Claims:CLAIMS
WE CLAIM:
1) A method for creating an eco-friendly concrete by recycling waste and industrial products, the method comprising: village and Highway Road construction using green cement is rapidly increasing in construction industry. With the help of advanced technologies, the construction industry problems in terms of time consumption are resolved. Many materials are used in construction field, but concrete has a major role in it. In the production of concrete, naturally occurring materials are used along with cement, which are expensive. To reduce that problem, recycling of waste and industrial byproducts are used to make concrete which is called Green concrete. Green concrete is an ecofriendly concrete and it had less maintenance, material and repair cost than the conventional concrete. This approach reduces the carbon dioxide emission by 32%. The use of these materials in road making is based on technical, economic, and ecological criteria. India has a large network of industries located in different parts of the country and many more are planned for the near future. Several million metric tons’ industrial wastes are produced in these establishments. If these materials can be suitably utilized in highway construction, the pollution and disposal problems may be partly resolved. Keeping in mind the need for bulk use of these solid wastes in India, it was thought expedient to test these materials and to develop specifications to enhance the use of these industrial wastes in road making, in which higher economic returns may be possible.
2) The method as claimed in claim 1, wherein the green cement is utilized in Village and Highway Road construction.
3) The method as claimed in claim 1, wherein the green cement is utilized to reduce the problem of recycling the waste and to use the industrial byproducts to make concrete which can be coined as green concrete.
4) The method as claimed in claim 1, wherein the green cement is utilized to produce ecofriendly concrete having less maintenance, material, repair cost than the conventional
concrete.
5) The method as claimed in claim 1, wherein the green cement is utilized to reduce carbon dioxide emission by 32% in concrete production and the use of these materials in road making is based on technical, economic, and ecological criteria.
6) The method as claimed in claim 1, wherein the green cement is utilized to establish a large network of industries located in different parts of the country, to effectively mobilize their industrial wastes to the road construction industry.
7) The method as claimed in claim 5, wherein the green cement is utilizes materials suitably in highway construction to overcome the pollution and disposal problems.
8) The method as claimed in claim 1, wherein the green cement is utilizes the solid wastes in bulk for village and highway Road construction.
9) A The method as claimed in claim 1, wherein the green cement is utilized to develop specifications to enhance the use of these industrial wastes in road construction which might result in higher economic returns. , Description:FIELD OF THE INVENTION
[0001] The present invention generally relates to a method and system for green construction. More specifically, the invention relates to a method and system for utilizing green concrete for village and highway road construction.
BACKGROUND OF THE INVENTION
[0002] In the entire world the growth of construction industries is increasing day by day. This growth in construction demands construction materials. The concrete is most extensively used building material in the world compared to any other material. The concrete is a mixture of coarse aggregates, sand, cement, water.
[0003] Few applications of concrete are construction of bridges, roads, columns, buildings etc. The advantages of concrete are workable, durable and steady mechanical properties of concrete.
[0004] The disadvantages of concrete such as high energy consumption at various stages, material cost, and environmental pollution etc. To overcome these disadvantages, “Green concrete” has been introduced.
[0005] The main aim of green concrete is to lower the material cost, energy consumption, reduce pollution and achieve reasonable development. Green concrete was produced and placed rapidly. Green concrete is also a concrete which is prepared with concrete waste or by-products of industries which requires less energy when compared to the conventional concrete.
[0006] The material used in green concrete are coarse aggregates, fine aggregates, fly ash, and water. Applications of a green concrete are construction of bridges, roads, columns, buildings etc.
[0007] Post construction pavement performance studies are to be done for these waste materials for the construction of low volume roads with two-fold benefits: (a) it will help clear valuable
land of huge dumps of wastes; (b) it will also help to preserve the natural reserves of aggregates, thus protecting the environment.
[0008] In the absence of other outlets, these solid wastes have occupied several acres of land throughout the country. Keeping in mind the need for reuse of these solid wastes in India, few measures were taken to test these materials and to develop specifications to enhance the use of these industrial wastes in making of road, in which higher economic returns may be possible.
[0009] The possible use of these materials should be developed for construction of low volume roads in different parts of our country.
