Description:DESCRIPTION:
Field of the invention:
[0001] The present disclosure generally relates to the technical field of concrete compositions, and more particularly, relates to a quaternary binder-based concrete composition for high-strength pavement applications that offers improved durability, enhanced load-bearing capacity, and superior environmental sustainability compared to traditional concrete formulations.
Background of the invention:
[0002] Concrete is an essential material in the construction industry, widely used due to its versatility, strength, and durability. The application of concrete in pavement construction requires it to endure heavy loads, varying weather conditions, and repeated wear over time. However, conventional concrete compositions often exhibit limitations, such as cracking, shrinkage, and reduced durability when exposed to extreme conditions. Furthermore, the reliance on ordinary Portland cement (OPC) in traditional concrete formulations significantly contributes to carbon emissions, thereby making it environmentally unsustainable.
[0003] In response to these challenges, the use of supplementary cementitious materials (SCMs) has gained prominence as a way to enhance concrete performance while reducing its environmental impact. SCMs such as fly ash, silica fume, and ground granulated blast-furnace slag (GGBS) have been used to partially replace OPC, thereby resulting in improved workability, durability, and strength. The integration of multiple SCMs into quaternary binder systems has shown promise in leveraging the synergistic effects of these materials to create optimized concrete formulations.
[0004] Quaternary binder systems combine OPC with three different SCMs to achieve enhanced hydration kinetics, refined microstructure, and superior resistance to environmental degradation. These systems not only reduce the carbon footprint associated with OPC production but also improve key performance metrics such as compressive strength, flexural strength, and durability under cyclic loads. This makes them particularly suited for demanding applications such as high-strength pavements.
[0005] Despite their advantages, the adoption of quaternary binder systems in pavement construction remains limited. Challenges such as inconsistent performance, variability in SCM quality, and the difficulty of achieving compatibility between binder components hinder their widespread implementation. Additionally, scalability and the cost-effectiveness of these systems for large-scale infrastructure projects pose further barriers to their adoption.
[0006] Another concern is the lack of standardized formulations and design methodologies for quaternary binder-based concrete. Variations in SCM proportions, curing conditions, and raw material properties can lead to performance inconsistencies. Engineers and designers often require more reliable and predictable solutions to ensure optimal results in pavement applications.
[0007] To address these limitations, there is a need for a quaternary binder-based concrete composition for high-strength pavement applications that offers improved durability, enhanced load-bearing capacity, and superior environmental sustainability compared to traditional concrete formulations. There is also a need for a quaternary binder-based concrete composition that can efficiently incorporate supplementary cementitious materials (SCMs) to reduce carbon emissions while maintaining strength and longevity. Further, there is also a need for a quaternary binder-based concrete composition that optimizes the interaction between multiple binders, which ensures consistent performance under varying environmental and mechanical conditions.
Objectives of the invention:
[0008] The primary objective of the invention is to provide a quaternary binder-based concrete composition for high-strength pavement applications that offers improved durability, enhanced load-bearing capacity, and superior environmental sustainability compared to traditional concrete formulations.
[0009] Another objective of the invention is to provide a quaternary binder-based concrete composition that significantly enhances the strength and durability of pavement applications, thereby ensuring long-lasting performance even under harsh weather conditions and heavy traffic loads.
[0010] Another objective of the invention is to develop a quaternary binder-based concrete composition that incorporates multiple binders, such as supplementary cementitious materials (SCMs), to reduce the environmental impact by lowering carbon emissions typically associated with conventional concrete mixtures.
[0011] Another objective of the invention is to provide a quaternary binder-based concrete composition that optimizes the use of quaternary binders, thereby enhancing load-bearing capacity and overall mechanical properties, while maintaining adequate workability during mixing and application.
[0012] Another objective of the invention is to create a quaternary binder-based concrete composition that balances sustainability with structural integrity, thereby making it suitable for a wide range of pavement applications, such as roads, highways, and industrial floors.
[0013] Another objective of the invention is to provide a quaternary binder-based concrete composition that ensures uniform distribution of binder materials throughout the mix, thereby facilitating consistent quality control and reliable performance in both small- and large-scale production processes.
