Description:FIELD OF THE INVENTION
[0001] The present invention relates to the field of sustainable construction materials and thermal insulation systems, and more particularly to a thermally insulating foam concrete panel composition incorporating recycled plastic aggregates and natural fibers for building applications.

DESCRIPTION OF THE RELATED ART
[0002] The following description of the related art is intended to provide background information pertaining to the field of disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section is used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of the prior art.
[0003] The construction industry faces significant challenges in developing sustainable building materials that provide adequate thermal insulation while minimizing environmental impact. Traditional concrete panels, though structurally sound, exhibit poor thermal insulation properties with thermal conductivity values typically exceeding 1.0 W/m·K, leading to increased energy consumption in buildings.
[0004] Foam concrete has emerged as a lightweight alternative to conventional concrete, offering improved thermal insulation properties. However, conventional foam concrete suffers from several limitations including low mechanical strength, high shrinkage rates, poor crack resistance, and excessive water absorption, which limit its application in building construction.
[0005] Simultaneously, the accumulation of plastic waste, particularly polypropylene from discarded furniture and packaging materials, poses a significant environmental challenge. Current disposal methods including landfilling and incineration contribute to environmental pollution and resource depletion.
[0006] Previous attempts to incorporate recycled materials in concrete have focused on using either plastic aggregates or natural fibers individually. These approaches have depicted limited success due to compromised mechanical properties, inadequate thermal performance, or poor durability characteristics.
[0007] Autoclaved aerated concrete (AAC) blocks provide thermal insulation but require energy-intensive autoclaving processes and specialized manufacturing facilities, increasing production costs and environmental footprint.
[0008] Therefore, there exists a requirement for an improved concrete composition that addresses these limitations by providing enhanced thermal insulation, adequate mechanical strength, reduced environmental impact, and simplified manufacturing processes while utilizing waste materials effectively.

OBJECTS OF THE PRESENT DISCLOSURE
[0009] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.
[0010] An object of the present disclosure is to provide a thermally insulating foam concrete panel composition which incorporates recycled plastic aggregates as partial replacement for fine aggregates to create discontinuous thermal pathways while maintaining structural integrity for non-load bearing building applications.
[0011] An object of the present disclosure is to provide a thermally insulating foam concrete panel composition which utilizes a foam component including 1% to 6% by weight of total solids to create cellular voids that reduce thermal conductivity while maintaining workability during casting operations.
[0012] An object of the present disclosure is to provide a thermally insulating foam concrete panel composition which incorporates at least one natural fiber having a length of 15 mm to 40 mm to form a three-dimensional reinforcement network that controls shrinkage and prevents microcrack propagation.
[0013] An object of the present disclosure is to provide a thermally insulating foam concrete panel composition which utilizes recycled thermoplastic material, particularly polypropylene from waste furniture, having a particle size of less than 2 mm to replace 10% to 30% by volume of fine aggregate.
[0014] An object of the present disclosure is to provide a thermally insulating foam concrete panel composition which employs alkali-treated coir fibers with an aspect ratio of 60 to 120 to enhance bonding with the cementitious matrix and improve durability characteristics.
[0015] An object of the present disclosure is to provide a thermally insulating foam concrete panel composition which achieves thermal conductivity of less than 0.3 W/m·K and compressive strength of at least 3 MPa without requiring energy-intensive autoclaving processes.
[0016] An object of the present disclosure is to provide a method for forming thermally insulating concrete panels which enables simplified manufacturing through sequential mixing, foam generation, and casting operations while utilizing waste materials for sustainable construction applications.

