Claims:5. CLAIMS
I/We claim:
1. A method (1) for preparation of eco-friendly brick and paver blocks, wherein the said method (1) comprises steps of;
mixing clay (2) in various proportions combined with waste rubber (3) or dry grass (7) or bagasse waste (4) or tree bark (5) or egg shells (6) or in other ecological wastes (8);
waste rubber (3) obtained from used and abandoned tires have been collected and these tires are crumbled in machine and rubber that passes through 2.36 mm sieve is being used;
the said rubber (3) should be free from deleterious materials such as stones, and other debris;
dry grass (7) obtained from yard waste is being collected. It is made ground into fine matter and it should pass through 2.36mm sieve and should be free from deleterious substances;
bagasse waste (4) is being collected and made into fine particles free from deleterious substance and the said material should be homogeneous and pass through 2.36mm sieve;
tree bark waste (5) is collected from trees and ground into fine powder that passes through 2.36mm sieve and it should be free from debris and deleterious material;
egg shells (6) are collected from various sources such as domestic and commercial sources and these are neatly washed and air dried for two days. They are ground into fine powder in a mixer, the said egg shell should pass 80-micron sieve;
other ecofriendly materials (8) could be used all raw materials should be stored in covered sheds suitable protected from rains.

2. The method (1) as claimed in claim 1, wherein the method (1) comprises an additional step of removing the said bricks from mould and air dried for 1-2 days, thereafter, water cured for a minimum period of 14 days, wherein curing is carried out by sprinkling water manually or by other means.

3. The method (1) as claimed in claim 1, wherein the method (1) comprises another step of performing compressive strength, absorption test, efflorescence test, and falling weight on so formed bricks after curing.

4. The method (1) as claimed in claim 1, wherein the method (1) leverages effective utilization of eco-friendly waste materials (8) replacing fine aggregate and cement.

5. The method (1) as claimed in claim 1, wherein using the method the compressive strength of with 40% replacement of fine aggregate with said crumbed rubber (3) is almost equal to the strength of conventional cement brick (17.8 N/mm2) on 28th day.

6. The method (1) as claimed in claim 1, wherein using the method the compressive strength with 40% replacement of fine aggregate with said dry grass (7) is almost equal to the strength of conventional cement brick (17.8 N/mm2) on 28th day.

7. The method (1) as claimed in claim 1, wherein using the method the compressive strength of 20% replacement of cement with said egg shell (6) powder results in a recommendable value of 11.00 N/mm2.

8. The method (1) as claimed in claim 1, wherein using the method the said eco-friendly bricks showed an encouraging result in compression.

6. DATE AND SIGNATURE

Dated this 16th February 2022
Agent Signature

(Mr. Srinivas Maddipati)
(IN/PA 3124)
Agent for the Applicant
, Description:4. DESCRIPTION
Technical Field of the Invention

The present invention relates to the field of construction and engineering mainly refers to preparation of bricks using recycled wastes.

Background of the Invention

The most basic and primary building material for construction of houses is the conventional brick. The rapid growth in today’s construction industry has obliged the civil engineers in searching for more efficient and durable alternatives far beyond the limitations of the conventional brick production.

A number of studies have been made and serious steps have been taken in manufacturing of bricks from several waste materials. However, the traditional mean of bricks production which has brought hazardous impacts to the context has not yet been changed or replaced by more efficient and sustainable one.

The current trend in bricks manufacturing is emphasising majorly on the use of post-consumer wastes and industrial by-products in the production process. Most of the researches went through enhancing the clay brick quality and properties by mixing the clay with various recycled wastes as foundry sand, granite sawing waste, harbor sediments, perlite, sugarcane, baggase ash, clay waste and fine waste of boron, sewage sludge, waste glass from structural wall and other different wastes

The prior art CN200943174Y discloses the utility model relates to a health-care pavement brick, which is set to solve the problems of poor foot-sense, easy fatigue when walking on top, possible bone damage for the current ground tilts. Wherein, the tilt body comprises upper and lower two layers which are fixed together. The upper layer is colored rubber surface and the lower layer is fabric rubber composite layer. The fabric is a nylon one and the rubber is a renewable one. The fabric rubber composite layer of the brick body is provided with or arranged with brick body interlinking structure.

