Description:BACKGROUND
Field of the invention
[001] Embodiments of the present disclosure generally relate to a concrete block and particularly to a concrete block manufactured using septage ashes and polyproplene fibres.
Description of Related Art
[002] Concrete blocks are fundamental building elements widely used in construction due to their strength, durability, and versatility. Traditional concrete block compositions primarily comprise cement, aggregates, water, and additives. The properties of these blocks largely depend on the choice and proportions of these constituents.
[003] Recent advancements in material science and sustainable practices have led to the exploration of alternative materials and methodologies to enhance the performance and sustainability of concrete blocks. Incorporating pozzolanic materials and polymeric fibers, for instance, has been observed to improve the strength and ductility of the blocks.
[004] Additionally, there is an increasing focus on sustainable practices in the construction industry, prompting the utilization of waste materials as resources. Septage ashes, derived from fecal sludge treatment, represent an abundant and potentially valuable source of material for construction applications, contributing to waste management and sustainable building practices.
[005] There is thus a need for a method for manufacturing concrete blocks that overcomes all the drawbacks of the prior existing solutions.
SUMMARY
[006] Embodiments in accordance with the present disclosure provide a concrete block. The concrete block comprising: a pozzolanic cementitious material, constituting 45% to 65% by weight of a total composition. The concrete block further comprising: fine aggregate and coarse aggregate, constituting 20% to 50% by weight of the total composition. The concrete block further comprising: polymeric fibers, constituting 0.01% to 1.0% by volume of the total composition. The polymeric fibers are glass chopped strands of 6 millimeters (mm) in length with a bulk density of 635 kilograms per cubic meter (kg/m3). The concrete block further comprising: septage ashes derived from a fecal sludge treatment, constituting 10% to 30% by weight of the total composition; water, constituting a water-to-cementitious material ratio maintained in a range of 0.30 to 0.60. The concrete block further comprising: a superplasticizer, constituting 0.3% by weight of the total composition.
[007] Embodiments in accordance with the present disclosure further provide a method for manufacturing a concrete block. The method includes comprising the steps of: mixing a pozzolanic cementitious material, fine and coarse aggregate materials, polymeric fibers, water, and septage ashes to form a concrete mixture; molding the concrete mixture into desired block shapes; and curing the molded blocks to obtain the concrete blocks.
[008] Embodiments of the present disclosure may provide a number of advantages depending on its particular configuration. First, embodiments of the present application may provide a method for manufacturing concrete blocks using septage ashes and polypropylene fibres.
[009] Next, embodiments of the present application may provide a method for manufacturing concrete blocks that reduce environmental impact due to CO2 emissions.
[0010] Next, embodiments of the present application may provide a method for manufacturing concrete blocks that reuses waste materials.
[0011] Next, embodiments of the present application may provide various configurations and applications of the concrete block described herein, optimizing its composition and manufacturing process to cater to specific requirements and applications in the construction industry.
[0012] Next, embodiments of the present application may provide a method for manufacturing concrete blocks that reduces landfills.
[0013] Next, embodiments of the present application may provide a method for manufacturing concrete blocks that reduces greenhouse gas emissions.
[0014] Next, embodiments of the present application may provide a method for manufacturing concrete blocks that have 16% less CO2 footprint.
[0015] These and other advantages will be apparent from the present application of the embodiments described herein.
[0016] The preceding is a simplified summary to provide an understanding of some embodiments of the present disclosure. This summary is neither an extensive nor exhaustive overview of the present disclosure and its various embodiments. The summary presents selected concepts of the embodiments of the present disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and still further features and advantages of embodiments of the present disclosure will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0018] FIG. 1A illustrates a perspective view depicting concrete blocks, according to an embodiment of the present disclosure;
[0019] FIG. 1B depicts a graph of mix proportion of elements Vs compression strength of the concrete blocks, according to an embodiment of the present disclosure; and
[0020] FIG. 2 depicts a flowchart of a method for manufacturing concrete blocks, according to an embodiment of the present disclosure.
[0021] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0022] The following description includes the preferred best mode of one embodiment of the present disclosure. It will be clear from this description of the disclosure that the disclosure is not limited to these illustrated embodiments but that the disclosure also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the disclosure is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the disclosure to the specific form disclosed, but, on the contrary, the disclosure is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure as defined in the claims.
[0023] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.
