Description:FIELD OF THE INVENTION
The present invention relates to construction materials, particularly to the development of sustainable masonry mortar compositions. More specifically, it relates to a method and system for improving hydration, durability, and shrinkage resistance of masonry mortar through internal curing using polyethylene glycol (PEG) and recycled autoclaved aerated concrete (AAC) block debris as partial aggregate replacement.
BACKGROUND OF THE INVENTION
Protection of intellectual property takes place through patent filings that simultaneously drive innovative material development in construction. Masonry mortar acts as the essential component which determines both the durability and structural integrity of masonry building elements. The research examines how Polyethylene Glycol 400 (PEG 400) concentrations at 1%, 2%, 3%, 4% and 5% when added by volume to cement affects the behavior of masonry mortar while using Autoclaved Aerated Concrete (AAC) block construction debris. Using internal curing with added moisture produces long-term hydration while it improves workability as well as durability characteristics and reduces shrinkage effects. The use of lightweight aggregate-based traditional internal curing agents faces both economic and environmental challenges when used in particular applications. Researchers studied how PEG 400 functions together with AAC debris components to affect strength development, water stability, and the efficiency of curing processes. Developing a sustainable mortar mix represents this work's main focus as it improves mechanical values and maintains hydrated conditions to increase service duration through green construction methods. Research outcomes from this study help produce sustainable construction practices that enable potential patent development for green masonry technology innovations.
US5695811A: Novel methods and compositions are disclosed for bonding a hydrating cement-based overlay onto a cement-based substrate. An integral bond is created between the overlay and the substrate by maximizing capillary suction through properly preparing the substrate and designing the overlay. The integral bond has an interface strength at least substantially similar to the substrate strength. The substrate is prepared to optimize the capillary suction by cleaning and optimal water saturation. Properly designing the overlay for optimal capillary suction involves optimizing the water/cement ratio of each layer of the overlay. A low water/cement ratio is generally optimal. In addition to incorporating a low amount of water, the water to cement ratio is minimized through the use of dispersants and mixing techniques. The design of the overlay can also include silica fume to increase the strength of the interface bond.
US20250058497A1: According to one or more embodiments of the present invention, modification of concrete within a pumping line is achieved with new designs of inline static mixers allowing passage of concrete material that is primarily of solids in the form of suspended minerals, cement and aggregates, and without benefit of the flow of additional fluid, such as the airflow driving a shotcrete process. According to one or more embodiments of the present invention, modification within a concrete pumping line is essential where unmodified concrete is necessary for purposes of batching or pumping, such as where the modification creates a very rapid set or an extreme thickening. According to one or more embodiments of the present invention, modification, unmodified concrete can be delivered to the point of inline modification at the end of a pumping line, where highly reactive components can then be intermixed. According to one or more embodiments of the present invention, this allows volume production of Roman Concrete or a hot mortar activated with quicklime, facilitates the inclusion of highly reactive shrinkage compensating agents, makes the use of alkali-activated or geopolymer concrete more practical for large-scale production, and makes possible very rapid additive-manufacturing methods with low-cost conventional delivered concrete.
Conventional masonry mortars often suffer from insufficient hydration, leading to shrinkage, microcracking, and reduced service life of masonry structures. Traditional internal curing agents, such as lightweight aggregates, are costly and may pose environmental concerns in large-scale applications. Simultaneously, construction and demolition activities generate substantial amounts of AAC block waste, which is often discarded, leading to environmental issues. There exists a pressing need for an economical and eco-friendly method to enhance mortar hydration and durability while addressing the disposal of AAC block debris. The present invention solves this problem by utilizing PEG as an internal curing agent in combination with AAC block debris as a fine aggregate replacement, thereby ensuring sustained hydration, improved durability, reduced shrinkage, and sustainable construction practices.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
The invention discloses a sustainable masonry mortar formulation integrating PEG at varying dosages with crushed AAC block debris as a partial replacement for fine aggregate. PEG functions as an internal curing agent by retaining moisture within the matrix, while AAC debris contributes to sustainable aggregate substitution. This combination results in improved hydration, reduced shrinkage, enhanced compressive and flexural strength, and increased long-term durability.
The system incorporates specific proportions of cement, sand or artificial fine aggregate, water, AAC debris, and PEG additives. Mortar compositions are optimized through laboratory testing, including slump, compressive strength, flexural strength, shrinkage, water absorption, and durability performance.