[0010] Therefore, in light of the above, there is a need for a method and system for formulating necessary specifications and attempting to maximize the use of solid wastes in different layers of the road pavement.
OBJECTIVES OF THE INVENTION
[0011] Minimize the void space between aggregates by optimizing the particle compositions and packing of material.
[0012] The objective of the invention is to reuse the aggregates, to improve the workability, stability, less shrinkage and increase durability and strength.
[0013] The other objective of the invention is to construct village and Highway Road using green concrete. With the help of advanced technologies, the construction industry problems are resolved in terms of time consumption.
[0014] The other objective of the invention is to reduce expense of the production of concrete along with reduction of the dependency on virgin materials.
[0015] The other objective of the invention is to reduce the problem of recycling of waste and use of industrial byproducts in concrete to coin it as a green concrete.
[0016] The other objective of the invention is to prepare a green material which would be eco friendly, reduced maintenance, material and repair cost than the conventional concrete.
[0017] The other objective of the invention is to reduce carbon dioxide emission by 32% in concrete production. The use of these materials in road making is based on technical, economic, and ecological criteria.
[0018] The other objective of the invention is to utilize these materials suitably in highway construction domain; to control pollution and counter disposal problems.
[0019] The other objective of the invention is to investigate these solid wastes for its suitability for the bulk usage in the construction industry.
[0020] The other objective of the invention is to develop specifications to enhance the use of these industrial wastes in road making, in which higher economic returns may be possible.
[0021] The other objective of the invention is to establish a large network of industries located in different parts of the country, to effectively mobilize their industrial wastes to the road construction industry.
[0022] Suitability of green concrete in structures:
1. There is sustainable development and no environmental pollution.
2. The construction cost is less.
3. It requires less maintenance and repair cost.
4. It improves the damping resistance of the structure.
5. It is easy to handle.
6. The green concrete is good thermal and fire resistant with sound insulation than the normal concrete.
7. The speed of construction can be improved.
SUMMARY OF THE INVENTION
[0023] Green Concrete: The green concrete is a revolutionary topic in the history of concrete manufacturing industries. It was first invented in Denmark in the year of 1998. Green concrete is a concrete that is made with construction waste or industrial byproducts or demolition wastes.
[0024] It requires less energy in its production and produces less carbon dioxide. The green concrete is an eco-friendly concrete, and less harm full to the environment. The reduction of carbon dioxide emission in the industry is 30% and the cost of construction is low when compared to the traditional concrete.
[0025] Need for Green Concrete:
a. The main ingredient in concrete is cement and it consists of lime stone (calcium carbonate).
b. The manufacturing process of cement ingredients are heated about 800-1000°c.
c. During the manufacturing of cement, the carbon dioxide is released.
d. Approximately 1kg of cement releases 900grams of carbon dioxide.
e. The green concrete has come in to the existence to reduce the carbon dioxide emission.
[0026] Fly ash is used in concrete admixtures to enhance the performance of concrete roads and bridges. Portland cement contains about 65 percent lime. Some of this lime becomes free and available during the hydration process.
[0027] when fly ash is present with free lime, it reacts chemically to form additional cementitious materials, improving many of the properties of the concrete.
[0028] There are many advantages of incorporating fly ash into a Portland cement concrete which have been demonstrated through extensive research and countless highway and bridge construction projects.
[0029] Benefits to concrete vary depending on the type of fly ash used, proportion used, other mix ingredients, mixing procedure, field conditions and placement.
[0030] Some of the advantages of fly ash in concrete are mentioned below:
1) Higher ultimate strength;
2) Reduced bleeding;
3) Reduced heat of hydration;
4) Reduced permeability;
5) Increased resistance to sulphate attack;
6) Increased resistance to alkali-silica reactivity (ASR);
7) Lowered costs;
8) Reduced shrinkage; and
9) Increased durability
[0031] Where does the Carbon dioxide come from in concrete?
Cement production is responsible for more than 6% of all carbon dioxide emission which is the major factor in the world. India is the third largest cement producer in the world and one of the largest consumers of cement production per capita in the world.
[0032] Rough figures are that India consumes about 1.2 Ton/Year/Capita, while as world average is 0.6 Ton/year/Capita. There are some efforts to reduce the carbon dioxide emission from concrete that is by the use of lower amount of cement and higher number of cementitious materials such as fly ash, blast furnace slag.