Another prior art CN101376577B relates to a plastic and solid waste composite building material which comprises the following raw materials: 30-60 weight parts of plastic and 40-70 weight parts of solid waste, wherein, the plastic is one or more mixture from polyethylene, polyvinyl chloride, polypropylene, polystyrene and polyethylene terephthalate; the solid waste is one or more mixture from of furnace slag, flyash, building material industry dust and dewatered sludge; and the building material is obtained by uniformly mixing the raw materials in proportion and delivering the raw materials to a pressing machine for press forming after the temperature is raised to 120-180o.

The present invention refers to preparation of bricks with solid wastes like sand, granite sawing waste, harbor sediments, perlite, sugarcane, baggase ash, clay waste and fine waste of boron, sewage sludge, waste glass from structural wall and other different wastes wherein said prior arts failed to disclose this innovation.

Brief Description of the Invention

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

This innovation presents an experimental study on the utilization of waste materials which replaces clay with (Plastic covers, Ceramic Powder, Egg Shell Powder, GGBS, Silica Fume, Rice Husk Ash and Lime Powder) and Fine Aggregate with (Recycled glass, Dry Grass, Dead Leaves, Tree barks powder, Sugar cane powder, crumbed rubber) to produce eco-friendly Bricks.

This project is an attempt to fill the gap of the past studies and suggest more sustainable and sophisticated methods of brick manufacturing in the future. 40 percent replacement of fine aggregate with crumbled rubber and dry grass in mortar bricks have given encouraging results, also the replacement of cement by egg shell powder at 20% has given a considerable result.

It is an object of the present invention to introduce ecofriendly bricks in the field of construction and engineering.

It is another object of the present invention to study properties such as skid resistance, abrasion resistance, deformation, volume change, fatigue resistance, Flexural test and environmental impact must be examined for comprehensive evaluation of this new eco-friendly materials.

It is yet another object of the present invention to show a more inferior performance than conventional cement bricks in compression, water absorption, falling weight and efflorescence, but showed an encouraging result in compression.

According to an aspect of the present invention, a method for preparation of eco-friendly crumb rubber brick & paver block is disclosed.

In accordance with the aspect of the present invention preparation of bricks with solid wastes like sand, granite sawing waste, harbor sediments, perlite, sugarcane, baggase ash, clay waste and fine waste of boron, sewage sludge, waste glass from structural wall and other different wastes is disclosed.

In accordance with the aspect of the present invention said bricks shall be removed from mould and air dried for 1-2 days, thereafter, air dried bricks should be water cured for a minimum period of 14 days wherein curing is carried out by sprinkling water manually or by other means.

In accordance with the aspect of the present invention wherein compressive Strength, absorption Test, efflorescence test, falling weight test was performed on the said eco-friendly bricks.

In accordance with the aspect of the present invention the effective utilization of eco-friendly waste materials has been identified and were replaced in the cement brick mixture as fine aggregate and cement is disclosed.

In accordance with the aspect of the present invention the said eco-friendly bricks have been observed to show a more inferior performance than conventional cement bricks in compression, water absorption, falling weight and efflorescence, but showed an encouraging result in compression.

Further objects, features, and advantages of the invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.

Fig 1 illustrates a block diagram refers to the aforementioned invention disclosing preparation steps and procedure of the said ecofriendly bricks.

Detailed Description of the Invention

It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

According to an exemplary embodiment of the present invention, a method for preparation of eco-friendly crumb rubber brick & paver block is disclosed.

Referring to the figures Fig 1 illustrates the exemplary embodiments of the present invention wherein the said method (1) comprises of, mixing clay (2) in various proportions combined with waste rubber (3) or dry grass (7) or bagasse waste (4) or tree bark (5) or egg shells (6) or in other ecological wastes (8). In one embodiment the said waste crumbled rubber (3) obtained from used and abandoned tires have been collected and these tires are crumbled in machine and rubber that passes through 2.36 mm sieve is being used. The said crumbled rubber (3) should be free from deleterious materials such as stones, and other debris.

