Description:BACKGROUND
Field of Invention
[001] Embodiments of the present invention generally relate to a building construction material and more particularly to a precast slab panel and a method of preparing the same.
Description of Related Art
[002] Wood waste refers to any form of wood or wood-based material that is discarded or no longer utilized for its original intended purpose. The wood waste encompasses various forms of wood, including lumber, sawdust, wood chips, bark, wood shavings, and wood scraps generated from industrial, commercial, residential, and construction activities. The wood waste can be derived from demolition projects, manufacturing processes, woodworking operations, tree pruning or removal, and furniture production, among other sources.
[003] At present, the wood waste is not widely utilized in concrete construction, primarily due to traditional practices and the prevalent use of other materials like aggregates and cement. Concrete construction typically relies on specific materials with established structural properties to ensure strength and durability. While, the wood waste is not currently be a standard component in concrete mixtures, ongoing research and development within the construction industry are exploring innovative approaches to incorporate recycled wood products or wood-derived materials into construction processes. These efforts aim to harness the potential benefits of wood waste, such as reduced environmental impact and enhanced sustainability, while meeting the stringent structural requirements of concrete applications.
[004] There is thus a need for a precast slab panel that can overcome the limitations of the prior art in a more efficient manner.
SUMMARY
[005] Embodiments in accordance with the present invention provide a precast slab panel. The precast slab panel comprising: a concrete material; a wood waste in a proportion ranging from 0.1% to 30% by fine aggregate size; and 0.5% fiber incorporated within the concrete material, wherein the wood waste is added as a replacement to a fine aggregate, and the fiber is added as an additive to enhance a thermal and acoustic insulation properties of the precast slab panel.
[006] Embodiments in accordance with the present invention provide a method of preparing a precast slab panel. The method comprising steps of: preparing a concrete material; incorporating a wood waste in a proportion ranging from 0.1% to 30% by fine aggregate size as a replacement for a portion of the fine aggregate in the concrete material; adding 0.5% fiber as an additive to the concrete material; mixing the concrete material, the wood waste, and the fiber to achieve a homogenous mixture; pouring the homogenous mixture into a mold; and allowing the poured mixture to cure and set within the mold to form the precast slab panel.
[007] Embodiments of the present invention may provide a number of advantages depending on its particular configuration. First, embodiments of the present application may provide a precast slab panel for building construction material.
[008] Next, embodiments of the present application may provide a method to effectively use of carpentry waste as a construction material.
[009] Next, embodiments of the present application may provide a method to effectively use wood waste.
[0010] Next, embodiments of the present application may provide a method to prepare a reinforced precast slab panel.
[0011] Next, embodiments of the present application may provide a sustainable building material.
[0012] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention 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
[0013] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0014] FIG. 1A illustrates a precast slab panel, according to an embodiment of the present invention;
[0015] FIG. 1B illustrates a mold for molding the precast slab panel, according to an embodiment of the present invention;
[0016] FIG. 1C illustrates dimensions of the precast slab panel, according to an embodiment of the present invention;
[0017] FIG. 1D illustrates reinforcement details of the precast slab panel, according to an embodiment of the present invention; and
[0018] FIG. 2 depicts a flowchart of a method for preparing the precast slab panel, according to an embodiment of the present invention.
[0019] 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
[0020] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
[0021] 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.
[0022] 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.
[0023] FIG. 1 illustrates a precast slab panel 100, according to an embodiment of the present invention. The precast slab panel 100 may be constructed using waste and recycled material for representing a promising development in sustainable building practices. According to an embodiment of the present invention, the precast slab panel 100 may be used in building construction material, road material, pavement construction, building blocks, and so forth. Embodiments of the present invention are intended to include or otherwise cover any use of the precast slab panel 100.
[0024] According to an embodiment of the present invention, the precast slab panel 100 may be shaped in distinct forms to form the street block or the building block. The distinct forms may be, but not limited to, a square shape, a rectangular shape, a star shape, a round shape, and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any distinct form of the precast slab panel 100.
[0025] The precast slab panel 100 may comprise constituents such as, but not limited to, a concrete material 102, a wood waste 104, and a fiber 106.
[0026] In an embodiment of the present invention, the concrete material 102 may comprise a mix of a binder, a sand, a water, and a fine aggregate. The concrete material 102 may be premixed in proportionate amounts for forming a structural foundation of the precast slab panel 100 and may be responsible for its strength and durability. The proportionate amounts and compositions of elements of the concrete material 102 may be carefully calibrated to achieve desired characteristics and performance of the precast slab panel 100, in an embodiment of the present invention.
