FORM 2
THE PATENTS ACT, TSTO
{39 of 1790}
&
THE PATENT RULES, 2003 COMPLETE SPECIFICATION
(See section 10; rule 13)
TITLE OF INVENTION
"RECYCLE OF ENVIRONMENTAL HAZARD -PLASTIC CARRIER AND FLY ASH FOR MANUFACTURING OF CONCRETE PRECAST MOULDS"
APPLICANTS
T and T Infra Limited
An Indian National organization registered at Office 1-5 Vishnu Vihar Al, Kondwa-Bibwewadi Road, Marketyard. Pune 37
Indian
(MAHARASHTRA} INDIA
And
PREAMBLE OF DESCRIPTION
The following specification particularly describes the invention and the manner in which it is particularly performed.

FIELD OF INVENTION:
The present invention discloses about a recycle of Environmental hazard waste-Plastic carrier and flyash for manufacturing of concrete precast moulds in any size, shape and colour. This is an environment friendly mix which will be helpful to recycle of plastic wastage and flyash without affecting the environment conditions, and this is also helpful in construction industry irrespective of type of project, in low cost as well as with same strength as compare to current practice of making moulds.
BACKGROUND OF INVENTION:
A lot of harms are caused by the increasing in use of plastic carrierin the last few the decades. Plastic carrier make up a large proportion of municipal waste and cause a lot of environmental, economic and social problems, including visual pollution, blocking the waterways and flood risk, reducing water penetration and soil improper ventilation, environmental pollution due to the long shelf life taking more than 500 years, entering the food chain of domestic animals and their deaths, the spread of some diseases such as encephalitis, dengue fever and malaria due to the persistence of water and reproduction of different insects, production of hazardous and poisonous leachate and subsequently their biodegradability, entering the human food chain and C02 emissions. Furthermore, plastics produce vinyl chloride gas, which is very dangerous and its exposures causes liver cancer. The widespread use of plastic carrier appears to contradict contemporary public policy to ensure sustainable development.
Humans are exposed to a large variety of toxic chemicals and microplastics through inhalation, ingestion, and direct skin contact, all along the plastic lifecycle. According to WWF, an average person could be ingesting approximately 5 grams of plastic every week. While the health impacts of plastics is still a rather new research area, scientific results to-date do indicate that the toxic chemical additives and pollutants found in plastics threaten human health on a global scale. Scientifically-proven health effects include causing cancer or changing hormone activity (known as endocrine disruption), which can lead to reproductive, growth, and cognitive impairment. Many of the toxic chemical additives have several other known health impacts, persist in the environment, and bioaccumulate in exposed organisms. Research also revealed that microplastics can harm our health, and act as vessels for pathogens to enter our system, increasing the spread of diseases.
Populations residing in areas surrounding thermal power plants face imminent environmental hazards due to large quantities of fly ash that have accumulated within their premises. A sizeable number of thermal power projects had missed the December 2017 deadline for the complete utilisation of fly ash, set by the Union Government of India. Fly ash is the toxic waste that is generated after the burning of coal or lignite. In January 2016, the Union Ministry of Environment, Forests and Climate Change had issued a notification (amending an earlier notification) and set a deadline for the exercise. It has also reiterated a set of constructive measures, already notified earlier, for the utilisation of accumulated fly ash.
We aim at developing a concrete product which can be made with plastic carrier and flyash composed of environmental waste hazards. An ideal concrete mould should have 3 main properties- it should have enough strength to sustain the load, it can be made with recycle material and it shall be easily made for application on the contra dory it should not emit large amounts of CO2 into the atmosphere on combustion.

