FORM-2
THE PATENT ACT,1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
(As Amended)
COMPLETE SPECIFICATION (See section 10;rule 13)
"BOTTOM ASH CONCRETE TETRA PODS"
THE TATA POWER COMPANY LIMITED, a corporation organized and existing under the laws of INDIA, of TROMBAY THERMAL POWER STATION, MAHUL ROAD, CHEMBUR, MUMBAI 400074, MAHARASHTRA, INDIA.
The following specification particularly describes the invention and the manner in which it is to be performed:

BOTTOM ASH CONCRETE TETRA PODS FIELD OF INVENTION
Embodiments of the present application relates to the usage of waste material produced by coal-fired boilers of thermal power plants in making eco-friendly heavy cement concrete article. More particularly, the invention provides tetrapods made using the waste by-product of process, for example, bottom ash from waste material associated with thermal power plant.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
At present there are large numbers of thermal power plants are in operation for generation of electricity. Coal is used as fuel in the Thermal power plants these power plants. Bottom ash and Fly ash are the two by products of coal firing. Fly ash has well established use in industrial applications. Whereas the bottom ash by virtue of its nature, chemical properties like presence of heavy metals, requires careful handling. It is either disposed to land filling with all possible treatment under the guidelines of pollution control board or application in any civil engineering application. Further disposal of bottom ash may further complicate the matters as it contains the soluble chemicals which can contaminate underground water aquifers, which are a frequent source of water supply for many people. This bottom ash handling has impacted on the operation and maintenance cost of plant. This lead us to think more appropriate way in gainful utilization of bottom ash. India has 7000+ sea coast, many times it is observed that due to rough sea conditions the shore has eroded and impacted badly on the property and human life. Furthermore, inland rivers due turn in to floor terrain due to heavy rain resulting in land erosion and impacting on the human life, animals and property. Tetrapod is largest cement concrete article which is used as wave breaker and an energy absorber to protect the land erosion in above cases. The consumption of raw material per Tetrapod is very huge. The raw material like sand is not easily available because of restriction laid by the government authorities on its exploration and even on the mining of stones. This has resulted on gap between demand and supply of TetrPod when there is a higher requirement.

Therefore, there is a need for an alternate source over conventional sources of raw material to construct Tetrapod.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the subject matter in order to provide a basic understanding of some of the aspects of subject matter embodiments. This summary is not an extensive overview of the subject matter. It is not intended to identify key/critical elements of the embodiments or to delineate the scope of the subject matter. Its sole purpose to present some concepts of the subject matter in a simplified form as a prelude to the more detailed description that is presented later.
The present invention is associated with the construction of Tetrapods using waste material from thermal power plant, for example, Bottom Ash. This gainful utilization of bottom ash helps in improving the O and M cost, also its application will help in reducing the land erosion and saving loss to human life and property across the globe.
A tetrapod that is formed in multiple units to protect a seashore from shore erosion is disclosed herein and the tetrapod if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
In an embodiment, the bottom ash of the coal is extracted from steam boiler at a thermal power plant, the bottom ash is transported with help of water and is stored in a pond, and the bottom ash is removed with help of an excavator from the pond and kept for natural drying. In an embodiment, size of the bottom ash particles varies across a range of mesh sieve sizes 100 to 200. In an embodiment, grade of bottom ash concrete decided is M30. In an embodiment, tetrapod weighs 2.5 metric ton (MT).

In an embodiment, based on per mix design for M30 grade of the bottom ash concrete, 754 kilogram per meter cube (kg/CuM) of Bottom ash is used per block for casting of the 2.5 MT of the weight of the tetrapod. In an embodiment, the caging comprises a main bar and stirrups to provide additional strength. In an embodiment, a first unit of the Tetrapod is demolded after 48 hours and kept for curing for 7 days. In an embodiment, to get optimum compressive strength of tetrapod being casted, cubes are taken at regular intervals. In an embodiment, the tetrapod is made using bottom ash as the fine aggregate by replacing conventional usage of sand completely using waste material of coal fired power plant.
The invention also provides a solution to Thermal Power plants in ash handling problems with the introduction of utilization in Tetrapod casting. The consumption of raw material per tetrapod casted is very high as compared with its utilization in other cement articles, for example, bricks, paver blocks etc. The conventional bottom ash is made with raw materials, for example, Cement + Sand (Fine aggregates) + Coarse aggregates. The present invention has designed the Tetrapod using: Cement + Waste material i.e. Bottom Ash ( as fine aggregate ) + Coarse aggregates. Here, sand is replaced completely (100%) by waste material i.e., Bottom ash. Till time the utilization of bottom was done by part replacement to sand, but this Bottom Ash Tetrapod is Sand less and made using 100% Bottom ash (which is a complete replacement to sand). This complete replacement helps in higher raw material consumption per unit of Tetrapod.
The invention process for making bricks comprise of the following steps:
1. Pre engineering works like finalising the Mix design, raw material proportion,
2. Removal of Bottom ash from pond and its natural drying,
3. Assembly of Tetrapod mould on site,
4. Raw material mixing as per proportion,
5. Casting of Tetrapod, and
6. Demoulding and Curing of Tetrapod.
As used herein, the term ‘curing’ refers to process of maintaining satisfactory moisture content and temperature in freshly cast concrete article for a definite period of time immediately after initial setting time to prevent the loss of moisture (and replenish the same) from the concrete and to maintain a favourable temperature for hydration to occur for a definite period by spraying water or wet covering with normal atmospheric temperature.