The invention further employs response surface methodology and statistical tools to optimize formulations, ensuring best performance across hydration, strength, and sustainability parameters.
The solution contributes to eco-friendly construction practices by reducing reliance on virgin aggregates, lowering environmental waste from AAC block disposal, and enhancing durability of structures through internal curing effects.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
Research methods for masonry mortar formulation evaluation include specific plans and procedures to assess internal curing enhancements. The research framework consists of these vital stages for evaluation purposes:
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
FIGURE 1: SYSTEM ARCHITECTURE
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Research methods for masonry mortar formulation evaluation include specific plans and procedures to assess internal curing enhancements. The research framework consists of these vital stages for evaluation purposes:
1. Performance deterioration occurs within traditional mortar since insufficient hydration leads to structural damage while reducing service life span. One major water retention limitation exists as a fundamental barrier against cement hydration completion and reduces the durability of long-term performance. Building waste production from the construction sector continues to rise which creates environmental trouble and depletes resources.
2. Building operators substitute debris materials to act as part of their fine aggregate content.
3. Researchers will apply factorial design to assess strength performance combined with workability properties combined with water retention capacity based on various waste material proportions.
4. The researchers will prepare several concrete mixes through diverse combinations of PEG 400 at different ratios between 1% and 5% together with sufficient binding agent levels.
5. Laboratory assessments will conduct standard tests for compressive strength, flexural strength and water absorption together with measures of shrinkage and durability of the materials.
6. The Response Surface Methodology (RSM) statistical tools will analyze the data through multiple design formulation methods to optimize formulation quality.
Material Proportions:
S.no Materials & Building Debris Material Proportion
1 Cement OPC 53 Grade
2 Crushed AAC block Construction Debris 0-100% - Replacement of FA
3 Fine Aggregate (As per IS 383 Specification) River sand or Artificial sand
4 Water-Binder Ratio 0.40 - 0.50
5 Polyethylene Glycol 400 (PEG 400) 1%, 2%, 3%, 4%, 5% by cement volume

This work intends to create a masonry mortar with debris, maximizing hydration, reducing shrinkage, and improving durability. Combining PEG 400 and AAC building waste makes the modified mix composition sustainable and maybe patent- eligible for environmentally friendly masonry uses.
Description of Every Step:
1. Material Properties: Choose a suitable type of cement, like Ordinary Portland Cement (OPC) of appropriate quality. Choose sand that satisfies the necessary standards in fine aggregate.
Use AAC trash as a partial replacement for fine aggregate to support environmentalism.
For internal curing, find the ideal molecular weight—that is, PEG-400 or PEG-600.
Make sure the water is fit for mixing and clear.
2. Design & Proportioning Mix: Create mix designs with different PEG dosages—0%, 1%, 2%, 3%, 4%, and 5%. Keep mix water-to-cement (w/c) ratios constant. Change workability as needed to reach intended consistency.
3. Fresh Properties: Slump flow and flow table tests help to evaluate the workability of fresh properties. To find out how PEG affects setting behavior, measure both starting and ending times.
4. Curing Methods: To assess their influence on mortar qualities, apply many curing techniques, including PEG-assisted internal curing, air curing, and water curing.
5. Hardened Properties: Testing compressive and flexural strengths at predetermined intervals helps evaluate hardened properties. Test performance durability and water absorption to gauge environmental factor resistance.
6. Optimization Methods: Analyze data using statistical techniques, including artificial neural network (ANN) modeling and regression analysis, to project results.
7. Performance Evaluation & Suggestion: Find the best PEG dosage: Analyze if AAC trash would be appropriate for mortar compositions. Based on results, suggest uses for sustainable masonry.
Integrating polyethylene glycol (PEG) into masonry mortar boosts its characteristics by augmenting porosity and mechanical strength via polymer impregnation methods.
The invention provides a method and system for formulating masonry mortar with improved hydration and durability. The mortar mix is prepared using cement, fine aggregates, crushed AAC block debris, water, and PEG additives.
Ordinary Portland Cement (OPC) of 53 grade or equivalent quality is employed as the binding material. Fine aggregate may consist of natural river sand or manufactured sand that conforms to required specifications. AAC block debris, crushed and sieved, is introduced as a partial replacement for fine aggregates in varying percentages ranging from 0% to 100%.