OBJECTS OF INVENTION:
The main object of the invention is to recycle the manmade waste and naturally available materials mixed in predetermined proportion to form a Hazard free concrete product in any shape and size to "Save Nature"
Another object of the invention is to recycle the naturally available waste and manmade by product in proper proportion using low cost machines already available in market.
Yet another object of the invention is to control CO2 emissions released into the atmosphere on combustion.
Another object of the invention is to develop a concrete product with high strength.
Yet another object of the invention is to protect the environment from waste hazard.
SUMMARY OF INVENTION:
Accordingly, the present invention discloses a recycle of environmental hazard waste products (plastic carrier and flyash) for manufacturing of concrete precast moulds in any size, shape and colour.
The plastic wastes are the waste available in nature like plastic carrier, plastic toys, plastic utensils, plastic furniture
The plastic carrier waste are the wastes which are normally dumped in environment. The Flyash is a bi-product from thermal power plant
The product has Strength of 50N/mm2. This composition can be used for any size and shape. Any type of plastic waste can be used from thickness of 5micron to 10mm thickness.
Processed flyash has been used as Cement (OPC) replacement. Plastic carrier/waste has to go through 3 steps process (Cleaning, Grinding and Heating) before application in mix.
Plastic carrier collected from dumping yard and processed till it became useful in concrete mix. Number of trials conducted with different proportion of plastic and flyash to achieve M50 Strength in 28 days. At present this composition can be used for structure with no reinforcement and non load bearing structures. User friendly criteria has been considered during the invention. Composite mix can be used in any size, shape and colour of concrete. Compressive strength of mix can be achieved from 15 N/mm to 50 N/mm within 28 days of casting. Higher grade can be achieved by introducing extra cementitious material and reducing w/c ratio with the help of chemical admixture. Mix Design can be optimized using good quality of materials. (Research has been done with local available material)

BRIEF DESCRIPTION OF INVENTION:
The present invention discloses a recycle of environmental hazard waste products (plastic carrier and flyash) for manufacturing of concrete precast moulds in any size, shape and colour. It is manufactured by using materials such as Cement (OPC), flyash, aggregate, water, admixture and heated plastic carrier. By this process, the waste plastic carrier and flyash can be utilised for manufacturing of concrete moulds which can be used in variety area of construction related work. It is an eco friendly material compare to existing concrete products as it has amount of plastic carrier waste and flyash. After incorporating of plastic carrier waste and flyash there is no any harmful effect on concrete properties and for environment too.
We have developed a mix composition to be used for construction purposes, by reducing the plastic carrier waste form the environment.
Grade of Composite mix can be vary depending on % of ingredients, it is ranging from 15 N/mm2 to 50 N/mm2
Each Grade contains one of the following binder agents viz. Cement (OPC), Aggregate, Other Cementitious Material along with other constituents.
If this is produced properly, it can become an ideal component for construction industry especially for non load bearing structures, pathways, roadways, highways, bridges, housing, building, factories, drainage work, water supply work etc. The common man can make this in their own locality which can help them to keep the environment free form plastic carries and can also help the problem of disposing/dumping the waste effectively. With content, it can effectively reduce the carbon footprint if used properly.
In a way, manufacturing of this composition can resolve three major crises, namely waste disposal, Health hazards and carbon emissions.
It can also give a boost to employment in the rural areas without incurring more cost on inventory of machines as this composition can be use in-house by using available construction equipment's and can generating revenue out of waste.
APPLICATIONS:
- Use for flooring
- Use for pedestrian walkway
- Use for parking area
- Use for Vehicular movement
Use as cover block for reinforcement
- Use for Road Median and kerb stone
- Use as tree plantation pot

BRIEF DESCRIPTION OF DRAWINGS:
According to the present invention the brief description of figures is as follows:
Figure 1 shows a flow diagram of the procedure and method to obtain said Composite Mix.
Figure 2 shows the summary of test certificates of raw material tested at NABL accredited laboratory
Figure 3 shows the Analysis of data and strength
Figure 4 Shows Process Photographs
Figure 5 Shows final product
Figure 6 Shows Application of Product
DETAILED DESCRIPTION OF INVENTION:
The present invention discloses a recycle of environmental hazard waste products (plastic carrier and flyash) for manufacturing of concrete precast moulds in any size, shape and colour which can be manufactured by using materials such as Cement (OPC), flyash, aggregate, water, admixture and plastic carrier. By this process, the waste plastic carrier and flyash can be utilised for manufacturing of concrete moulds which can be used in variety area of construction related work..
We have developed a mix composition to be used for construction purposes, by reducing the plastic carrier waste form the environment.
Grade of Composite mix can be vary depending on % of ingredients, it is ranging from 15 N/mm2 to 50 N/mm2
Each Grade contains one/or more than of the following binder agents viz. Cement (OPC), Aggregate, Other Cementitious Material along with other constituents.
If this is produced properly, it can become an ideal component for construction industry especially for non load bearing structures, pathways, roadways, highways, bridges, housing, building, factories, drainage work, water supply work etc. The common man can make this in their own locality which can help them to keep the environment free form plastic carries and can also help the problem of disposing/dumping the waste effectively. With content, it can effectively reduce the carbon footprint ifused properly.
They are categorised in grade asM15, M20, M25, M30, M35, M40, M45 and M50.
In a way, manufacturing of this composition can resolve three major crises, namely waste disposal, Health hazards and carbon emissions.
It can also give a boost to employment in the rural areas without incurring more cost on inventory of machines as this composition can be use in-house by using available construction equipment's and can generating revenue out of waste.

