Description:METHOD OF PRODUCING ECO-FRIENDLY CONCRETE COMPOSITE USING INDUSTRIAL WASTE FOR PREPARATION OF PAVER BLOCKS
BACKGROUND
Technical Field
[0001] The embodiment herein generally relates to a eco-friendly concrete composite and fermentation technology and more particularly, to a method of producing eco-friendly concrete composite using industrial waste for preparation of paver blocks.
Description of the Related Art
[0002] Generally, large rice production results in bulk quantities of rice husk ash and pond ash. Similar to the coal-based thermal power plants generate a sizable amount of pond ash, a by-product made up of bottom ash and fly ash. Further no existing prior arts use the industrial rice husk ash and pond ash in an effective manner.
[0003] Accordingly, there remains a need for a method of producing eco-friendly concrete composite using industrial waste for preparation of paver blocks.
SUMMARY
[0004] In view of the foregoing, embodiments herein provide a method of producing eco-friendly concrete composite using industrial wastes for preparation of paver blocks. The method includes collecting rice husk ash (RHA) with a high Silica content and fine particle size. The method further includes collecting contaminants free Pond Ash (PA) from coal-fired thermal power plants. The method further includes mixing the RHA and the Pond ash in a quantities of predefined values to partially replace sand in concrete mixtures, and cement to obtain eco-friendly concrete composite. The method further includes preparing paver blocks using the obtain eco-friendly concrete composite.
[0005] In some embodiments, the eco-friendly concrete composite provides improved matrix density.
[0006] In some embodiments, the eco-friendly concrete comprises optimum mix proportion of 20% of RHA and 30% of pond ash.
[0007] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0009] FIG. 1 illustrates a flow chart showing a method of producing eco-friendly concrete composite using industrial wastes for preparation of paver blocks, according to some embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[00010] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[00011] As mentioned, there remains a need for a method of producing eco-friendly concrete composite using industrial wastes for preparation of paver blocks. Referring now to the drawings, and more particularly to FIG. 1, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[00012] FIG. 1 illustrates a flow chart showing a method 100 of producing eco-friendly concrete composite using industrial wastes for preparation of paver blocks, according to some embodiments herein. At step 102, the method 100 includes collecting rice husk ash (RHA) with a high Silica content and fine particle size. At step 104, the method 100 includes collecting contaminants free Pond Ash (PA) from coal-fired thermal power plants. At step 106, the method 100 includes mixing the RHA and the Pond ash in a quantities of predefined values to partially replace sand in concrete mixtures, and cement to obtain eco-friendly concrete composite. At step 108, the method 100 includes preparing paver blocks using the obtain eco-friendly concrete composite. In a non-limiting example, the rice husk ash (RHA) and posh ash (PA) is sourced from Chhattisgarh industries.
[00013] In some embodiments, the eco-friendly concrete composite provides improved matrix density. The eco-friendly concrete comprises optimum mix proportion of 20% of RHA and 30% of pond ash.
[00014] In some embodiments, by completely transform the construction industry by significantly reducing dependence on non-renewable resources like sand and cement. It provides an economically and environmentally responsible answer to contemporary building problems. Waste management programs, industrial operations, sustainable building initiatives, and the development of infrastructure in both urban and rural areas are just a few of the sectors in which this innovation can be implemented.
[00015] Collecting and processing the materials is the first step in the process. Biomass power
[00016] Plants provide rice husk ash (RHA), which is carefully processed to guarantee a high
[00017] Silica content and fine particle size. To ensure uniformity and quality, pond ash—this comes from coal-fired thermal power plants—is screened to get rid of contaminants like sand.
[00018] For example, Pond ash is used at 30%, 40%, and 50% to partially replace sand in concrete mixtures, and RHA is used at 20% and 30% to replace cement. To maximize strength and performance, the proportions are established by thorough statistical analysis and experimental confirmation. Below table 1 and table 2 shows mix proportions for paver blocks and consolidated Experimental Result for M20 grade of concrete.
Mix Binder (%) Fine Aggregate (%) Remarks
Cement (%) RHA (%) Sand (%) Pond Ash (%)
M1 100 0 100 - Control Mix
M2 80 20 70 30 RHA 20%, Pond Ash 30%
M3 80 20 60 40 RHA 20%, Pond Ash 40%
M4 80 20 50 50 RHA 20%, Pond Ash 50%
M5 70 30 70
30 RHA 30%, Pond Ash 30%
M6 70 30 60 40 RHA 30%, Pond Ash 40%
M7 70 30 50 50 RHA 30%, Pond Ash 50%
Table 1
Mix Name Compressive Strength (MPa) Tensile Strength (MPa) Water Absorption (%) Workability (Slump, mm)
M1 Control Mix 26.8 2.67 4.0 75
M2 RHA 20%, Pond Ash 30% 27.5 3.1 3.5 70
M3 RHA 20%, Pond Ash 40% 26.5 2.5 4.5 65
M4 RHA 20%, Pond Ash 50% 24.0 2.3 4.8 60
M5 RHA 30%, Pond Ash 30% 25.0 2.5 5.2 66
M6 RHA 30%, Pond Ash 40% 23.5 2.35 5.6 62
M7 RHA 30%, Pond Ash 50% 21.0 2.1 5.6 58
Table 2
[00019] The control mix (M1) has a slump of 75 mm, indicating moderate workability. With M2 (RHA 20%, PA 30%), the slump decreases slightly to 70 mm as RHA increases water demand due to its high surface area. In M3 (40%) and M4 (50%), the slump reduces further to 65 mm and 60 mm, respectively, as higher pond ash content adds irregular, fine particles that reduce flowability. Similarly, in mixes with RHA 30% (M5–M7), workability decreases further, reaching 58 mm in M7 (RHA 30%, PA 50%). The combination of high RHA and pond ash percentages significantly increases water demand, making the mix less workable.
