FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)
1. Title of the invention. - SUPPLEMENTARY CEMENTITIOUS MATERIAL
2. Applicant(s)

(a) NAME : Alcolab (India) Pvt. Ltd.
(b) NATIONALITY : An Indian Company
(c) ADDRESS: Sukerkar Mansion, First floor, M.G. Road, Panaji,
Goa-403 001, India.
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD OF THE INVENTION
The present invention relates to supplementary cementitious material (designated herein as ALCCOFINE 1203) for incorporation into cement concrete (or cement mortar and blended cements) generally used in construction. The said supplementary cementitious material, ALCCOFINE 1203, increases the strength of the cement concrete (or cement either in addition or as a cement replacement) at all ages of testing i.e. 1 day, 3 days, 7 days and 28 days (and 56 days, 180 days etc).
BACKGROUND OF THE INVENTION
Hydraulic Cements like OPC, PSC, PPC etc. combine with water to form strength-giving cement compounds on hardening. The strength is inversely proportional to the water/cement proportion or ratio according to Abram's law.
The area of hydraulic cements, or cements which harden by reacting with water and give a water resistant product, may be most typically illustrated by reference to Portland cements. Portland cements are classified into five major types, by ASTM, according to chemical composition and according to properties to be achieved by the difference in chemical requirements. However, there is a great need to develop cements having much higher early strength to satisfy industrial needs of current construction practices.
US Patent No. 3,147,129 discloses a process for making cement from an aluminous source containing fluorine, which cement is based on Q12A7 type material along with fluorine compounds which cement may attain high ultimate strength properties upon addition of certain additives, although high strength is not developed early and is not in any way abnormally high without such additives.
US Patent No. 3,251,701 discloses C4A3S Portland type cement, which is expansive and may or may not develop early strength. US Patent No. 3,510,326 discloses C3A3CS containing additives to be admixed with a normal cement to

obtain expansion, and the resulting materials were very expansive and did not develop high early strength. US Patent No. 6,767,299 relates to an admixture for incorporation into hydraulic cement, mixtures that optionally include SCM's such as concrete, grouts, mortars, patching compounds and dry mixes for making the same, to produce cementitious compositions having high fluidity and high compressive strength. The combination of the superplasticizer and the accelerant used in this invention surprisingly has a synergistic effect on the early compressive strength of the cementitious composition and also enhances the fluidity of the cementitious composition allowing for increased reduction in water demand and the use of a lower W/cm ratio in practical applications.
The prior products are 'super plasticizers' and accelerators'. Super plasticizers
development of strength.
However, although this superplasticizer can be used to increase the early compressive strength of the cementitious composition, there is a need in the art to further increase the early compressive strength of the cementitious composition while still providing good flowability.
Supplementary cementitious materials (SCM) used in concrete production are known to contribute to cement concrete strengths (or cement mortar or cement). However, generally these result in lower early strengths of cement concrete, relative to concrete not incorporating (SCM).
also there. is one SCM product known as 'Silica Fume' which increases the strength, but has many disadvantages like large water demand, improper distribution in concrete and de-agglomeration of densified product resulting in possible chemical reaction affecting concrete durability. It is also a health hazard in its native fine form and mandated to be transported in liquefied form in many countries.

Thus there is need in the field for the concrete to achieve equal or more strength compared to concrete without incorporating SCM at all ages including one day values.
The Portland types of hydraulic cements have achieved only limited success that is limited to early strength only. They are functionally resulting in expansive or shrinkage compensating additives. Unlike this the present inventors have surprisingly found that ALCCOFINE-I203 of the present invention is an improved supplementary cementitious material which provides increased strengths at all ages, and not only higher early strength. ALCCOFINE-1203 of the present invention performs by improved packing which helps in dense microstructure which is intrinsic and larger amount of hydration which gives the improved quanta of strengths.
OBJECTIVE OF THE INVENTION
The primary objective of the invention is to provide a superior product to improve concrete strengths while functioning as a supplementary cementitious material (SCM) better in comparison to silica fume maintaining other properties as same.
Another objective of the invention is to help in increasing the quantity of ground granulated blast furnace slag that can be incorporated into concrete as an SCM.
SUMMARY OF THE INVENTION
It is an aspect of the present invention to provide_a supplementary cementitious material having an average particle size of 4 to 5 microns and fineness ranging from 6000 to 20000 sq/cm gm and adapted to be incorporated into material selected from cement, concrete and mortar.

DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an SCM, without all or any of the negative effects of Silica Fume at the same time improving all concrete properties.
The invention relates to a supplementary cementitious material having a composition typical of granulated blast furnace slag but with defined particle size so that the D50 of about less than 5μ is achieved and has a fineness of 8000 to 16000 sq cm/gm
With ordinary portland cement (OPC), supplementary cementitious materials (SCMs) like fly ash, ground granulated blast furnace slag (GGBS) etc may be added along with aggregates during the process of making concrete. In this case also the strength is inversely proportional to the water/cementitious content (OPC+SCM). The 28-day strength of concrete is taken as the 'bench-mark' strength universally and strengths at 1D,3D, and 7D etc provide the rate of strength development.
The specific strength attained in the latter case is dependent upon the nature/ characteristics of the SCMs
GGBS, a well-known SCM, is generally used at a fineness of 4000 sq.cm/gm (Blaine value). It is believed that increasing the fineness to about 6000 (Blaine) only increases the strength only marginally.
Present invention ALCCOFINE- 1203 is a product largely based on GGBS, but processed by grinding to a high surface area (Blaine-value but computed based on PSD) of around 12,000 sq.cm/gm.
At the same time it provides a very superior contribution to the performance on account of both chemical and physical properties being modified. The chemical composition especially the non-glassy part and the improved fineness in relation to the compactness resulting from the modification of the particle sizes and then-very distribution, contribute synergistically to the superior performance of the invention. Generally Ground Granulated Blast Furnace Slag used has a fineness of

4000 sq cm/gm and an average particle size of (D 50) about 25 microns. Alccofine 1203 has a much higher fineness 8000 to 16000 sq cm/gm D50 less than 5 microns.
ALCCOFINE 1203 has a particle size distribution of d50 (Avg. particle size) in the range of 4 to 5 microns. Composition of ALCCOFINE 1203 is primarily Calcium Alumino Silicate phases, while Silica Fume is Silica primarily (+90%).
The ALCCOFINE 1203 can be added to concrete or mortar or cement in the ratio of 2 to 70 percent of its cement content to result in a product of higher strength of the concrete, mortar or cement respectively being obtained. It can be added in addition to all other SCMS commonly used in concrete such as fly ash, Ground Granulated Blast Furnace Slag (GGBS), Metakaolin, Rice Husk Ash (RHA) and even silica fume etc. By addition of this material the resulting concrete properties such as consistency, cohesion are improved and colour is made lighter to give improved thermal barrier effect, (lower conductance).
The alteration of the non-glassy mineralogy in the present invention provides much improved reactivity of the calcium silicate and calcium aluminate phases in the glassy portion with the lime [Ca (OH) 2] released during the hydration of the cement part in the concrete. The chemical composition of non glassy part is Melilite phase which is a solid solution phase between gehlinite and akermanite. When slag is in a glassy state these phases contribute to the reactivity of slag going up with increasing ratio of gehlinite to akermanite in glass. Several other factors also contribute to the slag reactivity.
The size of particles of ALCCOFINE 1203 are all below 20 microns. These particles will fill the voids in the cement and result in a much smaller void system/denser packing. This brings in lesser water demand for same level of workability which in turn reduces the water to cement ratio to result in higher strength.

