Geopolymer Concrete, the perfect seasteading material



Inventors: Chan Han, Midland, MI
Aleksander J. Pyzik, Midland, MI




ALKALI Activated FLY-ASH Based Geopolymer Concrete
Ammar Motorwala1, Vineet Shah2, Ravishankar Kammula3, Praveena Nannapaneni4, Prof. D. B. Raijiwala5


The effects of replacement fly ash with diatomite in geopolymer mortar
Theerawat Sinsiri*1, Tanakorn Phoo-ngernkham1, Vanchai Sata2
and Prinya Chindaprasirt2


Method for treating wastes
US 5810920 A
To treat waste containing harmful metals such as lead, cadmium, mercury, chromium, copper, nickel, zinc, etc., the waste is mixed with a treating agent containing, as the essential constituent component, solid acid(s) and/or cement and additionally a caking inhibitor, kneaded with water where necessary, then solidified by curing. Harmful metals are thereby stabilized in the thus-solidified cakes and are not released therefrom.

(Wilfried Ellmer) #229

Has anybody done something seasteading relevant in Geopolymers already - a floating construction in the 20m size class for example…that allows some relevant data about service life expectance and general performance under real ocean conditions…any kind of cost benefit analysis ? compared to portland cement binders in concrete composite materials?


Has anybody done something seasteading relevant in Geopolymers already - a floating construction in the 20m size class for example…that allows some relevant data about service life expectance and general performance under real ocean conditions…any kind of cost benefit analysis ? compared to portland cement binders in concrete composite materials?

So far nobody has done any seasteading, regardless of materials. Meanwhile, anything that can undercut the cost of concrete, with the potential to last multiple generations, even millenia, is expected to be better than OPC

(Nick Gencarelle) #231

Actually there have been some recent hinges made from carbon so yes basalt can be made to do the same thing. It has great elasticity and wear potential in the right resins.


A note on Basalt Rebar. It comes in coils that store a considerable amount of energy, and retails that, without taking the curvature as a permanent ‘set’.

General practice seems to prefer taking the end out of the middle, allowing the clips to remain in place, to prevent unspooling.

Here, these folks are using an older coil, that used standard plastic strapping, so they had to remove all of the ties and used lacr C-clamp vice-grips and proceed to uncoil a portion, for a project. He states that a coil came apart and put a hole on a steel container, while doing so.

(George Hawirko) #233

This is a Rabit Hole I have been down many times and now prefer to stick with proven and available materials. Acrylic Polymer Cement will give you all the performance that Beta Projects need but will peep into this subject from the sidelines.


Part of the goal with true geopolymer cement is to reduce the cost, by using more affordable materials, rather than increasing the cost of existing cements.

One reason to eliminate OPC is the way calcium is negatively affected by seawater, while anoter is the corrosion of iron, within ferrocement.

Another is the expected durability of geopolymers, with potential to last many generations. Very few ferrocement constructs have survived over 100 years. Geopolymer has the potential to last 1000+ years. OPC does not have that potential.

(Wilfried Ellmer) #235

before “postulating all kind of things” … consider..


Fine by me. I wasn’t planning on replacing concrete at all. In order to replace concrete, you have to consider it viable. Before attempting to correct people, perhaps you should research the effects of seawater on OPC and steel reinforced OPC a tad further. If you plan to build for 100 years, more-or-less, I guess OPC COULD be considered viable, however it is not capable of millenial endurance. 150 years from now, we may all be dead, but what artifacts will we leave behind? When, not if, the concrete breaks down and the steel corrodes, it will become an underwater feature that decays. geopolymer has the potential to last millenia… Do you want to build to rival the pyramids in endurance, or a mud hut? I’d rather leave a lasting impression…

(Matias Volco) #237

The term I believe you’re referring to is “ruin value” which at sea I suppose translates to artificial coral reefs.