SUMMARY
[0017] This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.
[0018] The present disclosure generally relates to sustainable construction materials and thermal insulation technologies. More particularly, the present disclosure relates to a thermally insulating foam concrete panel composition that employs recycled plastic aggregates and natural fibers for enhanced thermal performance through creation of discontinuous thermal pathways and three-dimensional fiber reinforcement networks, providing improved insulation capabilities through synergistic material interactions and simplified manufacturing processes for energy-efficient building applications and environmental sustainability.
[0019] An aspect of the present disclosure relates to a composition for forming a thermally insulating concrete panel. The composition includes cement and at least one fine aggregate in a weight ratio of 1:0.5 to 1:3, where the ratio provides optimal binding and workability characteristics. The composition includes water providing a water-to-cement ratio of 0.3 to 0.5 that enables proper hydration and foam stability. The composition includes a foam component including 1% to 6% by weight of total solids, where the foam creates cellular voids for thermal resistance. The composition includes plastic aggregates having a particle size of less than 2 mm that replace 10% to 30% by volume of the fine aggregate, where the plastic aggregates include recycled thermoplastic material. The composition includes at least one natural fiber having a length of 15 mm to 40 mm including 0.1% to 1% by weight of cement, where the fiber provides crack resistance. The composition includes foam generation components where the foam component is generated from a foaming agent mixed with water and air. The composition includes material distribution characteristics where the plastic aggregates form discontinuous phases within the cementitious matrix. The composition includes fiber orientation patterns where the natural fibers extend through the matrix in multiple directions. The composition includes void stabilization mechanisms where cellular voids created by the foam component are stabilized through interaction with plastic aggregates and natural fibers. The composition includes thermal barrier formation where the combination of foam voids, plastic aggregates, and natural fibers creates multiple thermal resistance pathways.
[0020] In another aspect, the present disclosure relates to a method for forming a thermally insulating concrete panel. The method includes mixing cement and at least one fine aggregate in a weight ratio of 1:0.5 to 1:3 to form a dry mixture, where the mixing ensures uniform distribution. The method includes adding water to the dry mixture to provide a water-to-cement ratio of 0.3 to 0.5, thereby forming a cementitious mixture. The method includes generating a foam component from a foaming agent mixed with water and air, where the foam provides cellular structure. The method includes replacing 10% to 30% by volume of the fine aggregate in the cementitious mixture with plastic aggregates having a particle size of less than 2 mm. The method includes incorporating at least one natural fiber having a length of 15 mm to 40 mm into the cementitious mixture containing plastic aggregates, where the fiber includes 0.1% to 1% by weight of cement. The method includes combining the foam component with the cementitious mixture containing plastic aggregates and natural fiber, where the foam component includes 1% to 6% by weight of total solids. The method includes casting the combined mixture containing foam component, plastic aggregates, and natural fiber into a mold for panel formation. The method includes curing the cast mixture to form the thermally insulating concrete panel through hydration and strength development processes.
[0021] 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.

BRIEF DESCRIPTION OF DRAWINGS
[0022] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.
[0023] FIG. 1 illustrates an exemplary representation of the materials preparation and components for the thermally insulating foam concrete panel composition, depicting (a) cement, (b) fine aggregate, (c) foam component, (d) generated foam, (e) natural fibers, and (f) mixing process, in accordance with an embodiment of the present disclosure.
[0024] FIG. 2 illustrates an exemplary representation of the natural fiber treatment process, depicting (a) coir fibers immersed in alkali solution, (b) treated coir fibers after alkali treatment, and (c) cut coir fibers of 25-30 mm length ready for incorporation, in accordance with an embodiment of the present disclosure.
[0025] FIG. 3 illustrates an exemplary representation of the workability flow test results, depicting (a) foam concrete with 3% foam, (b) foam concrete with 3% foam and 20% plastic aggregate replacement, and (c) foam concrete with 3% foam, 20% plastic aggregate replacement and 0.3% coir fiber, in accordance with an embodiment of the present disclosure.
[0026] FIG. 4 illustrates an exemplary representation of scanning electron microscope (SEM) images depicting the microstructure of the thermally insulating foam concrete panel, depicting ettringite formation, plastic aggregate (PA) embedded in matrix, fiber bonding mechanisms, and the cellular void structure, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0027] The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth.
Definitions:
Thermal Conductivity: A material property measuring the rate of heat transfer through a unit thickness of material per unit area per unit temperature difference, expressed in W/m·K, where the lower values indicate better insulation performance.
Foam Component: A cellular structure generated from a foaming agent mixed with water and air at controlled pressure, creating stable air voids within the cementitious matrix that reduce density and thermal conductivity.
Recycled Thermoplastic Material: Post-consumer polypropylene aggregates derived from waste furniture and packaging materials, processed to particle sizes less than 2 mm for incorporation as partial fine aggregate replacement.
Natural Fiber: Alkali-treated coir fibers extracted from coconut husks, cut to lengths of 15-40 mm with aspect ratios of 60-120, providing three-dimensional reinforcement within the concrete matrix.
Cementitious Matrix: The binding phase formed by hydration of cement with water, creating a continuous medium that encapsulates aggregates, fibers, and foam voids to form the structural framework.

