Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. Title of the invention:“Development of marble waste concrete with waterless curing”
2. Applicant:
NAME NATIONALITY ADDRESS
1. Marwadi University
2.Prof. (Dr.) Ankur Bhogayata
3. Mr. Jay Pandya
4. Prof. (Dr.) Sandeep Sancheti
5. Prof. (Dr.) Rajendrasinh B. Jadeja
6. Dr. Tarak Vora INDIAN Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India

7. Mr. Sagar M. Ratapiya Nagnath Street, Soni Bazar, Old Morbi, Morbi, Gujarat 363641
8. Col. (Prof.) S. S. Sarangdevot Janardan Rai Nagar Rajasthan Vidyapeeth University, Udaipur Rd, Pratap Nagar, Udaipur, Rajasthan 313001
3. Preamble to the description
COMPLETE SPECIFICATION
The following specification particularly describes the invention and the manner in which it is to be performed:

Field of the Invention:
The present invention relates to the field of chemical.The present invention relates to a composite material used in construction. More specifically, the present invention relates to development of a novel concrete composition from waste marble materials. Further, the present invention provides waterless curing of marble waste concrete. Thepresent invention aims to mitigate the environmental hazards associated with the disposal of marble mining waste and promote eco-efficiency in the construction industry.
Background of the Invention:
Concrete is a widely used construction material in civil engineering applications. It is a composite material composed of cement, water, and aggregates such as sand and natural stones.The construction industry is a major consumer of natural resources and a significant contributor to environmental pollution. The production of traditional concrete involves the extraction of natural resources such as sand and stones, and the use of cement, which is a major source of greenhouse gas emissions. In addition, the disposal of waste materials generated during the production and use of concrete is also a major environmental concern.
The production of cement and concrete consumes a significant amount of natural resources, energy, and water. Additionally, it generates a substantial amount of waste and carbon emissions. Therefore, there is a growing interest in developing sustainable concrete materials that can reduce the environmental impact of concrete production while maintaining its structural and durability properties.
To address these issues, researchers have been exploring the use of waste materials, such as fly ash, slag, and silica fume, as partial replacements for cement in concrete. These waste materials can improve the strength and durability of concrete while reducing the amount of cement needed.
Marble waste is another waste material that has the potential to be used as a partial replacement for cement and natural aggregates in concrete. Marble waste is generated during the mining and processing of marble, and is usually disposed of in landfills or dumped in open areas, causing environmental problems.Marble mining results in high volumes of waste material such as marble slurry, marble sand, and marble stones, which pose hazardous impacts on the environment. Currently, the utilization of marble waste is limited to plaster and other secondary applications. There is a need to find innovative ways to use this waste material in construction, which will also help to reduce the use of natural materials like lime stones and quarry stones, and thus mitigate environmental degradation.There are several disclosurefor use of waste materials in concrete production.
IN202241022938provides a clear and concise overview of the use of Marble Sludge Powder and RecronFibre as a composite material in the concrete industry. It highlights the potential benefits of this approach, including reducing material use, lowering carbon emissions, and improving the mechanical properties of the concrete. The patent application demonstrates a commitment to finding sustainable and cost-effective solutions for the construction industry.
IN202311000421describes a system and method for manufacturing high-strength concrete using various materials to enhance the properties of the final product. By using specific ratios and percentages of cement, fine and coarse aggregate, metakaolin, ISF slag, WMP, C&D waste, and HSF, a concrete with a strength of 40 MPa can be produced. The use of hooked steel fibers, metakaolin, and a combination of WMP and ISF slag can increase the final product's strength. The method involves a specific mixing process, water addition, and curing and testing of concrete specimens. The use of these materials and processes can lead to a more durable and cost-effective product and promote sustainability in the construction industry by utilizing waste materials.
CN104591604A provides a composition for asphalt pavement that can be used for anti-slip road surfacing. The asphalt mixture is composed of the following components in weight percentage: 82-88% aggregate, 4-5% mineral powder, 3-6% asphalt, 0.2-0.4% lignin fibers, 1.72-2.7% iron silicide, 1.83-2.3% andalusite, 1.22-1.3% crushed powder of pasque flower, 0.01-0.1% acrylic acid acrylate-sulfonate copolymer, and 0.02-0.2% borate, totaling 100%. This asphalt mixture has a wide range of raw material sources, is low in cost, and has a simple preparation process, making it suitable for use in anti-slip road surfaces, while also improving stability and enhancing the absorption performance of environmental pollutants.
IN202241021202 investigate the potential of using cow dung ash as a partial replacement for cement in concrete production. The study evaluated different replacement rates of cow dung ash (ranging from 5% to 30%) and their impact on the compressive strength, split tensile strength, quick chloride penetrability, and water absorption of M25 grade concrete. The results indicated that the addition of cow dung ash extended the setting time of the concrete and improved its mechanical properties. Additionally, the use of cow dung ash and other eco-friendly materials like fly ash could offer a cheaper, more sustainable alternative to traditional concrete production.
Marble mining is an industry that generates a significant amount of waste, which has a negative impact on the environment. This waste is difficult to dispose of safely and is not being utilized on a large scale for sustainable applications in construction. This has resulted in a range of environmental hazards, including clogging of natural water streams and the accumulation of large piles of slurry and chips. Furthermore, it occupies a large land area for abundant storage, leading to a loss of land area.