Polyethylene glycol (PEG 400) is added by volume to cement at varying concentrations between 1% and 5%. The PEG serves as an internal curing agent, holding water molecules and releasing them gradually to sustain hydration of the cementitious matrix.
Mix proportions are carefully designed to maintain a water-to-binder ratio between 0.40 and 0.50. Multiple formulations are prepared with PEG dosages ranging from 0% to 5%, combined with different levels of AAC debris substitution.
Fresh mortar properties are assessed through workability tests such as slump flow and flow table analysis. The effect of PEG on initial and final setting times is recorded to determine influence on hydration kinetics.
Curing methods are applied, including conventional water curing, air curing, and PEG-assisted internal curing. Comparative analysis establishes the advantages of PEG-assisted internal curing over traditional methods.
Hardened mortar properties are evaluated at defined curing ages. Tests include compressive strength, flexural strength, shrinkage reduction, water absorption, and durability under environmental exposures. Results confirm that PEG enhances hydration, reduces shrinkage cracking, and improves strength development.
Statistical optimization using response surface methodology and artificial neural network models is employed to determine the most effective dosage of PEG and AAC debris proportion for performance enhancement. Regression modeling assists in predicting future behavior of mortar mixes.
The invention also contributes to sustainability by reducing dependency on virgin aggregates, recycling AAC block waste, and lowering the environmental footprint of mortar production.
The formulation is applicable to diverse construction scenarios, including masonry works, plastering, and repair mortars where long-term hydration and durability are critical.
By combining internal curing chemistry with recycled aggregates, the invention creates a durable and sustainable building material for green construction practices.
Best Method of Working
The best method involves preparing mortar using OPC 53 grade cement, fine aggregate (sand or manufactured sand), crushed AAC debris as fine aggregate replacement, PEG 400 at an optimum dosage of around 3% by volume of cement, and a water-to-binder ratio maintained at 0.45. The mortar is mixed to achieve desired workability and cured using PEG-assisted internal curing alongside conventional methods. This combination provides balanced hydration, minimal shrinkage, and improved durability, making it suitable for masonry units in sustainable construction projects.
, Claims:1. A masonry mortar composition for enhanced hydration and durability, comprising:
• cement as a binder;
• fine aggregate selected from natural sand or manufactured sand;
• crushed autoclaved aerated concrete (AAC) block debris as a partial replacement for fine aggregate;
• water maintained at a water-to-binder ratio in the range of 0.40 to 0.50; and
• polyethylene glycol additive incorporated at 1% to 5% by volume of cement, functioning as an internal curing agent.
2. The composition as claimed in claim 1, wherein the AAC block debris is included in proportions ranging from 10% to 100% replacement of fine aggregate.
3. The composition as claimed in claim 1, wherein the polyethylene glycol retains and gradually releases absorbed moisture to sustain cement hydration.
4. The composition as claimed in claim 1, wherein the composition exhibits improved compressive strength, flexural strength, and shrinkage resistance compared to conventional mortar.
5. The composition as claimed in claim 1, wherein the use of AAC debris reduces environmental waste and promotes sustainable construction practices.
6. A method for preparing a masonry mortar with enhanced hydration and durability, comprising the steps of:
• selecting cement, fine aggregate, crushed AAC block debris, water, and polyethylene glycol additive;
• replacing fine aggregate partially with crushed AAC block debris in predetermined proportions;
• adding polyethylene glycol in the range of 1% to 5% by volume of cement;
• mixing the cement, aggregate, AAC debris, water, and polyethylene glycol at a water-to-binder ratio of 0.40 to 0.50; and
• allowing the polyethylene glycol to provide internal curing by gradually releasing water to sustain hydration.
7. The method as claimed in claim 6, wherein the prepared mortar is subjected to curing conditions including PEG-assisted internal curing, water curing, and air curing for comparative evaluation.
8. The method as claimed in claim 6, wherein the mortar is tested for compressive strength, flexural strength, shrinkage resistance, and water absorption to determine performance.
9. The method as claimed in claim 6, wherein optimization of the formulation is carried out using statistical techniques including response surface methodology or regression analysis.
10. The method as claimed in claim 6, wherein sustainable construction practices are achieved by recycling AAC block debris and reducing reliance on natural fine aggregates.