Geopolymer Fireproofing Coating with Hydroxide Additives
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Solution Overview
Problem
Existing fireproofing materials, particularly geopolymer cements, face challenges in achieving high heat resistance, bonding strength, and durability while minimizing carbon dioxide emissions during production, and struggle to meet specific density and rheological requirements for building infrastructure protection.
Innovation Solution
A density-controlled geopolymer cementitious spray applied fireproofing material is developed, comprising a mixture of lightweight aggregates, alkali-activated cementitious materials, activators, set-time retardants, protein materials, alkali-resistant fibers, and water reducers, which can be applied using conventional spraying equipment to achieve desired equilibrium densities and exhibit superior compressive strength and bond strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If geopolymer cement is used as fireproofing material, then carbon dioxide emissions are reduced, but heat resistance and bonding strength are insufficient
Solution Approach 1:
The patent uses a composite material system combining geopolymer cement with aluminum hydroxide and magnesium hydroxide additives. The geopolymer matrix provides the base structure while the hydroxide additives contribute to heat resistance through decomposition reactions that absorb thermal energy and release water vapor, creating a synergistic effect that maintains both environmental benefits and thermal performance.
Solution Approach 2:
The patent modifies the chemical composition parameters of the geopolymer system by incorporating specific ratios of aluminum hydroxide and magnesium hydroxide (each 5-20 wt% of total composition). This parameter change transforms the material's thermal response characteristics, enabling it to withstand higher temperatures while maintaining the low-carbon advantage of geopolymer cement.
2Object-generated harmful factors
If geopolymer cement is used as fireproofing material, then carbon dioxide emissions are reduced, but bonding strength is insufficient
Solution Approach 1:
The composite formulation integrates geopolymer cement with aluminum hydroxide and magnesium hydroxide, where the hydroxide particles act as reinforcement phases. These additives improve the interfacial bonding between the geopolymer matrix and substrate, enhancing overall bonding strength while preserving the environmentally friendly characteristics of the geopolymer system.
3Ease of manufacture
If conventional spraying equipment is used, then application process is simple, but achieving desired density and rheological properties is difficult
Solution Approach 1:
The patent adjusts the rheological parameters of the fireproofing composition by incorporating specific amounts of aluminum hydroxide and magnesium hydroxide, which modify the flow characteristics and density. These compositional adjustments enable the material to be effectively sprayed using conventional equipment while achieving the desired density range and application performance.
Data Source
AI summary
A density controlled cold fusion concrete cementitious spray applied fireproofing material including a mixture of water, one or more of silicon dioxide, expanded glass, vermiculite, bottom ash, perlite, expanded shale, expanded polystyrene, and sulfonated formaldehyde, or other lightweight aggregates of various diameter sizes ranging from about 0.025 mm to about 12.5 mm in diameter; anhydrous or hydrous sodium or potassium metasilicate; waste from steel production consisting of Granulated Ground Blast Furnace Slag (GGBFS); high calcium or low calcium waste from coal combustion (fly ash or bottom ash); sodium tetraborate, sodium citrate dihydrate, citric acid, or boric acid; and an alkali-resistant micro-fiber.