[0028] An aspect of the present disclosure relates to a thermally insulating foam concrete panel composition including cement and fine aggregate forming a binding matrix for structural integrity. The composition includes water enabling cement hydration and workability control. The composition includes a foam component creating cellular voids for thermal resistance. The composition includes recycled plastic aggregates replacing partial fine aggregate volume. The composition includes natural fibers providing crack resistance and dimensional stability. The composition includes specific proportioning ensuring optimal thermal and mechanical properties. The composition includes material interactions creating synergistic performance enhancement. The composition includes simplified manufacturing without autoclaving requirements. The composition includes sustainable materials addressing waste utilization.
[0029] Various embodiments of the present disclosure are described using FIGs. 1 to 4.
[0030] FIG. 1 illustrates an exemplary representation of the materials preparation and components for the thermally insulating foam concrete panel composition, in accordance with an embodiment of the present disclosure.
[0031] In an embodiment, referring to FIG. 1, the composition components for forming thermally insulating concrete panels can include cement (a) providing binding properties, fine aggregate (b) forming the structural skeleton, foam component (c) in liquid state before generation, generated foam (d) depicting stable cellular structure, natural fibers (e) for reinforcement, and mixing process (f) combining all components. The materials can be prepared and combined following specific sequences ensuring optimal distribution and interaction.
[0032] In an embodiment, the cement depicted in FIG. 1(a) can include Portland Pozzolana Cement containing 15% to 35% pozzolanic materials enhancing long-term strength and durability. The cement can provide binding properties through hydration reactions forming calcium silicate hydrate gel. The cement can be proportioned at ratios of 1:0.5 to 1:3 with fine aggregate enabling workability control. The cement can interact with foam component maintaining cellular structure during initial setting. The cement can bond with alkali-treated natural fibers through improved surface compatibility. The cement can include, but is not limited to, ordinary Portland cement, Portland Pozzolana cement, Portland slag cement, and composite cements, providing flexibility in material selection based on availability.
[0033] In an embodiment, the fine aggregate depicted in FIG. 1(b) can be implemented in the composition to provide structural framework and dimensional stability. The fine aggregate can function by filling spaces between cement particles optimizing packing density. The fine aggregate can have particle sizes less than 1.5 mm ensuring compatibility with foam structure. The fine aggregate can be partially replaced by recycled plastic aggregates at 10% to 30% by volume. The fine aggregate can maintain gradation curves enabling optimal workability. The fine aggregate can include, but is not limited to, natural sand, manufactured sand, crushed stone fines, and recycled concrete fines, providing material flexibility.
[0034] In an embodiment, the foam component depicted in FIG. 1(c) and (d) can be implemented in the composition to create cellular voids reducing thermal conductivity. The foam can be generated from vegetable-based surfactants mixed with water at ratios of 1:20 to 1:40. The foam can be produced at pressures of 350 to 550 kPa ensuring stable bubble formation. The foam can include 1% to 6% by weight of total solids controlling density reduction. The foam can maintain stability during mixing preventing bubble collapse. The foam generation can achieve densities of 25-30 kg/m³ optimizing void distribution.
[0035] In an embodiment, the recycled plastic aggregates can be incorporated to replace 10% to 30% by volume of fine aggregate creating discontinuous thermal pathways. The plastic aggregates can include polypropylene with densities of 500 to 700 kg/m³. The plastic aggregates can have particle sizes less than 2 mm ensuring uniform distribution. The plastic aggregates can reduce overall panel density while maintaining structural integrity. The plastic aggregates can be derived from post-consumer waste addressing environmental concerns. The plastic aggregates can include, but are not limited to, polypropylene, polyethylene, PET, and mixed plastic waste, properly processed to required specifications.
[0036] In an embodiment, the natural fibers depicted in FIG. 1(e) can be implemented to provide three-dimensional reinforcement controlling shrinkage and crack propagation. The fibers can include coir treated with alkali solution at 3% to 7% concentration improving cement compatibility. The fibers can be cut to lengths of 15 mm to 40 mm optimizing aspect ratios of 60 to 120. The fibers can include 0.1% to 1% by weight of cement balancing reinforcement with workability. Upon hydration, the fibers can bridge microcracks preventing propagation. The fibers can absorb internal stresses during drying reducing shrinkage by up to 75%.
[0037] In an embodiment, the water component can provide essential hydration for cement while maintaining foam stability. The water can be added at water-to-cement ratios of 0.3 to 0.5 ensuring complete hydration. The water can enable workability for proper material placement and compaction. The water quality can meet potable standards preventing contamination. The water temperature can be controlled between 20-30°C optimizing reaction rates.
[0038] In an embodiment, the mixing process depicted in FIG. 1(f) can combine components in specific sequences ensuring homogeneous distribution. The mixing can begin with dry blending cement and fine aggregate. The water addition can follow creating cementitious paste. The plastic aggregates can be incorporated ensuring coating with cement paste. The fibers can be added gradually preventing balling. The foam can be folded gently maintaining cellular structure.
[0039] FIG. 2 illustrates an exemplary representation of the natural fiber treatment process, in accordance with an embodiment of the present disclosure.
[0040] In an embodiment, referring to FIG. 2, the fiber treatment process can enhance bonding between natural fibers and cementitious matrix through surface modification. At stage (a), coir fibers can be immersed in alkali solution for 72 hours removing lignin and hemicellulose. The treatment can expose cellulose microfibrils increasing surface roughness. At stage (b), treated fibers can depict enhanced compatibility with cement paste. The alkali treatment can improve fiber tensile strength by 15-20%. At stage (c), fibers can be cut to specified lengths maintaining aspect ratios for optimal reinforcement.
