Description:FIELD OF THE INVENTION
[001] The present disclosure relates to fine waste generated during kaolin mining based concrete composition. The present disclosure also provides a process of preparation of use of fine waste from kaolin mining based concrete composition. More specifically, the present invention relates to producing concrete with varying compressive strength at 28 days using different percentages of kaolin mining waste as a replacement of natural fine aggregate.

BACKGROUND OF THE INVENTION
[002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[003] Concrete is one of the second most widely used construction materials after water. Due to rapid growth in infrastructure and urbanization, there is a tremendous surge in consumption of construction materials. Also, the world has become more conscious of the sustainability and environmental friendliness of materials used in construction. According to Cement Sustainability Initiative report it is estimated that 25 billion tons of concrete is manufactured globally each year. The utilization of concrete is almost double than the use of other building materials like wood, steel, plastic and aluminum.
[004] Utilization of concrete is going to be doubled, due to rapid growth in infrastructure. Concrete is a homogenous mixture of cement, coarse aggregates, fine aggregates and water. Both coarse and fine aggregate constitute 70 to 75% of the volume of concrete and is used to give volume stability to concrete. Natural fine aggregates generally make about 25 to 30% volume of the total aggregates.
[005] Natural fine aggregates are generally extracted from the river bed. With the increase in sand mining, river sand has been banned in many states of India. The production of cement is a highly energy-intensive process and emits lots of carbon dioxide into the atmosphere. Moreover, the production of coarse and natural fine aggregates also requires huge energy for extraction from their natural source and delivering it to the site. Aggregates occupy 70 to 75% of the volume of which 30 to 35% of volume is occupied by natural fine aggregates.
[006] Sand extraction leads to the lowering of the water table on the river bottoms, reducing the supply of sediments therefore extraction of natural sand from river beds is banned by several state governments. Today, concrete professionals are looking for a suitable alternative to natural fine aggregate due to resource depletion and environmental restrictions.
[007] Kaolin mining is done in various regions across India. Kaolin clay is extracted from the mines to produce china clay [which is used for ceramic and other industrial applications]. When kaolin is extracted, residue which is left behind is thrown unattended and is unauthorized waste. This waste material at present is either thrown or disposed unorganized way of is used for filling up pits created due to the excavation of Kaolin and hence does not have any significant commercial value.
[008] Therefore in the present innovation, efforts are made to use this waste as a replacement for natural fine aggregates in concrete. Optimum percentage of replacement for natural fine aggregates is evaluated in concrete along with mechanical properties like compressive strength, flexural strength, and split tensile strength. It is observed that the compressive strength, the flexural and split tensile strength of concrete are all in the range of values specified in the Indian Standards and can be recommended for concrete work.
[009] In the present invention, fine waste from kaolin mining is generated while mining minerals used for manufacture of china clay is used as a replacement of natural fine aggregate and the optimum percentage is evaluated along with mechanical properties like compressive strength, flexural strength, and split tensile strength.
[0010] A lot of work has been done on the use of metakaolin as a supplementary cementitious material in concrete. Metakaolin is obtained when calcination of kaolin is done at a temperature of 700?. However, there are no studies relating to the use of kaolin clay waste as a replacement of natural fine aggregate.
[0011] The proposed invention can find applications in the construction industry, particularly in infrastructure projects. The invention has the potential to produce concrete that is sustainable and eco-friendly with a lesser carbon footprint.
[0012] Therefore, the proposed invention offers an innovative solution to the challenges associated with concrete compositions while addressing the environmental impact of sand extraction, making it an important development in the construction industry.