Bottom ash is by-product of coal firing in Thermal Power Plant which is considered as waste material. Bottom ash generation is continuous process, need large space for storage. It is needed to be handled as per the guidelines laid by pollution board. This activity involves tedious statutory compliances and huge expenditure. Tetrapod is largest cement article where the consumption of raw material is very high as compared to other articles like Bricks, Pavers and are used as wave breaker in protecting the seacoast and riverbanks from erosion and helps in preventing in the loss of life and property. Conventional Tetrapods are made with raw material like Cement + Sand (fine aggregate) + Coarse aggregates. Whereas the present invention describes a tetrapod formed using raw material as Cement + Bottom Ash (waste material, complete replacement of Sand) + Coarse aggregates. Here we have replaced the Fine aggregate i.e., sand completely (100%) by waste material i.e., Bottom Ash. This complete replacement of Sand by the waste material i.e., Bottom ash in cement article i.e., casting of Tetrapod is uniqueness of our product. In India Billion tons of Bottom ash is generated yearly and easily available than sand and which can be used for making Tetrapods. This solution of gainful utilization waste material in best way will lay the path of sustainable development.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The following drawings are illustrative of particular examples for enabling systems and methods of the present disclosure, are descriptive of some of the methods and mechanism, and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.
FIG. 1A exemplarily illustrates a process flow chart explaining the making of casting of bottom ash tetrapod, as an example embodiment of the present disclosure.
FIG. 1B exemplarily illustrates a stage of the casting of bottom ash tetrapod as explained in FIG. 1A, as an example embodiment of the present disclosure.

FIG. 2 exemplarily illustrates actual site execution associated with casting of bottom ash Tetrapod, as an example embodiment of the present disclosure.
FIG. 3 exemplarily illustrates use of bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure.
FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may represent both hardware and software components of the system. Further, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments now will be described. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.
It is to be noted, however, that the reference numerals used herein illustrate only typical embodiments of the present subject matter, and are therefore, not to be considered for limiting of its scope, for the subject matter may admit to other equally effective embodiments.
The specification may refer to “an”, “one” or “some” embodiment(s) in several lo cations. This does not necessarily imply that each such reference is to the same embodiment(s), or

that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, 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 will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include operatively connected or coupled. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items.
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 this disclosure pertains. It will be further understood that terms, such as 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.
FIG. 1A exemplarily illustrates a process flow chart explaining the making of casting of bottom ash tetrapod 100, as an example embodiment of the present disclosure and FIG. 1B exemplarily illustrates a stage of the casting of bottom ash tetrapod 100 as explained in FIG. 1A, as an example embodiment of the present disclosure. Based on Figure 1A and 1B, the process involves a step 102 involving pre-engineering and mix design of the tetrapod 100 followed by a step 104 of ash removal from waste material associated with thermal power plant at a pond and drying. The step 106 involves assembly of tetrapod mould on site which is followed by the step 108 that involves mixing of the raw material as per design. Now, in a step 110, the mixture comprising cement, bottom ash, and coarse aggregate are poured and casted to for the tetrapod 100 followed a step 112 by demoulding and curing of tetrapod 100 and the step 114 involving placing of tetrapod for shore protection. In other words, the

tetrapod is made using bottom ash as the fine aggregate by replacing conventional usage of sand completely using waste material of coal fired power plant.
As used herein, the term “Curing” is the maintenance of a satisfactory moisture content and temperature in cement concrete work for a period following placing and finishing of the product, so that the desired properties may develop. Curing has a strong influence on the properties of hardened concrete, proper curing will increase durability, strength, water tightness, abrasion resistance, volume stability, and resistance to freezing and thawing. there are many methods of curing like ponding and immersion, fogging and sprinkling and wet coverings etc. The present application uses spraying water and wet curing.
The tetrapod 100 is formed in multiple units to protect a seashore from shore erosion, wherein the tetrapod 100 if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold 116 for the tetrapod 100 is assembled and a reinforcement caging 118 is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
FIG. 2 exemplarily illustrates actual site execution associated with casting of bottom ash Tetrapod 100, as an example embodiment of the present disclosure. As also described above in FIGS. 1A and 1B, the invention utilizes the bottom ash as the main constituent in casting of the Tetrapod 100. Coal is used as fuel in the thermal power plant, on firing of coal in boiler the bottom ash formed which is taken away from the boiler with help of water and stored in pond. From pond, it is taken out for disposal or utilization. The sizes of the bottom ash particles vary greatly, some fines passing through a 100 to 200 mesh sieves. Pre engineering works are done before site execution. Grade of bottom ash concrete decided is M30. The mix design done for usage of bottom ash and got approved form the accredited. The Tetrapod 100 is generally named on its weight i.e., Tonnage. We set to cast the tetrapod 100 of weight 2.5 MT. Ash is removed with help of excavator from the pond and kept for natural drying. Raw material proportion fixed as per the mix design. As per mix design for M30 grade of bottom ash concrete, the 756 kg/CuM of bottom ash is used per block for casting of a 2.5 MT of

