Description:DESCRIPTION:
Field of the invention:
[0001] The present disclosure generally relates to the technical field of construction materials, and in specific, relates to a method for blending sea sand and crusher dust for use as fine aggregate in concrete, thereby offering a sustainable alternative in the production of concrete.
Background of the invention:
[0002] Fine aggregates, or sand, are the most important material that passes through a 4.75 mm IS sieve. It is used as a component of concrete that fills the cavities in coarse aggregate to produce compact concrete and to reduce the amount of cement. The shape of river sand is more rounded grains. Hence, it requires less water and cement to attain good workability, but it cannot be used in the future, as existing resources are overexploited. Scarcity of good-quality river sand has made the construction industries look for suitable replacements. One such alternative is “SEA SAND”. Sea sand if extracted from sea bed should not be used in its natural state, as it attacks the reinforcement. Because the salt content is high, it will retard the setting and hardening of cement and may cause efflorescence, but it may not have any effect on the ultimate strength of concrete. The high demand for river sand is an indication of development, especially for the construction industry. Thus, the alternative that is viable to replace the river sand is to use sea sand. In applying this alternative, the chloride content is the major problem that should be taken note of. High levels of chloride content are possible, affecting the strength of the constructed structure.

[0003] Fine aggregate is a critical component in the production of concrete. Traditionally, river sand has been the preferred fine aggregate due to its suitable grading and fineness properties. However, the exploitation of river sand has led to environmental concerns, including riverbed degradation and depletion. Additionally, the cost of procuring river sand has increased significantly due to its diminishing availability.

[0004] Sea sand is abundantly available but has been largely underutilized in concrete production due to its inconsistent grain size and the presence of salts. Crusher dust, a byproduct of stone crushing, offers an alternative to river sand, but its properties as the fine aggregate require improvement through blending.

[0005] In existing technology, a mixed sand for commercial concrete and a preparation method thereof. The mixed sand comprises mountain sand, stone chips, and sea sand. The mass ratio of the mountain sand to the stone chips to the sea sand is (4-5): 3-4: 1-2. The invention utilizes the advantages of various sands to complement each other to solve the problems that certain performance indexes of single sand are poor and do not meet the requirements, thus obviously improving the physical performance and the mechanical performance of the final product concrete, ensuring the production quality of the concrete and the mortar, and reducing the cost. However, the invention might harm the environment while extracting the mountain sand and the stone chips.

[0006] Therefore, there is a need for a method that utilizes the sea sand commonly available in coastal areas and the crusher dust to offer a cost-effective solution for fine aggregate and an environmentally friendly alternative to river sand, in concrete production, thus reducing the impact of riverbed degradation and addressing the depletion of natural sand resources. Furthermore, there is a need for a method that allows for flexibility in adjusting the proportions of sea sand and crusher dust, making it suitable for various construction applications, depending on the required fine aggregate characteristics.
Objectives of the invention:
[0007] The primary objective of the present invention is to provide a method for blending sea sand and crusher dust for use as fine aggregate in concrete, thereby offering a sustainable alternative in the production of concrete.

[0008] Another objective of the present invention is to provide a method that provides an environmentally friendly alternative to river sand, reducing the impact of riverbed degradation and addressing the depletion of natural sand resources.

[0009] Another objective of the present invention is to provide a method that utilizes the sea sand and the crusher dust, which are readily available and often less expensive than river sand, offering a cost-effective solution for fine aggregate in concrete production.

[0010] Another objective of the present invention is to provide a method that allows for the optimal use of locally available materials such as sea sand and crusher dust, reducing the need to transport river sand from distant locations, thereby lowering logistical costs and the carbon footprint.

[0011] Another objective of the present invention is to provide a method that blends sea sand and crusher dust within permissible limits for fineness modulus and meet the gradation standards (Zone II and Zone III) of IS 383-2016, ensuring their suitability for use in concrete and maintaining the desired strength, workability, and durability of the concrete mix.