To address these issues, a solution has been proposed in the form of a construction composite that utilizes hazardous marble mining wastes to prepare an environmentally friendly concrete mixture. The composite uses 90% of marble chips and 40% of marble slurry to replace the conventional sand and cement respectively in the concrete mix. This solution promotes the use of marble mining waste on a larger scale and in structural applications, resulting in two advantages in parallel. Firstly, it reduces the waste generated and mitigates the negative impact on the environment. Secondly, it reduces the use of fast vanishing natural materials, such as lime stones and crushed natural stones, obtained from stone quarries.
The reduction in cement in the mix further saves the emission of greenhouse gases. Additionally, the proposed mix does not require water curing in case of precast member manufacturing, saving time and reducing curing-related delays in manufacturing. Overall, the present invention offers a sustainable alternative that addresses the problem of hazardous marble mining waste while promoting environmental conservation and reducing the use of natural resources.
Objective of the Invention:
The main objective of the present invention is to develop an innovative concrete composite with waste marble materials which replaces conventional cement, sand, and aggregates.
Another objective of the present invention is to reduce the utilization of cement, natural sand, and aggregates to conserve the environment.
Yet anotherobjective of the present invention is to provide a simple method of preparing the composite and manufacturing the products without requiring any special equipment or skilled manpower.
Yet another objective of the present invention is to reduce the hazardous impact of marble mining activities on the environment and provide sustainable solutions for construction.
Yet another objective of the present invention is to produce cost-effective and less energy-intensive compared to conventional cement-based products.
Yet another objective of the present invention is to obtain a composite that is environmentally friendly and economical.
Summary of the Invention:
The present invention provides a concrete composite material from waste marble materials. The new composite material consists of two parts, namely binder paste and inert material. The binder paste is prepared by mixing the waste marble slurry (5.6% of total composite) in dried powder form and ordinary Portland cement (8.4% of total composite). The inert materials are waste marble sand in the form of fine marble chips up to 2mm particle size (32.4% of total composite), marble stones up to 10mm particle size (50% of total composite), and ordinary sand (3.6% of total composite). A chemical admixture is added to the mix as a hardener, comprising 4% of the total weight of the binder paste materials. The potable water is added to the dry mixture at a ratio of 0.45 water to binder paste materials.
The concrete composite material can be used to manufacture various construction products, such as flooring, wall cladding, masonry units, roofing tiles, and decorative furniture such as table tops, benches, and pots. The products are manufactured in a three-stage process of mix preparation, casting of the article, and ambient curing of 24 hours before use. The curing process is carried out in the unmolded state of the products, eliminating the need for separate water curing.The present invention also carry out various tests, such as the slump test, compressive strength test, impact strength test, and permeability test, which are performed to ensure the quality and strength of the material. The test results are compared to relevant codes of practice, and the quality of the material is determined based on the comparison.
The present invention offers several advantages, such as waste utilization, reduced use of natural materials, reduced greenhouse gas emissions, and cost-effectiveness compared to similar conventional cement-based products. The proposed concrete composite is suitable for both in-situ and precast manufacturing activities and products.
Detailed Description of the Invention:
The construction industry has been experiencing a growing demand for sustainable building materials that can replace traditional concrete and masonry products.In this context, the present invention is development of an innovative concrete composite material from marble waste, a by-product of the marble mining industrywhich replace traditional concrete components. The present concrete composite material is a mixture of marble slurry, marble sand, and marble stones, which can be used for non-structural and structural construction applications, including flooring, wall cladding, masonry units, roofing tiles, and decorative furniture such as table tops, benches, and pots.The present invention provides a novel concrete composite material from waste marble materials, which can be used in various construction products.
The following description relates to a particular manifestation of the present invention.Table 1 provides a list of materials used in the development of marble waste concrete with waterless curing. The said materials include 53 grade Ordinary Portland Cement (OPC cement), fine aggregates in the form ofordinary sand, coarse aggregates in the form of ordinary rock aggregates, dried marble slurry, marble sand chips, rapid hardening accelerator admixture, and potable water. Both aggregates are in compliance with IS 383-1970. Additionally, dried marble slurry, conforming to IS 12269-1987, is used as marble powder in the concrete mix, while marble sand (chips) complying with IS 383-1970 is used as an aggregate in the mix. A rapid hardening agent, complying with IS 9103-1999, is used as an admixture, which helps in speeding up the process of concrete setting and hardening. Finally, potable water, complying with IS 456-2000, is used as the mixing water in the concrete mix. All these materials, along with proper proportions and mixing, are used to develop high-strength, eco-friendly, and durable concrete with the effective utilization of waste materials.
Table 1: List of materials with its standards used
Sr. No. Material Specifications Conforming to IS: code
1 OPC cement 53 grade IS:12269-1987
2 Sand (Fine aggregates) Ordinary sand IS: 383-1970
3 Aggregates(coarse ggregates) Ordinary rock IS: 383-1970
4 Marble powder Dried marble slurry IS:12269-1987
5 Marble sand (Chips) Marble sand IS: 383-1970
6 Admixture(Accelerator) Rapid hardening agent IS: 9103-1999
7 Water Potable water IS: 456-2000