[0014] Another objective of the invention is to provide a quaternary binder-based concrete composition that enhances the compatibility of supplementary cementitious materials (SCMs), such as GBBS or fly ash with traditional Portland cement, thereby improving the physical and chemical bonding within the final concrete structure.
[0015] Yet another objective of the invention is to provide a quaternary binder-based concrete composition that promotes environmental sustainability in concrete pavement applications by utilizing alternative binders and materials, thereby contributing to the reduction of waste and energy consumption in construction projects.
[0016] Further objective of the invention is to provide a quaternary binder-based concrete composition that is cost-effective, practical to produce, and scalable for large-scale infrastructure projects, while offering a sustainable solution for high-strength pavement construction.
Summary of the invention:
[0017] The present disclosure proposes a quaternary binder-based concrete composition for high-strength pavement applications and method of preparation. The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview. It is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0018] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide a quaternary binder-based concrete composition for high-strength pavement applications that offers improved durability, enhanced load-bearing capacity, and superior environmental sustainability compared to traditional concrete formulations.
[0019] According to an aspect, the invention proposes a quaternary binder-based concrete composition that can efficiently incorporate supplementary cementitious materials (SCMs) to reduce carbon emissions while maintaining strength and longevity. The quaternary binder-based concrete composition optimizes the interaction between multiple binders, which ensures consistent performance under varying environmental and mechanical conditions.
[0020] In one embodiment herein, the quaternary binder-based concrete composition comprises 55 to 70 weight percentage of a primary binder, 25 to 35 weight percentage of a supplementary cementitious material (SCM), and 1 to 15 weight percentage of a secondary binder. The quaternary binder-based concrete composition is prepared to achieve enhanced compressive strength, and flexural strength for the high-strength pavement applications.
[0021] In one embodiment herein, the primary binder comprises Ordinary Portland Cement (OPC). The supplementary cementitious material (SCM) includes at least one of ground granulated blast furnace slag (GGBS) and fly ash (FA). The secondary binder comprises at least one of alccofine (AF), silica fume (SF), zeolite powder (ZP), and I-Crete.
[0022] In one embodiment herein, the quaternary binder-based concrete composition exhibits a compressive strength of at least 59.5 MPa after a curing period of at least 28 days, thereby making the quaternary binder-based concrete composition suitable for the high-strength pavement applications.
[0023] In one embodiment herein, the quaternary binder-based concrete composition exhibits a flexural strength of at least 5.30 MPa after a curing period of at least 28 days, thereby making the quaternary binder-based concrete composition suitable for the high-strength pavement applications.
[0024] According to an aspect, a method is disclosed for preparing a high-strength pavement using the quaternary binder-based concrete composition. First, at one step, the primary binder, at least one supplementary cementitious material (SCM), and at least one secondary binder are mixed to form the quaternary binder-based concrete composition. At another step, one or more aggregates and water are added to the quaternary binder-based concrete composition to form a concrete mix. At another step, the concrete mix is stirred to achieve a uniform distribution of the binders. Further, at another step, the concrete mix is placed and cured to form the high-strength pavement suitable for high-performance applications.
[0025] Further, objects and advantages of the present invention will be apparent from a study of the following portion of the specification, the claims, and the attached drawings.
Detailed description of drawings:
[0026] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, explain the principles of the invention.
[0027] FIG. 1 illustrates a schematic representation of a quaternary binder-based concrete composition, in accordance to an exemplary embodiment of the invention.
[0028] FIG. 2 illustrates a flowchart of a method for preparing a high-strength pavement using the quaternary binder-based concrete composition, in accordance to an exemplary embodiment of the invention.
[0029] FIG. 3 illustrates a graphical representation depicting setting time of a first group, in accordance to an exemplary embodiment of the invention.
[0030] FIG. 4 illustrates a graphical representation depicting setting time of a second group, in accordance to an exemplary embodiment of the invention.
[0031] FIG. 5 illustrates a bar chart comparing the compressive strength of concrete mixtures M0 to M13, in accordance to an exemplary embodiment of the invention.
[0032] FIG. 6 illustrates a bar chart comparing the compressive strength of concrete mixtures M0 to MF13, in accordance to an exemplary embodiment of the invention.