In accordance with the exemplary other embodiment other embodiment the said dry grass (7) which is obtained from yard waste is being collected. It is made ground into fine matter and it should pass through 2.36mm sieve and should be free from deleterious substances and in one embodiment the said bagasse waste (4) is being collected and made into fine particles free from deleterious substance and the said material should be homogeneous and pass through 2.36mm sieve.

In accordance with the exemplary embodiment of the present invention the tree bark waste (5) which is collected from trees and ground into fine powder that passes through 2.36mm sieve and it should be free from debris and deleterious material and also with egg shells (6) are collected from various sources such as domestic and commercial sources and these are neatly washed and air dried for two days. They are ground into fine powder in a mixer, the said egg shell should pass 80-micron sieve and also can be mixed with other ecofriendly materials (8) could be used all raw materials should be stored in covered sheds suitable protected from rains.

In accordance with the exemplary embodiment of the present invention the experimental results and mixing proportions of various embodiments were as follows:

Wherein the waste rubber obtained from used and abandoned tires have been collected. These tires are crumbled in machine. The rubber that passes through 2.36 mm sieve is being used. The rubber should be free from deleterious materials such as stones, and other debris.

The dry grass obtained from yard waste is being collected. It is made ground into fine matter. It should pass through 2.36mm sieve and should be free from deleterious substances.

Wherein bagasse waste is being collected and made into fine particles free from deleterious substances. The material should be homogeneous and pass through 2.36mm sieve.


Wherein the tree bark waste is collected from trees and ground into fine powder that passes through 2.36mm sieve. It should be free from debris and deleterious material.

Wherein the egg shells are collected from various sources such as domestic and commercial sources. These are neatly washed and air dried for two days. They are ground into fine powder in a mixer. The egg shell should pass 80 micron sieve.

All raw materials should be stored in covered sheds suitable protected from rains. Pan mixer of adequate capacity should be used for mixing/grinding various raw materials. The total quantity of raw materials proposed to be loaded in the pan mixer for each mix should not exceed the rated capacity of the mixer. Mixing should be carried out till such time uniformity in color and homogeneous mix is obtained. This is likely to take about 5 minutes. The mixing time should be adequate to ensure uniform and homogeneous mix without lumps.

Bricks shall be removed from mould and air dried for 1-2 days. Thereafter, air dried bricks should be water cured for a minimum period of 14 days. Curing is carried out by sprinkling water manually or by other means. It is recommended that the curing period may be extended during cold/wet weather.

Wherein minimum average compressive strength of brick shall not be less than 7.5 N/mm2 when tested as per IS-3495 (part-1): 1976. The compressive strength of any individual brick shall not fall below the minimum average compressive strength by not more than 20%. In case any test result of compressive strength exceeds 10.0 N/mm2 the same limited to 10.0 N/mm2 for the purpose of averaging. In case the locally manufactured clay bricks are of strength less than 7.5N/mm2, cement bricks of compressive strength less than 7.5N/mm2 but not less than 5.0N/mm2 can also be manufactured to compete with locally manufactured clay bricks.

Wherein the Compressive Strength, Absorption Test, Efflorescence Test, Falling weight Test was performed on Eco-Friendly Bricks were performed. From this study the effective utilization of eco-friendly waste materials have been identified and were replaced in the cement brick mixture as fine aggregate and cement. At present Crumbled rubber, Dry Grass, Dry sugarcane pulp, Tree bark were used in replacing fine aggregate in various proportions like 20%, 40%, 60%, 80% and 100%. Egg shell powder was used in replacing cement with 20% and 40%. On the Basis of the test results the following conclusions are drawn. These conclusions also include structural applications of secondary type from medium to low strength requirements, benefiting from other features of this type of brick and pavers.

The graph 1 represents comparison of compressive strength of conventional brick and different proportions of rubber brick. The abscissa represents different proportions of rubber whereas ordinate represents compressive strength in MPa. It is clear that 40% rubber brick attained maximum strength (14.64Mpa) near to that of conventional brick (17.80MPa). The minimum strength is attained to 100% rubber that is 3.15Mpa.