[0012] Another objective of the present invention is to provide a method that allows for flexibility in adjusting the proportions of sea sand and crusher dust, making it suitable for various construction applications, depending on the required fine aggregate characteristics.

[0013] Yet another objective of the present invention is to provide a method that is applicable in different geographic regions where sea sand and crusher dust are available, making it a versatile and globally relevant solution for obtaining fine aggregate.

[0014] Further objective of the present invention is to provide a method that contributes to sustainable construction practices by utilizing non-conventional materials like sea sand and crusher dust, helping conserve river sand and minimize environmental harm.
Summary of the invention:
[0015] The present disclosure proposes a method for blending sea sand with crusher dust as fine aggregate for concrete production. 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.

[0016] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide a method for blending sea sand and crusher dust for use as fine aggregate in concrete, thereby offering a sustainable alternative in the production of concrete.

[0017] According to one aspect, the invention provides the method for blending sea sand and crusher dust as fine aggregates. At one step, the sea sand and crusher dust materials are collected to determine the physical properties of sea sand and crusher dust and chemical properties of the sea sand. At another step, the sea sand and crusher dust materials are blended in multiple proportions to prepare a blended mixture of the sea sand and the crusher dust materials.

[0018] At another step, the sieve analysis is conducted on the blended mixture of the sea sand and the crusher dust for determining grain size distribution. At another step, the grain size distribution of the blended mixture is compared with standard grain sizes for fine aggregates in the concrete.

[0019] At another step, the fineness modulus of the blended mixture is determined, and select the blended mixture that matches the requirements for fine aggregates in concrete based on the grain size distribution and the fineness modulus. Further, at another step, the blended mixture of the sea sand and the crusher dust with permitted fineness modulus selected within the ranges of 2.3 to 3.1 for usage as fine aggregates in concrete production.

[0020] In one embodiment, the blended mixture of the sea sand and the crusher dust comprises 40 percentage of the sea sand and 60 percentage of the crusher dust by weight. The blended mixture of the sea sand and the crusher dust is configured to be utilized as the fine aggregates for the concrete production classified under a Zone II according to Indian Standard (IS) 383-2016.
[0021] In one embodiment, the fineness modulus of the blended mixture of the sea sand and the crusher dust is 2.6, which falls within the permissible range for fine aggregates used in concrete production, in accordance with IS 383-2016.

[0022] In one embodiment, the blended mixture of the sea sand and the crusher dust comprises 50 to 60 percentage of the sea sand, and 40 to 50 percentage of the crusher dust (by weight). The blended mixture of the sea sand and the crusher dust is configured to be utilized as the fine aggregates for the concrete production classified under a Zone III according to IS 383-2016.

[0023] In one embodiment, the fineness modulus of the blended mixture of the sea sand and the crusher dust matches within the permissible range from 2.3 to 3.1 for use as the fine aggregates in the concrete production.

[0024] In one embodiment, the physical properties of the sea sand and crusher dust materials are determined in order to evaluate parameters that include, specific gravity and bulk density of the materials. In one embodiment, the chemical properties of the sea sand are determined to evaluate the presence of salts and other chemical compounds that affect the durability of the concrete.

[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 flowchart of a method for blending sea sand and crusher dust as fine aggregates, in accordance to an exemplary embodiment of the invention.

[0028] FIG. 2A illustrates a graphical representation of crusher dust conforming to Zone II, in accordance to an exemplary embodiment of the invention.

[0029] FIG. 2B illustrates a graphical representation of sea sand conforming to Zone IV, in accordance to an exemplary embodiment of the invention.

[0030] FIG. 2C illustrates a graphical representation of a blended mixture of the crusher dust and sea sand falling under the Zone II, in accordance to an exemplary embodiment of the invention.

[0031] FIG. 2D illustrates a graphical representation of the blended mixture of the crusher dust and sea sand falling under a Zone III, in accordance to an exemplary embodiment of the invention.

