopolymerization potential of 28 samples of fly ash collected from 18 power plants
Develop chemical additives that enable the pouring of large volumes of geopolymer concrete
Development of additives that enable pumping and spraying of geopolymer grout

7. Accomplishments to Date
We are on the verge of lunching our first commercially viable product – sprayable geopolymer grout for the rehabilitation of manhole structures & sewer pipes
Develop formulation for stabilizing fly ash generated by waste-to-energy programs (incineration of municipal waste; Vancouver, Canada)

8. Plans for 2009-10 – New Applications
High-energy efficient, low-carbon footprint homes using geopolymer filled insulated concrete forms (ICF).
High temp grout material for oil/gas wells casing (2,500 F; 16,000 psi in 24 hrs)
Development of ‘Eco-Reef’, ultra low cost artificial rock for aiding costal restoration; production potential up to 30 million ton per year along AL-MS-LA-TX coastline)

9. Value Proposition