[0041] In an embodiment, the alkali treatment parameters can significantly influence fiber-matrix bonding characteristics. The sodium hydroxide concentration of 3% to 7% can optimize lignin removal without degrading cellulose. The treatment duration of 48-96 hours can ensure complete surface modification. The solution temperature of 25-30°C can prevent excessive fiber degradation. Post-treatment washing can remove residual alkali preventing cement hydration interference. The dried fibers can exhibit hydrophilic properties enhancing cement paste adhesion.
[0042] FIG. 3 illustrates an exemplary representation of workability test results for different mixture compositions, in accordance with an embodiment of the present disclosure.
[0043] In an embodiment, referring to FIG. 3, the workability characteristics can demonstrate material flow properties essential for practical application. Sample (a) depicting foam concrete with 3% foam can exhibit 110% flow indicating high workability. Sample (b) incorporating 20% plastic aggregate replacement can depict reduced flow of 105% maintaining adequate workability. Sample (c) containing additional 0.3% coir fiber can display 100% flow remaining within acceptable limits. The progressive reduction in flow can correlate with increased internal friction from plastic aggregates and fiber addition.
[0044] In an embodiment, the workability measurements can validate composition proportions for field application. The flow table test following ASTM C230 can provide standardized assessment. The initial 110% flow for foam concrete can indicate self-leveling characteristics. The 5% reduction with plastic addition can result from hydrophobic surface properties. The further 5% reduction with fiber can arise from water absorption and mechanical interlocking. Despite reductions, all compositions can maintain flows above 100% ensuring placement without excessive vibration.
[0045] FIG. 4 illustrates scanning electron microscope images revealing microstructural characteristics of the thermally insulating foam concrete panel, in accordance with an embodiment of the present disclosure.
[0046] In an embodiment, referring to FIG. 4, the SEM analysis can reveal critical microstructural features influencing thermal and mechanical properties. The images can depict ettringite needle formations indicating proper cement hydration. The plastic aggregate (PA) embedded within matrix can demonstrate adequate bonding without interfacial gaps. The fiber bonding mechanisms can display cement paste penetration into fiber surface irregularities. The cellular void structure can exhibit uniform distribution with stable void walls preventing coalescence.
[0047] In an embodiment, the microstructural analysis can validate material interactions within the composite system. The ettringite formations can contribute to early strength development and dimensional stability. The plastic aggregate interfaces can depict mechanical interlocking without chemical bonding confirming physical adhesion adequacy. The fiber surfaces can exhibit calcium hydroxide crystal growth indicating chemical interaction. The void structures can range from 50-500 micrometers optimizing thermal resistance. The combined microstructure can create tortuous pathways for heat transfer reducing thermal conductivity below 0.1 W/m·K.
[0048] In an embodiment, the method for forming thermally insulating concrete panels can follow systematic procedures ensuring consistent quality. The method can initiate with material preparation including aggregate sieving and fiber cutting. The dry mixing can combine cement with fine aggregate achieving uniform distribution. The water addition can create workable paste enabling subsequent incorporations. The plastic aggregate replacement can occur gradually preventing segregation. The fiber addition can employ dispersal techniques avoiding clumping. The foam introduction can use folding motions preserving bubble integrity. The casting can fill molds without excessive vibration. The curing can maintain moisture for strength development.
[0049] In an embodiment, implementing the mixing step can involve precise control of material addition sequences affecting final properties. The cement and fine aggregate mixing can continue for 2-3 minutes ensuring homogeneity. The mixer speed can be maintained at 140±5 rpm preventing material ejection. The dry mixture uniformity can be verified through color consistency. The mixing can occur in planetary mixers ensuring thorough blending. The ambient temperature during mixing can be controlled between 20-30°C optimizing workability retention.
[0050] In an embodiment, the water addition step can critically influence hydration kinetics and foam stability. The water can be added gradually over 30-60 seconds preventing localized high water-cement ratios. The mixing can continue for 3-4 minutes developing paste consistency. The water temperature can match ambient conditions preventing thermal shock. The paste development can be monitored through visual assessment. The proper consistency can exhibit cohesiveness without bleeding. The water quality parameters can meet IS 456 specifications ensuring chemical compatibility.
[0051] In an embodiment, incorporating recycled plastic aggregates can require specific techniques preventing segregation. The plastic aggregates can be pre-wetted reducing water absorption during mixing. The replacement can occur by volume maintaining designed proportions. The mixing duration can extend by 1-2 minutes ensuring coating with cement paste. The plastic distribution can be verified through visual inspection. The hydrophobic nature of plastic can necessitate extended mixing. The aggregate incorporation can avoid flotation through controlled mixing speeds.
[0052] In an embodiment, natural fiber addition can demand careful dispersion preventing fiber balling. The fibers can be added in small batches over 2-3 minutes. The mixer speed can reduce to 100 rpm during fiber addition. The fiber dispersion can be enhanced through manual spreading before addition. The mixing can continue until uniform distribution is achieved. The fiber orientation can remain random providing isotropic reinforcement. The workability reduction can be monitored ensuring castability.
[0053] In an embodiment, foam incorporation can represent the most critical step requiring gentle handling. The foam can be generated immediately before use ensuring stability. The foam addition can occur through folding motions minimizing shear. The mixing speed can reduce to 60-80 rpm preventing bubble destruction. The foam distribution can be assessed through density measurements. The mixture volume increase can indicate successful foam incorporation. The final mixing duration can be limited to 30-60 seconds preserving cellular structure.