Figure 1 shows a flow diagram of the procedure and method to obtain said Composition. The process involved in the manufacturing of the composition mix is as follows:
Initially the collection of naturally occurring Ingredients like Cement (OPC), Aggregate Water shall be collected. Plastic waste carriers are collected from dumping yard, flyash collected form thermal power plant ash distributor agency. The collected material is in its natural form and hence it is required to be processed further to bring it in the form which can be used for processing of said available raw material. Hence said ingredients are conditioned by using Cutting Machine and grinding machines. Mixing of ingredients in proper proportion using Drum Mixers as specified in the provided tables such that the mixture is thoroughly mixed with to form a homogenously mixed mixture. These thoroughly mixed mixtures are compacted either by manually operated or by using a vibrating table confirming to IS 2514:1963 to remover entrapped air from the mixture. By vibration process the mixture is compacted as well as it can be filtered by removing the entrapped air. After the Vibration operation the said mixture forms the shape of the desired moulds which can be removed from the mould after 6-12 hrs and are moved in the drying areas for drying operation for about 6-12hours at ambient temperature of 20 - 45° C. After drying of said products, they are stored in the curing tank for 7-14 days at Temperature of water 23-27 deg . These ready to use moulds are used in all aspect of construction field.
Manufacturing of the moulds is also eco-friendly as most of the constituents are easy to get and do not require processing to a large extent, that is, there are no emissions or indirect harms to the environment in its preparation and storage.
By making hard and with desired strength, transportation (if necessary) can be easier and handling can be made easy. Storage too can be simple as this only need a dry place to store. After analysis of the final product made with the composite mix, it is containing heated plastic carriers, waste flyash. In short, it proved to be economically as well as ecologically effective.
The recycling of a virgin plastic material can be done 2-3 times only, because after every recycling, the plastic material deteriorates due to thermal pressure and its life span is reduced. Hence recycling is not a safe and permanent solution for plastic waste disposal.
There are approximately 6-8 million tonnes of plastic waste entering the ocean every year globally
The total plastic in the ocean amounts to approximately 130-170 million tonnes Plastic packaging accounts for approximately 50-70% of all items recovered in coastal clean¬up efforts
In 2014 there was approximately 1kg of plastic in the ocean every 5kg offish approximately, and by approximately 2050 there will be more plastic than fish
Figure 4 provides the raw material for the composition of various types of mixtures prepared for analysis purpose. The actual quantity of the raw material used for producing of these types of the mixtures for preparing of samples which are further tested for its qualities by testing their values.
Figure 3 shows the test certificates done at Constrovision Engineering Consultants Pvt. Ltd. (CV),Sr.No.41/l,Nimbalkar wasti,Gujarwadi Phata,Katraj,Pune-411046( NABL Accredited Construction material testing laboratory. TC No.8218) We hereby attach test certificates for reference .

The process of manufacturing the Moulds for testing purpose M-50 involves,
1) The composition of Mixes as per required strength
2) Cement (OPC)+Flyash+Plastic Carrier+Aggregate+Water+Admixture total Density is between 2300-2550 Kg/m3
3) Heated Plastic is use as a binder.
4) Moulds are manufactured in any shape, size and colour having compressive strength range from 15N/mm to 60N/mm tested on 100x100x100mm concrete mould tested on 2000KN CTM. Curing period was 7-14 days, until strength is obtained as per grade specification.
5) Technical Specification of Composite mix M-50 with 0.3 % plastic: Total Density 2300-2550 kg/m3, Cement (OPC) 18.09%, Flyash 6.04%, Heated Plastic Carrier up to 0.072%, Aggregate 69.09%), Admixture 0.26% and Water 6.45%.
6) We claim that Composite mix ingredients containing Cement (OPC), Flyash, Aggregates, Plastic Carriers, Water and Chemical Admixture
The Formulation of Composite mix as specified in "M-50" the product of this invention
gives,
i) Compressive Strength (Minimum) 55N/mm2upto 65N/mm2 within 28 days
There is no any evaluation of fumes/gases during heating process of plastic carries.
Heating Process of Plastic carries has been taken care not to evolve any fumes or gases which
will be hazard to human health and environment
The waste will be collected and sorted in a dry location, Cleaning is required to remove foreign particles form waste material ,Crushing in required size is done by crushing process using Grinder. Heating of Plastic carries will be done at set temperature which is less than the temperature required for formation of gases during heating. Proportionate mixing and binding is done in a mechanical mixer. We can use any shape in any size with addition of colour pigment to obtain required colour.
Comparison Statement.