[0027] In an embodiment of the present invention, the binder may increase a bonding property of the precast slab panel 100. The binder may be, but not limited to, a vinyl binder, a paper stock binder, a poly-material binder, an asphalt binder and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the binder may be the cement. Embodiments of the present invention are intended to include or otherwise cover any type of the binder, including known, related art, and/or later developed technologies.
[0028] The wood waste 104 may be sourced from various origins, including but not limited to, construction and demolition sites, woodworking operations, furniture manufacturing facilities, tree pruning or removal, and industrial wood processing plants. The wood waste 104 may encompass a wide range of materials such as wood scraps, a sawdust, wood chips, bark, wood shavings, and so forth. Repurposing the wood waste 104 from these sources for use in the precast slab panel 100 may be aligned with sustainable and eco-friendly building practices.
[0029] The wood waste 104 may be added in a predefined particle size, tailored to suit the specific requirements of the concrete material 102. This particle size can vary based on the intended application and desired properties of the precast slab panel. For instance, the particles of the wood waste 104 may range from fine to coarse to achieve a balance between structural reinforcement and workability during the construction process. The size of the particles of the wood waste 104 may typically fall within a range of 1 millimeter to 20 millimeters, allowing for effective integration into the concrete mixture. Embodiments of the present invention are intended to include or otherwise cover any size of the particles of the wood waste 104, including known, related art, and/or later developed technologies.
[0030] The wood waste 104 may be strategically incorporated into the concrete material 102 as a replacement to the fine aggregate. In an embodiment of the present invention, the wood waste 104 may be added in a proportion ranging from 0.1% to 30% of the fine aggregate into the concrete material 102 for producing the precast slab panel 100. Embodiments of the present invention are intended to include or otherwise cover any proportion of the wood waste 104, including known, related art, and/or later developed technologies. This integration may involve ensuring a uniform distribution of the particles in the wood waste 104 to maximize a reinforcing potential while maintaining the overall structural integrity and strength of the precast slab panel 100. By controlling the particle size and distribution, the wood waste 104 may contribute to a sustainable and efficient use of waste resources in the construction industry.
[0031] In an embodiment of the present invention, the fiber 106 may be added as an additive to enhance a thermal and acoustic insulation properties of the precast slab panel 100. In an embodiment of the present invention, an amount of the fiber 106 added as an additive may be 0.5%. Embodiments of the present invention are intended to include or otherwise cover any amount of the fiber 106, including known, related art, and/or later developed technologies.
[0032] Embodiments of the present invention are intended to include or otherwise cover any type of the constituents of the precast slab panel 100, including known, related art, and/or later developed technologies. In an embodiment of the present invention, the fiber 106 may provide reinforcement strength to the binder 106. The fiber 106 may be, but not limited to, steel fiber, polypropylene fiber, glass fiber, asbestos fiber, carbon fiber, and so forth, according to an embodiment of the present invention. In an embodiment of the present invention, the fiber 106 may be synthetic fiber. Embodiments of the present invention are intended to include or otherwise cover any type of the fiber 106, including known, related art, and/or later developed technologies.
[0033] In an embodiment of the present invention, the precast slab panel 100 may further comprise a water reducer that may slow down a setting rate of the precast slab panel 100. The water reducer may be, but not limited to, a water retardant, a lignosulfonate, a hydroxycarboxylic acid, a hydroxylated polymer, a salt of melamine formaldehyde sulfonate, and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the water reducer may be a superplasticizer. Embodiments of the present invention are intended to include or otherwise cover any type of the water reducer, including known, related art, and/or later developed technologies.
[0034] FIG. 1B illustrates a mold 108 for molding the precast slab panel 100, according to an embodiment of the present invention. In an embodiment of the present invention, the concrete material 102, the wood waste 104, and the fiber 106 may be mixed to achieve a homogenous mixture. In an embodiment of the present invention, a color may also be added in the homogenous mixture. The color may be, but not limited to, a concrete color, a fabric color, an acid-fast dye, and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any type of color, including known, related art, and/or later developed technologies. The homogenous mixture may be poured into the mold 108 and may be allowed to cure and set within the mold 108 to form the precast slab panel 100. The precast slab panel 100 may be preserved under curing conditions for 28 days.
[0035] FIG. 1C illustrates dimensions of the precast slab panel, according to an embodiment of the present invention. According to an embodiment of the present invention, the dimensions of the precast slab panel 100 may be 70 millimeter in depth, 500 millimeter in breadth, and 600 millimeter in length. Embodiments of the present invention are intended to include or otherwise cover any dimensions of the precast slab panel 100, including known, related art, and/or later developed technologies.