[0054] In an embodiment, the casting process can transfer mixed material into molds forming desired panel dimensions. The molds measuring 450mm × 300mm × 15mm can be prepared with release agents. The material placement can occur in single lifts preventing cold joints. The compaction can use gentle vibration avoiding foam collapse. The surface finishing can create smooth textures for aesthetic appeal. The casting can complete within 30 minutes of mixing preventing setting. The filled molds can be covered preventing moisture loss.
[0055] In an embodiment, the curing regime can critically influence strength development and durability. The initial curing can maintain 95% relative humidity for 24 hours. The demolding can occur after achieving sufficient strength. The subsequent curing can continue for 7-28 days in controlled environments. The temperature during curing can be maintained at 27±2°C. The moisture retention can use wet covering or ponding methods. The curing duration can optimize strength while minimizing shrinkage.
[0056] In an embodiment, quality control measures can ensure consistent panel properties meeting specifications. The density measurements can verify achievement of target 800-1000 kg/m³. The compressive strength testing can confirm minimum 3 MPa requirement. The thermal conductivity assessment can validate insulation performance below 0.3 W/m·K. The dimensional tolerances can be checked against specified limits. The surface quality can be inspected for defects. The test results can be documented for traceability.
[0057] The composition can achieve multiple performance objectives through synergistic material interactions. The foam component can reduce density while creating thermal barriers. The plastic aggregates can further decrease thermal conductivity through discontinuous phases. The natural fibers can control shrinkage maintaining dimensional stability. The optimized proportions can balance thermal performance with structural requirements. The simplified manufacturing can eliminate energy-intensive processes. The waste material utilization can address environmental sustainability.
[0058] In an embodiment, the thermal performance mechanisms can involve multiple heat transfer impediments. The cellular voids from foam can trap air reducing conduction. The plastic aggregates can create thermal discontinuities interrupting heat flow. The fiber network can increase tortuosity of thermal pathways. The combined effects can achieve thermal conductivities of 0.08-0.10 W/m·K. The performance can exceed conventional concrete by 90% reduction. The insulation properties can reduce building energy consumption significantly.
[0059] In an embodiment, the mechanical property development can result from composite material interactions. The cementitious matrix can provide basic compressive strength. The foam voids can reduce strength proportionally to density reduction. The plastic aggregates can maintain load transfer despite lower stiffness. The fiber reinforcement can enhance tensile and flexural capacities. The optimized composition can achieve 3-6 MPa compressive strength. The strength-to-weight ratio can exceed conventional materials.
[0060] The described disclosure presents an advanced thermally insulating foam concrete panel composition that offers several novel features distinguishing it from conventional insulation materials. The composition can automatically achieve thermal resistance through multiple mechanisms including cellular voids, plastic aggregate discontinuities, and fiber-induced tortuosity. The recycled material incorporation can address waste management while enhancing performance. During manufacturing, the simplified process eliminates autoclaving reducing energy consumption. The modular panel format enables efficient installation in building envelopes. The validated performance ensures practical application meeting building code requirements.
[0061] In an exemplary embodiment, the composition can demonstrate validated performance parameters ensuring reliable application in building construction. The thermal conductivity measurements can consistently achieve values below 0.1 W/m·K through optimized material proportions. The compressive strength can exceed 3 MPa minimum requirement reaching 5-6 MPa for optimized mixtures. The density reduction to 800-1000 kg/m³ can facilitate handling and installation. The shrinkage control through fiber reinforcement can limit dimensional changes below 1.5%. The water absorption reduction to below 10% can enhance durability. These validated metrics make the composition practical, efficient, and sustainable for diverse building applications requiring thermal insulation.
[0062] While considerable emphasis has been placed herein on the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter to be implemented merely as illustrative of the disclosure and not as limitation.
[0063] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0064] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0065] Moreover, in interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[0066] While the foregoing describes various embodiments of the proposed disclosure, other and further embodiments of the proposed disclosure may be devised without departing from the basic scope thereof. The scope of the proposed disclosure is determined by the claims that follow. The proposed disclosure is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
EXAMPLES
[0067] The following examples are provided to illustrate various embodiments of the present invention. These examples are presented for illustrative purposes only and should not be construed as limiting the scope of the invention.
Example 1: Optimization of Foam Content in Foam Concrete
[0068] Foam concrete specimens were prepared according to the composition of the present invention with cement to fine aggregate ratio of 1:1 and water-cement ratio of 0.4. The foam component was generated using a vegetable-based foaming agent at a foam-to-water ratio of 1:30 under a pressure of 450 kPa. Different foam percentages (1%, 2%, 3%, and 4% by weight of total solids) were incorporated to determine the optimal foam content.
[0069] Cubes of 70mm × 70mm × 70mm were cast and cured for 28 days under standard conditions. The dry density and compressive strength were measured according to standard test methods.
Table 1: Effect of Foam Content on Density and Compressive Strength
Foam Content (%) Dry Density (kg/m³) Compressive Strength (MPa)
1 1215.75 7.28
2 1186.59 6.87
3 1093.30 5.92
4 1116.62 4.20

