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Load Bearing Materials From Pozzolanic Ash

Abstract: A fly ash based cement-free polymeric composite construction material for civil and mining applications, wherein the material comprises a mixture of fly ash, lime, aggregate, Gypsum and polymeric additive, prepared in water. The ratio of constituents thereof comprises; fly ash in a range of 40-80% of the overall dry weight; lime, preferably hydrated lime or lime sludge added as per the inherent lime content in the fly ash, in a range of 5-40% of the overall dry weight; overburden material or aggregate in a range of 10-40% of the overall dry weight; Gypsum in a range of 2-5% of the overall dry weight; and polymeric additive; wherein water content in the mixture is 0.35-0.55 times the cementing content consisting of fly ash, lime and Gypsum and up to 80% of water is replaced by the polymeric additive. According to the present invention, a method for making this fly ash based cement-free polymeric composite construction material is also provided. The material can be used directly or for moulding the components for respective targeted mining and civil engineering applications. FIGURE 1

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
17 May 2017
Publication Number
47/2018
Publication Type
INA
Invention Field
CHEMICAL
Status
Email
patent@royzz.com
Parent Application
Patent Number
Legal Status
Grant Date
2024-01-03
Renewal Date

Applicants

IITB-Monash Research Academy
IIT Bombay, Powai, Mumbai

Inventors

1. Tushar Gupta
1122 Janakpuri, Bareilly, UP 243122
2. Prof.T.N.Singh
Department of Earth Sciences, IIT Bombay, Powai, Mumbai - 400076
3. Dr.Mohan Yellishetty
Room 147,60,Clayton Campus, Monash University, Clayton,Melbourne Victoria - 3168