Tetrapod 100. This consumption is very high as compared to the consumption in other cement article like Brick/Paver block etc. The Tetrapod 100 mould 116 is assembled, and reinforcement caging 118 is placed (12mm main bar, 8mm stirrups to get additional strength). Raw materials are mixed with drum mixture with designed water cement ration. Mixture is poured and compaction is done with needle vibrator. The first ever unit is demoulded after 48 hr (later 24hr for each) and kept for curing for 7 days.
Referring to FIGS. 3 and 4, FIG. 3 exemplarily illustrates use of bottom ash tetrapod 100 for shore protection, as an example embodiment of the present disclosure and FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure. The resultant product has a fine finish, homogenous in nature, without any honeycombing, and is better than a conventional Tetrapod 100. The first sand less Tetrapod 100 is made using waste material i.e., bottom ash is ready for site placement. Multiple units of the Tetrapod 100 are then casted and placed along the shore for protection ass decided. To get the optimum compressive strength of product being casted, the cubes are taken at regular intervals. The cube test report came very well i.e., actual strength came in range of 35 MPA to 37 MPA against the designed value of 30 MPA. This has given the more strength to our product. Based on FIG. 3 the bottom ash tetrapod 100 is used for shore protection where multiple tetrapods 100 are positioned adjacent to a boundary wall or jetty formed of coal, or in other words, coal berth jetty boundary wall. The tetrapods 100 absorb the impact of the waves on the jetty walls.
In a short, summarised version of the bottom ash tetrapod 100, FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod 100 for shore protection, the tetrapod 100 if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. In an example based on the composition described above, Cement is 430 Kg/CuM, Fine aggregate - Bottom Ash is 754 Kg/CuM, Coarse aggregate - Metal I is 457 Kg/CuM, and Coarse aggregate - Metal II is 608 Kg/CuM.
The bottom ash tetrapod 100 provides a simple and useful solution on gainful utilization of bottom ash over the existing tedious handling. The bottom ash tetrapod 100 has manifold

benefits, for example, helping in reducing the bottom ash handling, minimizing the exploration of natural scarce resources like Sand, stone query mining, reducing the gap between demand and supply of Tetrapod 100 hence more projects on shore protection, riverbank training, flood protection can be taken which helps in saving the human being and loss to the property across the globe.
Although the invention has been described with 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. It is therefore, contemplated that such modifications can be made without departing from the scope of the present invention as defined.

My Claim:
1. A tetrapod that is formed in multiple units to protect a seashore from shore erosion,
wherein the tetrapod is formed with a mixture comprising;
cement as raw material within a range of 18 to 20%;
bottom ash of coal as fine aggregate within a range of 32 to 35%; and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%, wherein a mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and wherein the mixture is poured and compaction is performed with a needle vibrator.
2. The tetrapod as claimed in claim 1, wherein the bottom ash of the coal is extracted from steam boiler at a thermal power plant, wherein the bottom ash is transported with help of water and is stored in a pond, and wherein the bottom ash is removed with help of an excavator from the pond and kept for natural drying.
3. The tetrapod as claimed in claim 1, wherein size of the bottom ash particles varies across a range of mesh sieve sizes 100 to 200.
4. The tetrapod as claimed in claim 1, wherein grade of bottom ash concrete decided is M30.
5. The tetrapod as claimed in claim 1 is weighing 2.5 metric ton (MT).
6. The tetrapod as claimed in claim 5, wherein based on per mix design for M30 grade of the bottom ash concrete, 754 kilogram per meter cube (kg/CuM) of Bottom ash is used per block for casting of the 2.5 MT of the weight of the tetrapod.
7. The tetrapod as claimed in claim 1, wherein the caging comprises a main bar and stirrups to provide additional strength.
8. The tetrapod as claimed in claim 1, wherein a first unit of the Tetrapod is demolded after 48 hours and kept for curing for 7 days.

9. The tetrapod as claimed in claim 1, wherein to get optimum compressive strength of
tetrapod being casted, cubes are taken at regular intervals.
10. The tetrapod as claimed in claim 1 is made using bottom ash as the fine aggregate by
replacing conventional usage of sand completely using waste material of coal fired power
plant.

ABSTRACT
BOTTOM ASH CONCRETE TETRA PODS
A tetrapod that is formed in multiple units to protect a seashore from shore erosion, wherein the tetrapod if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
FORM-2
THE PATENT ACT,1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
(As Amended)
COMPLETE SPECIFICATION (See section 10;rule 13)
"BOTTOM ASH CONCRETE TETRA PODS"
THE TATA POWER COMPANY LIMITED, a corporation organized and existing under the laws of INDIA, of TROMBAY THERMAL POWER STATION, MAHUL ROAD, CHEMBUR, MUMBAI 400074, MAHARASHTRA, INDIA.
The following specification particularly describes the invention and the manner in which it is to be performed:

BOTTOM ASH CONCRETE TETRA PODS FIELD OF INVENTION
Embodiments of the present application relates to the usage of waste material produced by coal-fired boilers of thermal power plants in making eco-friendly heavy cement concrete article. More particularly, the invention provides tetrapods made using the waste by-product of process, for example, bottom ash from waste material associated with thermal power plant.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
At present there are large numbers of thermal power plants are in operation for generation of electricity. Coal is used as fuel in the Thermal power plants these power plants. Bottom ash and Fly ash are the two by products of coal firing. Fly ash has well established use in industrial applications. Whereas the bottom ash by virtue of its nature, chemical properties like presence of heavy metals, requires careful handling. It is either disposed to land filling with all possible treatment under the guidelines of pollution control board or application in any civil engineering application. Further disposal of bottom ash may further complicate the matters as it contains the soluble chemicals which can contaminate underground water aquifers, which are a frequent source of water supply for many people. This bottom ash handling has impacted on the operation and maintenance cost of plant. This lead us to think more appropriate way in gainful utilization of bottom ash. India has 7000+ sea coast, many times it is observed that due to rough sea conditions the shore has eroded and impacted badly on the property and human life. Furthermore, inland rivers due turn in to floor terrain due to heavy rain resulting in land erosion and impacting on the human life, animals and property. Tetrapod is largest cement concrete article which is used as wave breaker and an energy absorber to protect the land erosion in above cases. The consumption of raw material per Tetrapod is very huge. The raw material like sand is not easily available because of restriction laid by the government authorities on its exploration and even on the mining of stones. This has resulted on gap between demand and supply of TetrPod when there is a higher requirement.