Sr.No Existing Practice Our Research
1 Dumping of Plastic Waste carrier in dumping yard, only selected kind of plastic can be used for recycle. All kind of plastic can be used for composite mix
2 Plastic waste carries remain in surrounding which causes health hazards to human and animal Plastic waste carriers can be utilized in construction activity which will reduce the risk of health hazard to human and animal
3 Concrete Cover blocks and paving blocks are made with Cement, Cementitious material, Aggregate, water and admixture Composite Mix made with Cement, Cementitious material, Aggregate, water admixture, thermal power waste and plastic waste carrier
4 No contribution for green environment Contribution for green environment
5 No contribution for waste management in interest of Environment and country Contribution for waste management in interest of Environment and country
6 No contribution to reduce water pollution Contribution to reduce water pollution by utilizing in construction activity

We Claim: We Claim:
1. Environmental Free Composite mix comprising Plastic Carrier waste and Thermal Plant waste along with Cement, Aggregate, Admixture and Water.wherein said Plastic Carrier waste and Thermal Plant waste are the waste available in nature and/or from manmade origin.
2. The Environmental Free Composite mix claimed in claim 1, wherein said Thermal Plant waste and plastic waste is used in the mix can be in any form of state (Solid, Liquid, Semi-Solid, semi-liquid) Any type of plastic waste can be used from thickness 05 micron to 10 mm.
3. The Environmental Free Composite mix claimed in claim 1, wherein said the Composite mix has Fresh Concrete Density between 2300-2550 Kg/m3. (Density of mix can be varied if specific gravity/properties of materials changes)
4. The Environmental Free Composite mix claimed in claim 1, wherein said Composite mix has Cement (OPC) 18.09%, Flyash 6.04%,Plastic Carrier( in any form ) up to 0.072%, Aggregate (Coarse and Fine) 69.09%, Admixture 0.26% and Water 6.44%. (This % can be vary depending on end user requirements, If Properties of raw material changes mix design and % will be changed accordingly)
5. The Environmental Free Composite mix claimed in claim 1, wherein said Composite mix can be made with Cement (OPC), Flyash, GGBS, Alcofines, Silicafumes, Limestone, Plastic Carrier, Aggregate, Admixture, ultrafine material, Nano admixture and Water. (This can be depending on end user requirements) Any type of binder can be used for making this composition viz PPC, SRC, PSC, Rapid hardening cement, any type of cement and supplementary cementitious material.
6. The Environmental Free Composite mix claimed in claim 1, wherein said formulation of Composite mix provides upto strength of 60N/mm2 within 28days. We claim the mix can be made with different % of flyash, plastic, Cement and other cementitious material and other ingredients apart from the % mentioned in claim no 4
7. The Environmental Free Composite mix claimed in claim 1, can be used to manufacture precast concrete moulds in various sizes, shapes, colour and strength depending on where the said product is being used i.e. for domestic, industrial, commercial, and infrastructure purpose comes under any construction activity. This composited mix as claim in 1 can be used for any type of concrete works depending on strength criteria.
8. The Environmental Free Composite mix as claimed in claim 1, wherein This type of composition can be made with different % of ingredients depending on requirement. Plastic waste carrier can be in form of any state (Solid, Liquid, Semi-Solid, semi-liquid, Heated or non-heated plastic waste) and in any %.
9. The Environmental Free Composite mix claimed in claim l,is low cost composite mix with greater strength than the current mix adopted.

10. The Environmental Free Composite mix claimed in claim 1, can be made with or without flyash. If flyash is not available composite mix can be made with Cement, Plastic waste, Aggregates, Water and Admixture. It just need to be modified the design value and % to achieve proper mix.