OBJECTS OF THE INVENTION
[0013] An objective of the present disclosure is to provide a fine waste generated during kaolin mining-based concrete composition.
[0014] Another objective of the present disclosure is to provide a process of preparation of a fine waste generated during kaolin mining based concrete composition.
[0015] Another objective of the present disclosure is to replace natural fine aggregate fine waste generated during kaolin mining and in manufacturing of clay.
[0016] Another objective of the present disclosure is to find out how much to utilize effectively, fine waste generated during kaolin mining into concrete to make concrete sustainable.
[0017] Another objective of the present disclosure is to determine the optimum percentage of replacement of fine waste generated during kaolin mining without compromising on the compressive strength of concrete.
[0018] Another objective of the present disclosure is to determine the flexural strength of the said concrete with the replacement of natural sand.
[0019] Another objective of the present disclosure is to determine the split tensile strength of the said concrete with the replacement of natural sand.
[0020] Another objective of the present disclosure is to reduce the illegal disposal of fine waste generated during kaolin mining.
[0021] Another objective of the present disclosure is to provide concrete the concrete that is sustainable and eco-friendly concrete with a lesser carbon footprint.
[0022] Another objective of the present disclosure is to reduce the overall cost of concrete.
[0023] Another objective of the present disclosure is to stop/reduce the illegal river sand mining
[0024] Another objective of the present disclosure is to reduce the consumption of natural resource like river sand.

SUMMARY OF THE INVENTION
[0025] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in Detailed Description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0026] The present disclosure discloses a concrete composition comprising:
14 % to 18 % w/w of cement having volume in the range of 350-400 kg/m3;
42 % to 55 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3;
0 % to 35 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and/or fine waste generated during kaolin mining having volume in the range of 0-750 kg/m3; and Water upto 100%.
[0027] In some embodiments, the cement is selected from a group consisting of ordinary Portland cement of Grade 53, 43, 33.
[0028] In some embodiments, the cement is ordinary Portland cement of grade 53.
[0029] In some embodiments, the coarse aggregates having size in the range of 4.75 mm to 20 mm.
[0030] In some embodiments, the natural fine aggregates have a specific gravity of 2.58 and water absorption of 1.8%.
[0031] In some embodiments, the Kaolin sand waste had a specific gravity of 2.39, and a water absorption value of 0.12 %
[0032] In some embodiments, the natural fine aggregate is replaced with fine waste generated during kaolin mining by 25%, 50%, 75% to 100% respectively.
[0033] In some embodiments, the composition comprises:
14.5 % to 16.67 % w/w of cement having volume in the range of 350-400 kg/m3;
45.83 % to 50.0 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3;
27.08 % to 31.25 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and / or fine waste generated during kaolin mining having volume in the range of 0-750 kg/m3; and
Water up to 100%
[0034] The present disclosure also provides a process of preparation of a concrete composition. The process comprising the following steps:
a) dry mixing 42 % to 55 % w/w of coarse aggregates, 0 % to 35 % w/w of fine aggregates and or fine waste generated during kaolin mining to obtain dry mixture;
b) mixing 14 % to 18 % w/w of cement to dry mixture to obtain mixture I;
c) mixing water to mixture I to form the concrete composition; and
d) pouring the concrete mixture into moulds.
[0035] In some embodiments, the mixing steps a-c is carried out at a temperature in the range of 20-30 °C until a homogeneous mixture is obtained.
[0036] In some embodiments, 100 % of the natural fine aggregate is replaced with fine waste from kaolin mining.
[0037] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.