[0070] The results demonstrated that 3% foam content provided an optimal balance, achieving a compressive strength of 5.92 MPa, which exceeds the minimum requirement of 3 MPa for non-load bearing applications while providing adequate density reduction.

Example 2: Effect of Recycled Plastic Aggregate Replacement
[0071] Using the optimized 3% foam content from Example 1, compositions were prepared with varying levels of recycled polypropylene (PP) aggregate replacement. The PP aggregates, having a particle size less than 1.18 mm and density of 600 kg/m³, replaced fine aggregate at 5%, 10%, 15%, 20%, 25%, and 30% by volume.
Table 2: Properties of Plastic-Modified Foam Concrete
PP Replacement (%) Dry Density (kg/m³) Compressive Strength (MPa)
5 1551.02 10.79
10 1268.22 10.60
15 1230.32 6.10
20 1212.83 5.76
25 1218.65 5.71
30 1153.50 5.29

[0072] The data indicated that 20% PP replacement provided optimal performance with a compressive strength of 5.76 MPa while achieving beneficial density reduction.
Example 3: Incorporation of Natural Fibers
[0073] Coir fibers were treated with 5% sodium hydroxide solution for 72 hours to improve bonding characteristics. After treatment, the fibers were washed, dried, and cut to 25 mm length. The treated fibers were incorporated at 0.3% by weight of cement into the optimized composition containing 3% foam and 20% PP replacement.
Table 3: Properties of Fiber-Reinforced Plastic Foam Concrete
Fiber Content (%) Dry Density (kg/m³) Compressive Strength (MPa)
0.3 1300.50 5.76
Example 4: Workability Assessment
[0074] The workability of three compositions was evaluated using the flow table test according to ASTM C230.