[0033] FIG. 7 illustrates a bar chart comparing the flexural strength of concrete mixtures M1 to M4, in accordance to an exemplary embodiment of the invention.
Detailed invention disclosure:
[0034] Various embodiments of the present invention will be described in reference to the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.
[0035] The present disclosure has been made with a view towards solving the problem with the prior art described above, and it is an object of the present invention to provide a quaternary binder-based concrete composition for high-strength pavement applications that offers improved durability, enhanced load-bearing capacity, and superior environmental sustainability compared to traditional concrete formulations.
[0036] According to an exemplary embodiment of the invention, FIG. 1 refers to a schematic representation of a quaternary binder-based concrete composition 100. In one embodiment herein, the quaternary binder-based concrete composition 100 can efficiently incorporate supplementary cementitious materials (SCMs) to reduce carbon emissions while maintaining strength and longevity. The quaternary binder-based concrete composition 100 optimizes the interaction between multiple binders, which ensures consistent performance under varying environmental and mechanical conditions.
[0037] In one embodiment herein, the quaternary binder-based concrete composition 100 provides enhanced mechanical properties, thereby making it ideal for high-strength pavement applications. The quaternary binder-based concrete composition 100 comprises 55 to 70 weight percentage of a primary binder 102, 25 to 35 weight percentage of a supplementary cementitious material (SCM) 104, and 1 to 15 weight percentage of a secondary binder 106. This optimized blend of materials ensures a balanced combination of compressive strength, flexural strength, and durability, thereby making it suitable for infrastructure projects subjected to heavy loads and extreme environmental conditions. The incorporation of multiple binders facilitates improved chemical and physical bonding, which contributes to superior long-term performance.
[0038] In one embodiment herein, the primary binder 102 comprises Ordinary Portland Cement (OPC), which acts as the fundamental cementitious material in the quaternary binder-based concrete composition 100. OPC provides the essential hydration reaction needed to form the hardened matrix in concrete. The supplementary cementitious materials (SCMs) 104 used in the quaternary binder-based concrete composition 100 include at least one of ground granulated blast furnace slag (GGBS) and fly ash (FA). SCMs 104 enhance the durability and sustainability of the concrete. For instance, GGBS contributes to improved resistance against chloride penetration and sulfate attack, thereby making the pavement more resilient in harsh environmental conditions, while fly ash improves the workability and overall finishing of the concrete.
[0039] In one embodiment herein, the secondary binder 106 comprises at least one of alccofine (AF), silica fume (SF), zeolite powder (ZP), and I-Crete, all of which serve to enhance specific properties of the concrete. Alccofine and silica fume contribute to improving the microstructure of the concrete by filling voids and reducing permeability, while zeolite powder enhances chemical resistance. This multi-binder approach synergistically enhances the overall performance of the quaternary binder-based concrete composition 100.
[0040] In one embodiment herein, the quaternary binder-based concrete composition 100 demonstrates an exceptional compressive strength of at least 59.5 MPa after a curing period of at least 28 days. This high compressive strength is achieved through the precise formulation of binders and their compatibility, thereby ensuring the concrete can withstand significant static and dynamic loads. Such strength levels are critical for applications in heavy-duty pavements, such as highways, industrial floors, and airport runways. The long curing period allows the hydration of the binders to proceed fully, thereby ensuring that the resulting concrete achieves its maximum strength and durability. The inclusion of SCMs 104, such as GGBS and fly ash, contributes significantly to this performance by densifying the cement matrix and reducing micro-cracks during curing.
[0041] In one embodiment herein, the quaternary binder-based concrete composition 100 also exhibits a flexural strength of at least 5.30 MPa after a curing period of at least 28 days. Flexural strength is a key indicator of the pavement's ability to resist bending and cracking under dynamic loads, such as those caused by vehicular traffic. The enhanced flexural strength is attributed to the synergistic interaction between the primary binder 102, SCMs 104, and secondary binder 106, which together improve the tensile properties of the concrete matrix. This characteristic makes the quaternary binder-based concrete composition 100 especially suitable for pavements that require resistance to fatigue and wear over long service periods, even in demanding operational environments.