[0024] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0025] FIG. 1A illustrates a perspective view depicting concrete blocks 100, according to an embodiment of the present disclosure. The concrete blocks 100 may exhibit properties such as exceptional durability, high thermal resistance, and low water absorption, making them suitable for a wide range of construction applications. The concrete blocks 100 may be used for applications, referring but not limited to load-bearing walls, retaining walls, foundations, and structural components in residential, commercial, and industrial construction projects.
[0026] In an embodiment of the present invention, the concrete blocks 100 may comprise a compressive strength of 15 to 50 megapascals (MPa) after 28 days of curing, ensuring their suitability for demanding structural requirements in construction projects. According to embodiments of the present disclosure, the concrete blocks 100 may be produced using elements that may include but are not limited to pozzolanic materials, polymeric fibers, aggregates, water, septage ashes, and superplasticizers, carefully combined to achieve superior structural and sustainability characteristics.
[0027] In an embodiment of the present invention, the pozzolanic cementitious material may constitute 45% to 65% by weight of a total composition of the concrete block 100. In an embodiment of the present invention, the pozzolanic cementitious material may be, including but not limited to, a Portland cement, fly ashes, silica fumes, metakaolins, and so forth. Embodiments of the present disclosure are intended to include or otherwise cover any type of the pozzolanic cementitious material, including known, related art, and/or later developed technologies. In a preferred embodiment of the present invention, the pozzolanic cementitious material may be a Pozzalanic Portland cement of grade 53 with a Specific Gravity of 3.1.5. Embodiments of the present disclosure are intended to include or otherwise cover any grade of the Pozzalanic Portland cement, including known, related art, and/or later developed technologies.
[0028] In an embodiment of the present invention, the polymeric fibers may constitute 0.01% to 1.0% by volume of the total composition. In an embodiment of the present invention, the polymeric fibers may be, but not limited to, a polypropylene, a polyethylene, a polyester, and so forth. In an embodiment of the present invention, the polymeric fibers may be glass chopped strands. The glass chopped strands may be 6 millimeters (mm) in length with a bulk density of 635 kilograms per cubic meter (kg/m3), according to an embodiment of the present invention. The glass chopped strands may be of any length, according to the embodiment of the present invention.
[0029] In an embodiment of the present invention, the fine aggregate and the coarse aggregate, commonly, may constitute 20% to 50% by weight of the total composition. In an embodiment of the present invention, the fine aggregate may be River sand of 2.36 millimeters (mm) sieve size. In an embodiment of the present invention, the coarse aggregate may be retained in an 8 mm sieve and passes through a 12 millimeters (mm) sieve.
[0030] In an embodiment of the present invention, the water may constituted such that a water-to-cementitious material ratio may be maintained in a range of 0.30 to 0.60. In a preferred embodiment of the present invention, the water-to-cementitious material ratio may be 0.50%. Embodiments of the present disclosure are intended to include or otherwise cover any water-to-cementitious material ratio, including known, related art, and/or later developed technologies. In an embodiment of the present invention, the water may be potable water, ensuring the use of safe and clean water in the concrete block 100 to meet quality and environmental standards. In an embodiment of the present invention, the water may be recycled waste water. Embodiments of the present disclosure are intended to include or otherwise cover any type of the water, including known, related art, and/or later developed technologies.
[0031] In an embodiment of the present invention, the Septage ashes, derived from a fecal sludge treatment, may constitute 10% to 30% by weight of the total composition. In certain embodiments of the present invention, the septage ashes may be obtained from fecal sludge treatment plants utilizing processes such as an anaerobic biogas reactor, a gasification, an incineration, a pyrolysis, and so forth. The use of septage ashes not only may help in efficient waste management but also contributes to sustainable construction practices. Embodiments of the present disclosure encompass any ash obtained from faecal sludge treatment, whether processed through known, related art, or later developed technologies.
[0032] In an embodiment of the present invention, a superplasticizer may constitute 0.3% by weight of the total composition for enhancing a workability and a flow of the concrete mixture during production. Various types of superplasticizers, such as Polycarboxylate ether, may be employed to achieve the desired properties, according to the embodiment of the present invention.
[0033] According to further embodiments of the present invention, the concrete block 100 may comprise additives or admixtures selected from plasticizers, accelerators, retarders, air-entraining agents, corrosion inhibitors, and so forth.
