Geopolymer formulation and process thereof

A method of making a geopolymer formulation, the method comprising:

• placing a precursor into a chamber of milling equipment;
• placing an activator into the chamber of the milling equipment;
• and
• milling the precursor and the activator to produce a dry solid powder with a particle size in the range of 45 to 60 microns and produce a geopolymer formulation for making a functional geopolymer when combined with an aggregate and water.

A geopolymer formulation for making a functional geopolymer when combined with an aggregate and water, the geopolymer formulation comprising:

• a precursor including fly ash and blast furnace slag;
• and
• an activator including sodium hydroxide and sodium silicate or rice husk ash;
• wherein the geopolymer formulation is a dry solid powder with a particle size in the range of 45 to 60 microns, the geopolymer formulation is for a refractory geopolymer composite with a compressive strength of 5900 psi when cured at 160° F. for 24 hours prior to high temperature exposure.