Claims:We Claim:
1. A method of producing a compact and highly dense construction material, the method comprises a step of mixing:
a first set of cementitious material having mode average particle diameter (D1) in the range of 1/3 to 1/5 of a mode average particle diameter (D) of a smallest fine aggregate fraction of a raw construction material;
a second set of cementitious material having mode average particle diameter (D2) in the range of 1/3 to 1/5 of the mode average particle diameter (D1) of the first set of cementitious material;
a third set of cementitious material having mode average particle diameter (D3) in the range of 1/3 to 1/5 of the mode average particle diameter (D2) of the second set of cementitious material; and
a fourth set of cementitious material have mode average particle diameter (D4) in the range of 1/3 to 1/5 of the mode average particle diameter (D3) of the third set of cementitious material to obtain the construction material.

2. The method as claimed in claim 1 further comprises:
determining a smallest fine aggregate fraction of a raw construction material via applying a gradation process; and
determining the mode average particle diameter (D) of said smallest fine aggregate fraction.

3. The method as claimed in claim 2, wherein said gradation process comprises physical gradation of the raw construction material ranging from smallest fine aggregates to coarse aggregates.

4. The method as claimed in claim 1, further comprising:
determining, through a PSD curve analysis interpretation, a mode average particle diameter of the first set of cementitious material; and
subjecting the first set of cementitious material to a mechanical modification process in a controlled manner until its mode average particle diameter (D1) is in the range of 1/3 to 1/5 of the mode average particle diameter (D) of the smallest fine aggregate fraction of a raw construction material.
5. The method as claimed in claim 1, further comprising:
determining, through a PSD curve analysis interpretation, a mode average particle diameter of the second set of cementitious material; and
subjecting the second set of cementitious material to a mechanical modification process in a controlled manner until its mode average particle diameter (D2) is in the range of 1/3 to 1/5 of the mode average particle diameter (D1) of the first set of cementitious material.

6. The method as claimed in claim 1, further comprising:
determining, through a PSD curve analysis interpretation, a mode average particle diameter of the third set of cementitious material; and
subjecting the third set of cementitious material to a mechanical modification process in a controlled manner until its mode average particle diameter (D3) is in the range of 1/3 to 1/5 of the mode average particle diameter (D2) of the second set of cementitious material.

7. The method as claimed in claim 1, further comprising:
determining, through a PSD curve analysis interpretation, a mode average particle diameter of the fourth set of cementitious material; and
subjecting the fourth set of cementitious material to a mechanical modification process in a controlled manner until its mode average particle diameter (D4) is in the range of 1/3 to 1/5 of the mode average particle diameter (D3) of the third set of cementitious material.

8. The method as claimed in claim 1, wherein the second set of cementitious material is obtained by subjecting the first set of cementitious material to a mechanical modification process.

9. The method as claimed in claim 1, wherein the third set of cementitious material is obtained by subjecting the first or the second set of cementitious material to a mechanical modification process.

10. The method as claimed in claim 1, wherein the first set of cementitious material comprises at least one hydraulic material optionally along with at least one pozzolanic material.

11. The method as claimed in claim 10, wherein the first set of cementitious material comprises a combination of at least one hydraulic material and at least one pozzolanic material, with the at least one hydraulic material being present in amount greater than or equal to 20% of weight of the first set of cementitious material.

12. The method as claimed in claim 1, wherein the second set of cementitious material comprises at least one hydraulic material optionally along with at least one pozzolanic material.

13. The method as claimed in claim 12, wherein the second set of cementitious material comprises a combination of at least one hydraulic material and at least one pozzolanic material, with the at least one hydraulic material being present in amount greater than or equal to 20% of weight of the second set of cementitious material.

14. The method as claimed in claim 1, wherein the third set of cementitious material comprises at least one hydraulic material optionally along with at least one pozzolanic material.