Therefore, there is a need for an alternate source over conventional sources of raw material to construct Tetrapod.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the subject matter in order to provide a basic understanding of some of the aspects of subject matter embodiments. This summary is not an extensive overview of the subject matter. It is not intended to identify key/critical elements of the embodiments or to delineate the scope of the subject matter. Its sole purpose to present some concepts of the subject matter in a simplified form as a prelude to the more detailed description that is presented later.
The present invention is associated with the construction of Tetrapods using waste material from thermal power plant, for example, Bottom Ash. This gainful utilization of bottom ash helps in improving the O and M cost, also its application will help in reducing the land erosion and saving loss to human life and property across the globe.
A tetrapod that is formed in multiple units to protect a seashore from shore erosion is disclosed herein and the tetrapod if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
In an embodiment, the bottom ash of the coal is extracted from steam boiler at a thermal power plant, the bottom ash is transported with help of water and is stored in a pond, and the bottom ash is removed with help of an excavator from the pond and kept for natural drying. In an embodiment, size of the bottom ash particles varies across a range of mesh sieve sizes 100 to 200. In an embodiment, grade of bottom ash concrete decided is M30. In an embodiment, tetrapod weighs 2.5 metric ton (MT).

In an embodiment, based on per mix design for M30 grade of the bottom ash concrete, 754 kilogram per meter cube (kg/CuM) of Bottom ash is used per block for casting of the 2.5 MT of the weight of the tetrapod. In an embodiment, the caging comprises a main bar and stirrups to provide additional strength. In an embodiment, a first unit of the Tetrapod is demolded after 48 hours and kept for curing for 7 days. In an embodiment, to get optimum compressive strength of tetrapod being casted, cubes are taken at regular intervals. In an embodiment, the tetrapod is made using bottom ash as the fine aggregate by replacing conventional usage of sand completely using waste material of coal fired power plant.
The invention also provides a solution to Thermal Power plants in ash handling problems with the introduction of utilization in Tetrapod casting. The consumption of raw material per tetrapod casted is very high as compared with its utilization in other cement articles, for example, bricks, paver blocks etc. The conventional bottom ash is made with raw materials, for example, Cement + Sand (Fine aggregates) + Coarse aggregates. The present invention has designed the Tetrapod using: Cement + Waste material i.e. Bottom Ash ( as fine aggregate ) + Coarse aggregates. Here, sand is replaced completely (100%) by waste material i.e., Bottom ash. Till time the utilization of bottom was done by part replacement to sand, but this Bottom Ash Tetrapod is Sand less and made using 100% Bottom ash (which is a complete replacement to sand). This complete replacement helps in higher raw material consumption per unit of Tetrapod.
The invention process for making bricks comprise of the following steps:
1. Pre engineering works like finalising the Mix design, raw material proportion,
2. Removal of Bottom ash from pond and its natural drying,
3. Assembly of Tetrapod mould on site,
4. Raw material mixing as per proportion,
5. Casting of Tetrapod, and
6. Demoulding and Curing of Tetrapod.
As used herein, the term ‘curing’ refers to process of maintaining satisfactory moisture content and temperature in freshly cast concrete article for a definite period of time immediately after initial setting time to prevent the loss of moisture (and replenish the same) from the concrete and to maintain a favourable temperature for hydration to occur for a definite period by spraying water or wet covering with normal atmospheric temperature.

Bottom ash is by-product of coal firing in Thermal Power Plant which is considered as waste material. Bottom ash generation is continuous process, need large space for storage. It is needed to be handled as per the guidelines laid by pollution board. This activity involves tedious statutory compliances and huge expenditure. Tetrapod is largest cement article where the consumption of raw material is very high as compared to other articles like Bricks, Pavers and are used as wave breaker in protecting the seacoast and riverbanks from erosion and helps in preventing in the loss of life and property. Conventional Tetrapods are made with raw material like Cement + Sand (fine aggregate) + Coarse aggregates. Whereas the present invention describes a tetrapod formed using raw material as Cement + Bottom Ash (waste material, complete replacement of Sand) + Coarse aggregates. Here we have replaced the Fine aggregate i.e., sand completely (100%) by waste material i.e., Bottom Ash. This complete replacement of Sand by the waste material i.e., Bottom ash in cement article i.e., casting of Tetrapod is uniqueness of our product. In India Billion tons of Bottom ash is generated yearly and easily available than sand and which can be used for making Tetrapods. This solution of gainful utilization waste material in best way will lay the path of sustainable development.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The following drawings are illustrative of particular examples for enabling systems and methods of the present disclosure, are descriptive of some of the methods and mechanism, and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.
FIG. 1A exemplarily illustrates a process flow chart explaining the making of casting of bottom ash tetrapod, as an example embodiment of the present disclosure.
FIG. 1B exemplarily illustrates a stage of the casting of bottom ash tetrapod as explained in FIG. 1A, as an example embodiment of the present disclosure.