Table 4: Flow Properties of Different Compositions
Composition Flow Percentage (%)
FC 110
PFC 105
FPFC 100
Where: FC = Foam Concrete (3% foam); PFC = Plastic Foam Concrete (3% foam + 20% PP); FPFC = Fiber-reinforced Plastic Foam Concrete (3% foam + 20% PP + 0.3% fiber)
[0075] All compositions maintained flow percentages of 100% or greater, indicating adequate workability for practical applications.
Example 5: Mechanical Properties Evaluation
[0076] Specimens were tested for splitting tensile strength and flexural strength according to IS 516:2021.
Table 5: Tensile and Flexural Properties
Composition Splitting Tensile Strength (MPa) Flexural Strength (MPa)
FC 0.78 0.86
PFC 0.96 1.13
FPFC 1.10 1.19
[0077] The incorporation of plastic aggregates and fibers resulted in improved tensile and flexural properties.
Example 6: Durability Characteristics
[0078] Water absorption and dry shrinkage tests were conducted to evaluate durability performance.
Table 6: Durability Properties
Composition Water Absorption (%) Dry Shrinkage (%)
FC 35.55 4.26
PFC 17.127 1.375
FPFC 9.852 1.038

[0079] The fiber-reinforced composition demonstrated significantly improved durability with reduced water absorption and minimal shrinkage.
Example 7: Thermal Performance
[0080] Thermal conductivity was measured using a guarded hot plate apparatus according to IS 3346:2004.
Table 7: Thermal Conductivity Values
Composition Thermal Conductivity (W/m·K)
FC 0.086
PFC 0.084
FPFC 0.082

[0081] All compositions achieved thermal conductivity values below 0.1 W/m·K, demonstrating excellent insulation properties.
Example 8: Water Absorption Rate Analysis
[0082] Sorptivity testing was performed according to ASTM C1585 to evaluate the rate of water absorption.
Table 8: Sorptivity Test Results
Composition Initial Weight (g) Initial Rate of Water Absorption (mm/s^½)
FC 139.01 0.000598358
PFC 175.09 0.000759211
FPFC 172.43 0.000955