15. The method as claimed in claim 14, wherein the third set of cementitious material comprises a combination of at least one hydraulic material and at least one pozzolanic material, with the at least one hydraulic material being present in amount greater than or equal to 20% of weight of the third set of cementitious material.

16. The method as claimed in claim 1, wherein the fourth set of cementitious material is selected from a group comprising at least one pozzolanic material, at least one silica based material and combinations thereof.
17. The method as claimed in any of claims 10 to 15, wherein the at least one hydraulic material is selected from a group comprising of Portland cement, modified Portland cement, or masonry cement, ground granulated blast-furnace slag, hydraulic hydrated lime, white cement, calcium aluminate cement, silicate cement, phosphate cement, high-alumina cement, magnesium oxychloride cement, oil well cements, and combinations thereof.

18. The method as claimed in any of claims 10 to 16, wherein the at least one pozzolanic material is selected from a group comprising of fly ash, blast furnace slag, volcanic ash material, quartz material, pond ash, chemically modified fly ash, chemically modified blast furnace slag, chemically modified quartz, and combinations thereof.

19. The method as claimed in claim 1, wherein an amount (W1) of the first set of cementitious material is in a range of 66 to 80 wt% of the construction material.

20. The method as claimed in claim 1, wherein an amount (W1) of the first set of cementitious material is about 75 wt% of the construction material.

21. The method as claimed in claim 1, wherein an amount (W2) of the second set of cementitious material is in a range of 20 to 34 wt% of the first set of cementitious material.

22. The method as claimed in claim 1, wherein an amount (W2) of the second set of cementitious material is about 25 wt% of an amount (W1) of the first set of cementitious material.

23. The method as claimed in claim 1, wherein an amount (W3) of the third set of cementitious material is in a range of 20 to 34 wt% of an amount (W2) of the second set of cementitious material.

24. The method as claimed in claim 1, wherein an amount (W3) of the third set of cementitious material is about 25 wt% of an amount (W2) of the second set of cementitious material.

25. The method as claimed in claim 1, wherein an amount (W4) of the second set of cementitious material is in a range of 20 to 34 wt% of an amount (W3) of the third set of cementitious material.

26. The method as claimed in claim 1, wherein an amount (W4) of the second set of cementitious material is about 25 wt% of an amount (W3) of the third set of cementitious material.
, Description:TECHNICAL FIELD
The present invention relates to a method of producing a compact and highly dense construction material.

BACKGROUND
Concrete is a highly consumable and utilizable man-made construction material on earth. Infrastructure such as buildings, roads, airports, dams, ports are always considered as the key indicator of development. Developing such infrastructure always requires the use of construction material such as raw/aggregate concrete materials along with the ordinary Portland cement. The use of ordinary raw construction material always questions the final strength of infrastructure. Ordinary Portland cement plays a major role to ensure the higher strength of the concrete infrastructure. However, the ordinary Portland cement poses a great threat to the environmental imbalance in terms of air pollution, deforestation, and/or soil erosion.

Further, the production of the ordinary Portland cement consumes very high amount of energy and on the other hand produces high amount of CO2. Hence, it is always desirable to minimize the use of ordinary Portland cement and maximize the strength of the construction material. However, the strength and durability of concrete infrastructure always depends on the quality of material, lattice structure, and ratio of the ordinary Portland cement mixed with the raw construction materials. On the other hand modifying the mechanical and chemical properties as well as minimizing the ordinary Portland cement ratio gives adverse effect on the final strength and durability of the concrete infrastructure.

Hence, it is a continuous attempt by the researchers to produce a compact and highly dense construction material with minimum use of ordinary Portland cement. At the same time, it is also desirable to maintain the final strength and durability of the concrete infrastructure. It is also noted that the strength and durability of the concrete infrastructure depends on the particle bonding of the ordinary Portland cement along with the particles of other raw/aggregate concrete materials.