The development of marble waste concrete with waterless curing consists of two main parts:
Part I: Composite development
The conventional concrete is innovatively modified by replacing cement, sand, and aggregates with marble slurry, marble sand, and marble stones in specific proportions. The new concrete composite consists of two parts namely binder paste and inert material.
a) Binder paste is developed by mixing the marble slurry (5.6 % of total composite) in dried powder form, ordinary Portland cement (8.4 % of total composite).
b) The inter materials are waste marble sand in form of fine marble chips up to 2mm particle size (32.4% of total composite), marble stones up to 10mm particle size (50% of total composite), ordinary sand (3.6% of total composite).
The chemical admixture as hardener will be added in the mix by 4% of the total weight of the binder paste materials and potable water will be added in the dry mixture with 0.45 as a ratio of water to binder paste making materials in dry state.
Part II: Product manufacturing
Multipurpose construction products will be manufactured by using the innovative concrete composite consisting of waste marble materials.This can be used to manufacture various construction products like flooring, wall cladding, masonry units, roofing tiles, and indoor/outdoor furniture like table tops, benches, and pots.
The manufacturing of above mentionedproducts will follow three stage processes:
(a) mix preparation,
(b) casting of the article and
(c) ambient curing of 24 hrs before use.
The curing process will be carried out in the unmolded state of the products and there will not be any separate water curing required unlike conventional concrete composite. However, the manufacturing will not require any special equipments or the skilled manpower.
The process of preparing the construction composite or concrete mixture using the innovative ingredients involves several steps as follows:
1. The marble powder (slurry in dried state), marble chips of small size (up to 2mm) and marble waste stones (up to 20mm) are mixed in dry form along with appropriate proportions and with ordinary Portland cement and sand.
2. After dry mixing, water and chemical admixture (Hardening agent) are mixed gradually in the dry mix prepared in step 1.
3. The mixture is thoroughly mixed in mechanical mixer or concrete pan mixture as per the standard numbers of revolutions.
4. The prepared mixture is poured in the member Molds as per the desired product to be manufactured. OR the mixture is poured in the scaffolding / form works installed at the site for casting of concrete members namely beams, columns, slabs and foundations.
5. The members (Pre-cast) are allowed to set for 24 hrs. and later demolded and transported for use or application. In case of in-situ casting, the normal curing treatment will be given to the members.
6. The prepared concrete mixture evaluated for properties of concrete mix namely (but not limited to);
a. slump test (For fresh state response)
b. compacting factor test (For fresh state response)
c. compressive strength test (For hardened state response)
d. splitting tensile strength test(For hardened state response)
e. flexure strength test(For hardened state response)
f. impact strength test(For hardened state response)
g. Thermal conductivity test(For hardened state response)
h. water permeability test(For hardened state response)
i. acid and sulfate resistance test(For hardened state response)
j. abrasion test (For hardened state response)
The mix design proportions provided in the table 2 which shows the percentage of each ingredient to be used in the concrete mixture.
Table 2: Mix design proportions
Cement
(%) Sand
(%) Aggregates
(%) Marble slurry
(%) Marble Sand
(%) Total
(%) Sand Repalcement with marble sand
(%) Cement Repalcement with marble slurry powder
(%) Admixture
(%) of fine mixture of cement and marble slurry
8.4 3.6 50 5.6 32.4 100 90 40 4