[0032] FIG. 2E illustrates a graphical representation of the blended mixture of the crusher dust and sea sand falling under the Zone IV, in accordance to an exemplary embodiment of the invention.
Detailed invention disclosure:
[0033] 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.

[0034] 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 method for blending sea sand and crusher dust for use as fine aggregate in concrete, thereby offering a sustainable alternative in the production of concrete.

[0035] According to one exemplary embodiment of the invention, FIG. 1 refers to a flowchart 100 of the method for blending sea sand and crusher dust for use as fine aggregate in concrete. At step 102, the sea sand and crusher dust materials are collected to determine the physical properties of sea sand and crusher dust and chemical properties of the sea sand. At step 104, the sea sand and crusher dust materials are blended in multiple proportions to prepare a blended mixture of the sea sand and the crusher dust materials.

[0036] At step 106, the sieve analysis is conducted on the blended mixture of the sea sand and the crusher dust for determining grain size distribution. At step 108, the grain size distribution of the blended mixture is compared with standard gradations for fine aggregates used in concrete.

[0037] At step 110, the fineness modulus of the blended mixture is determined, and the blended mixture that matches the requirements for fine aggregate in concrete making based on the grain size distribution and the fineness modulus is selected. Further, at step 112, the blended mixture of the sea sand and the crusher dust has fineness modulus in the ranges of 2.3 to 3.1 for use as fine aggregates in concrete production.

[0038] In one embodiment, the blended mixture of the sea sand and the crusher dust comprises 40 percentage of the sea sand and 60 percentage of the crusher dust by weight. The blended mixture of the sea sand and the crusher dust is configured to be utilized as the fine aggregates for the concrete production classified under Zone II according to Indian Standard (IS) 383-2016.

[0039] In one embodiment, the fineness modulus of the blended mixture of the sea sand and the crusher dust is 2.6, which falls within the permissible range for fine aggregates used in concrete production, in accordance with IS 383-2016 standards.

[0040] In one embodiment, the blended mixture of the sea sand and the crusher dust comprises 50 to 60 percentage of the sea sand, and 40 to 50 percentage of the crusher dust (by weight). The blended mixture of the sea sand and the crusher dust is configured to be utilized as the fine aggregates for the concrete production classified under a Zone III according to IS 383-2016.

[0041] In one embodiment, the fineness modulus of the blended mixture of the sea sand and the crusher dust matches within the permissible range from 2.3 to 3.1 for use as the fine aggregates in the concrete production.

[0042] In one embodiment, the physical properties of the sea sand and crusher dust materials are determined to evaluate parameters that include, specific gravity, and bulk density of the sea sand and crusher dust materials. In one embodiment, the chemical properties of the sea sand are determined to evaluate the presence of salts and other chemical compounds that affect the durability of the concrete.

[0043] In one embodiment herein, the sea sand is tested in a laboratory, which has specific gravity of 2.65 and upon conducting gradation analysis, the sea sand is found to fall in a Zone IV as per IS 383-2016 with a fineness modulus of 1.91. The fines content of sea sand is 0.2 percent. The loose and compacted bulk densities of sea sand tested are 1794.96 kg/m3 and 1917.03 kg/m3 respectively. Upon testing chemical properties of sea sand as per IS code and TxDOT Designation standards, the pH is 7.35, organic matter is 0.225 percent, total soluble sulphates as SO4 is 0.05 percent, Na2SO4 is 0.07 percent, and chloride content is 0.02 percent (as depicted in Table. 2). As the sea sand used in the present work is collected from coastal areas, it is free from considerable amounts of chlorides and sulphates as it gets washed away due to rainfall (as depicted in Table. 1).