Generally, during the concreting process the raw/aggregate concrete material particles along with the ordinary Portland cement particles are closely packed to form the hard rock like concrete structure. The cement reaction chemistry in the presence of the raw/aggregate concrete particles, cement particles, and water to undergo the hydration process are the reactions on which the final strength and durability of the concrete infrastructure depends. This hydration process along with the packing efficiency of the cement and aggregate particles provide high strength to the final concrete structure.

Further, it is a known fact that by improving the packing efficiency of the raw/aggregate concrete particles the amount of cement as required for binding said raw/aggregate concrete particles is minimized. Accordingly, it is always desirable to produce a compact and highly dense construction material which can provide maximum binding capability to the raw/aggregate concrete particles.

Further, the maximum binding capability of the raw/aggregate concrete particles also increases the overall strength of the final concrete infrastructure. The binding capacity can be increased when the cement and the aggregate particles are closely packed in the three dimensional structure. Generally, the ordinary Portland cement ratio is increased to achieve the higher binding capability of the concrete aggregate particles. Further, the cement reaction kinetic is also very important to attain the maximum binding capability of the concrete aggregate particles to form compact and highly dense construction material.

There are conventional methods for attaining said results of producing closely packed construction materials and the aggregate particles. Said methods include mixing ordinary Portland cement, fine aggregate materials, and course aggregate materials in an optimum percentage to obtain a proper ratio of the particle packing structure.

In one method, composite cements are prepared with low clinker dosage and high flexural compression ratio. The preparation method is to mix three size ranges of powder particles 1) high-activity supplementary cementing material with grain size less than 8mu m; 2) cement clinker particles with the grain size 8-24mu m; 3) low-activity supplementary cementing material or inert filler with the grain size 24-80mu m and obtain the composite cement. The volume percentages of the three size ranges of powder particles are 25-40%, 25-30% and 30-45% respectively. The clinker volume percentage of the composite cement is 25-30%.

In one method, a binder premix is prepared that reduces associated emissions of carbon dioxide by the final concrete. As such, the binder premix includes from 0.2% to 63% of a material of an ultrafine particle size category, including individual particles with a D90 value less than 1 µm and/or with a BET specific surface area greater than 5 m2/g; from 8% to 63% of selected Portland cement including particles with a D90 value less than 30 µm and from 25% to 85% of a material, other than the cement, of a fine particle size category, including particles for which the D10 and D90 values are from 1 µm to 120 µm and with a BET specific surface area less than 5 m2/g.

In one method, new concrete compositions are prepared. Such concrete includes in parts by weight: 100 Portland cement; 50 to 200 of a sand having a single grading with a D10 to D90 between 0.063 and 5 mm, or a mixture of sands, the finest sand having a D10 to D90 between 0.063 and 1 mm and the coarsest sand having a D10 to D90 between 1 and 4 mm; 10 to 50 of a particulate, substantially non-pozzolanic material having a mean particle size less than 15 µm; 0.1 to 10 of a water-reducing super plasticizer; and 10 to 30 of water; concrete is substantially free of silica fume.

In another method, an ultra-high-performance, self-compacting light-colored concrete is prepared. Such concrete comprises a cement; a mixture of calcined bauxite sands of different grain sizes, the finest sand having an average grain size of less than 1 mm and the thickest sand having an average grain size of less than 10 mm; optionally silica fume, whereby 90% of the particles thereof have a size of less than 1 mm and the average diameter is approximately 0.5 mm, said silica fume representing at most 15 parts by weight per 100 parts of cement; an antifoaming agent; water-reducing superplasticiser; optionally fibers; and water. Concrete also comprises: ultrafine calcium carbonate particles having a specific surface area that is equal to or greater than 10 m2/g and a form factor (IF) that is equal to or greater than 0.4. The grain size distribution of the cements, sands, ultrafine calcium carbonate particles and silica fume is such that at least three, and at most five, different grain size ranges are present; the ratio between the average diameter of one grain size range and that of the range immediately above is approximately 10.