[0036] FIG. 1D illustrates reinforcement details of the precast slab panel, according to an embodiment of the present invention. After, curing, testing to check a compression strength and a durability of the precast slab panel 100 may be performed.
[0037] According to an embodiment of the present invention, the precast slab panel 100 may be characterized by stress properties. In a preferred embodiment of the present invention, the stress properties may be durability test and micro-characterization. Embodiments of the present invention are intended to include or otherwise cover any stress properties, including known, related art, and/or later developed technologies. In an embodiment of the present invention, a target compressive strength (fck) may be set to achieve 30 megapascals (MPa). To attain this strength, a reinforcement strategy may involve three main bars, each with a 10-millimeter diameter, strategically placed within the structural element. These main bars may be integral for withstanding an applied load and ensuring the necessary structural robustness. Additionally, three distribution bars of the same 10-millimeter diameter have been incorporated, enhancing the load-bearing capacity and overall structural integrity. The spacing between these bars may be maintained at 150 millimeters from center to center, ensuring an optimal distribution and alignment of the reinforcement throughout a structural element. This thoughtfully devised reinforcement configuration may be pivotal in meeting stipulated strength requirements while ensuring structural stability and longevity.
[0038] According to an embodiment of the present invention, the precast slab panel 100 may undergo strength testing. In a preferred embodiment of the present invention, the strength testing may involve a tensile strength and a compressive strength. Embodiments of the present invention are intended to include or otherwise cover any strength testing, including known, related art, and/or later developed technologies.
[0039] FIG. 2 depicts a flowchart of a method 200 for preparing the precast slab panel 100, according to an embodiment of the present invention.
[0040] At step 202, the precast slab panel 100 may be prepared using the concrete material 102.
[0041] At step 204, the precast slab panel 100 may incorporate the wood waste 104 in the proportion ranging from 0.1% to 30% as a replacement for a portion of the fine aggregate in the concrete material 102.
[0042] At step 206, the precast slab panel 100 may be prepared by adding the 0.5% fiber 106 as the additive to the concrete material 102.
[0043] At step 208, the precast slab panel 100 may be prepared by mixing the concrete material 102, the wood waste 104, and the fiber 106 to achieve the homogenous mixture.
[0044] At step 210, the precast slab panel 100 may be prepared by pouring the homogenous mixture into the mold 108.
[0045] At step 212, the precast slab panel 100 may be prepared by allowing the poured mixture to cure and set within the mold 108 to form the precast slab panel 100.
[0046] While the invention 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 invention 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.
[0047] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope the invention 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 precast slab panel (100), characterized in that the precast slab panel (100) comprising:
a concrete material (102);
a wood waste (104) in a proportion ranging from 0.1% to 30% of a fine aggregate; and
0.5% fiber (106) incorporated within the concrete material (102), wherein the wood waste (104) is added as a replacement to the fine aggregate, and the fiber (106) is added as an additive to enhance a thermal and acoustic insulation properties of the precast slab panel (100).
2. The precast slab panel (100) as claimed in claim 1, wherein the wood waste (104) and fiber (106) are sourced from industrial waste.
3. The precast slab panel (100) as claimed in claim 1, wherein the concrete material (102) comprises a mix of a binder, a sand, a water and the fine aggregate.
4. The precast slab panel (100) as claimed in claim 3, wherein the binder may be a cement.
5. The precast slab panel (100) as claimed in claim 1, wherein dimensions of the precast slab panel (100) are 70 millimeter in depth, 500 millimeter in breadth, and 600 millimeter in length.
6. A method for manufacturing a precast slab panel (100) for building construction, comprising the steps of:
preparing a concrete material (102);
incorporating a wood waste (104) in a proportion ranging from 0.1% to 30% by fine aggregate size as a replacement for a portion of the fine aggregate in the concrete material (102);
adding 0.5% fiber (106) as an additive to the concrete material (102);
mixing the concrete material (102), the wood waste (104), and the fiber (106) to achieve a homogenous mixture;
pouring the homogenous mixture into a mold (108); and
allowing the poured mixture to cure and set within the mold (108) to form the precast slab panel (100).
7. The method of claim 6, further comprising preserving the precast slab panel (100) under curing conditions for 28 days prior to testing.
8. The method as claimed in claim 6, comprising a step of characterizing the precast slab panel (100) for a durability and a micro-characterization test.

Date: October 12, 2023
Place: Noida

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