The graph 2 represents comparison of compressive strength of conventional brick and different proportions of dry grass bricks. The abscissa represents different proportions of rubber whereas ordinate represents compressive strength in MPa. It is clear that 40% dry grass brick attained maximum strength (12.39 Mpa) near to that of conventional brick (17.80MPa). The minimum strength is attained to 80% rubber that is 0.89 Mpa.

The graph 3 represents comparison of compressive strength of conventional brick and different proportions of sugar cane bricks. The abscissa represents different proportions of rubber whereas ordinate represents compressive strength in MPa. It is clear that a huge deviation of strength from the conventional brick strength is observed.

The graph 4 represents comparison of compressive strength of conventional brick and different proportions of tree bark brick. The abscissa represents different proportions of rubber whereas ordinate represents compressive strength in MPa. It is clear that there is a significant difference in strength of conventional and tree bark brick.

The graph 5 represents comparison of compressive strength of conventional brick and different proportions of egg shell bricks. The abscissa represents different proportions of rubber whereas ordinate represents compressive strength in MPa. It is clear that 20% rubber brick attained maximum strength (10.76Mpa).

The graph 6 represents overall comparison of conventional brick with different proportions of various bricks. The abscissa represents different proportions of various bricks whereas ordinate represents the compressive strength in MPa. It is seen that maximum strength is attained to 40% rubber followed by 40% dry grass bricks. The minimum strength is attained to sugarcane bricks.

The graph 7 represents overall comparison of conventional brick with different proportions of various bricks. The abscissa represents different proportions of various bricks whereas ordinate represents the maximum compressive strength in MPa. It is seen that maximum strength is attained to rubber brick followed by dry grass brick. The minimum strength is attained to sugarcane brick.

From this study the effective utilization of eco-friendly waste materials have been identified and were replaced in the cement brick mixture as fine aggregate and cement. At present Crumbled rubber, Dry Grass, Dry sugarcane pulp, Tree bark were used in replacing fine aggregate in various proportions like 20%, 40%, 60%, 80% and 100%. Egg shell powder was used in replacing cement with 20% and 40%. On the Basis of the test results the following conclusions are drawn. These conclusions also include structural applications of secondary type from medium to low strength requirements, benefiting from other features of this type of brick and pavers.

1. The compressive strength of crumbled rubber brick with 40% replacement of fine aggregate with crumbed rubber is 14.64 N/mm2. It is almost equal to the strength of conventional cement brick (17.8 N/mm2) on 28th day.
2. The compressive strength of Dry grass brick with 40% replacement of fine aggregate with dry grass is 12.39 N/mm2. It is almost equal to the strength of conventional cement brick (17.8 N/mm2) on 28th day.
3. The compressive strength of sugar cane brick in various proportions were not at all encouraging. So, using of sugarcane pulp in brick manufacturing is not recommendable.
4. The compressive strength of Tree bark brick in various proportions were not at all encouraging. So, using of tree bark in brick manufacturing is not recommendable.
5. The compressive strength of Egg Shell brick with 20% replacement of cement with egg shell powder is 11.00 N/mm2. It is a recommendable value.
From the test results, it is found that the compressive strengths of eco-friendly bricks, Crumbled rubber brick, Dry grass brick, Egg Shell brick showed acceptable aesthetics. The use of these ecofriendly materials resulted in an appreciable reduction of block unit weight from 3.37 kg/m3 to 2.7 kg/m3, which is recommended for using as a construction material like brick and pavers.

Only a few numbers of engineering properties of eco-friendly bricks have been examined in this study, other properties such as skid resistance, abrasion resistance, deformation, volume change, fatigue resistance, Flexural test and environmental impact must be examined for comprehensive evaluation of this new eco-friendly materials.

Overall, Eco-friendly bricks have been observed to show a more inferior performance than conventional cement bricks in compression, water absorption, falling weight and efflorescence, but showed an encouraging result in compression. Thus, crumbled rubber bricks have a great potential to be used for pedestrian pavements, flooring of indoor games. The replacement of fine aggregate with crumbled rubber which is produced from waste tires will reduce the consumption of primary aggregates and produce a high value use for the wastes.

The described exemplary embodiments are to be considered in all respects only as illustrative and not restrictive. Variations in the arrangement of the structure are possible falling within the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

It is therefore submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.