In another method, the packing density of blended cement paste is increased by theoretically finding out a gap-graded particle size distribution (PSD) and modifying according to the wet density of actual paste. This resulted in a decreased water requirement and an increased packing density of blended cement paste, and modified gap-graded PSDs gave further effects. The microstructure of gap-graded blended cements was much more homogeneous and denser than that of reference blended cement, therefore both early and late mechanical properties of low clinker gap-graded blended cements was improved significantly and even higher than those of Portland cement.

In another method, carbon dioxide emissions from concrete are prevented by adding mineral admixtures like fly ash and metakaolin. In one experimental result, by replacing 30% of cement with fly Ash, and 10% of cement with metakaolin, workability and compressive strength for packing of the concrete were greatly improved.

In another method, by appropriately selecting the particle size distributions of cement and fly ash, equivalent 1d and 28d strengths are achieved with about a 35% volumetric replacement of cement with fly ash, while maintaining the same volume fraction of water in the mixture, thus providing an actual 35% reduction in cement content.

However, still such methods do not provide the required optimum particle packing and do not ensure the prolonged life and high strength of the construction material.

SUMMARY
In view of the aforesaid needs and shortcomings in the state of the art, in an aspect, the present invention provides a method of producing a compact and highly dense construction material.

It will be apparent to a person skilled in the art that the present invention is a method of producing a compact and highly dense construction material. Further, said method is adapted to overcome the outdated composition of the ordinary concrete materials and provide improved binding capabilities to the concrete aggregate particles of the construction materials.

In accordance with the present invention, the method comprises a step of mixing: a first set of cementitious material having mode average particle diameter (D1) in the range of 1/3 to 1/5 of the mode average particle diameter (D) of a smallest fine aggregate fraction of a raw construction material; a second set of cementitious material having mode average particle diameter (D2) in the range of 1/3 to 1/5 of the mode average particle diameter (D1) of the first set of cementitious material; a third set of cementitious material having mode average particle diameter (D3) in the range of 1/3 to 1/5 of the mode average particle diameter (D2) of the second set of cementitious material; and a fourth set of cementitious material have mode average particle diameter (D4) in the range of 1/3 to 1/5 of the mode average particle diameter (D3) of the third set of cementitious material to obtain the construction material.

The advantages of the present invention include, but are not limited to, providing Micro to Nano particle level lattice void fillers by mixing the constituent materials, each having graded diameter with respect to other material. This results in making the final construction material compact and dense, & increases the durability index of the construction material. Further, the dense packing structure of the construction material provides maximum improved binding capability to the aggregate particles and better cements reaction kinetic. Further, such mixing minimizes the overall use of the ordinary Portland cement. Additionally, such mixing provides overall reduction of carbon foot prints, overall reduction in clinker factor, improved binding property, optimizing the total water demand, and better utilization of pozzolanic materials in concrete production. In addition, the method is an environment-friendly method.

This together with the other aspects of the present invention along with the various features of novelty that characterized the present disclosure is pointed out with particularity in claims annexed hereto and forms a part of the present invention. For better understanding of the present disclosure, its operating advantages, and the specified objective attained by its uses, reference should be made to the accompanying descriptive matter in which there is illustrated exemplary embodiment of the present invention.

DETAILED DESCRIPTION
The exemplary embodiment described herein detail for illustrative purposes are subjected to many variations. It should be emphasized, however, that the present invention is not limited to method of producing the compact and highly dense construction material(s). It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

Unless otherwise specified, the terms, which are used in the specification and claims, have the meanings commonly used in the field of infrastructure construction and cement/concrete industry. Specifically, the following terms have the meanings indicated below.

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 item.

The terms “having”, “comprising”, “including”, and variations thereof signify the presence of an embodiment.

The term "spontaneous hydration property" refers to early and/or immediate hydration of a material when such material is mixed with water. Tricalcium silicate is an example of such spontaneous hydration property.