[0033] 1 ton of concrete produces carbon dioxide varying between 0.05-0.13 %. Around 95% of all carbon dioxide emission from a cubic meter of concrete is from manufacturing of cement. The reduction of carbon dioxide emission can be achieved through the greater use of cementitious materials.
[0034] Cement:
The most of carbon dioxide in concrete is from manufacturing process of cement. A cubic meter of concrete contains approximately 10% of cement by weight out of all ingredients, cement produces the high amount of carbon dioxide. The following reaction takes place in the manufacturing process of cement.
CaCo3=CaO+Co2
[0035] Aggregates:
The use of virgin aggregates in concrete results to about 1% of all carbon dioxide emissions from a cubic meter of concrete. Therefore, the alternate aggregates which are used in concrete is desirable. The use of local aggregates and recycled aggregates are promising constituents to reduce the transportation cost, fuel cost, carbon dioxide emission.
[0036] Material used for Green Concrete:
Green concrete construction materials are composed of renewable, rather than nonrenewable resources. The green concrete materials are environmentally responsible because the impacts are considered over the life of structure. The available material for green concrete is listed below:
[0037] Locally available:
Construction materials, components and systems found locally and regionally results in saving energy and resources transported to the site.
[0038] Re-furnished or re-manufactured:
It includes saving a material from disposals, repairing, restoring, or generally improving the appearance, performance, quality, functionality.
BRIEF DESCRIPTION OF THE DIAGRAM
[0039] The accompanying figures where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the invention.
[0040] FIG. 1 illustrates a process flow life cycle of green concrete construction in accordance with an embodiment of the invention.
[0041] FIG. 2 illustrates a CO2 emissions status in accordance with an embodiment of the invention.
[0042] FIG. 3 illustrates the green cement construction process in accordance with an embodiment of the invention.
DESCRIPTION OF THE INVENTION
[0043] Accordingly, the system components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0044] In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article or composition that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article or composition. An element proceeded by "comprises . . . a" does not, without more constraints, preclude the existence of additional identical elements in the process, method, article or composition that comprises the element.
[0045] The possible use of these materials should be developed for construction of low-volume roads in different parts of our country. A review of various Industrial wastes for use in the construction of highway has been discussed in this paper.
[0046] FIG. 1 illustrates a process flow life cycle of green concrete construction in accordance with an embodiment of the invention.
[0047] The waste materials are fly ash, blast furnace slag, cement kiln dust phosphogypsum, waste plastic bags, foundry sand and colliery sand, which are the industrial wastes posing problems in the disposal and being deposited near the industries in India.
[0048] In fertilizer industries the Phosphate rock, is processed to make phosphoric acid contains about 70 percent calcium phosphate, also contains a large number of impurities, such as calcium fluoride, chlorides, chromium, and many other compounds.
[0049] In the wet process the phosphate rock is treated with sulfuric acid to produce the phosphoric acid which is the finished product in the fertilizer industry.
[0050] The by-product remaining after the acid conversion is largely calcium sulfate and has been given the name phosphogypsum. Phosphate production generates huge amounts of wastes. The production of each ton of phosphoric acid is accompanied by the production of 4½ tons of phosphogypsum.
[0051] The phosphogypsum is stored in open-air storage areas known as stacks. The stacks form as the slurry containing the by-product phosphogypsum is pumped onto a disposal site. Over time the solids in the slurry build up and forms stack.
[0052] The stacks are generally built on unused or mined out land on the processing site. The surface area covered by stacks ranges from about 5 to 740 acres. The height ranges from about 10 to 200 feet.
[0053] Re-useable or re-cycled:
It is the selected material that can be easily dismantled, reused and recycled at end of their useful life of structure. The materials are used in the green concrete are as follows:
[0054] Coarse aggregates:
1) Fresh local aggregate
2) Recycled Demolition Waste Aggregate
3) Recycled Concrete Material
4) Blast Furnace Slag ¬
[0055] Fine aggregates:
1) Manufactured Sand for Concrete
2) Recycled Glass Aggregate
3) Blast Furnace Slag
4) Fly Ash
[0056] Water
Potable water
[0057] Coarse Aggregates:
The coarse aggregates graded in fractions between 5mm and 40mm, differences in particle shape and surface texture affect the void content and frictional properties of concrete. The coarse aggregates used in the concrete is more than 50% Fresh local aggregates: The fresh local aggregates are available from quarrying sites.
