DESC:“ADVANCED PORTLAND POZZOLANA CEMENT WITH ZETA POTENTIAL SHIELD”

FIELD OF INVENTION

This invention relates to an advanced Portland Pozzolana Cement with zeta potential shield. The cement is inherent with multi features of Zeta Potential Shield (induced to enhance superplasticizer adsorption), self-healing, high initial strength, denser structure, resistance to chemical attacks.

The present invention is designed to shield the concrete from the harmful attacks of sulphate, chloride and alkali by inducing zeta potential, that results in enhancing superplasticizer adsorption, improving workability by increasing cubic C3A (tri-calcium aluminate), Calcium Aluminate Silicate Hydrate (CASH) gel formation leading to denser structure, neutralizing the positive and negative ion charges of chemicals thereby increasing the durability and longevity of structures.

BACKGROUND OF INVENTION

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.

The Portland Pozzolana Cement available in the market consists of following chemical composition:

PPC
SiO2 34-36%
Al2O3 9.5-10.5%
Fe2O3 4-4.5%
CaO 40-42%
MgO 1.4-1.7%
SO3 2.2-2.4%
Na2O 0.40-0.50%
K2O 1.0-1.10%

The existing Portland Pozzolana Cement lacks of Zeta Potential Shield and optimum particle size distribution of cement obtained through ultra-advanced grinding technology contributing to a more homogenous and cohesive mix. So that, the unique property of this cement resists chemical attack with self-healing, better workability, better finish, less bleeding, less shrinkage, less cracks, less pores and more durability of structures.

Thus, there is no particular prior art available regarding PPC having features like Zeta Potential Shield, self-healing property, high early strength gains, better workability, higher density, reduced bleeding, reduced shrinkage, reduction of pores, better finish, better adhesive properties and resistance to chemical attack.

In view of the above, the present invention has been introduced so as to address the aforesaid shortcomings.

OBJECTS OF THE INVENTION

An object of the invention is to provide an advanced Portland Pozzolana Cement, which obviates drawbacks of the prior art.

Another object of the invention is to provide an advanced Portland
Pozzolana Cement with chemical shield.

Still another object of the invention is to provide an advanced Portland Pozzolana Cement, which is manufactured using Nano- technology.

Yet another object of the invention is to provide an advanced Portland Pozzolana Cement, which is equipped with features like induced Zeta Potential to enhance superplasticizer adsorption, self-healing, high initial strength with resistance to chemical attack.

These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY OF INVENTION

One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.

According to the invention, there is provided an advanced Portland Pozzolana Cement with zeta potential shield comprising of the following elements/components:

By wt.
Silica (SiO2) 29-32%
Alumina (Al2O3) 10-11%
Ferric oxide (Fe2O3 ) 4.0-4.2%
Lime (CaO) 43-47%
Magnesia (MgO) 1.5-1.8%
Sulfate (SO3) 2.4-2.6%
Sodium oxide (Na2O) 0.5-0.65%
Potassium Oxide (K2O) 1.0-1.2%

Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

DETAIL DESCRIPTION OF THE INVENTION OF PREFERRED EMBODIMENT

While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

This invention makes a disclosure regarding a technology pertaining to invention on an advanced Portland Pozzolana Cement with zeta potential shield comprising of following components with some tolerance limit:

By wt.
Silica (SiO2) 29-32%
Alumina (Al2O3) 10-11%
Ferric oxide (Fe2O3 ) 4.0-4.2%
Lime (CaO) 43-47%
Magnesia (MgO) 1.5-1.8%
Sulfate (SO3) 2.4-2.6%
Sodium oxide (Na2O) 0.5-0.65%
Potassium Oxide (K2O) 1.0-1.2%

Features of the present invention can be discussed herein under:

Zeta Potential Shield – Zeta Potential Shield is a double-layered protective shield favored by Aluminium Hydroxide [Al(OH)3] which protects the concrete from the harmful chemical attacks like sulphates, chlorides, alkalis etc. Also, aluminum hydroxide reduces the pH which results in positive zeta potential and strong superplasticizer adsorption.

Activation of Pozzolana in Bangur Magna Cement results in chain length of tobermorite increase in the structure of the C-S-H and C-A-S-H gel formed. This densely packed structure yields excellent mechanical properties.

Improved workability of cement mortar and concrete by increased cubic form of C3A.

High 1-day strength – Provides a very high 1 day strength of around 15+ MPa in Portland Pozzolana Cement that facilitates faster construction, early de- shuttering, hence sustains to un-favorable environment.

Nano Particle Size Technology – Optimum particle size maintained by Advanced Grinding technology. Better workability, better finish, less bleeding, less shrinkage, less cracks, less pores and more durability of structures.

Superior Packaging – Tamper-proof packaging in LPP bags that maintains the factory freshness and avoids moisture absorption.

Superior product quality ensures hassle-free construction, low maintenance cost, superior finish and stronger construction compared to others.

Mechanism of working of present invention is presented herein below:

- Zeta Potential induced enhanced superplasticizer adsorption hence denser structure, shield of Aluminum Hydroxide [Al(OH)3] and optimum particle size distribution protects the concrete from the harmful attacks of sulphate, chloride and alkali, thereby increasing the durability and longevity of structures.
- During hydration process, a dense glue like gel is formed.
- It acts as a binder that holds all the ingredients of concrete together and imparts early strength to concrete. The dense microstructure makes concrete structures impermeable and prevents harmful chemicals from entering the concrete thus protecting the reinforcement and finally providing higher durability to concrete structures. The optimum percentage of alumina contributes to the high 1-day strength thus making construction faster and economical.

