Description:FIELD OF THE INVENTION

[0001] The present invention relates to a method for producing a low-carbon Engineered Cementitious Composite (ECC) produce low-carbon Engineered Cementitious Composite (ECC) from sustainable materials. The method aims for comparable setting times and mechanical properties to traditional ECC, reducing environmental impact. The method also ensures uniformity and workability via controlled aggregate sizing, improving construction performance and minimizing defects.

BACKGROUND OF THE INVENTION

[0002] The producing a low-carbon Engineered Cementitious Composite (ECC) fundamentally aims to reduce the environmental footprint of cement production, primarily by cutting CO2 emissions. This is achieved by significantly replacing Ordinary Portland Cement (OPC) with sustainable supplementary cementitious materials (SCMs) like fly ash, ground granulated blast furnace slag (GGBS), or calcined clays. The process involves precisely proportioning these alternative binders with fine aggregates, water, and a small volume of discontinuous fibers (e.g., PVA or PE), often utilizing superplasticizers to maintain workability. The ultimate goal is to create an ECC with comparable or enhanced mechanical properties, especially its characteristic high ductility and crack control, all while substantially reducing embodied carbon and promoting more sustainable construction practices.

[0003] Traditional concrete production methods are limited primarily by their significant environmental impact. The creation of Ordinary Portland Cement (OPC) is highly energy-intensive, accounting for roughly 8% of global CO2 emissions due to limestone calcination and fuel combustion, alongside extensive water and raw material consumption. Beyond ecological concerns, these conventional techniques often struggle with ensuring consistency and uniformity in the final product. Achieving precise control over aggregate sizing and mixture workability are challenging, potentially leading to varied mechanical properties and increased construction defects. This are necessitating costly on-site rectifications, material waste, and compromise structural durability. Furthermore, the absence of predictive modeling in traditional approaches often requires exhaustive trial-and-error, impeding material optimization and delaying the innovation of more sustainable solutions.

[0004] US20200317572A1 discloses an Engineered Cementitious Composites (ECC) and cement products including Engineered Cementitious Composites are provided. The ECC can include cement, sugar cane bagasse ash, and fiber. The sugar cane bagasse ash can be processed to provide a partial cement or sand replacement in ECCs and cement products.

[0005] CN106693063A discloses an invention relates to anti-collapse calcium-silicon-based composite bone cement as well as a preparation method and application thereof. The calcium-silicon-based composite bone cement is obtained by blending a solid phase raw material and a liquid phase raw material according to a liquid-solid ratio of 0.4-1.2mL/g, wherein the solid phase raw material is a calcium-silicon-based material, and the liquid phase raw material is a sodium alginate solution. The novel injectable calcium-silicon-based bioactive bone cement is prepared by utilizing the characteristics of calcium-silicon-based bone cement and the sodium alginate, and the preparation method is simple. A composite bone cement material has excellent injectability, plasticity and collapse resistance, thus being suitable for the dental department, the orthopedics department, and the like.

[0006] Conventionally, many methods are available in the market for producing ECC but existing methods often fail to produce truly low-carbon ECC with comparable performance, leading to high environmental impact. They also struggle to ensure consistent workability and uniformity, complicating on-site application and increasing defects. Furthermore, current solutions lack predictive modeling, necessitating inefficient trial-and-error for material optimization.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a method produces high-performance, low-carbon ECC using sustainable materials, reducing environmental impact. The method ensures consistent workability and uniformity, improving construction efficiency and minimizing defects, while its predictive model optimizes material design.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of producing a low-carbon Engineered Cementitious Composite (ECC) that achieves comparable setting time and mechanical properties to conventional ECC while using sustainable materials, thus reducing the environmental impact of cement production and promoting sustainable construction practices.

[0010] Another object of the present invention is to develop a device that is capable of ensure the ECC mixture maintains good workability and uniformity through controlled aggregate sizing for consistent performance in construction applications, therefore facilitating easier placement and consolidation on-site, minimizing defects.