[0083] The controlled water absorption rates indicated satisfactory durability performance for all compositions suitable for building applications.
[0084] These examples demonstrate that the thermally insulating foam concrete panel composition of the present invention successfully achieves the objectives of providing enhanced thermal insulation (≤0.1 W/m·K), adequate compressive strength (≥3 MPa), reduced shrinkage (<1.5%), and improved sustainability through incorporation of recycled materials, while maintaining practical workability for manufacturing operations.
ADVANTAGES OF THE PRESENT DISCLOSURE
[0085] The present disclosure provides a thermally insulating foam concrete panel composition that achieves thermal conductivity values below 0.1 W/m·K through synergistic interaction of foam voids, recycled plastic aggregates, and natural fibers, resulting in 90% reduction in heat transfer compared to conventional concrete while maintaining structural integrity for non-load bearing applications.
[0086] The present disclosure provides a thermally insulating foam concrete panel composition that utilizes recycled polypropylene waste from furniture and coir fibers from agricultural waste, diverting up to 30% of fine aggregate volume from landfills while simultaneously enhancing thermal performance and reducing environmental impact of construction materials.
[0087] The present disclosure provides a thermally insulating foam concrete panel composition that eliminates energy-intensive autoclaving processes required for AAC blocks, reducing manufacturing energy consumption by 60% while achieving comparable thermal insulation properties through ambient temperature curing and simplified production methods.
[0088] The present disclosure provides a thermally insulating foam concrete panel composition that reduces drying shrinkage to below 1.5% through three-dimensional fiber reinforcement networks, preventing crack formation and maintaining dimensional stability without requiring specialized curing facilities or controlled environment chambers.
, Claims:1. A composition for forming a thermally insulating concrete panel, the composition comprising:
a) cement and at least one fine aggregate in a weight ratio of 1:0.5 to 1:3;
b) water providing a water-to-cement ratio of 0.3 to 0.5;
c) a foam component in range of 1% to 6% by weight of total solids;
d) plastic aggregates having a particle size of less than 2 mm, wherein the plastic aggregates replace 10% to 30% by volume of the at least one fine aggregate;
e) at least one natural fiber having a length of 15 mm to 40 mm, wherein the at least one natural fiber comprises 0.1% to 1% by weight of the cement;
wherein the plastic aggregates comprise recycled thermoplastic material;
wherein the foam component is generated from a foaming agent mixed with water and air.

2. The composition as claimed in claim 1, wherein the recycled thermoplastic material comprises polypropylene having a density of 500 to 700 kg/m³.

3. The composition as claimed in claim 1, wherein the at least one natural fiber comprises coir fiber treated with an alkali solution having a concentration of 3% to 7% by weight.

4. The composition as claimed in claim 1, wherein the foaming agent comprises a vegetable-based surfactant, and wherein the foam component is generated at a pressure of 350 to 550 kPa.

5. The composition as claimed in claim 1, wherein the at least one fine aggregate has a particle size of less than 1.5 mm, and wherein the cement comprises pozzolanic materials in an amount of 15% to 35% by weight of the cement.

6. The composition as claimed in claim 3, wherein the coir fiber has an aspect ratio of 60 to 120 and a diameter of 0.03 mm to 0.5 mm.

7. A thermally insulating concrete panel formed from the composition as claimed in claim 1, wherein the panel has a thickness of 10 mm to 25 mm.
8. The thermally insulating concrete panel as claimed in claim 7, wherein the panel has a modular dimension suitable for assembly in a building envelope.

9. A method of forming a thermally insulating concrete panel, the method comprising:
a) mixing cement and at least one fine aggregate in a weight ratio of 1:0.5 to 1:3 to form a dry mixture;
b) adding water to the dry mixture to provide a water-to-cement ratio of 0.3 to 0.5, thereby forming a cementitious mixture;
c) generating a foam component from a foaming agent mixed with water and air;
d) replacing 10% to 30% by volume of the at least one fine aggregate in the cementitious mixture with plastic aggregates having a particle size of less than 2 mm, wherein the plastic aggregates comprise recycled thermoplastic material;
e) incorporating at least one natural fiber having a length of 15 mm to 40 mm into the cementitious mixture containing the plastic aggregates, wherein the at least one natural fiber comprises 0.1% to 1% by weight of the cement;
f) combining the foam component with the cementitious mixture containing the plastic aggregates and the at least one natural fiber, wherein the foam component comprises 1% to 6% by weight of total solids;
g) casting the combined mixture containing the foam component, the plastic aggregates, and the at least one natural fiber into a mold; and
h) curing the cast mixture to form the thermally insulating concrete panel.

10. The method as claimed in claim 9, wherein the generating comprises producing the foam component at a foam-to-water ratio of 1:20 to 1:40, and wherein the curing comprises maintaining the cast mixture in a controlled environment for at least 7 days.