The term "induced hydration property" refers to later, slow and/or time dependent hydration of a material when such material is mixed with water. Dicalcium silicate is an example of such induced hydration property.

The term “mechanically modified particle” is understood to mean here a particle of a material modified mechanically into a prerequisite particle size by applying a desired force and energy.

The term “electrically modified particle” is understood to mean here a particle of a material charged electrically by applying an electrical energy.

The term “chemically modified particle” refers to a particle of a material charged/activated chemically to achieve desired chemical reaction and/or results.

The term “gradation process” is understood to mean here a process of physical gradation of the selected raw construction material. Specifically in the present invention such “gradation process” is adopted to produce smallest fine aggregate fraction.

The term “lattice void filler” is understood to mean here a particle act as fillers which can fill a lattice voids in the admixture of construction material.

It should be noted that the term pozzolanic material as referenced here in below means material having capability of binding in the presence of water as understood in the art.

The mode average particle diameter as provided herein is understood to be the peak of the particle frequency distribution curve. In simple words the mode is the highest peak seen in the particle frequency distribution curve. The mode represents the particle size (or size range) most commonly found in the particle frequency distribution curve.

The smallest fine aggregate mode average particle diameter is termed herein as the mode average particle diameter of the smallest fine particles present in the raw construction material. The smallest fine aggregate mode average particle diameter thus provides a clear cut idea of lattice void fillers being smallest particle of the raw construction material.

Further, the particle-size distribution (PSD) analysis is termed herein as the mathematical expression of finding about the ratio/proportion of various particle size ranges which are present in given raw construction material. Generally, volume, area, length, and quantity are used as standard dimensions for determining the particle amount present in the raw construction material. However, volume of the raw construction material sample is considered as the easiest dimension and/or way of finding out the ratio of various particles size ranges present in the given raw construction sample.

Due to the current worldwide pressure to decrease the CO2 emission, government bodies are looking for better technologies and products which produces lower carbon foot prints. Cement production is one of the major industry which produces very high amount of CO2¬. Hence it is always desirable to find out better ways of cutting down the overall CO2 release during cement and concrete production. However, still this cannot be considered as the final and total solution of minimizing the CO2 release as cement and concrete production itself releases standard amount of CO2.

There is another solution of reducing the use of cement in the concrete production but still said cement reduction¬ has adverse effect on the final strength of the concrete infrastructure. Accordingly, the present method of producing a compact and dense construction material is engineered in such a way that it automatically reduces the overall use of cement and at the same time provides improved binding capabilities and higher strength to the final concrete infrastructure.

The method of producing a compact and highly dense construction material as described in the present invention is specially engineered method which produces lattice void fillers to fill the voids in the lattice structure of the raw construction material. Said lattice void fillers are engineered to the Macro-Nano level to ensure improved durability and strength of the final construction material.

Further, the present method provides a means of better utilization of the pozzolanic materials and at the same time shows enhancement of early strength characteristics despite of a substantial addition of pozzolanic materials.

Accordingly, the present method of producing a compact and dense construction material includes steps of mixing a first set of cementitious material having mode average particle diameter (D1) in the range of 1/3 to 1/5 of the mode average particle diameter (D) of a smallest fine aggregate fraction of a raw construction material; a second set of cementitious material having mode average particle diameter (D2) in the range of 1/3 to 1/5 of the mode average particle diameter (D1) of the first set of cementitious material; a third set of cementitious material having mode average particle diameter (D3) in the range of 1/3 to 1/5 of the mode average particle diameter (D2) of the second set of cementitious material; and a fourth set of cementitious material have mode average particle diameter (D4) in the range of 1/3 to 1/5 of the mode average particle diameter (D3) of the third set of cementitious material to obtain the construction material.