Tricalcium aluminate + gypsum + water ? Ettringite + heat
C3A + 3CSH2 + 26H ? C6AS3H32

In case of sufficient alumina content,

C3S + C2S + C3A + H2O (Water) = Calcium Alumina Silicate
Hydrate (CASH) Gel + Ca(OH)2 + Heat (Exothermic Process)

The optimum particle size distribution of cement is obtained through ultra-advanced grinding technology contributing to a more homogenous and cohesive mix. This contributes to faster hydration process, early strength gain, better workability, higher density, reduced bleeding, reduced shrinkage, reduction of pores, better finish and better adhesive properties.

ADVANTAGES OF INVENTION

The invention is based on Zeta Potential Shield, manufactured using Nano-technology. Zeta Potential Shield is induced to enhance superplasticizer adsorption, CASH gel formation, double-layered protective shield of Aluminium Hydroxide [Al(OH)3] which protects the concrete from the harmful chemical attacks like sulphates, chlorides, alkalis etc. It has high initial strength, resists to chemical attack, self-healing property etc.

APPLICATION

The Chemical shield/ Zeta Potential Shield is necessary for important concrete works like foundations, columns, slabs, beams, rafts, etc. in all exposure conditions.

Thus, the Cement of invention gives rise to denser concrete structure with lower affinity to chemical, hence protects the concrete from harmful attacks of sulphate, chloride and alkali.

Example: Chemically proof building with reduced deterioration of building structures on aggressive environmental exposure and self-healing.
TEST RESULTS (To show better performance of invention over prior art(s)):
PARAMETERS UNIT PPC (Prior Art) PPC (Present Invention)
SiO2 % 34-36 29-32
Al2O3 % 9.5-10.5 10-11
Fe2O3 % 4-4.5 4.0-4.2
CaO % 40-42 43-47
MgO % 1.4-1.7 1.5-1.8
SO3 % 2.2-2.4 2.4-2.6
Na2O % 0.40-0.50 0.50-0.65
K2O % 1.0-1.10 1.0-1.2
Setting time
Initial Minutes 180-200 160-180
Final Minutes 240-270 200-230
Soundness test
LC Exp. Mm 1-2 1-2
AC Exp. % 0.04-0.05 0.05-0.07
Compressive Strength
1 Day MPa 11-14 17-20
3 Day MPa 20-23 26-29
7 Day MPa 26-29 34-37
28 Day MPa 39-41 44-50
PSD between 3-30 microns % 50-55 65-75
Concrete Cube(M-25)
28 days MPa 33-35 40-42
Self-Healing test after 56 days MPa 30-32 40-42

C3S % 25-32 30-42
Cubic C3A % 1.5-3.0 2-3

Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.

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 of all groups used in the appended claims.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogues to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.

The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.

The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

,CLAIMS:We Claim

1. An advanced Portland Pozzolana Cement with zeta potential shield comprising of the following elements/components:

By wt.
Silica (SiO2) 29-32%
Alumina (Al2O3) 10-11%
Ferric oxide (Fe2O3 ) 4.0-4.2%
Lime (CaO) 43-47%
Magnesia (MgO) 1.5-1.8%
Sulfate (SO3) 2.4-2.6%
Sodium oxide (Na2O) 0.5-0.65%
Potassium Oxide (K2O) 1.0-1.2%

2. The advanced Portland Pozzolana Cement with zeta potential shield as claimed in claim 1 involves the following:

Setting time
Initial 160-180 Minutes
Final 200-230 Minutes
Soundness
LC Exp. 1-2 mm
AC Exp. 0.05-0.07 %
Compressive Strength
1 Day 17-20 MPa
3 Day 26-29 MPa
7 Day 34-37 MPa
28 Day 44-50 MPa
PSD between 3-30 microns 65-75 %
Concrete Cube(M-25)
28 days 40-42 MPa
Self-Healing test after 56 days 40-42 MPa

C3S 30-42 %
Cubic C3A 2-3 %

3. The advanced Portland Pozzolana Cement with zeta potential shield as claimed in claim 1 or 2, is associated with below features:

Zeta Potential Shield is a double-layered protective shield favored by Aluminium Hydroxide [Al(OH)3] which protects the concrete from the harmful chemical attacks like sulphates, chlorides, alkalis;

Activation of Cement of invention leads to chain length of tobermorite increase in the structure of the C-A-S-H gel formed, this densely packed structure yields excellent mechanical properties;

Improved workability of cement mortar and concrete by increased cubic form of C3A;
High 1-day strength Provides a very high 1 day strength of around 15+ MPa that facilitates faster construction, early de- shuttering;

Maintenance of Optimum particle size by Advanced Grinding technology with better workability, better finish, less bleeding, less shrinkage, less cracks, less pores and more durability of structures;

Tamper-proof packaging in LPP bags that maintains the factory freshness and avoids moisture absorption;

Hassle-free construction, low maintenance cost, superior finish and stronger construction.

4. The advanced Portland Pozzolana Cement with zeta potential shield as claimed in claims 1-3 is based on Zeta Potential Shield,manufactured using Nano-technology, in which Zeta Potential Shield is induced to enhance superplasticizer adsorption, CASH gel formation, double-layered protective shield of Aluminium Hydroxide [Al(OH)3] which protects the concrete from the harmful chemical attacks including sulphates, chlorides, alkalis.