Specification

FORM - 2 THE PATENTS ACT, 1970 (39 of 1970) & THE PATENTS RULES, 2003 COMPLETE SPECIFICATION (See section 10 and rule 13) Title: Load Bearing Materials from Pozzolanic Fly Ash Applicant : IITB MONASH RESEARCH ACADEMY Nationality: INDIAN Address : IIT Bombay Powai, Mumbai 400 076, India THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER, IN WHICH IT IS TO BE PERFORMED FIELD OF INVENTION The present invention relates to an environment friendly, economic, and efficient fly ash based construction material. In particular, the present invention relates to a fly ash based, cement free, polymeric construction material. More particularly, the present invention relates to a fly ash based cement-free polymeric construction material for civil and mining applications. BACKGROUND OF INVENTION The voluminous coal burning in coal-powered power plants causes huge amounts of fly ash being generated each year. This is particularly burdensome especially in countries like India where ash content of coal is very high (30-50%). These vast quantities of fly ash are never utilized fully, which results in a large portion thereof to be dumped in form of open ash pond or ash dykes. This wastes large land areas, simultaneously causing environmental problems like particulate pollution in local areas, the pollution of water bodies by heavy metal leaching, etc. This affects both flora and fauna of the region adversely. Urgent need of utilization of these vast amounts of fly ash generated each year, particularly in coal-powered power plants has led to many possible avenues of use of fly ash. However, even after many efforts, almost half of the fly ash still remains unused due to challenges like transportation cost, lack of research and huge volumes. Concrete and construction industry utilizes largest percentage of fly ash, since fly ash is a pozzolan and it starts exhibiting cement like properties when conjugated with a source of lime. This nature of fly ash has resulted in its use in various construction places as a partial replacement of cement. Even though the fly ash is fairly cheap, the processing of materials with fly ash either requires additional binders or requires special curing conditions of higher temperature, pressure etc., which not only increases costs but can also be environmentally taxing. In addition, the application becomes costlier due to transportation costs. The following are the major factors contributing to the underuse of fly ash: Though the cost of fly ash is very less, the associated transportation cost, i.e. the cost of transporting ash from the place of generation (coal burning power plants) to place of application (generally civil construction in towns and cities) is quite high. Huge volumes of fly ash generated in coal burning plants are being used in various fields of application, however, their proportional utilization is quite less as compared to the volume of ash being continuously generated. There is also a lack of research with regards to the utilization of the fly ash to its full potential, especially in using its pozzolanic nature during its application. PRIOR ART WO 2009007994 A2 discloses a composition of the material for the production of fly ash pre-polymerized resin composites. More particularly the invention relates to polymeric binding compositions and particularly to coating compositions useful as an adhesive for clay bricks, fly ash bricks, aerated concrete blocks, cement blocks etc., used as building blocks for civil construction activities, as plaster/render for building surfaces, as a crack filler, as a repair plaster, as a fire and heat resistant plaster/ mastic etc. The product is designed to be used in building / construction industry as a self-curing, crack resistant, eco-friendly, ready to use composite useful as a brick / block laying adhesive, render/plaster, crack filler, repair plaster, etc. The composition composed of ultrafine pulverized fly ash, a low viscosity Poly vinyl acetate (VAM), styrene acrylic, pure acrylic, CNSL (cashew nut shell liquid), Silicon, Shellac type emulsion polymer as a binder and water. The composition also preferably contains one or more of a dispersant, a de-foamer, a plasticizer, a thickener, a drying agent, preservative, a fungicide, silica or quartz fillers of different mesh and an ingredient to control the pH of the composition. However, it uses fly ash with cementitious and polymeric binding compositions. In particular, it uses coating compositions primarily for civil/building construction. W01997009283 A1 discloses the composite materials having fly ash as a constituent is manufactured into a sulfur-less gypsum-like material, a Portland cement-like material and a lightweight aggregate. Methods for making such composite materials include combining precipitated calcium carbonate and either Class C-fly ash, Class F-fly ash and/or bottom ash in particular ratios by adding water to dry material and subsequently allowing the material to dry to create the above-described products. Methods for forming and using such composites include the use of a single piece gatefold form for casting manifold surfaces, a panel system for forming concrete walls and a system for creating retaining walls. However, unlike the present invention, the composite material proposed in this document is manufactured as a sulfur-less gypsum-like material, a Portland cement-like material and a lightweight aggregate to be used for casting components by a single-piece gatefold form for low-load applications only. WO 2002075052 A1 discloses a pavement structure for use in applications where special requirements to load bearing capacity and durability must be fulfilled, for example in warehouses, on docks, airports, distribution centers, retail areas, goods terminals, industrial floors, production halls and other places where heavy loads and excessive wear can be expected, said material consists of an asphalt part and a slurry part, said asphalt having a porosity of 20 - 40 %, and said slurry substantially completely fills the voids in the asphalt, the slurry being a composite material comprising a binder, additives and water, and optionally cement, micro-silica, fly ash or other pozzolanic materials as well as optionally sand or other fine aggregates, wherein the pavement material (1) comprises at least one reinforcement layer (3, 4, 21). Furthermore, a method for the construction of a pavement, as well as use of a material is disclosed. However, here the pavement structure includes an asphalt part having voids and a slurry part to substantially fills these voids completely. The slurry is a composite material comprising a binder, additives and water, and optionally cement, micro-silica, fly