DETAILED DESCRIPTION OF THE INVENTION
[0038] The following is a detailed description of embodiments of the disclosure. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0039] Unless the context requires otherwise, throughout the specification which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”
[0040] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0041] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable.
[0042] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it is individually recited herein.
[0043] All processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0044] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0045] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0046] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0047] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description that follows, and the embodiments described herein, is provided by way of illustration of an example, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.
[0048] It should also be appreciated that the present invention can be implemented in numerous ways, including as a system, a method, or a device. In this specification, these implementations, or any other form that the invention may take, may be referred to as processes. In general, the order of the steps of the disclosed processes may be altered within the scope of the invention.
[0049] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0050] Concrete is a homogenous mixture of cement, coarse aggregates, natural fine aggregates and water. Both coarse and natural fine aggregate constitute 70% of the volume of concrete and is used to give volume stability to concrete. Natural fine aggregates generally make about 30% volume of the total aggregates.
[0051] The present disclosure discloses a concrete composition comprising:
14 % to 18 % w/w of cement having volume in the range of 350-400 kg/m3;
42 % to 55 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3;
27.08 % to 31.25 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and / or fine waste generated during kaolin mining having volume in the range of 0-750 kg/m3; and
Water upto 100% depending upon allowable water cement ratio.
[0052] In some embodiments, the cement is selected from a group consisting of ordinary Portland cement of grade 53, 43, 33.
[0053] In some embodiments, the cement is ordinary Portland cement of grade 53.
[0054] In some embodiments, the coarse aggregates having size in the range of 4.75 mm to 20 mm.
[0055] In some embodiments, the natural fine aggregates have a specific gravity of 2.58 and water absorption of 1.8%.
[0056] In some embodiments, the fine waste generated during kaolin mining had a specific gravity of 2.39, and a water absorption value of 0.12 %
[0057] In some embodiments, the natural fine aggregate is replaced with fine waste generated during kaolin mining by 25%, 50%, 75% to 100% respectively.
[0058] In some embodiments, the composition comprises:
14.5 % to 16.67 % w/w of cement having volume in the range of 350-400 kg/m3;
45.83 % to 50.0 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3;
27.08 % to 31.25 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and or fine waste generated during kaolin mining having volume in the range of 0-750 kg/m3; and
Water upto 100% depending upon allowable water cement ratio.
[0059] The present disclosure also provides a process of preparation of a concrete composition. The process comprising the following steps:
a) dry mixing 42 % to 55 % w/w of coarse aggregates, 0 % to 35 % w/w of natural fine aggregates and 1 % to 35 % w/w of fine waste generated during kaolin mining to obtain dry mixture;
b) mixing 14 % to 18 % w/w of cement to dry mixture to obtain mixture I;
c) mixing water to mixture I to form the concrete composition; and
d) pouring the concrete mixture into moulds.
[0060] In some embodiments, the mixing steps a-c is carried out at a temperature in the range of 20-30 °C until a homogeneous mixture is obtained.
[0061] In some embodiments, 100 % of the natural fine aggregate is replaced with fine waste from kaolin mining.
[0062] The present invention relates to producing concrete up to 25-30 MPa of compressive strength at 28 days using different percentages of kaolin waste sand as a replacement of natural natural fine aggregate. The sand is replaced with kaolin mining waste by 25%, 50%, 75% to 100% respectively.
[0063] Said composition of the present invention mainly comprises of:
14 % to 18 % w/w of cement having volume in the range of 350-400 kg/m3;
42 % to 55 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3;
27.08 % to 31.25 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and or fine waste generated during kaolin mining having volume in the range of 0-750 kg/m3; and
Water upto 100%.
[0064] In some embodiments, the composition comprises 14 % to 15 % w/w, or 14 % to 16 % w/w, or 14 % to 17 % w/w, or 15 % to 18 % w/w, or 16 % to 18 % w/w or 17 % to 18 % w/w or 15 % to 17 % w/w of cement.
[0065] In some embodiments, the composition comprises 48 % to 55 % w/w, or 44 % to 55 % w/w, or 45 % to 55 % w/w, or 42 % to 50 % w/w, or 50 % to 55 % w/w or 53% to 55 % w/w or 44 % to 50 % w/w of coarse aggregate.
[0066] In some embodiments, the composition comprises 0 % to 5 % w/w, or 5 % to 10 % w/w, 10 % to 15 % w/w, or 15 % to 20 % w/w, or 20 % to 25 % w/w, or 25 % to 35 % w/w, or or 27 % to 35 % w/w, or 29 % to 35 % w/w, or 31 % to 35 % w/w, or 33 % to 35 % w/w or 27% to 32 % w/w or 27 % to 31 % w/w of natural fine aggregate.
[0067] In some embodiments, the composition comprises 1 % to 35 % w/w, or 5 % to 35 % w/w, or 10 % to 35 % w/w, or 15 % to 35 % w/w, or 20 % to 35 % w/w or 25% to 35 % w/w or 30 % to 35 % w/w, or 1 % to 31 % w/w of fine waste generated during kaolin mining.
[0068] In some embodiments, the composition comprises:
14.5 % to 16.67 % w/w of cement having volume in the range of 350-400 kg/m3;
45.83 % to 50.0 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3;
27.08 % to 31.25 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3; and or kaolin clay waste having volume in the range of 0-750 kg/m3
[0069] In some embodiments, the cement is selected from a group consisting of ordinary Portland cement of grade 53, 43, 33. In some embodiments, the cement is selected from ordinary Portland cement of 53 grade.
[0070] In some embodiments, the compressive strength of cement is minimum 53 MPa at 28 days.
[0071] In some embodiments, the coarse aggregates are procured from a local source. In some embodiments, the coarse aggregates have size in the range of 4.75 mm and 20 mm.
[0072] In some embodiments, Natural fine aggregates are also procured from a local source. In some embodiments, the natural fine aggregates have a specific gravity of 2.58 and water absorption of 1.8%. In some embodiments, the natural fine aggregates is selected from natural sand (river banks).
[0073] In some embodiments, the loose bulk density is 1442 kg/m3 and the rodded bulk density was 1650 kg/m3. Natural fine aggregates (Sand) belonged to Zone II.
[0074] In some embodiments, fine waste generated during kaolin mining had a specific gravity of 2.39, and a water absorption value of 0.12 %. In some embodiments, the loose bulk density was 1520 kg/cm3 while the rodded bulk density was 1590 kg/m3. The grading of fine waste generated during kaolin mining is given in Table 1.
Table 1: Grading of fine kaolin mine waste
I.S. Sieve Size Wt. of waste fine aggregates Retained (gm) % retained Cum% retained % passing
4.75 mm 0 0 0 100
2.36 mm 257.2 51.89 51.89 48.11
1.18 mm 177.6 35.84 87.783 12.217
600 microns 41.4 8.35 96.08 3.92
300 microns 14.6 2.95 99.03 0.97
150 microns 4 0.81 99.84 0.16
Pan 0.8 0.16 100 0