Further, the method includes the steps of determining the mode average particle diameter (D) of the smallest fine aggregate fraction. Accordingly, a smallest fine aggregate fraction of the raw construction material is determined by applying a gradation process. The gradation process comprises physical gradation of the raw construction material ranging from smallest fine aggregate to coarse aggregates. Thereafter, mode average particle diameter (D) of the smallest fine aggregate fraction is determined. In one implementation, said determination is performed through particle-size distribution (PSD) analysis of said smallest fine aggregate fraction of the raw constructional material.

Further, the method includes the steps of obtaining the first set of cementitious material having the mode average particle diameter (D1). Accordingly, a mode average particle diameter of the first set of cementitious material is determined through a PSD curve analysis interpretation. The first set of cementitious material is then subjected to a mechanical modification process in a controlled manner until its mode average particle diameter (D1) is in the range of 1/3 to 1/5 of the mode average particle diameter (D) of the smallest fine aggregate fraction of a raw construction material.

Further, the method includes the steps of obtaining the second set of cementitious material having the mode average particle diameter (D2). Accordingly, a mode average particle diameter of the second set of cementitious material is determined through a PSD curve analysis interpretation. The second set of cementitious material is then subjected to a mechanical modification process in a controlled manner until its mode average particle diameter (D2) is in the range of 1/3 to 1/5 of the mode average particle diameter (D1) of the first set of cementitious material.

Further, the method includes the steps of obtaining the third set of cementitious material having the mode average particle diameter (D3). Accordingly, a mode average particle diameter of the third set of cementitious material is determined through a PSD curve analysis interpretation. The third set of cementitious material is then subjected to a mechanical modification process in a controlled manner until its mode average particle diameter (D3) is in the range of 1/3 to 1/5 of the mode average particle diameter (D2) of the second set of cementitious material.

Further, the method includes the steps of obtaining the fourth set of cementitious material having the mode average particle diameter (D4). Accordingly, a mode average particle diameter of the fourth set of cementitious material is determined through a PSD curve analysis interpretation. The fourth set of cementitious material is then subjected to a mechanical modification process in a controlled manner until its mode average particle diameter (D4) is in the range of 1/3 to 1/5 of the mode average particle diameter (D3) of the third set of cementitious material.

In one implementation, compositions of said second set of cementitious material and first second set of cementitious material may be same or substantially same. In such implementation, said second set of cementitious material is obtained by subjecting the first set of cementitious material to a mechanical modification process. In one implementation, compositions of said third set of cementitious material and said first set of cementitious material may be same or substantially same. In such implementation, said third set of cementitious material is obtained by subjecting the first set of cementitious material to a mechanical modification process. In one implementation, compositions of said third set of cementitious material and said second set of cementitious material may be same or substantially same. In such implementation, said third set of cementitious material is obtained by subjecting the second set of cementitious material to a mechanical modification process.

Further, said first set of cementitious material comprises at least one hydraulic material optionally along with at least one pozzolanic material. In one implementation, the first set of cementitious material comprises a combination of at least one hydraulic material and at least one pozzolanic material, with the at least one hydraulic material being present in amount greater than or equal to 20% of weight of the first set of cementitious material.

Further, said second set of cementitious material comprises at least one hydraulic material optionally along with at least one pozzolanic material. In one implementation, the second set of cementitious material comprises a combination of at least one hydraulic material and at least one pozzolanic material, with the at least one hydraulic material being present in amount greater than or equal to 20% of weight of the second set of cementitious material.

Further, said third set of cementitious material comprises at least one hydraulic material optionally along with at least one pozzolanic material. In one implementation, the third set of cementitious material comprises a combination of at least one hydraulic material and at least one pozzolanic material, with the at least one hydraulic material being present in amount greater than or equal to 20% of weight of the third set of cementitious material.

Further, one implementation said fourth set of cementitious material is selected from a group comprising at least one pozzolanic material, at least one silica based material and combinations thereof.