Method of preparing the composite and articles:
Following are the steps of the making of the composite and preparing:
Table 3: Method of preparing the composite / article
Step Process/ Actions Special conditions/requirements/remarks
1 Material Procurement All materials from consistent sources
2 Measuring the ingredients as per the specific proportions Standard balance apparatus
3 Preparing binder in a dry state by mixing cement and waste marble slurry Machine mixing at room temperature
4 Mixing of marble sand, natural sand, marble stones in dry state Machine mixing at room temperature
5 Mixing of water and chemical admixture as per the specific proportions Machine mixing at room temperature
6 Dry mixing of binder and inert materials in mixer drum Machine mixing at room temperature
7 Wet mixing of binder materials, inert materials and water prepared in step 5 Machine mixing at room temperature
8 Filling up the molds using freshly mixed composite as per the application/manufacturing requirement Manual pouring of form works at room temperature
9 Curing of products / articles for 24 hrs at ambient temperature within the molds Hardening and drying of mixture at room temperature
It is essential to follow the mix proportion to obtain a durable and reliable concrete mix that can withstand the intended loads and environmental conditions.The proportions ensure that the mix has the right consistency, strength, and workability to meet the desired specifications. It is also important to ensure that the materials used are of good quality and meet the appropriate standards. The proper mixing, curing, and testing are essential to ensure the final concrete mix meets the required strength and durability criteria.
The mix proportion provided specifies the amount of materials needed to prepare a concrete mixture for one cubic meter. The mix includes cement, marble powder, sand, marble chips, and aggregates of 10mm and 20mm.
Composition comparation of conventional and the present invention product:
The amount of cement required is 216 kg, while 144 kg of marble powder is needed. The sand required is 81.2 kg, while the marble chips amount to 730.8 kg. The aggregates needed for the mix are 639 kg of 10mm aggregate and 645 kg of 20mm aggregate. For proper mixing of the materials, 140 kg of water is required. Additionally, 14.4 kg of admixture is needed to enhance the properties of the concrete mixture.
Table 4: Mix proportion for one cubic meter of proposed mixture
Cement In Kg Marble Powder In Kg Sand In Kg Marble Chips In Kg Aggregate 10mm in Kg Aggregate 20mm in Kg Water in Kg Admixture in Kg
216 144 81.2 730.8 639 645 140 14.4