[0042] According to an exemplary embodiment of the invention, FIG. 2 refers to a flowchart 200 of a method for preparing a high-strength pavement using the quaternary binder-based concrete composition 100. The method begins with the preparation of the quaternary binder-based concrete composition 100 by mixing the primary binder 102, at least one supplementary cementitious material (SCM) 104, and at least one secondary binder 106 in predetermined weight proportions at step 202. This step ensures that the binders are uniformly distributed, thereby forming the foundation of the concrete mix. Subsequently, at step 204, one or more aggregates, such as coarse and fine aggregates, and water are added to the quaternary binder-based concrete composition 100 to form a concrete mix. The ratio of water to cementitious materials is controlled to achieve the desired workability and mechanical properties.
[0043] Next, at step 206, the concrete mix is stirred thoroughly using appropriate mixing equipment to ensure uniform dispersion of the binders and aggregates. Finally, at step 208, the concrete mix is placed into the designated pavement formwork and subjected to a controlled curing process. The curing ensures that the concrete achieves the desired mechanical strength, durability, and resistance to environmental factors, thereby making it suitable for high-performance applications such as roads, highways, and industrial infrastructure.
[0044] In one embodiment herein, the replacement of cement with ground granulated blast furnace slag (GGBS) and incorporating 2% I-Crete significantly enhances the performance of the pavement. This optimized blend improves durability, compressive strength, flexural strength, and workability, thereby making it ideal for heavy-duty pavement applications. By reducing permeability, it ensures superior resistance to environmental degradation, while the lower heat of hydration minimizes the risk of thermal cracking, even in large-scale pours. Furthermore, the quaternary binder-based concrete composition 100 aligns with sustainability goals by reducing the carbon footprint associated with traditional cement use and promoting the inclusion of recycled aggregates, thereby supporting eco-friendly construction practices. Adhering to relevant IRC (Indian Roads Congress) and IS (Indian Standards) guidelines, the quaternary binder-based concrete composition 100 delivers long-term performance with reduced maintenance requirements, thereby making it a reliable and sustainable choice for the high-strength pavement applications in infrastructure projects.
[0045] In one embodiment herein, I-Crete derived from industrial waste can function as an efficient supplementary cementitious material (SCM) 104 for concrete mixtures, thereby enabling a greater inclusion of construction and demolition waste in pavement applications. Its addition not only increases the percentage of recycled content in pavement-quality concrete but also enhances the eco-friendliness and biodegradability of the final product. By significantly lowering the carbon footprint of concrete production, I-Crete contributes to environmentally sustainable construction practices. Furthermore, its integration offers commercial advantages, as it supports cost-effective solutions for large-scale infrastructure projects. By facilitating the use of recycled materials, I-Crete aligns with the principles of a circular economy, thereby reducing dependence on raw materials and minimizing the environmental impact of pavement construction.
[0046] According to an exemplary embodiment of the invention, FIG. 3 refers to a graphical representation 300 depicting setting time of a first group. In one embodiment herein, the composition details of the first group are represented in table 1. The first group comprises various mineral admixtures, such as Ordinary Portland Cement (OPC), Ground Granulated Blast Furnace Slag (GGBS), Silica Fume (SF), Zeolite Powder (ZP), Alccofine (AF), and I-Crete
[0047] Table 1:
Series Cement Mixes
M0 (Control) OPC 100%
M1 70% of OPC, 30% of GGBS
M2 65% of OPC, 30% of GGBS, 5% of AF
M3 60% of OPC, 30% of GGBS, 10% of AF
M4 55% of OPC, 30% of GGBS, 15% of AF
M5 65% of OPC, 30% of GGBS, 5% of SF
M6 60% of OPC, 30% of GGBS, 10% of SF
M7 55% of OPC, 30% of GGBS, 15% of SF
M8 65% of OPC, 30% of GGBS, 5% of ZP
M9 60% of OPC, 30% of GGBS, 10% of ZP
M10 55% of OPC, 30% of GGBS, 15% of ZP
M11 69% of OPC, 30% of GGBS, 1% of I-Crete
M12 68.5% of OPC, 30% of GGBS, 1.5% of I-Crete
M13 68% of OPC, 30% of GGBS, 2 % of I-Crete

[0048] According to graph 300 and table 1, for an initial setting time, Alccofine (AF) at a 5% concentration in M2 mixture exhibited an increase in setting time. Conversely, Silica Fume (SF) led to a reduction in the initial setting time across concentrations of 5%, 10%, and 15% in M5, M6, and M7 mixtures, respectively, which might be attributed to the lower cement content or its ability to reduce water demand.