[0075] In some embodiments, the present disclosure provides a process of preparation of a concrete composition. The process comprises the following steps:
a) dry mixing 42 % to 55 % w/w of coarse aggregates, 25 % to 35 % w/w of natural fine aggregates and 1 % to 35 % w/w of fine waste generated during kaolin mining to obtain dry mixture;
b) mixing 14 % to 18 % w/w of cement to dry mixture to obtain mixture I;
c) mixing water to mixture I to form the concrete composition; and
d) pouring the concrete mixture into moulds.
[0076] In some embodiments, the cement is mixed with dry aggregates for 5 to 8 minutes to obtain mixture I.
[0077] Evaluation of compressive strength for concrete mixtures was done using 3000 kN capacity hydraulic compression testing machine. Cube specimens of were cast and measurement of compressive strength was done at 7 and 28 days respectively in accordance with (IS 516-2021). An average of three cubes was taken for measuring the compressive strength. The compressive strength of concrete cubes was evaluated with replacement of 25%, 50%, 75% and 100% of natural fine aggregate with fine waste generated during kaolin mining.
[0078] The flexural strength of concrete mixtures was evaluated after 28 days of curing using a 250 kN flexural testing machine. Beams of mm were used to evaluate flexural strength of concrete in accordance to test procedure as laid in (IS 516-2021).
[0079] The split tensile test was performed using a Universal testing machine. Evaluation of the split tensile test of concrete was carried out using 150 mm diameter and 300 mm height cylindrical specimens in accordance with (IS 516- 2021).
[0080] The concrete mix design was carried out for target strength of 30 MPa. The mix proportion consisted combination of ingredients; between 350 and 400 kg of cement per m3, between 1100 – 1200 kg of coarse aggregate material per m3 and 191 killograms per m3 of water and 650 – 750 kg of natural fine aggregate per m3 of concrete. As a replacement for natural fine aggregate, various percentages of fine waste generated during kaolin mining was employed. The mix design procedure is a process used to determine the appropriate proportions of various ingredients (such as cement, aggregates, water, and admixtures) to create a concrete mix with desired properties and performance characteristics. This is done by selecting water cement ratio, estimating water content, adjusting aggregate proportions and estimating cement content based on recommendations given in IS 10262:2019. After this various trial mixtures are conducted to arrive at required target strength. Table 2, shows various trial mixes with varying percentage of fine waste generated during kaolin mining as replacement of natural fine aggregates.
Table 2:- Mix Design Proportions
Mix Cement
(kg/m3) Natural fine aggregate (kg/m3) Coarse Aggregate
(kg/m3) Water
(kg/m3)
River Sand Fine waste from Kaolin clay Mining
Mix-0 380 695 0 1134 191
Mix-1 380 521.25 173.75 1134 191
Mix-2 380 347.5 347.5 1134 191
Mix-3 380 173.75 521.25 1134 191
Mix-4 380 0 695 1134 191