[0011] Yet another object of the present invention is to develop a device that is capable of create a predictive model using statistical analysis to relate the setting time and mechanical properties of the ECC for optimized material design and performance, thus enabling more efficient material selection and formulation, reducing the need for extensive trial-and-error.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a method for producing a low-carbon Engineered Cementitious Composite (ECC) that ensures ECC mixture workability and uniformity via controlled aggregate sizing, improving on-site placement and reducing defects. Additionally, the method aims to create a predictive model relating ECC setting time and mechanical properties for optimized material design, reducing trial-and-error.

[0014] According to an embodiment of the present invention, A method for producing a low-carbon Engineered Cementitious Composite (ECC), comprising, mixing cement with 35% fly ash (FA), 25% granite slurry powder (GSP), and 5% nano-silica (NS) by weight as binders to form a cementitious matrix, adding recycled aggregates sourced from demolished concrete waste as fine aggregate, incorporating a hybrid fiber mix of recycled steel scrap and polypropylene (PP) fibers into the cementitious matrix, blending the mixture with water to form a fresh ECC composite, casting the ECC composite into test specimens, curing the test specimens under controlled conditions to achieve a hardened state with comparable setting time and mechanical properties to conventional ECC, the recycled aggregates have a particle size of less than 4.75 mm to ensure workability and uniformity in the ECC matrix, the penetration resistance test follows ASTM C403 standards to accurately measure the setting times of the ECC mixture, the varying proportions of fly ash range from 30% to 40%, granite slurry powder from 20% to 30%, and nano-silica from 3% to 7% by weight of cement and the correlation analysis uses statistical methods to establish a predictive model for setting time and mechanical property relationships in the ECC.

[0015] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a flowchart depicting workflow of a method for producing a low-carbon Engineered Cementitious Composite (ECC).

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0018] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0019] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0020] The present invention relates to a method for producing a low-carbon Engineered Cementitious Composite (ECC) for producing low-carbon ECC using sustainable materials, aiming for comparable performance to conventional ECC and reducing environmental impact. It also creates a predictive model relating ECC setting time and mechanical properties, optimizing material design and reducing trial-and-error.

[0021] Referring to Figure 1, a flowchart depicting workflow of a method for producing a low-carbon Engineered Cementitious Composite (ECC) is illustrated. The present invention relates to a method for producing Engineered Cementitious Composite (ECC) that combines sustainability with high performance. This innovative method utilizes recycled materials and optimized binder compositions to create an environmentally friendly ECC with mechanical properties comparable to conventional ECC, suitable for various construction applications. The invention addresses the growing need for sustainable construction materials by reducing carbon emissions and incorporating waste materials, while maintaining desirable setting times and strain-hardening characteristics.

[0022] The method begins with the preparation of a cementitious matrix by mixing cement with supplementary materials: 35% fly ash (FA), 25% granite slurry powder (GSP), and 5% nano-silica (NS) by weight. Fly ash, a byproduct of coal combustion, and granite slurry powder, a waste from stone processing, reduce the reliance on traditional cement, lowering the carbon footprint. Nano-silica enhances the matrix's strength and durability by improving particle packing and accelerating hydration. The proportions of these binders can be adjusted within specific ranges—30% to 40% for fly ash, 20% to 30% for granite slurry powder, and 3% to 7% for nano-silica—to optimize performance based on project requirements.

[0023] After, fine aggregates sourced from demolished concrete waste are incorporated into the cementitious matrix. These recycled aggregates, with a particle size of less than 4.75 mm, ensure workability and uniformity in the ECC matrix. By reusing concrete waste, the method promotes a circular economy and reduces landfill waste. To enhance tensile strength and ductility, a hybrid fiber mix of recycled steel scrap and polypropylene (PP) fibers is added. This combination imparts strain-hardening behavior, allowing the ECC to withstand significant deformation without failure, a key feature for applications requiring crack resistance and durability.

[0024] The mixture is then blended with water to form a fresh ECC composite. The water content is carefully controlled to achieve a workable consistency suitable for casting. The fresh composite is cast into test specimens, such as dog-bone-shaped molds, which are ideal for evaluating tensile properties. After casting, the specimens undergo curing under controlled conditions to achieve a hardened state. The curing process is designed to match the setting time and mechanical properties of conventional ECC, ensuring practical applicability in construction.