FIG. 2 exemplarily illustrates actual site execution associated with casting of bottom ash Tetrapod, as an example embodiment of the present disclosure.
FIG. 3 exemplarily illustrates use of bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure.
FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may represent both hardware and software components of the system. Further, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments now will be described. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.
It is to be noted, however, that the reference numerals used herein illustrate only typical embodiments of the present subject matter, and are therefore, not to be considered for limiting of its scope, for the subject matter may admit to other equally effective embodiments.
The specification may refer to “an”, “one” or “some” embodiment(s) in several lo cations. This does not necessarily imply that each such reference is to the same embodiment(s), or

that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, 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 will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include operatively connected or coupled. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items.
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 this disclosure pertains. It will be further understood that terms, such as 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.
FIG. 1A exemplarily illustrates a process flow chart explaining the making of casting of bottom ash tetrapod 100, as an example embodiment of the present disclosure and FIG. 1B exemplarily illustrates a stage of the casting of bottom ash tetrapod 100 as explained in FIG. 1A, as an example embodiment of the present disclosure. Based on Figure 1A and 1B, the process involves a step 102 involving pre-engineering and mix design of the tetrapod 100 followed by a step 104 of ash removal from waste material associated with thermal power plant at a pond and drying. The step 106 involves assembly of tetrapod mould on site which is followed by the step 108 that involves mixing of the raw material as per design. Now, in a step 110, the mixture comprising cement, bottom ash, and coarse aggregate are poured and casted to for the tetrapod 100 followed a step 112 by demoulding and curing of tetrapod 100 and the step 114 involving placing of tetrapod for shore protection. In other words, the

tetrapod is made using bottom ash as the fine aggregate by replacing conventional usage of sand completely using waste material of coal fired power plant.
As used herein, the term “Curing” is the maintenance of a satisfactory moisture content and temperature in cement concrete work for a period following placing and finishing of the product, so that the desired properties may develop. Curing has a strong influence on the properties of hardened concrete, proper curing will increase durability, strength, water tightness, abrasion resistance, volume stability, and resistance to freezing and thawing. there are many methods of curing like ponding and immersion, fogging and sprinkling and wet coverings etc. The present application uses spraying water and wet curing.
The tetrapod 100 is formed in multiple units to protect a seashore from shore erosion, wherein the tetrapod 100 if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold 116 for the tetrapod 100 is assembled and a reinforcement caging 118 is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
FIG. 2 exemplarily illustrates actual site execution associated with casting of bottom ash Tetrapod 100, as an example embodiment of the present disclosure. As also described above in FIGS. 1A and 1B, the invention utilizes the bottom ash as the main constituent in casting of the Tetrapod 100. Coal is used as fuel in the thermal power plant, on firing of coal in boiler the bottom ash formed which is taken away from the boiler with help of water and stored in pond. From pond, it is taken out for disposal or utilization. The sizes of the bottom ash particles vary greatly, some fines passing through a 100 to 200 mesh sieves. Pre engineering works are done before site execution. Grade of bottom ash concrete decided is M30. The mix design done for usage of bottom ash and got approved form the accredited. The Tetrapod 100 is generally named on its weight i.e., Tonnage. We set to cast the tetrapod 100 of weight 2.5 MT. Ash is removed with help of excavator from the pond and kept for natural drying. Raw material proportion fixed as per the mix design. As per mix design for M30 grade of bottom ash concrete, the 756 kg/CuM of bottom ash is used per block for casting of a 2.5 MT of

Tetrapod 100. This consumption is very high as compared to the consumption in other cement article like Brick/Paver block etc. The Tetrapod 100 mould 116 is assembled, and reinforcement caging 118 is placed (12mm main bar, 8mm stirrups to get additional strength). Raw materials are mixed with drum mixture with designed water cement ration. Mixture is poured and compaction is done with needle vibrator. The first ever unit is demoulded after 48 hr (later 24hr for each) and kept for curing for 7 days.
Referring to FIGS. 3 and 4, FIG. 3 exemplarily illustrates use of bottom ash tetrapod 100 for shore protection, as an example embodiment of the present disclosure and FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure. The resultant product has a fine finish, homogenous in nature, without any honeycombing, and is better than a conventional Tetrapod 100. The first sand less Tetrapod 100 is made using waste material i.e., bottom ash is ready for site placement. Multiple units of the Tetrapod 100 are then casted and placed along the shore for protection ass decided. To get the optimum compressive strength of product being casted, the cubes are taken at regular intervals. The cube test report came very well i.e., actual strength came in range of 35 MPA to 37 MPA against the designed value of 30 MPA. This has given the more strength to our product. Based on FIG. 3 the bottom ash tetrapod 100 is used for shore protection where multiple tetrapods 100 are positioned adjacent to a boundary wall or jetty formed of coal, or in other words, coal berth jetty boundary wall. The tetrapods 100 absorb the impact of the waves on the jetty walls.
In a short, summarised version of the bottom ash tetrapod 100, FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod 100 for shore protection, the tetrapod 100 if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. In an example based on the composition described above, Cement is 430 Kg/CuM, Fine aggregate - Bottom Ash is 754 Kg/CuM, Coarse aggregate - Metal I is 457 Kg/CuM, and Coarse aggregate - Metal II is 608 Kg/CuM.
The bottom ash tetrapod 100 provides a simple and useful solution on gainful utilization of bottom ash over the existing tedious handling. The bottom ash tetrapod 100 has manifold

benefits, for example, helping in reducing the bottom ash handling, minimizing the exploration of natural scarce resources like Sand, stone query mining, reducing the gap between demand and supply of Tetrapod 100 hence more projects on shore protection, riverbank training, flood protection can be taken which helps in saving the human being and loss to the property across the globe.
Although the invention has been described with 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. It is therefore, contemplated that such modifications can be made without departing from the scope of the present invention as defined.