Further, said at least one hydraulic material can be selected from a group comprising of Portland cement, modified Portland cement, or masonry cement, ground granulated blast-furnace slag, hydraulic hydrated lime, white cement, calcium aluminate cement, silicate cement, phosphate cement, high-alumina cement, magnesium oxychloride cement, oil well cements, and combinations thereof.

Further, the at least one Saidpozzolanic material can be selected from a group comprising of fly ash, blast furnace slag, volcanic ash material, quartz material, pond ash, chemically modified fly ash, chemically modified blast furnace slag, chemically modified quartz, and combinations thereof.

In one implementation, amount (W1) of the first set of cementitious material is in a range of 66 to 80 wt% of the construction material; more preferably about 75 wt% of the construction material.

In one implementation, amount (W2) of the second set of cementitious material is in a range of 20 to 34 wt% of the first set of cementitious material; more preferably about 25 wt% of an amount (W1) of the first set of cementitious material.

In one implementation, amount (W3) of the third set of cementitious material is in a range of 20 to 34 wt% of an amount (W2) of the second set of cementitious material; more preferably about 25 wt% of an amount (W2) of the second set of cementitious material.

In one implementation, amount (W4) of the second set of cementitious material is in a range of 20 to 34 wt% of an amount (W3) of the third set of cementitious material; more preferably about 25 wt% of an amount (W3) of the third set of cementitious material.

Thus, the aspect of the present invention is directed to an environmental friendly method of producing a compact and highly dense construction material having improved binding property. Further, said engineered method of producing a compact and highly dense construction material improves the overall durability and property of the final concrete structure.

Particularly, the present method of producing a compact and dense construction material provides overall reduction of carbon foot prints, overall reduction in clinker factor, improved binding property, better utilization of pozzolanic materials in concrete production are some examples of the desired benefits achieved by the present invention.

Further, the present invention provides a specially engineered method of producing a compact and dense construction material having smallest fine aggregate fraction of a raw construction material. Said method of producing a compact and highly dense construction material utilizes much reduced amount of cement materials while preparing the concrete admixture.

Said method of producing a compact and highly dense construction material comprises determining a smallest fine aggregate fraction of a raw construction material via applying a gradation process to a selected raw material. For an example sand is one of the raw construction material of the concrete admixture, sand particles seems to be of equal diameter with naked eyes but while determining them at Macro to Nano particle size level range lies between 2mm to 64 mm particle diameter. Further said gradation process is adopted for physical gradation of raw construction material ranging from smallest fine aggregates to coarse aggregates.

Further, the method comprises determining mode average particle diameter (D) of said smallest fine aggregate fraction via a particle-size distribution (PSD) analysis of said smallest fine aggregate fraction. The particle distribution analysis (PSD) is the list of values of mathematical function that defines the relative amount, typically by mass, of particles present according to size. Particle size distribution plays a vital role in understanding physical and chemical properties of the selected raw construction material, more specifically it affects the strength and load bearing property of the selected raw construction material.

Said particle-size distribution (PSD) analysis resulting into formation of a series of lattice void fillers ranging from a micro to nano particle size level corresponds to mode average particle diameter (D) of the smallest fine aggregate fraction of the raw construction material. Further, said series of lattice void fillers comprises of a continuous series of materials selected from hydraulic material(s), i.e., the material particle(s) having spontaneous hydration property, pozzolanic material(s), i.e., material particle(s) having induced hydration property, silica based material(s), and combinations thereof that have graded mode average diameters.

Said spontaneous hydration property refers to immediate hydration of the material, in other words when such material is mixed with water then said material absorbs water immediately, more specifically the material chemically combines with the water molecules spontaneously during hydration. Tricalcium silicate is an example of such spontaneous hydration property.

The material particles having spontaneous hydration property or hydraulic material is selected from a group comprising of a normal ordinary Portland cement, mechanically modified ordinary Portland cement, Portland cement, modified Portland cement, or masonry cement, ground granulated blast-furnace slag, hydraulic hydrated lime, white cement, calcium aluminate cement, silicate cement, phosphate cement, high-alumina cement, magnesium oxychloride cement, oil well cements, and combinations thereof.