[0025] To ensure quality and consistency, the method includes standardized testing procedures. The penetration resistance test, conducted per ASTM C403 standards, measures the setting times of the ECC mixture accurately. Additionally, direct tensile strength tests using dog-bone-shaped specimens assess the strain-hardening behavior under uniaxial tension, confirming the material’s ability to form multiple fine cracks rather than catastrophic fractures. A correlation analysis employing statistical methods establishes a predictive model linking setting times and mechanical properties, enabling precise optimization of the ECC formulation.

[0026] This invention provides a sustainable, high-performance alternative to traditional ECC by integrating recycled materials and low-carbon binders. The method’s flexibility in binder proportions, combined with rigorous testing, ensures adaptability to diverse construction needs while promoting environmental responsibility. The resulting low-carbon ECC offers comparable strength, durability, and workability to conventional ECC, making it an ideal choice for eco-conscious infrastructure projects.

[0027] The present invention best in the manner, where the invention involves preparing the sustainable, high-performance Engineered Cementitious Composite (ECC) by combining recycled materials with optimized binder compositions. Initially, the cementitious matrix is formed by mixing cement with supplementary materials—35% fly ash (FA), 25% granite slurry powder (GSP), and 5% nano-silica (NS) by weight—where fly ash and granite slurry powder, waste by-products, reduce reliance on traditional cement and lower carbon emissions, while nano-silica enhances strength and durability through improved particle packing and hydration acceleration. Proportions of these binders can be adjusted within specified ranges (30-40% FA, 20-30% GSP, 3-7% NS) based on project requirements. Recycled concrete waste serves as fine aggregates (<4.75 mm particle size), promoting reuse and circular economy. To improve tensile strength and ductility, hybrid fibers—recycled steel scrap and polypropylene (PP)—are incorporated to induce strain-hardening behaviour, allowing for crack resistance and durability. The mixture is blended with controlled water content to achieve workable consistency and cast into test specimens, such as dog-bone-shaped moulds, for evaluating tensile properties. Specimens undergo curing under controlled conditions to ensure appropriate setting times and mechanical performance. Standardized testing, including ASTM C403 penetration resistance tests for setting time and direct tensile strength tests, assesses performance and strain-hardening behaviour. Statistical correlation analysis links setting times and mechanical properties, enabling precise formulation optimization. This method results in a low-carbon ECC with comparable strength, durability, and workability to conventional ECC, providing a sustainable, adaptable, and environmentally responsible construction material suitable for diverse infrastructure applications.

[0028] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A method for producing a low-carbon Engineered Cementitious Composite (ECC), comprising:

i) mixing cement with 35% fly ash (FA), 25% granite slurry powder (GSP), and 5% nano-silica (NS) by weight as binders to form a cementitious matrix;
ii) adding recycled aggregates sourced from demolished concrete waste as fine aggregate;
iii) incorporating a hybrid fiber mix of recycled steel scrap and polypropylene (PP) fibers into the cementitious matrix;
iv) blending the mixture with water to form a fresh ECC composite; and
v) casting the ECC composite into test specimens; and
vi) curing the test specimens under controlled conditions to achieve a hardened state with comparable setting time and mechanical properties to conventional ECC.

2) The method as claimed in claim 1, wherein the recycled aggregates have a particle size of less than 4.75 mm to ensure workability and uniformity in the ECC matrix.

3) The method as claimed in claim 1, wherein the penetration resistance test follows ASTM C403 standards to accurately measure the setting times of the ECC mixture.

4) The method as claimed in claim 1, wherein the direct tensile strength test is conducted using dog-bone-shaped specimens to evaluate strain-hardening behavior under uniaxial tension.

5) The method as claimed in claim 1, wherein the varying proportions of fly ash range from 30% to 40%, granite slurry powder from 20% to 30%, and nano-silica from 3% to 7% by weight of cement.

6) The method as claimed in claim 1, wherein the correlation analysis uses statistical methods to establish a predictive model for setting time and mechanical property relationships in the ECC.