[0044] Table. 1
S. No Engineering Property Value
1. Specific gravity 2.65
2. Grain size distribution
1. Gravel (%)
2. Sand (%)
3. Fines (%)
0
99.8
0.2
3. Bulk Density (kg/m3)
i. Loose state
ii. Compacted state
1794.96
1917.03
4. Bulking of sand (%) 6
5. Fineness modulus 1.91

[0045] Table. 2:
S. No Chemical Property Value Codes
1. pH 7.35 IS2720(Part26) -1987
2. Organic matter 0.225 % IS2720(Part22) -1987
3. Total soluble sulphates
1. As SO4
2. As Na2SO4
0.05 %
0.07 %
-
IS2720(Part27) -1977
4. Chloride 0.02 % As per TxDOT Designation:
Tex-620-J (2008)

[0046] In one embodiment herein, the crusher dust is from leptynite origin and having a specific gravity of 2.68 and the fineness modulus of 2.88 (as depicted in Table. 3). Upon conducting gradation analysis, it is found to fall under Zone II category as per IS383-2016. The fines content of crusher dust originated from Leptynite rock is about 10.6 percent (as depicted in Table. 3). The grain size distribution of the crusher dust having gravel size of 0.6 percent, sand size of 89.4 percent, and fines of 10.6 percent.

[0047] Table. 3:
S. No Engineering Properties Value
1. Specific gravity 2.68
2. Grain size distribution
• Gravel size (%)
• Sand size (%)
• Fines (%)
0.6
89.4
10.6
3. Fineness Modulus 2.88

[0048] According to another exemplary embodiment of the invention, FIG. 2A refers to a graphical representation 200 of the crusher dust confirming to Zone II. In one embodiment herein, the graph having an x-axis that represents sieve size (mm) from 0.1 to 10, and a y-axis that represents percentage finer (%) from 0 to 100. In one embodiment herein, the graph having at least three-line indicators that include red color, green color, and blue color. The red line represents the particle size distribution of the crusher dust. It shows how the percentage of particles finer than a given sieve size varies with the sieve size.

[0049] The green and blue lines represent the upper and lower limits of Zone II gradation material, as defined in IS 383-2016. These limits specify the acceptable range of particle sizes for fine aggregate in concrete. That conformance to Zone II for the crusher dust, particle size distribution curve should lie between the upper and lower limit curves. Based on the graph, it appears that the crusher dust does not fully conform to the Zone II. While some portions of the crusher dust curve lie within the Zone II limits, there are sections that exceed the upper limit. This indicates that the crusher dust contains a higher proportion of larger particles than allowed for the Zone II fine aggregate.

[0050] According to another exemplary embodiment of the invention, FIG. 2B refers to a graphical representation 202 of the sea sand confirming to Zone IV gradation. In one embodiment herein, the graph having an x-axis that represents sieve size (mm) from 0.1 to 10, and a y-axis that represents percentage finer (%) from 0 to 100. In one embodiment herein, the entire sea sand curve lies within the Zone IV limits and thereby it is not suitable for use in its original form as Zone 4 gradation material cannot be used in concrete making.

[0051] According to another exemplary embodiment of the invention, FIG. 2C refers to a graphical representation 204 of the blended mixture of the crusher dust and sea sand falling under the Zone II. In one embodiment herein, the graph having an x-axis that represents the sieve size (mm) from 0.1 to 10, and the y-axis that represents the percentage finer (%) from 0 to 100.The blended mixtureof the sea sand and the crusher dust has a balanced particle size distribution, with a suitable combination of fine and coarser particles. The combination of the sea sand and crusher dust may have the synergistic effect on the particle size distribution, resulting in the blended mixture that falls within the Zone II limits.

[0052] The blended mixture of sea sand and crusher dust conforms to Zone II grading, thereby indicating its suitability for use as fine aggregate in concrete. Its balanced composition, synergistic effect, and advantageous properties make it a promising choice for construction applications.

[0053] Table. 4:
Sieve size Proportion of Blended mixture
80%SS+
20%CD 70%SS+
30%CD 60%SS+
40%CD 50%SS+
50%CD 40%SS+
60%CD
Cumulative Percentage Passing
10 mm 100 100 100 100 100
4.75 mm 99.92 99.88 99.6 99.8 99.8
2.36 mm 97.1 95.28 92.9 91.3 86.5
1.18 mm 92.7 89.2 84.2 81.3 69.7
600 µm 82.7 78.3 70.2 68.4 54.8
300 µm 17.9 20.3 15.9 21.2 16.7
150 µm 2.9 4.6 5.2 5.4 6.3
75 µm 1.2 2.1 2.9 3.2 4.3
Fineness
Modulus 2.07 2.12 2.32 2.33 2.66
Specific
Gravity 2.660 2.664 2.667 2.673 2.676

[0054] The blended mixture of 70 percentage of sea sand and 30 percentage of crusher dust, the blend of 60 percentage of sea sand and 40 percentage of crusher dust, and the blended mixtureof 50 percent of sea sand and 50 percent of crusher dust (by weight) fall under Zone III category. The blended mixture of 80 percentage of sea sand and 20 percentage of crusher dust, by weight falls under the Zone IV gradation. According to IS383-2016, blends falling under the Zone II and the Zone III categories can be used as fine aggregate in the concrete production. Therefore, the blended mixtureof 40 percent of sea sand and 60 percent of crusher dust (by weight) can be used as the Zone II fine aggregate in concrete.

[0055] Among the three blended mixtures falling under the Zone III category, using the blend of 60 percentage of sea sand and 40 percentage of crusher dust, the blend of 50 percentage of sea sand and 50 percentage of crusher dust (by weight) as fine aggregate results in optimal utilization of both sea sand and crusher dust. Therefore, the blended mixture of 60 percentage of sea sand and 40 percentage of crusher dust, the blend of 50 percentage of sea sand and 50 percentage of crusher dust (by weight) are used as the Zone III fine aggregates in the concrete production.

[0056] According to another exemplary embodiment of the invention, FIG. 2D refers to a graphical representation 206 of the blended mixture of the crusher dust and sea sand falling under Zone III gradation. In one embodiment herein, the graph having x-axis that represents the sieve size (mm) from 0.1 to 10, and y-axis that represents the percentage finer (%) from 0 to 100 that of the sieve size. In one embodiment herein, the blended mixture of 70 percentage of sea sand and 30 percentage of crusher dust, the blended mixture of 60 percentage of sea sand and 40 percentage of crusher dust, the blended mixture of 50 percentage of sea sand and 50 percentage of crusher dust, and the blended mixture of 40 percentage of sea sand and 60 percentage of crusher dust (by weight) fall within the Zone III category, making them suitable for use as the fine aggregates in concrete production. The balanced composition, synergistic effect, and optimized proportions contribute to their suitability for various construction applications.

[0057] According to another exemplary embodiment of the invention, FIG. 2E refers to a graphical representation 208 of the blended mixture of the crusher dust and sea sand falling under the Zone IV. In one embodiment herein, the graph having the x-axis that represents the sieve size (mm) from 0.1 to 10, and the y-axis that represents the percentage of finer (%) from 0 to 100. In one embodiment herein, the red line represents the particle size distribution of the blended mixture of 80 percentage of sea sand and 20 percentage of crusher dust (by weight). The Zone IV limits the green and blue lines represent the upper and lower limits, respectively, as defined in IS 383-2016.For the blended mixture to conform to the Zone IV, its particle size distribution curve should lie between the upper and lower limit curves.

[0058] Based on the graph, the blend mixture of 80 percentage of sea sand and 20 percentage of crusher dust (by weight) might conform to the Zone IV gradation. The entire blended mixture curve lies within the Zone IV limits, thereby indicating that its particle size distribution is well within the acceptable range for the fine aggregate in the concrete production. In one embodiment herein, the blended mixture contains a high proportion of the sea sand, which is typically finer than the crusher dust. This contributes to the overall fine particle size of the blend mixture. The sea sand often falls within the Zone IV range due to its natural particle size distribution. The combination of sea sand and crusher dust may have the synergistic effect on the particle size distribution, resulting in the blended mixture that falls within the Zone IV limits.