[0081] For carrying out compressive strength, cubes were prepared and cured for 7 and 28 days respectively in water. The cubes were then tested in compressive testing machine as per IS 516- 2021. The compressive strength was obtained by dividing the maximum load at failure by the cross-sectional area of the sample.
Compressive Strength = Maximum Load at Failure / Cross-Sectional Area
[0082] The compressive strength varied between 16.3 MPa and 17.43 MPa at 7 days and 26.0 MPa to 30.5 MPa at 28 day. The replacement of natural fine aggregates was done with fine waste generated during kaolin mining ranging from 25% to 100% as indicated in Mix M1 to M4.

Table 3: Compressive Strength on 7 and 28 Days Respectively
Mix-0_Replacement of Natural fine aggregate by 0% of fine waste from kaolin mining
Sr. No. Strength at 7 Days (MPa) Strength at 28 Days (MPa)
1 14.6 25.9
2 14.2 25.4
3 14.3 25.7
Average 14.37 25.67
Mix-1_Replacement of Natural fine aggregate by 25% of fine waste from kaolin mining
Sr. No. Strength at 7 Days (MPa) Strength at 28 Days (MPa)
1 14.6 27.9
2 18.1 22.6
3 16.3 27.2
Average 16.33 25.9
Mix-2_Replacement of Source Material by 50% of fine waste from kaolin mining
Sr. No. Strength at 7 Days (MPa) Strength at 28 Days (MPa)
1 21.5 20
2 22.6 17.5
3 22 24.1
Average 22.03 20.53
Mix-3_Replacement of Source Material by 75% of fine waste from kaolin mining
Sr. No. Strength at 7 Days (MPa) Strength at 28 Days (MPa)
1 22.9 36.9
2 22.8 40.4
3 24 37.2
Average 23.23 38.17
Mix-4_Replacement of Source Material by 100% of fine waste from kaolin mining
Sr. No. Strength at 7 Days (MPa) Strength at 28 Days(MPa)
1 18.9 30
2 17.9 30
3 15.5 31.4
Average 17.43 30.47

[0083] The split tensile strength was carried out in accordance to IS 516- 2021 on a cylindrical concrete specimen of 150 mm in diameter and 300 mm in length. The specimen was placed in universal testing machine on the lower plate and load is typically applied through two hardened steel plates that are placed diametrically opposite to each other on the cylindrical specimen. Split tensile strength of concrete is calculated by following formula by taking average of three specimens
Split Tensile Strength
The Split Tensile Strength varied from 3.2 MPa to 3.8 MPa at 28 days when the replacement of the natural fine aggregate made with kaolin waste was done ranging from 25% to 100%. Split Tensile Strength for regular concrete with 100% natural fine particles was 2.9 MPa.
Table 4: Split Tensile Strength Test on 28 Days for 100% replacement of natural fine aggregates
Sr. No. Peak Stress (MPa) Peak Load (KN) Peak Load (N) Tensile Strength (N)
1 10.2 230.2 230200 3.26
2 10.9 247.4 247400 3.50
3 12.0 270.0 270000 3.82
Avg. Strength 3.53