The material specifications for the concrete mix provide important details about the materials that should be used to achieve the desired strength and durability. The characteristic compressive strength of the concrete is specified as 30 MPa. The maximum size of the aggregate is 20mm, and the exposure condition is severe. The fineness range of FA (fly ash) is between 300-400 cm2/kg.
The workability of the concrete should be 60-65mm as measured by the slump test. The method of concreting should be pumpable. An accelerator should be added to the mixture in the amount of 4% of the binder weight.
The specific gravity of FA, CA (coarse aggregate), and admixture are 2.75, 2.65, and 1.145, respectively. The water absorption of CA and FA is 0.50% and 1%, respectively. The sand used in the mixture should be in Zone 1, while the fineness modulus of both sand and marble chips (marble sand) should be between 4 to 6 (IS:383-1970). The fineness of the marble slurry powder should be between 2 to 3 (IS:4031-1996) Part -1. The temperature at the time of mixture preparation should be between 15°C to 30°C.
Table 5: Material specifications for mixture
Characteristic Compressive Strength 30 MPa
Maximum Size of the aggregate 20 mm
Exposure Condition Severe
Fineness range of FA 300-400cm2/kg
Workability (Slump) 60-65 mm
Method of concreting Pumpable
Chemical Admixture (Accelerator) 4% of binder wt.
Specific Gravity of FA 2.75
Specific Gravity of CA 2.75
Specific Gravity of FA 2.65
Specific Gravity of admixture 1.145
Water Absorption of CA 0.50%
Water Absorption of FA 1%
Zone of Sand Zone 1
Fineness of marble slurry powder 2 to 3 (IS:4031-1996) Part -1
Fineness modulus of sand and marble chips (marble sand) 4 to 6 (IS:383-1970)
Temperature at the time of mixture preparation 150C to 300C