[0049] In one embodiment herein, Zeolite Powder (ZP) showed a consistent increasing trend in the initial setting time as its content increased from 5%, 10%, and 15% in M8, M9, and M10 mixtures, highlighting its slower hydration reaction. The inclusion of 30% GGBS extended the setting duration, thereby confirming its role in delayed hydration. However, I-Crete presented a decrease in strength when its concentration is raised by 2% in M13 mixture, possibly due to its unique material properties. Regarding a final setting time, all tested cementitious materials, such as OPC, GGBS, SF, ZP, AF, and I-Crete demonstrated an increasing trend with their inclusion at varying concentrations at 5%, 10%, and 15% in M2 to M13 mixtures. Among these, Zeolite Powder exhibited the most significant increase in the final setting time, indicating its strong impact on the extended hydration process.
[0050] According to an exemplary embodiment of the invention, FIG. 4 refers to a graphical representation 400 depicting setting time of a second group. In one embodiment herein, the composition details of the second group are represented in table 2. The second group comprises various mineral admixtures, such as Ordinary Portland Cement (OPC), Fly Ash (FA), Silica Fume (SF), Zeolite Powder (ZP), Alccofine (AF), and I-Crete.
[0051] Table 2:
Series Cement Mixes
M0 (Control) OPC 100%
MF1 70% of OPC, 30% of FA
MF2 65% of OPC, 30% of FA, 5% of AF
MF3 60% of OPC, 30% of FA, 10% of AF
MF4 55% of OPC, 30% of FA, 15% of AF
MF5 65% of OPC, 30% of FA, 5% of SF
MF6 60% of OPC, 30% of FA, 10% of SF
MF7 55% of OPC, 30% of FA, 15% of SF
MF8 65% of OPC, 30% of FA, 5% of ZP
MF9 60% of OPC, 30% of FA, 10% of ZP
MF10 55% of OPC, 30% of FA, 15% of ZP
MF11 69% of OPC, 30% of FA, 1% of I-Crete
MF12 68.5% of OPC, 30% of FA, 1.5% of I-Crete
MF13 68% of OPC, 30% of FA, 2 % of I-Crete

[0052] In the second group, Fly Ash (FA) is incorporated into the quaternary binder system to evaluate its influence on the initial and final setting times. A significant synergy is noted between Silica Fume (SF) and Fly Ash (FA), which collectively enhanced the resistance properties of the concrete. In particular, the addition of Fly Ash complemented the performance of Silica Fume by improving the blend's workability and durability. However, the impact on setting times varied across different compositions.
[0053] In one embodiment herein, Alccofine (AF) demonstrated a pronounced effect on the initial setting time, with a 40% increase recorded in MF2 mixture. Despite this initial rise, the inclusion of various pozzolanic materials caused the initial setting time to decline in subsequent mixtures, thereby suggesting a balancing effect when multiple binders are combined. For the final setting time, Silica Fume (SF) at a 10% concentration in MF6 led to a marked increase in both initial and final setting times, thereby indicating its ability to slow down the hydration process when used in moderate amounts. The addition of Fly Ash in MF1 to MF13 mixtures introduced fluctuations in both initial and final setting times, thereby underscoring its complex interaction with other components. These fluctuations suggest that Fly Ash has the potential to serve as an alternative to Silica Fume in specific pavement applications, particularly where flexibility in setting time is desired.
[0054] According to an exemplary embodiment of the invention, FIG. 5 refers to a bar chart 500 comparing the compressive strength of concrete mixtures M0 to M13. In one embodiment herein, the casting and testing of these mixtures are conducted in accordance with IS 4031:2005, thereby ensuring standardized procedures for evaluating compressive strength. The results depicted in the bar chart 500 reveal significant variations in compressive strength across the mixtures, with several demonstrating notable improvements over the M0 control mixture. At 28 days, the best-performing mixture, M13, achieved a remarkable compressive strength of 59.5 MPa, reflecting a 2.6% improvement over the control mixture (M0), which measured 58 MPa. Similarly, the M6 mixture exhibited a compressive strength of 59 MPa, marking a 1.7% enhancement. While these improvements might appear modest, they are particularly significant given the partial substitution of Ordinary Portland Cement (OPC) with supplementary cementitious materials (SCMs) 104 and industrial by-products, thereby reducing the environmental impact of concrete production.