[00020] The control mix (M1) has water absorption of 4.0%. In M2 (RHA 20%, PA 30%), water absorption decreases slightly to 3.5% as the pozzolanic reaction of RHA improves matrix density. However, with higher pond ash content in M3 (40%) and M4 (50%), water absorption increases to 4.5% and 4.8%, respectively, due to increased porosity from the irregular and fine particles of pond ash. Similarly, for mixes with RHA 30% (M5–M7), water absorption increases significantly, reaching 5.6% in M7 (RHA 30%, PA 50%). The high porosity of RHA and the excessive pond ash content create a less dense matrix, allowing more water to penetrate.
[00021] The compressive strength of the control mix (M1) is 26.8 MPa, which serves as a baseline for comparison. In M2 (RHA 20%, PA 30%), the strength slightly increases to 27.5 MPa due to the pozzolanic activity of RHA, which reacts with calcium hydroxide to produce additional calcium silicate hydrate (C-S-H), enhancing strength. Additionally, moderate pond ash content improves particle packing. However, as pond ash content increases in M3 (40%) and M4 (50%), the compressive strength decreases to 26.5 MPa and 24.0 MPa, respectively, as excessive replacement reduces the availability of cementitious material, weakening the matrix. A similar trend is observed in mixes with RHA 30% (M5–M7), where compressive strength drops further, reaching 21.0 MPa in M7 (RHA 30%, PA 50%) due to a significant reduction in matrix cohesion. Overall, compressive strength improves at moderate RHA and pond ash levels but declines with excessive replacement as the concrete's binding capacity is compromised
[00022] The control mix (M1) has a tensile strength of 2.67 MPa. In M2 (RHA 20%, PA 30%), tensile strength increases slightly to 3.1 MPa due to the pozzolanic activity of RHA, which improves the bond between cement paste and aggregates. However, as pond ash content increases in M3 (40%) and M4 (50%), the tensile strength decreases to 2.5 MPa and 2.3 MPa, respectively, due to reduced cementitious material and weaker bonding. In mixes with RHA 30% (M5–M7), tensile strength further declines, reaching 2.1 MPa in M7 (RHA 30%, PA 50%). This reduction is caused by excessive replacement, which compromises the concrete's cohesive strength.
[00023] The optimum mix proportion is M2 (RHA 20%, PA 30%) due to its balanced performance across all parameters. This mix achieves the highest compressive strength (27.5 MPa), slightly exceeding the control mix, due to the pozzolanic activity of RHA, which enhances the formation of calcium silicate hydrate (C-S-H), and the filler effect of moderate pond ash content that improves the packing density. The tensile strength also improves to 3.1 MPa, indicating better bonding in the matrix. Additionally, water absorption is reduced to 3.5%, reflecting a denser and less permeable concrete structure. Although workability decreases slightly to a slump of 70 mm, it remains within acceptable limits for practical applications. The combination of moderate RHA and pond ash content ensures improved strength and durability without compromising workability.
[00024] The same product has additional uses, such as different building block, concrete casting, coastal and marine structures, road and pavement layer construction, lightweight structural concrete, precast concrete products, and disaster-resilient building.
[00025] By using industrial by-products, specifically pond ash and rice husk ash (RHA), as partial substitutes for cement and sand in the manufacturing of paver blocks, this idea presents a novel approach to sustainable construction. RHA, a by-product of biomass power plants, has pozzolanic qualities and is high in silica, which improves the blocks' strength and longevity. An efficient substitute for natural sand is pond ash, a fine material produced by coal-based thermal power plants that increases the workability and lowers the weight of the paver bricks.
[00026] The method evaluates key characteristics such compressive strength, water absorption, tensile strength, and abrasion resistance while experimenting with different replacement levels—20% and 30% for RHA as a cement substitute, and 30%, 40%, and 50% for pond ash as a sand substitute. In addition to performing on par with traditional options, the resulting environmentally friendly paver blocks also help to minimize resource extraction, lower carbon emissions, and support efficient waste management. This method offers a cost-effective and ecologically friendly substitute for conventional materials while promoting the circular economy and sustainable building techniques
[00027] An advantage of the method 100 provides positive aspects for the environment
[00028] An advantage of the method 100 reduced costs of pavement blocks.
[00029] An advantage of the method 100 provides Increased strength and durability
[00030] An advantage of the method 100 provides resource efficiency
[00031] An advantage of the method 100 is that the method 100 supports waste Management.
[00032] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practised with modification within the scope of the appended claims.
, Claims:We claim:
1. A method (100) of producing eco-friendly concrete composite using industrial wastes for preparation of paver blocks, the method (100) comprising:
collecting (102) rice husk ash (RHA) with a high Silica content and fine particle size;
collecting (104) contaminants free Pond Ash (PA) from coal-fired thermal power plants;
mixing (106) the RHA and the Pond ash in a quantities of predefined values to partially replace sand in concrete mixtures, and cement to obtain eco-friendly concrete composite; and
preparing (108) paver blocks using the obtain eco-friendly concrete composite.
2. The method (100) as claimed in claim 1, wherein the eco-friendly concrete composite provides improved matrix density.
3. The method (100) as claimed in claim 1, wherein the eco-friendly concrete comprises optimum mix proportion of 20% of RHA and 30% of pond ash.