[0034] Embodiments of the present disclosure are intended to cover any superplasticizer, including known types, related art, or those developed in the future, allowing for optimization and customization of the concrete block composition.FIG. 1B depicts a graph 102 of mix proportion of elements Vs compression strength of the concrete blocks, according to an embodiment of the present disclosure. The graph 102 may provide a visual representation of how adjustments in the mix proportion of the pozzolanic cementitious material, the aggregates, the polymeric fibers, the septage ashes, the water, and the superplasticizer may influence the overall compressive strength of the resulting concrete blocks. The graph 102 shows data points that may illustrate a correlation between these elements, curing duration, and an achieved compressive strength, aiding in the optimization of the concrete block composition for specific structural requirements and applications. As shown in the graph 102, the influence of the septage ashes on concrete properties was studied by preparing several concrete mixes connecting the different amount of the septage ashes. The mix with septage ash content 10,20 and 30% has shown decrement in the compressive strength at 28 days curing than conventional concrete. Leaching of material from the concrete was observed at over dosage of the Septage ashes. An increase in septage ashes in the concrete decreased the compression strength by 25%, 44% and 54% respectively in 7 days of curing. Gradually strength increased at 28 days. There is no appreciable increase in strength after 28 days. The septage ash 20% mix with 0.06% (by volume of concrete) glass chopped strand has shown a development in compressive strength and merely meets the actual strength of the conventional concrete at 28 days curing.
[0035] FIG. 2 depicts a flowchart of a method 200 for manufacturing the concrete blocks 100, according to an embodiment of the present disclosure.
[0036] At step 202, the concrete blocks 100 are produced by mixing the pozzolanic cementitious material, the fine and coarse aggregate materials, the polymeric fibers, the water, and the septage ashes to form the concrete mixture.
[0037] At step 204, the concrete blocks 100 are produced by molding the concrete mixture into the desired block shapes.
[0038] At step 206, the concrete blocks 100 are produced by curing the molded blocks to obtain the concrete blocks 100.
[0039] While the disclosure has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
[0040] This written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined in the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims. , Claims:CLAIMS
I/We Claim:
1. A concrete block (100) comprising:
a pozzolanic cementitious material, constituting 45% to 65% by weight of a total composition;
fine aggregate and coarse aggregate, constituting 20% to 50% by weight of the total composition;
polymeric fibers, constituting 0.01% to 1.0% by volume of the total composition, wherein the polymeric fibers are glass chopped strands;
septage ashes derived from a fecal sludge treatment, constituting 10% to 30% by weight of the total composition;
water, constituting a water-to-cementitious material ratio is maintained in a range of 0.30 to 0.60; and
a superplasticizer, constituting 0.3% by weight of the total composition.
2. The concrete block (100) as claimed in claim 1, wherein the pozzolanic cementitious material is selected from a Portland cement, fly ashes, silica fumes, metakaolins, or a combination thereof.
3. The concrete block (100) as claimed in claim 1, wherein the polymeric fibers are selected from a polypropylene, a polyethylene, a polyester, or a combination thereof.
4. The concrete block (100) as claimed in claim 1, wherein the septage ashes are obtained from fecal sludge treatment plants utilizing processes such as anaerobic biogas reactor, gasification, incineration, or pyrolysis.
5. The concrete block (100) as claimed in claim 1, further comprising additives or admixtures selected from plasticizers, accelerators, retarders, air-entraining agents, corrosion inhibitors, or a combination thereof.
6. The concrete block (100) as claimed in claim 1, wherein a compressive strength of the concrete block (100) is in a range of 15 to 50 megapascals (MPa) after 28 days of curing.
7. The concrete block (100) as claimed in claim 1, wherein the fine aggregate is River sand of 2.36 millimeters (mm) sieve size.
8. The concrete block (100) as claimed in claim 1, wherein the coarse aggregate is retained in an 8 millimeters (mm) sieve and passes through a 12 millimeters (mm) sieve.
9. The concrete block (100) as claimed in claim 1, wherein the superplasticizer is Polycarboxylate ether.
10. A method for manufacturing a concrete block (100), comprising the steps of:
mixing a pozzolanic cementitious material, fine and coarse aggregate materials, polymeric fibers, water, and septage ashes to form a concrete mixture;
molding the concrete mixture into desired block shapes; and
curing the molded blocks to obtain the concrete blocks (100).

Date: October 11, 2023
Place: Noida

Nainsi Rastogi
Patent Agent (IN/PA-2372)
Agent for the Applicant