[0055] The results at earlier curing stages further underscore the potential of these optimized formulations. At 3 days, M13 exhibited a compressive strength of 37 MPa, representing a substantial 23.3% increase compared to the control mixture (M0) at 30 MPa. Similarly, M6 attained 35 MPa, which is 16.7% higher than M0. This demonstrates that the incorporation of certain combinations of SCMs 104 and industrial admixtures can significantly enhance the early strength development, crucial for fast-track construction applications. The 7-day compressive strength followed a similar trend, with M13 and M6 achieving 22.5% and 20% increases, respectively, over the control mixture's 40 MPa. Remarkably, mixtures such as M1 and M2 exhibited slightly lower early strength, likely due to the gradual nature of pozzolanic reactions, which are known to enhance long-term strength. By 28 days, these mixtures had largely caught up to their counterparts, highlighting the delayed but robust strength contribution of pozzolanic materials.
[0056] The consistent superior performance of mixtures such as M13 and M6 across all curing ages underscores the successful balancing of early strength contribution from Ordinary Portland Cement (OPC) with long-term strength enhancement from Fly Ash, Silica Fume, and Alccofine. The data validates the ability of these novel binder systems to not only match but exceed the performance of traditional Ordinary Portland Cement (OPC) concrete, thereby offering pathways to more sustainable concrete production without compromising structural integrity.
[0057] In one embodiment herein, I-Crete demonstrates exceptional potential as an innovative binder component in cementitious mixtures, thereby offering a range of benefits in both strength development and workability. The performance of mixtures incorporating I-Crete, particularly M13, is prominently highlighted in the compressive strength results across all testing ages, showcasing the material's adaptability and efficiency in enhancing concrete performance. At just 3 days, the M13 mixture achieves an impressive compressive strength of 37 MPa, marking a 23.3% increase over the control mixture (M0). This significant early strength gain underscores I-Crete's ability to accelerate the hydration process and promote rapid hardening, a feature highly desirable for fast-track construction schedules where early load-bearing capacity is crucial.
[0058] By 7 days, M13 continues to outperform the control mixture with a compressive strength of 49 MPa, reflecting a 22.5% improvement. This sustained strength development indicates that the pozzolanic reactions facilitated by I-Crete not only contribute to early-age performance but also create a strong foundation for the long-term durability of the material. Most notably, at 28 days, the compressive strength of M13 peaks at 59.5 MPa, surpassing the control mixture by 2.6%. This consistent strength improvement across all curing periods highlights I-Crete's dual role in enhancing early-age properties while maintaining or even improving long-term strength, a critical balance for high-performance concrete applications.
[0059] In addition to its strength-enhancing properties, the study reveals that I-Crete contributes to improved workability by reducing the water demand of the concrete mix by 2% at its respective replacement level. This reduction in water requirement ensures better flowability and ease of handling during placement and compaction, while also indirectly reducing shrinkage-related issues. Importantly, this improved workability does not compromise the strength properties, making I-Crete an ideal additive for achieving superior performance with optimized mix designs.
[0060] Moreover, the incorporation of I-Crete aligns with the industry's sustainability goals, as its use allows for partial cement replacement, thereby reducing the overall carbon footprint of concrete production. The environmental impact of cement manufacturing, a significant contributor to global CO₂ emissions, can be mitigated by leveraging supplementary cementitious materials such as I-Crete. Its ability to enhance strength, reduce cement dependency, and improve workability positions.