[0084] Concrete beams of 100 mm x 100mm x 500 mm were prepared for carrying out flexural strength on flexure testing machine in accordance to IS 516-2021. The beams were tested after 28 days of curing. Loading was done at constant rate until fracture of specimen. The flexural strength of concrete varied between 3.8 MPa to 4.3 MPa at 28 days with a replacement of 25% and 100%. The target strength of M25 grade concrete’s flexural value is 3.5 MPa which is excelled by the flexural strength value of the beam having fine waste generated during kaolin mining.
Table 5: Flexural Strength Test on 28 Days for 100% replacement of natural fine aggregates
Sr. No Load (KN) Flexural Strength (MPa)
1 7.5 3.75
2 7.5 3.75
3 8.5 4.25
Avg. Strength 3.92

[0085] Thus the concrete with 100% replacement of natural fine aggregate meets the Indian Standard codal requirements.
[0086] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT INVENTION
[0087] The present disclosure provide a fine waste generated during kaolin mining based concrete composition.
[0088] The present disclosure provide a process of preparation of a fine waste generated during kaolin mining based concrete composition.
[0089] The present disclosure replaces natural fine aggregate with fine waste generated during kaolin mining and in manufacturing of clay.
[0090] The present disclosure finds out how much to utilize effectively, fine waste from kaolin mining into concrete to make concrete sustainable.
[0091] The present disclosure determines the optimum percentage of replacement of fine waste from kaolin mining without compromising on the compressive strength of concrete.
[0092] The present disclosure determines the flexural strength of the said concrete with the replacement of natural sand.
[0093] The present disclosure determines the split tensile strength of the said concrete with the replacement of natural sand.
[0094] The present disclosure reduces the illegal disposal of clay mining waste.
[0095] The present disclosure provides a concrete the concrete that is sustainable and eco-friendly concrete with a lesser carbon footprint.
[0096] The present disclosure reduces the overall cost of concrete.
[0097] The present disclosure stops/reduces the illegal river sand mining
[0098] The present disclosure reduces the consumption of natural resource like river sand.

, Claims:1. A concrete composition comprising:
14 % to 18 % w/w of cement having volume in the range of 350-400 kg/m3;
42 % to 55 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3; and
0 % to 35 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and or fine waste from kaolin mining having volume in the range of 0-750 kg/m3; and
water up to 100%.
2. The composition as claimed in claim 1, wherein the cement is selected from a group consisting of ordinary Portland cement of grade 53, 43, 33.
3. The composition as claimed in claim 1, wherein the cement is ordinary Portland cement of grade 53.
4. The composition as claimed in claim 1, wherein the coarse aggregates having size in the range of 4.75 mm to 20 mm.
5. The composition as claimed in claim 1, wherein the natural fine aggregates have a specific gravity of 2.58 and water absorption of 1.8%.
6. The composition as claimed in claim 1, wherein the Kaolin sand waste had a specific gravity of 2.39, and a water absorption value of 0.12 %
7. The composition as claimed in claim 1, wherein the natural fine aggregate is replaced with fine waste from kaolin mining by 25%, 50%, 75% to 100% respectively.
8. A process of preparation of a concrete composition comprising:
a) dry mixing 42 % to 55 % w/w of coarse aggregates, 0 % to 35 % w/w of natural fine aggregates and 1 % to 35 % w/w of fine waste from kaolin mining to obtain dry mixture;
b) mixing 14 % to 18 % w/w of cement to dry mixture to obtain mixture I;
c) mixing water to mixture I to form the concrete composition; and
d) pouring the concrete mixture into moulds.

9. The process as claimed in claim 8, wherein the mixing steps a-c is carried out at a temperature in the range of 20-30 °C until a homogeneous mixture is obtained.
10. The composition as claimed in claim 1 comprising:
14.5 % to 16.67 % w/w of cement having volume in the range of 350-400 kg/m3;
45.83 % to 50.0 % w/w of coarse aggregate having volume in the range of 1100-1200 kg/m3; and
27.08 % to 31.25 % w/w of natural fine aggregate having volume in the range of 650-750 kg/m3 and or fine waste from kaolin mining having volume in the range of 0-750 kg/m3; and
Water upto 100%.
11. The composition as claimed in claim 1, wherein 100 % of the natural fine aggregate is replaced with fine waste from kaolin mining.