[0058] These aggregates may not be of high-quality stones like granite, basalt etc. but they are of lower quality, recycled Demolition waste aggregates which can be used in concrete mix design.
[0059] The estimation of construction waste generation per capita ranges from 0.4-0.8 kg per day per person. The demolition waste can be recycled and reused.
[0060] The demolition waste can be converted in to coarse aggregates by breaking it in to small pieces of approximately 20 & 10 mm in size. The colour and shape of recycled aggregates is as shown in the below figure. The recycled aggregates properties vary from time to time and place to place.
[0061] The specific gravity of recycled aggregates is less than the normal concrete because it contains mixture of materials. The properties of recycled aggregates are suitable then such aggregates can be used in concrete mix design.
[0062] concrete with recycled aggregates similar to that of normal concrete. The failure of cubes/fracture pattern is similar to normal concrete.
[0063] The sources of recycled concrete materials are demolition of existing building slabs, concrete pavement and bridge structures from private facilities.
[0064] Blast furnace slag:
The waste product from the manufacturing of pig iron and rapid cooling by water molten slag is known as blast furnace slag. The non-metallic co-product produced in the process of steel production is called blast furnace slag. Iron ore is converted to iron by removing the impurities using slagging agents such as coke ash etc.
[0065] The conversion of molten slag to non-metallic liquid contains silicates, alumina silicates of calcium on the top of molten iron. The molten slag is separated from the liquid metal and then cooled.
[0066] The slag product is produced in different forms depending upon the method used to cool the molten slag. The blast furnace slag consists of aluminates, silicates, alumina silicates, silicates.
[0067] Fine aggregates:
Fresh river sand: Fresh River sand is available from the river bed. This sand is useful to manufacture green concrete. Manufacturing sand: Sand can also be manufactured from crushers in the quarrying site.
[0068] On crushing rock stone, it is sieved through the set of sieves between 40-6 mm size. The remaining part passing through the 6 mm sieve is called sand dust.
[0069] The sand dust is a by-product from manufacturing of coarse aggregates. Stone dust is in the form of cubical shape but would also depend upon the type of rock being crushed
[0070] Cementation’s material fly ash:
Fly ash is a by-product produced from the operation of coal fired power plants. The divided fine particles from the exhaust gases are collected in electrostatic precipitator. These particles are called fly ash.
[0071] The color changing from grey to black represents the increasing percentage of carbon. The particle of fly ash is very smooth and spherical shape. Particles ranges from 1 to 150 µm in diameter.
[0072] Technical benefits of the fly ash in green concrete:
1. Higher ultimate strength
2. Increased durability
3. Improved workability
4. Reduced bleeding
5. Reduced shrinkage.
[0073] Green concrete mix design:
The mix design of green concrete is the same procedure for conventional concrete or traditional concrete. The constituent materials of concrete are as shown in below figure. They occupy minimum volume and to give minimum voids in the concrete. The individual materials of concrete results in large voids. Achieving higher density for concrete would be possible by using smaller particles together.
[0074] Now-a-days disposal of different wastes produced from different Industries is a great problem. These materials pose environmental pollution in the nearby locality because many of them are non-biodegradable. In recent years, applications of industrial wastes have been considered in road construction with great interest in many industrialized and developing countries.
[0075] Those skilled in the art will realize that the above recognized advantages and other advantages described herein are merely exemplary and are not meant to be a complete rendering of all of the advantages of the various embodiments of the invention.
[0076] The system, as described in the invention or any of its components may be embodied in the form of a computing device. The computing device can be, for example, but not limited to, a general-purpose computer, a programmed microprocessor, a micro-controller, a peripheral integrated circuit element, and other devices or arrangements of devices, which can implement the steps that constitute the method of the invention. The computing device includes a processor, a memory, a non-volatile data storage, a display, and a user interface.
[0077] In the foregoing specification, specific embodiments of the invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.