[0061] According to an exemplary embodiment of the invention, FIG. 6 refers to a bar chart 600 comparing the compressive strength of concrete mixtures M0 to MF13. In one embodiment herein, the bar chart 600 illustrates the compressive strength development of various cementitious mixtures (M0 to MF13) at 3, 7, and 28 days, with the control mixture (M0) serving as the baseline for comparison. The modified mixtures incorporating supplementary cementitious materials (SCMs) 104 and secondary binders 106 show notable improvements in both early and long-term compressive strength. These findings underscore the potential of SCMs in enhancing the overall performance of concrete. At 3 days, significant early strength gains are observed in specific mixtures. MF13 achieved a compressive strength of 37 MPa, a 23.3% improvement compared to the 30 MPa of the control mixture. Similarly, MF6 demonstrated a strength of 35 MPa, reflecting a 16.7% increase. This early strength development highlights the ability of certain SCM 104 combinations to accelerate the hydration process, making these mixtures highly suitable for fast-paced construction projects.
[0062] At 7 days, the trend of improved performance continued. MF13 reached 49 MPa, a 22.5% increase over the control mix’s 40 MPa, while MF6 achieved 48 MPa, representing a 20% improvement. These results demonstrate the synergistic effects of Fly Ash (FA), Silica Fume (SF), and Zeolite Powder (ZP), which enhance intermediate-stage hydration and strength gain. The 28-day compressive strength results further validate the effectiveness of the modified mixtures. MF13 exhibited a peak strength of 59.5 MPa, surpassing 58 MPa of the control mixture (M0) by 2.6%, while MF6 closely followed with 59 MPa, marking a 1.7% increase. Although the percentage improvements at this stage were modest compared to earlier ages, they are significant given the partial replacement of cement with SCMs 104 and secondary binders 106. MF13 can be considered as the quaternary binder-based concrete composition 100.
[0063] In one embodiment herein, Fly Ash (FA) played a notable role in the mixtures, contributing to slower early strength development but significantly enhancing long-term compressive strength. Zeolite Powder (ZP), on the other hand, reduced water demand in the mixes, which lowered the water-to-binder ratio and resulted in improved compressive strength. This reduction in water demand also improved workability, further enhancing the practicality of these modified concrete mixtures.
[0064] In one embodiment herein, I-Crete incorporation, particularly evident in MF13 mixture, leads to superior strength development across all ages. The 23.3% increase in 3-day strength and the 22.5% increase in 7-day strength, compared to the control mix, highlight I-Crete's ability to significantly enhance early-age performance. Even at 28 days, MF13 maintains its lead with a 2.6% strength increase over the control. This consistent outperformance, coupled with the reported 2% decrease in water demand, positions I-Crete as a promising additive for creating high-performance concrete. Its ability to improve both early and long-term strength, while simultaneously reducing water demand, indicates its potential for producing more sustainable, efficient, and environmentally friendly concrete mixtures.
[0065] According to an exemplary embodiment of the invention, FIG. 7 refers to a bar chart 700 comparing the flexural strength of concrete mixtures M1 to M4. In one embodiment herein, the flexural strength of the concrete mixtures M1 to M4 at 28 days is represented in table 3.
[0066] Table 3:
Mixture Mixture type Flexural strength (Mpa) for 28 days
M1 Control mixture 6.01
M2 Mixture with 100% of Recycled Aggregate (RA) 4.95
M3 Mixture with 100% of RA and 30% of GGBS as cement replacement 4.26
M4 Mixture with 100% of RA, 30% of GGBS as cement replacement, and 2% of I-Crete 5.30

[0067] According to FIG. 7 and table 3, M1 represents the control mixture, while M2 represents a mixture with 100% of recycled aggregate (RA). M3 represents a mixture with 100% of RA and 30% of GGBS as cement replacement. M4 represents a mixture with 100% of RA, 30% of GGBS as cement replacement, and 2% of I-Crete. According to IRC: 58:2015, the 28-day flexural strength of pavement quality concrete must not be less than 4.5 MPa. In the M40 grade mix, optimum proportions of I-Crete with GGBS, fine aggregate, and coarse aggregate in a 60:40 ratio are used. Recycled aggregate (20mm-10mm) replaces 60% of the total coarse aggregate, while the remaining 40% consists of conventional aggregate (10mm).
[0068] From a strength perspective, the mixture M4 (5.3 MPa) shows an improvement over the mixtures M2 (4.95 MPa) and M3 (4.26 MPa). Compared to M3, M4 exhibits a 24.4% increase in flexural strength, and compared to M2, it shows a 7.1% increase. This demonstrates the potential of I-Crete in enhancing the flexural strength of pavement quality concrete, particularly when used in combination with recycled aggregates, thereby making it a sustainable and high-performance option for pavement applications.