ash or other pozzolanic materials and optionally sand or other fine aggregates. Moreover, the pavement material comprises at least one reinforcement layer of fibers, wires or rods. Whereas, the present invention is fly ash based and without any reinforcement structure. WO 2013123391 A1 discloses a paving material which is useful to accommodate efficient movement of heavy loads, including but not limited to heavy loads necessitated by large-scale agricultural operations. The paving material comprises a vinyl acetate ethylene dispersible polymer, pure lime or air-lime and/or waste material. The document also discloses a process for producing such a paving material for improving the durability of dirt or gravel road by making a multi-layered superior surface including an inferior layer of said polymer and lime and compacting the superior surface on said road. However, this material is different from the present invention consisting of a cement-free polymeric construction material using high volumes of fly ash. Further, several other related patents we also studied and analyzed for their application in the fields concerned with subject matter of this invention, which are elaborated in the following: US RE30943 entitled: Stabilized mixture, includes a mixture composed of cement kiln dust (4-16%), fly ash (6-24%), aggregate (60-90%), OPC 1% and 88% fly ash composite. The mixture was prepared according to the method in ASTM C-593 using a mechanical compacter for 7, 14, 28 days, 100°F curing and 4 hours dipping. This mixture can be used as base course of road and some part of surface course, which achieves good strength in a short time. However, the disadvantage of this mixture is the additional cost and energy requirement due to mechanical compaction. However, it uses cement and ash content used is very little and it has less strength and no water resistance. EP 0479411 A2 entitled: Block moulded of coal ash for civil engineering and construction work, includes fly ash (40-80%), aggregates, feldspar, bentonite and dolomite (20-60%) and moulded by dry type press and burning at 1300°C. These very high strength blocks can be used for pavement blocks and hollow blocks for pavements and sidewalks. However, it requires a cost-intensive manufacturing process by the use of high pressure and temperature. US 8323398 B2 entitled: Construction material based on activated fly ash, includes fly ash (55-80%), BF slag (5-40%), alkaline silicates (0.8-4%), alkaline carbonates (1,5-9%) and a strong base booster. It is made by prepping activated slurry, by prepping a dry mix of aggregate and fly ash and by mixing them and adding an activator. This is a green material having a very high strength at lower curing time, it uses no cement and can be used as a substitute of cement anywhere. However, it uses heavy alkali and other alkaline materials, thus incurs additional costs, and needs complex logistics. US 0055374 A1 entitled: Fly ash used in construction applications, includes pulverized fly ash (45%), coarse fly ash (45%) and kiln dust (10%). It is made by mixing all constituents with water (15%) in a mould and applying a pressure (600001b in 2 x 2 inch). Due to its high strength, it can be used for facing wall, retaining wall block, paving or patio stones, pottery, parking, barrier, floor, mortar, brick etc. Further, a higher utilization of fly ash also makes it a green material, However, the cost of this material is very high due to compression process used in its preparation. Moreover, it offers no special protection against hydrological resistance. US 6669773 B2 entitled: Fly ash/mixed plastic aggregate and products made therefrom, includes fly ash (10-90%) and polymers including plastics and others (10-90%). It is made by melt-blending of fly ash and polymers and then cooling the blend. It can be used as a synthetic lightweight aggregate for concrete, asphalt etc. and therefore is a useful green product giving good strength for concrete. However, it requires additional logistics and cost of preparation without any significant enhancement in strength as compared to Ordinary Portland Cement (OPC). US 2564690 A entitled: Hydrated lime-fly ash fine aggregate cement, includes fly ash, hydrated lime and aggregate. It is made by curing with water being put regularly. It can be used as a cement and protective coating as a composite. It is an easy green material, comparatively low-strength having several applications. However, it offers no hydrological resistance analysis or enhancement. US 3854968 A entitled: Lime-fly ash cementitious mixture with improved hardening and expansion characteristics, includes fly ash (10-15%), lime sulphate > 1%, or lime + Gypsum (1-3%) aggregate. It is made at 100°F by curing for require time. It can be used as a subsurface base material or as a soil stabilization agent due to its good strength. It is also a green material. However, it has no hydrological consideration and requires additional cost of curing due to the requirement of oven and also compression in some cases. US 2937581 A entitled: Road building method, includes crude fly ash (10-30%), soil (70-90%) and lime (2-9%). The method involves mixing the composition with water, compacting it, curing for one week to one year, remixing, compaction and setting to ambient conditions. The method is excellent for subsurface and road making. It is a good alternative to traditional binders. However, it takes long time for curing and involves a lengthy process. Moreover, the remixing does not make it usable throughout the long process cycle. Further, it offers no protection against water. NON-PATENT LITERATURE & DISADVANTAGES THEREOF The article entitled: Use of Recycled Aggregate and Fly Ash in Concrete Pavement published in American J. of Engineering and Applied Sciences 4 (2): 201-208, 2011 discusses the problem of recycled materials aggregate from the demolished concrete structures and fly ash from burning coal to shows the possible application as structural and non-structural components in concrete structures. This article aims to evaluate the feasibility of using concrete containing recycled concrete aggregate (RCA) and fly ash (FA) in concrete pavement. For this purpose, two water cement ratios (0.45 and 0.55), the compressive strength, modulus of elasticity and flexural strength for concrete with recycled aggregate.25% in mass and fly ash 0.25% in mass replacing cement were considered. The material properties of recycled aggregate concrete with fly ash indicate comparable results with that of concrete with natural aggregate and without fly ash. Therefore, this recycled aggregate could be used in concrete pavement to promote sustainability of concrete. However, fly