Organisms regenerate while relics are fragile. I believe part of the point of Ocean Colonization is to provide a physical platform upon a blank sheet for a new more ephemeral cyber-civilization, where we need to extract as much value and intelligence from the least amount and cost of material as possible - if we ever want to turn the moon into a self-replicating computer, we need to start with what makes economic sense now. Bounding computer operations and transactions to precious land-based cities makes less sense each passing day. An affordable and proven alternative must be found. Wheels need to be adapted, not re-invented.


More of a difference as to which scale is more lasting. the shells of Diatoms are many millenia old and enduring, the pyramids are several and decaying, while cities and large concrete structures may be large, but they are more ephemeral. The rigidity of the design, vs adaptability, is where the problem lies. Concrete isn’t even designed to be permanent, therefor it doesn’t last. The pharaohs built for their vision of eternity and it has endured, but the diatoms lived brief spans and their shells endure. The larger and more complicated, the less permanent, while simpler forms are more enduring.

Concrete relies on water, structurally. Geopolymer uses water, but water isn’t part of the structure. I need better supplies and better work space, but the difference is like mud and pottery. Fired pottery is not water soluble, yet, before being fired, it is essentially mud (and called that). The reactions within geopolymer are equivalent to pottery firing, in that they initially use water, but water is not a structural member, within the final product, nor is the final product water soluble.

(Nick Gencarelle) #239

Personally I would have zero problems replacing OPC with Geopolymers. Recent tests with basalt fabrics increased over forty times the flexural modulus of the geopolymer. I would have the basalt treated with a zirconium sizing if possible like AR glass for advanced alkaline resistance but no matter it will outlive OPC many times, a much thinner, lighter wall can be poured saving lots of weight which for a boat is great.
The hull would be treated with a further waterproofing anyway so keeping water out to begin with. When adding layers to beef up or repair -successive layers of Geopolymers actually bond together unlike Portland that makes a seam. Incredibly fire and freeze resistant. You could also try an ultra high strength concrete and have similar or even better properties.

(Wilfried Ellmer) #240

Sounds interesting. Did you do some testing of your own ? - Would you mind to share the results ? Is flexural modus increase a “desired result” ? Why did you mention Zirconium sizing and advanced alkaline resistence ? If you postulate outlive Portland Cement many times - how did you come to this conclusion ? Why is waterproofing a concern ? - non of the current marine concrete structures uses “waterproofing”. Why do you postultate a seam problem in first place - marine concrete engineering has seam design very well under control. Why is increasing changing any of the binder properties a advantage ? … any thoughts you want to share on this ? .

@NickGri From your posting i understand that you are one of the few who actually have a genuine knowledge on the field - so i am eager to hear more from you on each of the points you mentioned.:+1: - please comment much more and much more detailed. Many on these forums are actually in search of expert info to learn from - instead of pointless arguing …
| extraoridinary concrete floating structures | project list | technology evaluation |

(Nick Gencarelle) #241

My tests were done by Dr. Kriven and her staff at U. Illinois. She is a world’s leading expert for Geopolymers. Yes zirconium adds alkaline resistance that’s what they put on AR glass. Accelerated life testing shows basalt outliving steel in concrete for over 100+ years. Water is the main culprit in creating the corrosion, so of course it makes sense to prevent water penetration to begin with. Crystalline agents Etc.and coatings are available. Yes flexural modulus means impacts will take a bend before breaking. Being able to repair a hole with geopolymer means it bonds together. Portland would just stick somewhat to the surface and never be as good as the original. You would have to etch grooves into the concrete to make a good connection and even then it would only be contacting not bonding.

(Nick Gencarelle) #242

Concrete wicks and adsorbs water. Small cracks in northern climates freeze and then the ice expands spalling the concrete. Not so bad in southern climates, but water still reacts with the alkalis and chemicals and accelerates galvanic response that corrodes the steel and concrete. Most concrete actually may harden fully in 28 days but really can take years to fully harden but still wicks water. In some places like treatment plants the sulphur gases given off create microbes that eat the concrete. The basalt fibers do not support growth of microbes.

(Larry G) #244

Geopolymer is really hitting the mainstream commercialization: