Claims:We Claim:

1. A method for producing a compact and highly dense construction material, the method comprises steps of:
determining a smallest fine aggregate fraction of a raw construction material via applying a gradation process;
determining a mode average particle diameter (D) of the said smallest fine aggregate fraction; and
setting up a series of lattice void fillers ranging from a macro to Nano particle size level, wherein the said series of lattice void fillers correspond to the said mode average particle diameter (D) of the said smallest fine aggregate fraction of the raw construction material.

2. The method as claimed in claim 1, wherein the said gradation process comprises physical gradation of the raw construction material ranging from smallest fine aggregates to coarse aggregates.

3. The method as claimed in claim 1, wherein the said mode average particle diameter (D) of the smallest fine aggregate fraction is determined via a particle-size distribution (PSD) analysis of the said smallest fine aggregate fraction.

4. The method as claimed in claim 1, wherein the said series of lattice void fillers comprises a continuous series of particles selected from at least one of material particles having spontaneous hydration property, material particles having induced hydration property.

5. The method as claimed in claim 4, wherein the said continuous series of particles comprises particles starting from a first series of particles having a mode average particle diameter (D1), and ending at a last series of particles having a mode average particle diameter (DN).

6. The method as claimed in claim 5, wherein the said first series of particles have a mode average particle diameter (D1) in the order of 1/3rd to 1/5th of the mode average particle diameter (D) of said smallest fine aggregate fraction.

7. The method as claimed in claim 5, wherein each of the said continuous series of particles have a modified mode average particle diameter (D2, D3, D4 …… DN) in order of 1/3rd to 1/5th of the mode average particle diameter of a previous series of particles.

8. The method as claimed in claim 7, wherein the said mode average particle diameter of the said continuous series of particles is modified via at least one of a mechanical process, an electrical process, a chemical process.

9. The method as claimed in claim 4, wherein the said material particles having spontaneous hydration property is selected from at least one of a normal Ordinary Portland Cement, a mechanically modified Ordinary Portland Cement, a chemically modified fly ash, a chemically modified blast furnace slag.

10. The method as claimed in claim 4, wherein the said material particles having induced hydration property is selected from:
a normal pozzolanic material having a mode average particle diameter (D1), wherein the said pozzolanic material is selected from a fly ash, a blast furnace slag, a volcanic ash material, a quartz material;
a mechanically modified pozzolanic material having a mode average particle diameter ranging from (D2) to (DN), wherein the said mechanically modified pozzolanic material is selected from a mechanically modified fly ash, a mechanically modified blast furnace slag, a mechanically modified volcanic ash material, a mechanically modified quartz material.
, Description:FIELD OF THE DISCLOSURE

[0001] The present invention relates to a method for producing a compact and highly dense construction material having a series of lattice void fillers ranging from a Macro to Nano particle size level. More specifically, the invention provides a method for producing a compact and highly dense construction material which minimizes the overall use of the ordinary Portland cement in the construction industry. The invention provides a high workability with low water consumption and highly dense construction material. Further, the said method for producing a compact and highly dense construction material enhances the use pozzolonic materials in the construction material such as concrete. Accordingly, the present invention reduces the overall dependency over the use of ordinary raw construction material and provides compact and highly dense construction material for the construction industry using mechanical and chemical modification. The said method for producing a compact and highly dense construction material provides a Macro to Nano particle size level fillers for the voids in lattice arrangement to increase the strength characteristics and durability index of the final construction material.

BACKGROUND OF THE DISCLOSURE

[0002] Concrete is a highly consumable and utilizable man-made construction material on earth. Infrastructure such as buildings, roads, airports, dams, ports are always considered as the key indicator of development. Developing such infrastructure always requires the use of construction material such as raw/aggregate concrete materials alongwith the ordinary Portland cement. The use of ordinary raw construction material always questions the final strength of infrastructure. Ordinary Portland cement plays a major role to ensure the higher strength of the concrete infrastructure. However, the ordinary Portland cement poses a great threat to the environmental imbalance in terms of air pollution, deforestation, and/or soil erosion.

[0003] Further, the production of the ordinary Portland cement consumes very high amount of energy and on the other hand produces high amount of CO2. Hence, it is always desirable to minimize the use of ordinary Portland cement and maximize the strength of the construction material. However, the strength and durability of concrete infrastructure always depends on the quality of material, lattice structure and ratio of the ordinary Portland cement mixed with the raw construction materials. On the other hand modifying the mechanical and chemical properties as well as minimizing the ordinary Portland cement ratio gives adverse effect on the final strength and durability of the concrete infrastructure.

[0004] Hence, it is a continuous attempt by the researchers to produce a compact and highly dense construction material with minimum use of ordinary Portland cement. At the same time, it is also desirable to maintain the final strength and durability of the concrete infrastructure. It is also noted that the strength and durability of the concrete infrastructure depends on the particle bonding of the ordinary Portland cement alongwith the particles of other raw/aggregate concrete materials.

[0005] Generally, during the concreting process the raw/aggregate concrete material particles alongwith the ordinary Portland cement particles are closely packed to form the hard rock like concrete structure. The cement reaction chemistry in the presence of the raw/aggregate concrete particles, cement particles and water to undergo the hydration process are the reactions on which the final strength and durability of the concrete infrastructure depends. This hydration process alongwith the packing efficiency of the cement and aggregate particles provide high strength to the final concrete structure.

[0006] Further, it is a known fact that improving the packing efficiency of the raw/aggregate concrete particles minimizes the amount of cement as required for binding the said raw/aggregate concrete particles together to form the hard concrete structure. Accordingly, it is always desirable to produce a compact and highly dense construction material which can provide maximum binding capability to the raw/aggregate concrete particles.

[0007] Further, the maximum binding capability of the raw/aggregate concrete particles also increases the overall strength of the final concrete infrastructure. The binding capacity can be increased when the cement and the aggregate particles are closely packed in the three dimensional structure. Generally, the ordinary Portland cement ratio is increased to achieve the higher binding capability of the concrete aggregate particles. Further, the cement reaction kinetic is also very important to attain the maximum binding capability of the concrete aggregate particles to form compact and highly dense construction material.

[0008] Hence, it is important to provide a method for producing a compact and highly dense construction material which can provide maximum improved binding capability to the aggregate particles and also have better cement reaction kinetic.

[0009] There are conventional methods for attaining the said results of producing closely packed construction materials and the aggregate particles. The said methods include mixing ordinary Portland cement, fine aggregate materials, and course aggregate materials in an optimum percentage to obtain a proper ratio of the particle packing structure. However, still such methods do not provide the required optimum particle packing and do not ensure the prolonged life and high strength of the construction material.

[0010] Hence, there is a need of a method for producing a compact and highly dense construction material which can provide Macro to Nano particle level lattice void fillers to make the material compact and dense to increase the durability index of the final construction material ensuring the low usage of the Portland cement.

SUMMARY

[0011] In view of the aforesaid needs and shortcomings in the state of the art, in an aspect, the present invention provides a method for producing a compact and highly dense construction material.

[0012] It will be apparent to a person skilled in the art that the present invention is a method for producing a compact and highly dense construction material. Further, the said method is adapted to overcome the outdated composition of the ordinary concrete materials and provide improved binding capabilities to the concrete aggregate particles of the construction materials.

[0013] Further, the present method for producing a compact and highly dense construction material implies a gradation process to determine a smallest fine aggregate fraction and then find out their mode average particle diameter (D) of a raw construction material.

[0014] Further, the said gradation process comprises physical gradation of the raw construction materials ranging from smallest fine aggregates to coarse aggregates.

[0015] Further, the said gradation process results into formation of a series of lattice void fillers ranging from a Macro to Nano particle size level. These series of lattice void fillers correspond to the mode average particle diameter (D) of the smallest fine aggregate fraction to the raw construction material.

[0016] In an aspect, the said mode average particle diameter (D) of the smallest fine aggregate fraction is determined via a particle-size distribution (PSD) analysis of the smallest fine aggregate fraction.

[0017] In an aspect, the said series of lattice voids fillers comprises of a continuous series of particles selected from material particles having spontaneous hydration property and material particles having induced hydration property.

[0018] Further, the continuous series of particles comprises of particles starting from a first series of particles having a mode average particle diameter (D1) and ending at a last series of a particles having a mode average particle diameter (DN).

[0019] In an aspect, the said series of particles have a mode average particle diameter (D1) in the order of 1/3rd to 1/5th of the mode average particle diameter (D) of the smallest fine aggregate fraction.

[0020] Further, the said continuous series of particles have a modified mode average particle diameter (D2, D3, D4 ….. DN) in order of 1/3rd to 1/5th of the mode average particle diameter of a previous series of particles. It is well understood to a person skilled in the art that the said mode average particle diameter of the continuous series of particles can be further modified as per the demand and need of the smallest fine aggregate mode average particle diameter of the particular aggregate of the raw construction materials.

[0021] In another aspect, the present method for producing a compact and highly dense construction material also includes a mechanical, electrical and chemical modification process. The mode average particle diameter of the said continuous series of particles is modified via any of the said mechanical, electrical and chemical modification process.

[0022] In the present invention the said series of lattice voids fillers comprises of a continuous series of material particles. The selection of the material particles of a continuous series of particles is based on their hydration properties and selected from the material particles having spontaneous hydration property and material particles having induced hydration property.

[0023] Further the said material particles having spontaneous hydration property are selected from one of the normal ordinary Portland cement, mechanically modified ordinary Portland cement, a chemically modified fly ash and chemically modified blast furnace slag.

[0024] In another aspect, the said material particles having induced hydration property are selected form normal pozzolanic material and mechanically modified pozzolanic material. Further the said normal pozzolanic material having a mode average particle diameter (D1) is selected form fly ash, blast furnace slag, volcanic ash material and quartz material.

[0025] Further, mechanically modified pozzolanic material having a mode average particle diameter ranging from (D2) to (DN) is selected from mechanically modified fly ash, mechanically modified blast furnace slag, mechanically modified volcanic ash material and mechanically modified quartz material.

[0026] In yet another aspect, the said series of lattice void fillers ranging from Macro to Nano particle size level comprising continuous series of particles selected form material particles having spontaneous hydration property and induced hydration property. The said materials are selected to increase the strength characteristics and durability of the final construction material.

[0027] Thus, the aspects of the present invention are directed to an environmental friendly method for producing a compact and highly dense construction material, with improved binding properties.

[0028] Particularly, the present method for producing a compact and highly dense construction material provides overall reduction of carbon foot prints, overall reduction in clinker factor, improved binding property, optimizing the total water demand, better utilization of pozzolanic materials in concrete production are some examples of the desired benefits achieved by the present invention.

[0029] This together with the other aspects of the present invention along with the various features of novelty that characterized the present disclosure is pointed out with particularity in claims annexed hereto and forms a part of the present invention. For better understanding of the present disclosure, its operating advantages, and the specified objective attained by its uses, reference should be made to the accompanying descriptive matter in which there are illustrated exemplary embodiments of the present invention.

DESCRIPTION OF THE DRAWINGS

[0030] The advantages and features of the present invention will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing, in which:

[0031] FIG. 1-2 illustrate the vacant voids at Macro-Micro-Nano level and shows the arrangement of particles in relation to the mode average particle diameter D, D1, D2, D3, D4…. DN.

DESCRIPTION OF THE INVENTION

[0032] The exemplary embodiment described herein detail for illustrative purposes are subjected to many variations. It should be emphasized, however, that the present invention is not limited to method for producing the compact and highly dense construction material. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

[0033] Unless otherwise specified, the terms, which are used in the specification and claims, have the meanings commonly used in the field of infrastructure construction and cement/concrete industry. Specifically, the following terms have the meanings indicated below.

[0034] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0035] The terms “having”, “comprising”, “including”, and variations thereof signify the presence of an embodiment.

[0036] The term "spontaneous hydration property" refers to early and/or immediate hydration of a material when such material is mixed with water. Tricalcium silicate is an example of such spontaneous hydration property.

[0037] The term "induced hydration property" refers to later, slow and/or time dependent hydration of a material when such material is mixed with water. Dicalcium silicate is an example of such induced hydration property.

[0038] The term “mechanically modified particle” is understood to mean here a particle of a material modified mechanically into a prerequisite particle size by applying a desired force and energy.

[0039] The term “electrically modified particle” is understood to mean here a particle of a material charged electrically by applying a electrical energy.

[0040] The term “chemically modified particle” refers to a particle of a material charged/activated chemically to achieve desired chemical reaction and/or results.

[0041] The term “gradation process” is understood to mean here a process of physical gradation of the selected raw construction material. Specifically in the present invention such “gradation process” is adopted to produce smallest fine aggregate fraction.

[0042] The term “lattice void filler” is understood to mean here a particle act as fillers which can fill a lattice voids in the admixture of construction material.

[0043] It should be noted that the term "pozzolanic material" as referenced hereinbelow means material having capability of binding in the presence of water as understood in the art.

[0044] The mode average particle diameter as provided herein is understood to be the peak of the particle frequency distribution curve. In simple words the mode is the highest peak seen in the particle frequency distribution curve. The mode represents the particle size (or size range) most commonly found in the particle frequency distribution curve.

[0045] The smallest fine aggregate mode average particle diameter is termed herein as the mode average particle diameter of the smallest fine particles present in the raw construction material. The smallest fine aggregate mode average particle diameter thus provides a clear cut idea of lattice void fillers being smallest particle of the raw construction material.

[0046] Further, the particle-size distribution (PSD) analysis is termed herein as the mathematical expression of finding about the ratio/proportion of various particle size ranges which are present in given raw construction material. Generally, volume, area, length, and quantity are used as standard dimensions for determining the particle amount present in the raw construction material. However, volume of the raw construction material sample is considered as the easiest dimension and/or way of finding out the ratio of various particles size ranges present in the given raw construction sample.

[0047] Due to the current worldwide pressure to decrease the CO2 emission, government bodies are looking for better technologies and products which produces lower carbon foot prints. Cement production is one of the major industry which produces very high amount of CO2¬. Hence it is always desirable to find out better ways of cutting down the overall CO2 release during cement and concrete production. However, still this cannot be considered as the final and total solution of minimizing the CO2 release as cement and concrete production itself releases standard amount of CO2.

[0048] There is another solution of reducing the use of cement in the concrete production but still the said cement reduction¬ has adverse effect on the final strength of the concrete infrastructure. Accordingly, the present method for producing a compact and dense construction material is engineered in such a way that it automatically reduces the overall use of cement and at the same time provides improved binding capabilities and higher strength to the final concrete infrastructure.

[0049] The method for producing a compact and highly dense construction material as described in the present invention is specially engineered method which produces lattice void fillers to fill the voids in the lattice structure of the raw construction material. The said lattice void fillers are engineered to the Micro-Nano level to ensure improved durability and strength of the final construction material.

[0050] Further, the present method provides a means of better utilization of the pozzolanic materials and at the same time shows enhancement of early strength characteristics despite of a substantial addition of pozzolanic materials.

[0051] Accordingly, the present method for producing a compact and dense construction material includes series of lattice void fillers comprises a continuous series of particles selected from one of material particles having spontaneous hydration property and material particles having induced hydration property. The particles of the said continuous series starting from a first series of particles having a mode average particle diameter (D1) and ending at a last series of particles having a mode average particle diameter (DN).

[0052] The said material particles having spontaneous hydration property. It is to be well understood by a person skilled in the art that materials which shows such spontaneous hydration property can be selected from normal ordinary Portland cement, mechanically modified ordinary Portland cement, chemically modified fly ash, chemically modified blast furnace slag and other know material particles which shows such spontaneous hydration property. The said first series of particles having a mode average particle diameter (D1) in order of 1/3rd to 1/5th of the mode average particle diameter (D) of smallest fine aggregate fraction.

[0053] In a preferred embodiment, the said material particles having induced hydration property is selected from one of a normal pozzolanic material, a mechanically modified pozzilanic material. The said normal pozzolanic material having a mode average particle diameter (D1) is selected form fly ash, blast furnace, slag, a volcanic ash material, and quartz material. Further, the said mechanically modified pozzolanic material having a mode average diameter (D2) to (DN) is selected form a mechanically modified fly ash, mechanically modified blast furnace slag, mechanically modified volcanic ash material and mechanically modified quartz material.

[0054] It is well understood to a person skilled in the art that the said mode average particle diameter of the particles of the continuous series can be further modified as per the mode average particle diameter of the smallest fine aggregate particle of a particular raw construction material.

[0055] Further, the mode average particle diameter (D) of the smallest fine aggregate fraction is determined by the particle-size distribution (PSD) analysis of the said smallest fine aggregate fraction of the raw constructional mateial.

[0056] In yet another embodiment, the said voids are filled by the series of lattice void fillers to produce a compact and dense construction material from a Macro to Nano particle size level. The said series of lattice void fillers corresponds to the said mode average particle diameter (D) of the said smallest fine aggregate fraction of the raw construction material.

[0057] Thus, the aspect of the present invention is directed to an environmental friendly method for producing a compact and highly dense construction material having improved binding property. Further, the said engineered method for producing a compact and highly dense construction material improves the overall durability and property of the final concrete structure.

[0058] Particularly, the present method for producing a compact and dense construction material provides overall reduction of carbon foot prints, overall reduction in clinker factor, improved binding property, better utilization of pozzolanic materials in concrete production are some examples of the desired benefits achieved by the present invention.

BEST MODE OF WORKING

[0059] The best mode of working of the present invention provides a specially engineered method for producing a compact and dense construction material having smallest fine aggregate fraction of a raw construction material. The said method for producing a compact and highly dense construction material utilizes much reduced amount of cement materials while preparing the concrete admixture.

[0060] The said method for producing a compact and highly dense construction material comprising determining a smallest fine aggregate fraction of a raw construction material via applying a gradation process to a selected raw material, for an example sand is one of the raw construction material of the concrete admixture, sand particles seems to be of equal diameter with naked eyes but while determining them at Macro to Nano particle size level range lies between 2mm to 64 mm particle diameter. Further the said gradation process is adopted for physical gradation of raw construction material ranging from smallest fine aggregates to coarse aggregates.

[0061] Further, determining mode average particle diameter (D) of the said smallest fine aggregate fraction via a particle-size distribution (PSD) analysis of the said smallest fine aggregate fraction. More specifically the particle distribution analysis (PSD) is the list of values of mathematical function that defines the relative amount, typically by volume, of particles present according to size. Particle size distribution plays a vital role in understanding physical and chemical properties of the selected raw construction material, more specifically it affects the strength and load bearing property of the selected raw construction material

[0062] The said particle-size distribution (PSD) analysis resulting into formation of a series of lattice void fillers ranging from a Macro to Nano particle size level corresponds to mode average particle diameter (D) of the smallest fine aggregate fraction of the raw construction material. Further, the said series of lattice void fillers comprises of a continuous series of particles selected from the material particles having spontaneous hydration property and material particles having induced hydration property.

[0063] The said spontaneous hydration property refers to immediate hydration of the material, in other words when such material is mixed with water then the said material absorbs water immediately, more specifically the material chemically combines with the water molecules spontaneously during hydration. Tricalcium silicate is an example of such spontaneous hydration property.

[0064] The materials particles having spontaneous hydration property is selected from one of a normal ordinary Portland cement, mechanically modified ordinary Portland cement, a chemically modified fly ash, chemically modified blast furnace slag.