My Claim:
1. A tetrapod that is formed in multiple units to protect a seashore from shore erosion,
wherein the tetrapod is formed with a mixture comprising;
cement as raw material within a range of 18 to 20%;
bottom ash of coal as fine aggregate within a range of 32 to 35%; and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%, wherein a mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and wherein the mixture is poured and compaction is performed with a needle vibrator.
2. The tetrapod as claimed in claim 1, wherein the bottom ash of the coal is extracted from steam boiler at a thermal power plant, wherein the bottom ash is transported with help of water and is stored in a pond, and wherein the bottom ash is removed with help of an excavator from the pond and kept for natural drying.
3. The tetrapod as claimed in claim 1, wherein size of the bottom ash particles varies across a range of mesh sieve sizes 100 to 200.
4. The tetrapod as claimed in claim 1, wherein grade of bottom ash concrete decided is M30.
5. The tetrapod as claimed in claim 1 is weighing 2.5 metric ton (MT).
6. The tetrapod as claimed in claim 5, wherein based on per mix design for M30 grade of the bottom ash concrete, 754 kilogram per meter cube (kg/CuM) of Bottom ash is used per block for casting of the 2.5 MT of the weight of the tetrapod.
7. The tetrapod as claimed in claim 1, wherein the caging comprises a main bar and stirrups to provide additional strength.
8. The tetrapod as claimed in claim 1, wherein a first unit of the Tetrapod is demolded after 48 hours and kept for curing for 7 days.

9. The tetrapod as claimed in claim 1, wherein to get optimum compressive strength of
tetrapod being casted, cubes are taken at regular intervals.
10. The tetrapod as claimed in claim 1 is made using bottom ash as the fine aggregate by
replacing conventional usage of sand completely using waste material of coal fired power
plant.

ABSTRACT
BOTTOM ASH CONCRETE TETRA PODS
A tetrapod that is formed in multiple units to protect a seashore from shore erosion, wherein the tetrapod if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
FORM-2
THE PATENT ACT,1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
(As Amended)
COMPLETE SPECIFICATION (See section 10;rule 13)
"BOTTOM ASH CONCRETE TETRA PODS"
THE TATA POWER COMPANY LIMITED, a corporation organized and existing under the laws of INDIA, of TROMBAY THERMAL POWER STATION, MAHUL ROAD, CHEMBUR, MUMBAI 400074, MAHARASHTRA, INDIA.
The following specification particularly describes the invention and the manner in which it is to be performed:

BOTTOM ASH CONCRETE TETRA PODS FIELD OF INVENTION
Embodiments of the present application relates to the usage of waste material produced by coal-fired boilers of thermal power plants in making eco-friendly heavy cement concrete article. More particularly, the invention provides tetrapods made using the waste by-product of process, for example, bottom ash from waste material associated with thermal power plant.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
At present there are large numbers of thermal power plants are in operation for generation of electricity. Coal is used as fuel in the Thermal power plants these power plants. Bottom ash and Fly ash are the two by products of coal firing. Fly ash has well established use in industrial applications. Whereas the bottom ash by virtue of its nature, chemical properties like presence of heavy metals, requires careful handling. It is either disposed to land filling with all possible treatment under the guidelines of pollution control board or application in any civil engineering application. Further disposal of bottom ash may further complicate the matters as it contains the soluble chemicals which can contaminate underground water aquifers, which are a frequent source of water supply for many people. This bottom ash handling has impacted on the operation and maintenance cost of plant. This lead us to think more appropriate way in gainful utilization of bottom ash. India has 7000+ sea coast, many times it is observed that due to rough sea conditions the shore has eroded and impacted badly on the property and human life. Furthermore, inland rivers due turn in to floor terrain due to heavy rain resulting in land erosion and impacting on the human life, animals and property. Tetrapod is largest cement concrete article which is used as wave breaker and an energy absorber to protect the land erosion in above cases. The consumption of raw material per Tetrapod is very huge. The raw material like sand is not easily available because of restriction laid by the government authorities on its exploration and even on the mining of stones. This has resulted on gap between demand and supply of TetrPod when there is a higher requirement.

Therefore, there is a need for an alternate source over conventional sources of raw material to construct Tetrapod.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the subject matter in order to provide a basic understanding of some of the aspects of subject matter embodiments. This summary is not an extensive overview of the subject matter. It is not intended to identify key/critical elements of the embodiments or to delineate the scope of the subject matter. Its sole purpose to present some concepts of the subject matter in a simplified form as a prelude to the more detailed description that is presented later.
The present invention is associated with the construction of Tetrapods using waste material from thermal power plant, for example, Bottom Ash. This gainful utilization of bottom ash helps in improving the O and M cost, also its application will help in reducing the land erosion and saving loss to human life and property across the globe.
A tetrapod that is formed in multiple units to protect a seashore from shore erosion is disclosed herein and the tetrapod if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
In an embodiment, the bottom ash of the coal is extracted from steam boiler at a thermal power plant, the bottom ash is transported with help of water and is stored in a pond, and the bottom ash is removed with help of an excavator from the pond and kept for natural drying. In an embodiment, size of the bottom ash particles varies across a range of mesh sieve sizes 100 to 200. In an embodiment, grade of bottom ash concrete decided is M30. In an embodiment, tetrapod weighs 2.5 metric ton (MT).