Further said induced hydration property refers to slow and time dependent hydration of the material, in other words when such material is mixed with water then it absorbs water in a slow manner and also time dependent, more specifically the material chemically combines with the water molecules in a slow pace during hydration. Dicalcium silicate is an example of such induced hydration property.

Said materials having induced hydration property or the pozzolanic material is selected from a group comprising of fly ash, blast furnace slag, volcanic ash material, quartz material, pond ash, chemically modified fly ash, chemically modified blast furnace slag, chemically modified quartz, and combinations thereof.

Said continuous series of materials comprises materials starting from a first set of cementitious materials having a mode average particle diameter (D1), and ending at a fourth set of cementitious materials having a mode average particle diameter (D4). Further said first set of cementitious materials is having mode average particle diameter (D1) in the order of 1/3rd to 1/5th of the mode average particle diameter of the smallest fine aggregate fraction.

Further, said continuous series of materials have a modified mode average particle diameter (D2, D3, and D4) in the order of 1/3rd to 1/5th of the mode average particle diameter of a previous series of materials. These said mode average particle diameter of said continuous series of materials is modified via one of a mechanical process, chemical process and electrical process.

This continuous series of different particle sizes having a defined mode average particle diameter is achieved via various particle size modification processes such as mechanical process, chemical process and electrical process. This optimization of different particle sizes having a continuous series of different mode average particle diameter provides compact fillers of lattice void of the particle lattice structure ranging from Micro to Nano level. This mixture provides a perfect particle chemistry to fill the maximum voids of the particle lattice structure and also improves the chemistry related to the early settings and the latter settings of the concrete material.

In said modification processes, the particle size can be modified into a prerequisite particle size by applying a desired force and energy. More specifically modifying the particle size to a desired size level via any of the process involving application of machines such as but not limited to grinding, crushing, milling, steam jet milling with superheated steam, particle breakdown by electrical force, particle breakdown by magnetic force should be considered as the examples of application of machines for modifying the material particle size to a desired size level.

The smallest fine aggregate mode average particle diameter as described herein means the mode average particle diameter of the smallest fine particles of the concrete aggregate. The main purpose for determining the mode average particle diameter of the smallest fine particles of construction material is to fill the lattice void structure of the concrete aggregate with the specially engineered method.

In an exemplary embodiment, the mode average particle diameter of said raw construction material has to be understood by the examples of D1, D2, D3, and D4 mode average particle diameter. Where, the D1 mode average particle diameter is understood to be those materials whose mode average diameter is approximately 1/3rd to 1/5th of the smallest fine aggregate mode average particle diameter.

Further, the D2 mode average particle diameter is understood to be the materials whose mode average diameter is approximately 1/3rd to 1/5th of the materials having D1 mode average particle diameter. Accordingly, the D3 mode average particle diameter is understood to be the materials whose mode average diameter is approximately 1/3rd to 1/5th of the materials having D2 mode average particle diameter. Similarly, the D4 mode average particle diameter is understood to be the materials whose mode average diameter is approximately 1/3rd to 1/5th of the materials having D3 mode average particle diameter.

After careful experimental observation it is concluded that the present method of producing a compact and highly dense construction material satisfy all the mechanical properties, chemical properties, setting time property, fineness property as well as the production cost as required in the various concrete industry standards. The present invention, therefore, provides improved strength and setting properties at the same time provides maximum utilization of pozzolanic materials instead of ordinary Portland cement in the concrete industry.

While the invention has been described with respect to specific method which include presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described embodiment that fall within the spirit and scope of the invention. It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. Variations and modifications of the foregoing are within the scope of the present invention. Accordingly, many variations of these embodiments are envisaged within the scope of the present invention.

The foregoing descriptions of specific embodiment of the present invention have been presented for purposes of description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiment were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiment with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the present invention.