The target strength of the mixture should be calculated using the formula
Note on target strength of the mixture:
Fck = fck + 1.65*S = = 30+ 1.65*5 = 38.25 Mpa ;fck = Characteristic strength, S=Standard Deviation
OR
Fck = fck + X = 30 + 6.5 = 36.5 Mpa; X =Factor based on grade of concrete
Select whichever is higher should be considered as the target strength of the mix.In this case, the target strength of the mix is 38.25 MPa or 36.5 MPa, depending on the calculation method used.
Overall, following these material specifications for the mixture is crucial to ensure that the concrete is strong, durable, and suitable for the severe exposure conditions. It is also important to ensure that the materials used are of good quality and meet the appropriate standards. The proper mixing, curing, and testing are essential to ensure the final concrete mix meets the required strength and durability criteria.
Main embodiment of the present invention, a marble waste concrete composite with waterless curingcomprising of:
a) a binder paste made by mixing 5.6%of marble slurry in dried powder form and 8.4 % of ordinary Portland cement;
b) an inert materialare 32.4% of waste marble sand in form of fine marble chips up to 2 mm particle size, 50% of marble stones up to 10 mm particle size, and 3.6 % of ordinary sand;and
c) a chemical admixture as hardener prepared by adding 4% of the binder paste materials and potable water in the dry mixture with 0.45 as a ratio of water to binder paste making materials in dry state;
wherein said concrete composite is environmentally friendly, less energy-intensive, improved strength and economical in construction industry.
Another embodiment of the present invention, the said concrete composite reduces the usage of conventional cement by 40% and natural sand and aggregates by 90%.
Another embodiment of the present invention, the proportions of the conventional and waste ingredients in a unit volume of the mix are 8.4% cement (OPC), 3.6% natural sand, 50% natural aggregates, 5.6% marble slurry and 32.4% marble chips sand-sized particles.
Another embodiment of the present invention, said concrete composite comprises of 144 kg of marble powder, 730.8 kgmarble chips, 639 kg of 10 mm aggregate and 645 kg of 20 mm aggregate, 140 kg of water and 14.4 kg of admixture.
Another embodiment of the present invention, said concrete composite made up from process involves mix preparation, casting of the material, and ambient curing of 24 hours in the unmolded statewithout separate water curing before use.
Another embodiment of the present invention, the compressive strength of said concrete composite is 30 MPa.
Another embodiment of the present invention, the workabilityas measured by the slump testof said concrete composite is in the ragne of 60 – 65 mm.
Another embodiment of the present invention, the impact strength test of said concrete composite is 30 to 38 no. of blows.
Another embodiment of the present invention, the permeability test of said concrete composite is 2 x 10-9 to 1.2 x 10-9 cm/sec.
Another embodiment of the present invention, the maximum load-bearing capacity of concrete composite is 36 N/mm2 to 41 N/mm2.
Another embodiment of the present invention, a method of development of marble waste concrete compositecomprising the steps of:
a) The marble powder slurry in dried state, marble chips of up to 2 mm size and marble waste stones up to 20 mm size are mixed in dry form along with appropriate proportions and with ordinary Portland cement and sand;
b) After dry mixing, water and chemical admixture as hardening agent are mixed gradually in the dry mix prepared in step a;
c) The mixture is thoroughly mixed in mechanical mixer or concrete pan mixture as per the standard numbers of revolutions;
d) The prepared mixture is poured in the member/pre-castmolds as per the desired product to be manufactured;
e) The members/pre-cast are allowed to set for 24 hours and later demolded and transported for use or application;
f) In case of in-situ casting, the normal curing treatment will be given to the members;
g) The prepared concrete composite evaluated for properties of concrete mix slump test, compacting factor test, compressive strength test, splitting tensile strength test, flexure strength test, impact strength test, thermal conductivity test, water permeability test, acid and sulfate resistance test, and abrasion test;
Wherein temperature at the time of composite preparation is in between 15°C to 30°C.
In the construction industry, various tests are performed to ensure the quality and strength of the materials used. One of the most commonly used tests is the slump test, which measures the consistency and workability of concrete. The reference result values for this test are 50mm to 100mm, as per IS 456-2000 and IS 1199-1959, while the result values for the present invention range from 60mm to 65mm.
Another important test is the compressive strength test, which determines the maximum load-bearing capacity of concrete. The reference result values for this test are 30 N/mm2 to 38 N/mm2, as per IS 516-2021 part-1, while the result values for the present invention range from 36 N/mm2 to 41 N/mm2.
The impact strength test, as per ACI 544-2R and ASTM D3763, measures the ability of concrete to withstand impact or shock. The reference result values for this test are 20 to 25 no. of blows, while the result values for the present invention range from 30 to 38 no. of blows.
Similarly, the permeability test determines the ability of concrete to allow water to pass through it. The reference result values for this test are 4 x 10-9 to 2 x 10-9 cm/sec, as per IS 3085-1965, while present invention result values range from 2 x 10-9 to 1.2 x 10-9 cm/sec.
These tests are performed as per relevant codes of practice such as IS: 456-2000, IS: 1199-1959, IS: 516-2021 part-1, ACI 544-2R, ASTM D3763, IS: 3085-1965, IS: 3346-1980, IS: 9284-1979, IS: 13311-1992 part-1 and part-2. By comparing the reference result values with present invention result values, we can determine the quality and strength of the concrete being tested.
Table 6: Tests and results ranges of the mixture prepared and relevant codes
Sr.no. Name of test Reference result values / range Present inventionresult values /range Relevant code of practice
1 Slump test 50mm to 100mm 60mm to 65mm IS: 456-2000
IS: 1199-1959
2 Compacting factor test 0.95 to 1 0.97 to 0.99 IS: 1199-1959
3 Compressive strength test 30 N/mm2 to 38 N/mm2 36 N/mm2 to
41 N/mm2 IS: 516-2021 part-1
4 Splitting tensile strength test 2.8 N/mm2 to 3.83 N/mm2 3.2 N/mm2 to
4.1 N/mm2 IS: 516-2021 part-1
5 Flexure strength test 3 N/mm2 to
5 N/mm2 3.8 N/mm2 to
4.8 N/mm2 IS: 456-2000
6 Impact strength test 20 to 25 no. of blows 30 to 38 no. of blows ACI 544-2R
ASTM D3763
7 Impact strength test (No. of blows for final crack ) 35 to 45 no. of blows 50 to 62 no. of blows ACI 544-2R
ASTM D3763
8 Permeability test (water) 4 x10-9to 2x10-9 cm/sec 2 x10-9 to 1.2 x10-9 cm/sec IS: 3085-1965
9 Acid resistance test (weight loss) (3-5% concentration) 6 to 10 % 4 to 6% IS: 3085-1965
10 Sulfate resistance test (3-5% concentration) +2 to -4 % volume change +1 to -2% volume change IS: 3085-1965
11 Thermal conductivity test 2.1 to 1.5 W/m K 1.8 to 1.2
W/m K IS: 3346-1980
12 Abrasion resistance test 0.16 to 0.40 in % of loss of weight 0.18 to 0.25 % of loss of weight IS: 9284-1979
13 Shrinkage test 20% to 70% by volume 10% to 30% by volume IS: 1199-1959
14 Rebound hammer test 30 N/mm2 to 38 N/mm2 36 N/mm2 to
41 N/mm2 IS: 13311-1992 part-2
15 Ultra pulse velocity test 3000 to 4500 m/s 4000 to 5000 m/s IS: 13311-1992 part-1
16 Modulus of elasticity test 2500 N/mm2 2450 N/mm2 to 2500 N/mm2 IS: 516-2021
part-1
17 Air voids 4.5 to 6.5 % 3.5 to 4.5 % IS: 1199-1959
18 Wet Density 2300 to 2400 kg/m3 2400 to 2600 kg/m3 IS: 1199-1959