[0065] Further the said induced hydration property refers to slow and time dependent hydration of the material, in other words when such material is mixed with water then it absorbs water in a slow manner and also time dependent, more specifically the material chemically combines with the water molecules in a slow pace during hydration. Dicalcium silicate is an example of such induced hydration property.

[0066] The said materials having induced hydration property is selected form a pozzolanic materials having mode average particle diameter (D1), are selected form fly ash, blast furnace slag, volcanic ash material and quartz material. Further, mechanically modified pozzolanic materials having a mode average particle diameter ranging from (D2) to (DN) are selected from mechanically modified fly ash, mechanically modified blast furnace slag, mechanically modified volcanic ash material, mechanically modified quartz material.

[0067] The said continuous series of particles comprises particles starting from a first series of particles having a mode average particle diameter (D1), and ending at a last series of particles having a mode average particle diameter (DN). Further the said first series of particles having mode average particle diameter (D1) in the order of 1/3rd to 1/5th of the mode average particle diameter of a previous series of particles.

[0068] Further the said continuous series of particles have a modified mode average particle diameter (D2, D3, D4 …. DN) in the order of 1/3rd to 1/5th of the mode average particle diameter of a previous series of particles.

[0069] The said continuous series of different particle sizes having a defined mode average particle diameter is achieved via various particle size modification processes such as mechanical process, chemical process and electrical process. This optimization of different particle sizes having a continuous series of different mode average particle diameter provides compact fillers of lattice void of the particle lattice structure ranging from Macro to Nano level. This mixture provides a perfect particle chemistry to fill the maximum voids of the particle lattice structure and also improves the chemistry related to the early settings and the latter settings of the concrete material.

[0070] In the said modification processes, especially during the mechanical process, the particle size can be modified into a prerequisite particle size by applying a desired force and energy. More specifically modifying the particle size to a desired size level via any of the process involving application of machines such as but not limited to grinding, crushing, milling, steam jet milling with superheated steam, particle breakdown by electrical force, particle breakdown by magnetic force should be considered as the examples of application of machines for modifying the material particle size to a desired size level.

[0071] The smallest fine aggregate mode average particle diameter as described herein means the mode average particle diameter of the smallest fine particles (D) of the concrete aggregate. The main purpose for determining the mode average particle diameter of the smallest fine particles (D) of construction material is to fill the lattice void structure of the concrete aggregate with the specially engineered method.

[0072] In an exemplary embodiment as shown in figure 1 and figure 2, the mode average particle diameter of the said raw construction material has to be understood by the examples of D1, D2, D3, D4…. DN mode average particle diameter. Where, the D1 mode average particle diameter is understood to be those particles whose mode average diameter is approximately 1/3rd to 1/5th of the smallest fine aggregate mode average particle diameter (D).

[0073] Further, the D2 mode average particle diameter is understood to be the particles whose mode average diameter is approximately 1/3rd to 1/5th of the particles having D1 mode average particle diameter. Accordingly, the D3 mode average particle diameter is understood to be the particles whose mode average diameter is approximately 1/3rd to 1/5th of the particles having D2 mode average particle diameter. Similarly, the D4 mode average particle diameter is understood to be the particles whose mode average diameter is approximately 1/3rd to 1/5th of the particles having D3 mode average particle diameter.

[0074] After careful experimental observation it is concluded that the present method for producing a compact and highly dense construction material satisfy all the mechanical properties, chemical properties, setting time property, fineness property as well as the production cost as required in the various concrete industry standards.

[0075] The present invention provides improved strength and setting properties at the same time provides maximum utilization of pozzolanic materials instead of ordinary Portland cement in the concrete industry.

[0076] While the invention has been described with respect to specific method which include presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described embodiment that fall within the spirit and scope of the invention. It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. Variations and modifications of the foregoing are within the scope of the present invention.

[0077] Accordingly, many variations of these embodiment are envisaged within the scope of the present invention.

[0078] The foregoing descriptions of specific embodiment of the present invention have been presented for purposes of description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiment were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiment with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the present invention.