[0069] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the quaternary binder-based concrete composition 100 for high-strength pavement applications offers improved durability, enhanced load-bearing capacity, and superior environmental sustainability compared to traditional concrete formulations. The quaternary binder-based concrete composition 100 significantly enhances the strength and durability of pavement applications, thereby ensuring long-lasting performance even under harsh weather conditions and heavy traffic loads. The quaternary binder-based concrete composition 100 incorporates multiple binders, such as supplementary cementitious materials (SCMs) 104, to reduce the environmental impact by lowering carbon emissions typically associated with conventional concrete mixtures.
[0070] The quaternary binder-based concrete composition 100 optimizes the use of quaternary binders, thereby enhancing load-bearing capacity and overall mechanical properties, while maintaining adequate workability during mixing and application. The quaternary binder-based concrete composition 100 balances sustainability with structural integrity, thereby making it suitable for a wide range of pavement applications, such as roads, highways, and industrial floors. The quaternary binder-based concrete composition 100 ensures uniform distribution of binder materials throughout the mix, thereby facilitating consistent quality control and reliable performance in both small- and large-scale production processes.
[0071] The quaternary binder-based concrete composition 100 enhances the compatibility of supplementary cementitious materials (SCMs) 104 such as GBBS, or fly ash (FA) with traditional Portland cement, thereby improving the physical and chemical bonding within the final concrete structure. The quaternary binder-based concrete composition 100 promotes environmental sustainability in concrete pavement applications by utilizing alternative binders and materials, thereby contributing to the reduction of waste and energy consumption in construction projects. The quaternary binder-based concrete composition 100 is cost-effective, practical to produce, and scalable for large-scale infrastructure projects, while offering a sustainable solution for high-strength pavement construction.
[0072] It will readily be apparent that numerous modifications and alterations can be made to the processes described in the foregoing examples without departing from the principles underlying the invention, and all such modifications and alterations are intended to be embraced by this application.
, Claims:CLAIMS:
I/We Claim:
1. A quaternary binder-based concrete composition (100) for high-strength pavement applications, comprising:
55 to 70 weight percentage of a primary binder (102);
25 to 35 weight percentage of a supplementary cementitious material (SCM) (104); and
1 to 15 weight percentage of a secondary binder (106),
whereby the quaternary binder-based concrete composition (100) is prepared to achieve enhanced compressive strength, and flexural strength for the high-strength pavement applications.
2. The quaternary binder-based concrete composition (100) as claimed in claim 1, wherein the primary binder (102) comprises Ordinary Portland Cement (OPC).
3. The quaternary binder-based concrete composition (100) as claimed in claim 1, wherein the supplementary cementitious material (SCM) (104) includes at least one of ground granulated blast furnace slag (GGBS) and fly ash (FA).
4. The quaternary binder-based concrete composition (100) as claimed in claim 1, wherein the secondary binder (104) comprises at least one of alccofine (AF), silica fume (SF), zeolite powder (ZP), and I-Crete.
5. The quaternary binder-based concrete composition (100) as claimed in claim 1, wherein the quaternary binder-based concrete composition (100) exhibits a compressive strength of at least 59.5 MPa after a curing period of at least 28 days, thereby making the quaternary binder-based concrete composition (100) suitable for the high-strength pavement applications.
6. The quaternary binder-based concrete composition (100) as claimed in claim 1, wherein the quaternary binder-based concrete composition (100) exhibits a flexural strength of at least 5.30 MPa after a curing period of at least 28 days, thereby making the quaternary binder-based concrete composition (100) suitable for the high-strength pavement applications.
7. A method of preparing high-strength pavements using a quaternary binder-based concrete composition (100), comprising:
mixing a primary binder (102), at least one supplementary cementitious material (SCM) (104), and at least one secondary binder (106) to form the quaternary binder-based concrete composition (100);
adding one or more aggregates and water to the quaternary binder-based concrete composition (100) to form a concrete mix;
stirring the concrete mix to achieve a uniform distribution of the binders; and
placing and curing the concrete mix to form the high-strength pavements suitable for high-performance applications.