ash use according to this study is limited to just 15% for optimum results, unlike the present invention using high volumes of fly ash without any difficulty. Another article by Quiroz, Oscar Inez entitled: "Recycling waste latex paint in overlays, rigid pavements, and pervious concrete" published in 2011 in UNLV Theses, Dissertations, Professional Papers, and Capstones, page 1223. The article discusses the study on recycling waste latex paint (WLP) in concrete consisted of three phases. The 1st phase determined the ability to replace commercial latex with WLP in concrete for overlays. The 2nd phase aimed at recycling waste latex paint in rigid pavement concrete and to find similarities between WLP concrete and styrene-butadiene rubber (SBR) latex concrete. Finally, the 3rd phase studies the effects of using WLP in pervious concrete. However, it can use maximum 25% fly ash as cementitious replacement in WLP compared to high volume fly ash use proposed as per the present invention. The article entitled: Analysis and Design of a Stabilized Fly Ash as Pavement Base Material by A. Hilmi Lav, M. Aysen Lav, A. Burak Goktepe discusses a study to utilize a class F fly ash as base material in road pavements. Since class F fly ashes do not manifest desirable engineering properties for this purpose, the material was stabilized with cement. Fly ash may be utilized with or without aggregate as a pavement layer. Here, only aggregate free stabilized mixtures (fly ash and cement only) were used to utilize high volumes of this waste material. Cement content in the stabilized, laboratory prepared samples were between 2%, 4%, 8% and 10% by total weight. Initially, Texas triaxial test was performed to obtain the fundamental properties of the cement stabilized material for analyzing the pavement structure. However, this study uses cement (2-10% by weight) stabilized fly ash as base material for the construction of road pavements. Whereas, the present invention proposes a cement-free polymeric construction material using high volumes of fly ash. The article entitled: Class F Fly-Ash-Amended Soils as Highway Base Materials (Journal of Materials in Civil Engineering 17(6) ■ December 2005) discloses Class F fly ash cannot be used alone in soil stabilization applications as it is not self-cementing. An activator such as Portland cement or lime must be added to produce cementitious products often called pozzolan stabilized mixtures. The developed mixture must possess adequate strength and durability, should be easily compacted, and be environmentally friendly. Roadways have a high potential for large volume use of the fly ash stabilized soils. The main objective of this study is to investigate the use of Class F fly ash amended soil-cement or soil-lime as base layers in highways. Results of the study show that the strength of a mixture is highly dependent on the curing period, compaction energy, cement content, and water content at compaction. However, this study uses confirms that lime treatment does not provide sufficient strength for designing the mixtures as highway bases. Therefore, cement must necessarily be used for producing cementitious products (for the construction of road pavements. Whereas, the present invention proposes a cement-free polymeric construction material using high volumes of fly ash. The article entitled: Properties of FaL-G masonry blocks by Jayasudha R. K., Radhakrishna, Niranjan P.S. published in the International Journal of Research in Engineering and Technology (elSSN: 2319-1163|plSSN: 2321-7308) discusses that Fly ash, Lime and gypsum are industrial wastes generated in millions of tones every year. Utilization of these materials is effective way of disposing the pollutants. In this research fly ash, lime, and gypsum were used in definite proportion along with quarry dust to produce FaL-G blocks which were tested for compressive strength, water absorption, IRA, density, flexure and modulus of elasticity. Masonry prisms were constructed using FaL-G blocks to determine shear bond strength, flexural bond strength, low rise masonry shear, modulus of elasticity, compressive strength and masonry efficiency. It was found that FaL-G masonry blocks can replace conventional masonry units. However, this study does not use any cement-free polymeric construction material using high volumes of fly ash as disclosed by the present invention. Moreover, it confirms only the suitability of the material in a specific masonry block form and not as a cement-free polymeric construction material freely useful in civil/ mining construction activities according to this invention. Therefore, none of the patent or non-patent literature discussed above discloses the basic composition/features disclosed by the present invention. OBJECTS OF THE INVENTION Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows: An object of the present invention is to provide an economic, effective and environment friendly construction material for use mining and civil industries. Another object of the present invention is to provide a construction material which is cement free. Still another object of the present invention is to provide a polymer construction material which is based on abundantly available fly ash. Yet another object of the present invention is to provide a fly ash based polymer construction material that does not require any additional binders or special curing conditions of temperature, pressure etc. A further object of the present invention is to provide a fly ash based polymer construction material, which contains a large volume of fly ash to make it a low-cost material. A still further object of the present invention is to provide a sustainable construction material, which can replace timber in making props, pillars or columns, beams and similar applications. A yet further object of the present invention is to provide a sustainable construction material, which can be used directly for the construction of haul roads, pavements, dump slopes and the like. These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way. SUMMARY OF THE INVENTION In accordance with the present invention, there is provided a fly ash based cement-free polymeric composite construction material for civil and mining applications, wherein the material comprises a mixture of fly ash, lime, aggregate, Gypsum and polymeric additive, prepared in water. Typically, the percentage composition of the constituents thereof is variable as a function of the class of the fly ash utilized therein. Typically, the percentage composition of the constituents thereof is variable as a function of the percentage of the lime and the pozzolanic reactants Aluminum Oxide (Al203), Ferric Oxide