The present invention consists of several novelties that make it a sustainable and eco-efficient alternative as compared to traditional concrete and masonry products as follow:
• The mix design utilizes specific material proportions that have specific ranges of replacement of conventional concrete materials with waste marble materials.
• The articles / products made with the proposed composite reduces usage of conventional cement by 40% and natural sand and aggregates by 90% which are the parameters establishing the excellence of the composite towards the environmental conservation and eco-efficiency of the composite.
• The mix utilizes substantial amounts of waste marble in nearly all forms and particle sizes, thereby reducing the hazardous impact of the pollution caused by the marble mining activities on the environment.
• The manufacturing process does not require water curing, which reduces water usage and waste, and the products are ready to use after 24 hours of ambient curing within the molds.
• The present concrete composite can be effectively use for non structural and structural construction applications without any change in the proportions (mix design) of the materials.
• The proposed concrete composite is suitable for in-situ as well as precast manufacturing activities and products.
• The products prepared with the proposed composite are cost effective and less energy intensive compared to the similar conventional cement based products.
In the present invention, a new concrete composite has been developed by replacing the conventional concrete making materials with waste marble materials. It consists of two parts, namely binder paste and inert material.
The present invention offers several advantages in the field of construction by utilizing hazardous marble mining waste.
• It provides large scale use of waste and prevents the use of natural virgin materials in construction without compromising on the primary properties of the conventional composites.
• The present invention offers improved strength compared to the given conventional mixture of concrete, thereby improving the structural integrity of the construction.
• It reduces the emission of greenhouse gases by reducing mining activity for lime stone and quarry stones.
• The process for incorporating the waste material is simple and does not involve any energy-intensive pre-treatments. This direct addition of waste in the composite material replaces the conventional materials.
• In addition, curing requirements by water in case of precast members are completely removed. The use of waste products as raw materials also reduces the material and manufacturing cost.
• Overall, the present invention offers a cost-effective and environmentally sustainable solution for the construction industry.
The present invention offers a solution to the environmental impact caused by marble mining and waste disposal. Instead of discarding marble chips, slurry, and powder as waste, the present invention utilizes 90% of it to create a composite material. This composite material can be used to manufacture various construction products, including flooring, wall cladding, masonry units, roofing tiles, and decorative furniture for indoor and outdoor use. The manufacturing process involves three stages: mix preparation, casting, and ambient curing for 24 hours. The products do not require any additional water curing, unlike traditional concrete composites. This manufacturing process is simple and does not require special equipment or skilled labor, making it suitable for small, medium, and large-scale production. The use of this waste material not only helps address the environmental problem, but also reduces the need for conventional cement, sand, and aggregates, making it a cost-effective and eco-efficient alternative. , Claims:We claim,
1. A marble waste concrete composite with waterless curing comprising of:
a) a binder paste made by mixing 5.6%of marble slurry in dried powder form and 8.4 % of ordinary Portland cement;
b) an inert materialare 32.4% of waste marble sand in form of fine marble chips up to 2 mm particle size, 50% of marble stones up to 10 mm particle size, and 3.6 % of ordinary sand;and
c) a chemical admixture as hardener prepared by adding 4% of the binder paste materials and potable water in the dry mixture with 0.45 as a ratio of water to binder paste making materials in dry state;
wherein said concrete composite is environmentally friendly, less energy-intensive, improved strength and economical in construction industry.