In an embodiment, based on per mix design for M30 grade of the bottom ash concrete, 754 kilogram per meter cube (kg/CuM) of Bottom ash is used per block for casting of the 2.5 MT of the weight of the tetrapod. In an embodiment, the caging comprises a main bar and stirrups to provide additional strength. In an embodiment, a first unit of the Tetrapod is demolded after 48 hours and kept for curing for 7 days. In an embodiment, to get optimum compressive strength of tetrapod being casted, cubes are taken at regular intervals. In an embodiment, the tetrapod is made using bottom ash as the fine aggregate by replacing conventional usage of sand completely using waste material of coal fired power plant.
The invention also provides a solution to Thermal Power plants in ash handling problems with the introduction of utilization in Tetrapod casting. The consumption of raw material per tetrapod casted is very high as compared with its utilization in other cement articles, for example, bricks, paver blocks etc. The conventional bottom ash is made with raw materials, for example, Cement + Sand (Fine aggregates) + Coarse aggregates. The present invention has designed the Tetrapod using: Cement + Waste material i.e. Bottom Ash ( as fine aggregate ) + Coarse aggregates. Here, sand is replaced completely (100%) by waste material i.e., Bottom ash. Till time the utilization of bottom was done by part replacement to sand, but this Bottom Ash Tetrapod is Sand less and made using 100% Bottom ash (which is a complete replacement to sand). This complete replacement helps in higher raw material consumption per unit of Tetrapod.
The invention process for making bricks comprise of the following steps:
1. Pre engineering works like finalising the Mix design, raw material proportion,
2. Removal of Bottom ash from pond and its natural drying,
3. Assembly of Tetrapod mould on site,
4. Raw material mixing as per proportion,
5. Casting of Tetrapod, and
6. Demoulding and Curing of Tetrapod.
As used herein, the term ‘curing’ refers to process of maintaining satisfactory moisture content and temperature in freshly cast concrete article for a definite period of time immediately after initial setting time to prevent the loss of moisture (and replenish the same) from the concrete and to maintain a favourable temperature for hydration to occur for a definite period by spraying water or wet covering with normal atmospheric temperature.

Bottom ash is by-product of coal firing in Thermal Power Plant which is considered as waste material. Bottom ash generation is continuous process, need large space for storage. It is needed to be handled as per the guidelines laid by pollution board. This activity involves tedious statutory compliances and huge expenditure. Tetrapod is largest cement article where the consumption of raw material is very high as compared to other articles like Bricks, Pavers and are used as wave breaker in protecting the seacoast and riverbanks from erosion and helps in preventing in the loss of life and property. Conventional Tetrapods are made with raw material like Cement + Sand (fine aggregate) + Coarse aggregates. Whereas the present invention describes a tetrapod formed using raw material as Cement + Bottom Ash (waste material, complete replacement of Sand) + Coarse aggregates. Here we have replaced the Fine aggregate i.e., sand completely (100%) by waste material i.e., Bottom Ash. This complete replacement of Sand by the waste material i.e., Bottom ash in cement article i.e., casting of Tetrapod is uniqueness of our product. In India Billion tons of Bottom ash is generated yearly and easily available than sand and which can be used for making Tetrapods. This solution of gainful utilization waste material in best way will lay the path of sustainable development.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The following drawings are illustrative of particular examples for enabling systems and methods of the present disclosure, are descriptive of some of the methods and mechanism, and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.
FIG. 1A exemplarily illustrates a process flow chart explaining the making of casting of bottom ash tetrapod, as an example embodiment of the present disclosure.
FIG. 1B exemplarily illustrates a stage of the casting of bottom ash tetrapod as explained in FIG. 1A, as an example embodiment of the present disclosure.

FIG. 2 exemplarily illustrates actual site execution associated with casting of bottom ash Tetrapod, as an example embodiment of the present disclosure.
FIG. 3 exemplarily illustrates use of bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure.
FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may represent both hardware and software components of the system. Further, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments now will be described. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.
It is to be noted, however, that the reference numerals used herein illustrate only typical embodiments of the present subject matter, and are therefore, not to be considered for limiting of its scope, for the subject matter may admit to other equally effective embodiments.
The specification may refer to “an”, “one” or “some” embodiment(s) in several lo cations. This does not necessarily imply that each such reference is to the same embodiment(s), or

that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, 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 will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include operatively connected or coupled. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items.
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 this disclosure pertains. It will be further understood that terms, such as 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.
FIG. 1A exemplarily illustrates a process flow chart explaining the making of casting of bottom ash tetrapod 100, as an example embodiment of the present disclosure and FIG. 1B exemplarily illustrates a stage of the casting of bottom ash tetrapod 100 as explained in FIG. 1A, as an example embodiment of the present disclosure. Based on Figure 1A and 1B, the process involves a step 102 involving pre-engineering and mix design of the tetrapod 100 followed by a step 104 of ash removal from waste material associated with thermal power plant at a pond and drying. The step 106 involves assembly of tetrapod mould on site which is followed by the step 108 that involves mixing of the raw material as per design. Now, in a step 110, the mixture comprising cement, bottom ash, and coarse aggregate are poured and casted to for the tetrapod 100 followed a step 112 by demoulding and curing of tetrapod 100 and the step 114 involving placing of tetrapod for shore protection. In other words, the

tetrapod is made using bottom ash as the fine aggregate by replacing conventional usage of sand completely using waste material of coal fired power plant.
As used herein, the term “Curing” is the maintenance of a satisfactory moisture content and temperature in cement concrete work for a period following placing and finishing of the product, so that the desired properties may develop. Curing has a strong influence on the properties of hardened concrete, proper curing will increase durability, strength, water tightness, abrasion resistance, volume stability, and resistance to freezing and thawing. there are many methods of curing like ponding and immersion, fogging and sprinkling and wet coverings etc. The present application uses spraying water and wet curing.
The tetrapod 100 is formed in multiple units to protect a seashore from shore erosion, wherein the tetrapod 100 if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. A mold 116 for the tetrapod 100 is assembled and a reinforcement caging 118 is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and the mixture is poured and compaction is performed with a needle vibrator.
FIG. 2 exemplarily illustrates actual site execution associated with casting of bottom ash Tetrapod 100, as an example embodiment of the present disclosure. As also described above in FIGS. 1A and 1B, the invention utilizes the bottom ash as the main constituent in casting of the Tetrapod 100. Coal is used as fuel in the thermal power plant, on firing of coal in boiler the bottom ash formed which is taken away from the boiler with help of water and stored in pond. From pond, it is taken out for disposal or utilization. The sizes of the bottom ash particles vary greatly, some fines passing through a 100 to 200 mesh sieves. Pre engineering works are done before site execution. Grade of bottom ash concrete decided is M30. The mix design done for usage of bottom ash and got approved form the accredited. The Tetrapod 100 is generally named on its weight i.e., Tonnage. We set to cast the tetrapod 100 of weight 2.5 MT. Ash is removed with help of excavator from the pond and kept for natural drying. Raw material proportion fixed as per the mix design. As per mix design for M30 grade of bottom ash concrete, the 756 kg/CuM of bottom ash is used per block for casting of a 2.5 MT of