Documents

Application Documents

# Name Date
1 Power of Attorney [17-05-2017(online)].pdf 2017-05-17
2 Form 1 [17-05-2017(online)].pdf 2017-05-17
3 Drawing [17-05-2017(online)].pdf 2017-05-17
4 Description(Complete) [17-05-2017(online)].pdf_799.pdf 2017-05-17
5 Description(Complete) [17-05-2017(online)].pdf 2017-05-17
6 Form 3 [18-05-2017(online)].pdf 2017-05-18
7 Assignment [18-05-2017(online)].pdf 2017-05-18
8 201721017300-Proof of Right (MANDATORY) [22-12-2017(online)]_65.pdf 2017-12-22
9 201721017300-Proof of Right (MANDATORY) [22-12-2017(online)].pdf 2017-12-22
10 Abstract1.jpg 2018-08-11
11 201721017300-OTHERS [30-12-2021(online)].pdf 2021-12-30
12 201721017300-EDUCATIONAL INSTITUTION(S) [30-12-2021(online)].pdf 2021-12-30
13 201721017300-FORM 18 [31-12-2021(online)].pdf 2021-12-31
14 201721017300-RELEVANT DOCUMENTS [14-01-2022(online)].pdf 2022-01-14
15 201721017300-POA [14-01-2022(online)].pdf 2022-01-14
16 201721017300-FORM 13 [14-01-2022(online)].pdf 2022-01-14
17 201721017300-FER.pdf 2022-01-21
18 201721017300-FORM-8 [24-02-2022(online)].pdf 2022-02-24
19 201721017300-RELEVANT DOCUMENTS [29-04-2022(online)].pdf 2022-04-29
20 201721017300-PETITION UNDER RULE 138 [29-04-2022(online)].pdf 2022-04-29
21 201721017300-OTHERS [02-05-2022(online)].pdf 2022-05-02
22 201721017300-FER_SER_REPLY [02-05-2022(online)].pdf 2022-05-02
23 201721017300-DRAWING [02-05-2022(online)].pdf 2022-05-02
24 201721017300-COMPLETE SPECIFICATION [02-05-2022(online)].pdf 2022-05-02
25 201721017300-CLAIMS [02-05-2022(online)].pdf 2022-05-02
26 201721017300-ABSTRACT [02-05-2022(online)].pdf 2022-05-02
27 201721017300-US(14)-HearingNotice-(HearingDate-14-11-2023).pdf 2023-10-16
28 201721017300-Correspondence to notify the Controller [06-11-2023(online)].pdf 2023-11-06
29 201721017300-Annexure [06-11-2023(online)].pdf 2023-11-06
30 201721017300-PETITION UNDER RULE 138 [27-11-2023(online)].pdf 2023-11-27
31 201721017300-OTHERS [27-11-2023(online)].pdf 2023-11-27
32 201721017300-EDUCATIONAL INSTITUTION(S) [27-11-2023(online)].pdf 2023-11-27
33 201721017300-Written submissions and relevant documents [29-12-2023(online)].pdf 2023-12-29
34 201721017300-PatentCertificate03-01-2024.pdf 2024-01-03
35 201721017300-IntimationOfGrant03-01-2024.pdf 2024-01-03

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