2. The marble waste concrete composite as claimed in claim 1, wherein thesaid concrete composite reduces the usage of conventional cement by 40% and natural sand and aggregates by 90%.

3. Themarble waste concrete composite as claimed in claim 1, wherein the proportions of the conventional and waste ingredients in a unit volume of the mix are 8.4% cement (OPC), 3.6% natural sand, 50% natural aggregates, 5.6% marble slurry and 32.4% marble chips sand-sized particles.

4. The marble waste concrete composite as claimed in claim 1, wherein said concrete composite comprises of 144 kg of marble powder, 730.8 kgmarble chips, 639 kg of 10 mm aggregate and 645 kg of 20 mm aggregate, 140 kg of water and 14.4 kg of admixture.

5. The marble waste concrete composite as claimed in claim 1, wherein said concrete composite made up from process involves mix preparation, casting of the material, and ambient curing of 24 hours in the unmolded statewithout separate water curing before use.

6. The marble waste concrete composite as claimed in claim 1, wherein compressive strength of said concrete composite is 30 MPa.

7. The marble waste concrete composite as claimed in claim 1, wherein workabilityas measured by the slump testof said concrete composite is in the ragne of 60 – 65 mm.

8. The marble waste concrete composite as claimed in claim 1, wherein impact strength test of said concrete composite is 30 to 38 no. of blows.

9. The marble waste concrete composite as claimed in claim 1, wherein permeability test of said concrete composite is 2 x 10-9 to 1.2 x 10-9 cm/sec.

10. The marble waste concrete composite as claimed in claim 1, wherein maximum load-bearing capacity of concrete composite is 36 N/mm2 to 41 N/mm2.

11. A method of developmentof marble waste concrete compositecomprising the steps of:
a) The marble powder slurry in dried state, marble chips of up to 2 mm size and marble waste stones up to 20 mm size are mixed in dry form along with appropriate proportions and with ordinary Portland cement and sand;
b) After dry mixing, water and chemical admixture as hardening agent are mixed gradually in the dry mix prepared in step a;
c) The mixture is thoroughly mixed in mechanical mixer or concrete pan mixture as per the standard numbers of revolutions;
d) The prepared mixture is poured in the member/pre-castmolds as per the desired product to be manufactured;
e) The members/pre-cast are allowed to set for 24 hours and later demolded and transported for use or application;
f) In case of in-situ casting, the normal curing treatment will be given to the members;
g) The prepared concrete composite evaluated for properties of concrete mix slump test, compacting factor test, compressive strength test, splitting tensile strength test, flexure strength test, impact strength test, thermal conductivity test, water permeability test, acid and sulfate resistance test, and abrasion test;
Wherein temperature at the time of composite preparation is in between 15°C to 30°C.
Dated 25thApr, 2023

ChothaniPritibahenBipinbhai
Reg. No.: IN/PA-3148
For and on behalf of the applicant