Tetrapod 100. This consumption is very high as compared to the consumption in other cement article like Brick/Paver block etc. The Tetrapod 100 mould 116 is assembled, and reinforcement caging 118 is placed (12mm main bar, 8mm stirrups to get additional strength). Raw materials are mixed with drum mixture with designed water cement ration. Mixture is poured and compaction is done with needle vibrator. The first ever unit is demoulded after 48 hr (later 24hr for each) and kept for curing for 7 days.
Referring to FIGS. 3 and 4, FIG. 3 exemplarily illustrates use of bottom ash tetrapod 100 for shore protection, as an example embodiment of the present disclosure and FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod for shore protection, as an example embodiment of the present disclosure. The resultant product has a fine finish, homogenous in nature, without any honeycombing, and is better than a conventional Tetrapod 100. The first sand less Tetrapod 100 is made using waste material i.e., bottom ash is ready for site placement. Multiple units of the Tetrapod 100 are then casted and placed along the shore for protection ass decided. To get the optimum compressive strength of product being casted, the cubes are taken at regular intervals. The cube test report came very well i.e., actual strength came in range of 35 MPA to 37 MPA against the designed value of 30 MPA. This has given the more strength to our product. Based on FIG. 3 the bottom ash tetrapod 100 is used for shore protection where multiple tetrapods 100 are positioned adjacent to a boundary wall or jetty formed of coal, or in other words, coal berth jetty boundary wall. The tetrapods 100 absorb the impact of the waves on the jetty walls.
In a short, summarised version of the bottom ash tetrapod 100, FIG. 4 exemplarily illustrates composition of the bottom ash tetrapod 100 for shore protection, the tetrapod 100 if formed with a mixture comprising cement as raw material within a range of 18 to 20%, bottom ash of coal as fine aggregate within a range of 32 to 35%, and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%. In an example based on the composition described above, Cement is 430 Kg/CuM, Fine aggregate - Bottom Ash is 754 Kg/CuM, Coarse aggregate - Metal I is 457 Kg/CuM, and Coarse aggregate - Metal II is 608 Kg/CuM.
The bottom ash tetrapod 100 provides a simple and useful solution on gainful utilization of bottom ash over the existing tedious handling. The bottom ash tetrapod 100 has manifold

benefits, for example, helping in reducing the bottom ash handling, minimizing the exploration of natural scarce resources like Sand, stone query mining, reducing the gap between demand and supply of Tetrapod 100 hence more projects on shore protection, riverbank training, flood protection can be taken which helps in saving the human being and loss to the property across the globe.
Although the invention has been described with 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. It is therefore, contemplated that such modifications can be made without departing from the scope of the present invention as defined.

My Claim:
1. A tetrapod that is formed in multiple units to protect a seashore from shore erosion,
wherein the tetrapod is formed with a mixture comprising;
cement as raw material within a range of 18 to 20%;
bottom ash of coal as fine aggregate within a range of 32 to 35%; and coarse aggregates comprising a first course aggregate within a range of 18 to 22% and a second course aggregate within a range of 25 % 30%, wherein a mold for the tetrapod is assembled and a reinforcement caging is placed, wherein a mixture of the cement, the bottom ash, and the coarse aggregates are mixed inside a drum with a predefined water-cement ratio, and wherein the mixture is poured and compaction is performed with a needle vibrator.
2. The tetrapod as claimed in claim 1, wherein the bottom ash of the coal is extracted from steam boiler at a thermal power plant, wherein the bottom ash is transported with help of water and is stored in a pond, and wherein the bottom ash is removed with help of an excavator from the pond and kept for natural drying.
3. The tetrapod as claimed in claim 1, wherein size of the bottom ash particles varies across a range of mesh sieve sizes 100 to 200.
4. The tetrapod as claimed in claim 1, wherein grade of bottom ash concrete decided is M30.
5. The tetrapod as claimed in claim 1 is weighing 2.5 metric ton (MT).
6. The tetrapod as claimed in claim 5, wherein based on per mix design for M30 grade of the bottom ash concrete, 754 kilogram per meter cube (kg/CuM) of Bottom ash is used per block for casting of the 2.5 MT of the weight of the tetrapod.
7. The tetrapod as claimed in claim 1, wherein the caging comprises a main bar and stirrups to provide additional strength.
8. The tetrapod as claimed in claim 1, wherein a first unit of the Tetrapod is demolded after 48 hours and kept for curing for 7 days.

9. The tetrapod as claimed in claim 1, wherein to get optimum compressive strength of
tetrapod being casted, cubes are taken at regular intervals.
10. The tetrapod as claimed in claim 1 is made using bottom ash as the fine aggregate by
replacing conventional usage of sand completely using waste material of coal fired power
plant.