[0059] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the method is disclosed. The proposed method provides an environmentally friendly alternative to river sand, reducing the impact of riverbed degradation and addressing the depletion of natural sand resources. The proposed method utilizes the sea sand and the crusher dust, which are readily available and often less expensive than river sand, offering a cost-effective solution for fine aggregate in concrete production. The proposed method allows for the optimal use of locally available materials such as sea sand and crusher dust, reducing the need to transport river sand from distant locations, thereby lowering logistical costs and the carbon footprint.

[0060] The proposed method blends of sea sand and crusher dust that fall within permissible limits for fineness modulus and meet the gradation standards (Zone II and Zone III) of IS 383-2016, ensuring their suitability for use in concrete and maintaining the desired strength, workability, and durability of the concrete mix. The proposed method allows for flexibility in adjusting the proportions of sea sand and crusher dust, making it suitable for various construction applications, depending on the required fine aggregate characteristics.

[0061] The proposed method is applicable in different geographic regions where sea sand and crusher dust are available, making it a versatile and globally relevant solution for obtaining fine aggregate. The proposed method contributes to sustainable construction practices by utilizing non-conventional materials like sea sand and crusher dust, helping conserve river sand and minimize environmental harm.

[0062] 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 method for blending sea sand and crusher dust as fine aggregates, comprising:
collecting sea sand and crusher dust materials and determining physical properties of the sea sand and crusher dust materials and chemical properties of the sea sand material;
blending the sea sand and crusher dust materials in multiple proportions to prepare a blended mixture of the sea sand and the crusher dust materials;
conducting a sieve analysis on the blended mixture of the sea sand and the crusher dust materials for determining grain size distribution;
comparing the grain size distribution of the blended mixture with standard grain sizes for fine aggregates in a concrete;
determining fineness modulus of the blended mixture and selecting the blended mixture that match the requirements for fine aggregates in concrete based on the grain size distribution and the fineness modulus; and
selecting the blended mixture of the sea sand and the crusher dust with permitted fineness modulus selected within the ranges of at least 2.3 to 3.1 for usage as fine aggregates in concrete production.
2. The method as claimed in claim 1, wherein the blended mixture of the sea sand and the crusher dust materials comprises:
40 percentage of the sea sand by weight; and
60 percentage of the crusher dust by weight.
3. The method as claimed in claim 2, wherein the blended mixture of the sea sand and crusher dust materials is configured to be utilized as the fine aggregates for a concrete production classified under Zone II category according to Indian Standard (IS) 383-2016 gradation standards.
4. The method as claimed in claim 2, wherein the fineness modulus of the blended mixture of the sea sand and crusher dust materials is 2.6, which falls within the permissible range for the fine aggregates used in the concrete production, in accordance with IS 383-2016 standards.
5. The method as claimed in claim 1, wherein the blended mixture of the sea sand and crusher dust materials comprises:
50 to 60 percentage of the sea sand material by weight; and
40 to 50 percentage of the crusher dust material by weight.
6. The method as claimed in claim 5, wherein the blended mixture of the sea sand and crusher dust materials is configured to be utilized as the fine aggregates for the concrete production classified under Zone III grading of IS 383-2016.
7. The method as claimed in claim 5, wherein the fineness modulus of the blended mixture of the sea sand and crusher dust materials are match within the permissible range from 2.3 to 3.1 for use as the fine aggregates in the concrete production.
8. The method as claimed in claim 1, wherein the physical properties of the sea sand and crusher dust materials are determined in order to evaluate parameters include specific gravity, and bulk density of sea sand and crusher dust materials.
9. The method as claimed in claim 1, wherein the chemical properties of the sea sand are determined to evaluate presence of salts and other chemical compounds that effects durability of the concrete.