The particle size distribution helps by improving the packing density in the initial cementitious mix. The design of the particle size distribution to achieve very low voids in the invention is transferred to the cementitious matrix to reduce the original void system in a major way and on hydration to bring in a pore structure which is finer and mainly fine sized pores is present.
The invention makes concrete to achieve a higher strength with its addition and improves durability by refinement of its pore structure in the hardened concrete.
The slump of the concrete is also relatively higher; such a concrete will have a far better durability performance.
Similarly cement mortar strength is improved. Blended cements can be made to achieve a higher strength by incorporating the invention in appropriate doses at the same time remaining within specifications.
Composition of the invention:
The invention comprises of a product supplementary cementitious material (ALCCOFINE 1203) based on blast furnace slag of the following composition:
Large Glassy phase, small non- glassy phase.
The oxide composition of the granulated slag, (including glassy and non glassy) is:
CaO 30 - 40%
Si02 30-35%
A12O3 15 -22%
Fe203 1.0-3%
MgO 8-10%
S03 0 to 4 %

Mn203 0.23 - 0.26%
Na20 0.08 to 0.12%
K20 0.02 to 0.22%
Glass content (Min) 90%
The product is obtained from hot blast Furnace slag which is subject at controlled temperature to water granulation to result in high glass content and the low non glassy part is of optimum mineralogical type to provide high reactivity of the resulting granulated slag.
The above granulated slag is processed by the size reduction process using conventional mills having particle separation classifiers. The slag is processed along with addition of:
a) Fibrous glass 0 - 35%
b) Gypsum (CaS04.2H20
Or anhydrite 0-10%
c) Potassium Aluminum 0-5% Silicate
d) Nano-silica 0-5%
e) Poly carboxylate Ether 0 - 5%
Fibrous glass is similar to slag and enhances reactivity of ALCCOFINE, other compounds also contribute to better reactivity in their own way.
The above are added either all or in any combination to result in an extremely high fineness with a computed 'Blaine' value of 6000 to 20000 sq.cm/gm more specifically between 8000-16000 sq. cm /gm based on particle size values

determined experimentally through appropriate instrument i.e. Particle size analyzers.
The present invention is now demonstrated by way of illustrative non limiting examples. The following specific examples will serve further to illustrate the practice and advantages of this invention.
Example 1:
This example relates to the addition of ALCCOFINE 1203, to replace traditionally used Silica fume, achieve equivalent or better concrete in otherwise the same mix composition.
In a typical concrete mix 10% cement is replaced by ALCCOFINE 1203. Hence in a concrete mix with 400 Kg/m3 of cement, 40 Kgs of cement is reduced to be substituted by ALCCOFINE 1203. Similarly silica fume is also substituted 40 kg of cement in a parallel mix. All other ingredients are of similar quantities. The evaluation of fresh concrete by the slump test gives a value of 150 mm for ALCCOFINE 1203 compared to 90 mm for silica fume. This larger slump is due to improved particle packing and the same is desirable. The strengths of hardened concrete are also all higher at similar ages and 28 days as well.
Table-1: TRIAL WITH ALCCOFINE 1203 IN COMPARISON WITH SILICA FUME MIX

Sr
No MATERIAL UNIT REFERENCE MIX ALCCOFINE
1203
1 Ordinary Portland cement kgs 360 360
2 Silica Fumes kgs 40 0
3 ALCCOFINE 1203 kgs 0 40

4
Water Content kgs 160 160
5 W/binder Ratio (Ratio of 4 to S nos 1+2+3) Ratio 0.4 0.4
Admixture(Polycarboxylate
Ether base) 0.50%
(of Snos 1+2+3) 0.50%
(of Snos 1+2+3)
Slump(mm) Initial mm 90 150
30 min mm - 100
60 min mm - ~
COMPRESSIVE STRENGTH(MPa)
24 Hours MPa 22.7 32.93
3 Days MPa 35.65 43.11
7 Days MPa 47.3 50.5
28 Days MPa 61.05 70.85
Thus concretes compared with cement having equal amount of silica fume as the amount of ALCCOFINE 1203, the present invention ALCCOFINE 1203 provides better compressive strength of concrete when measured at different ages i.e. 1,3,7 & 28 days.
For 10% replacement of cement by ALCCOFINE-1203 the strength and other important properties are given in Table 1 along with values for 10% replacement by Silica Fumes, for comparison.

The strength of concrete using ALCCOFINE- 1203 at various percentage replacements for typical concrete mix is given in Table 1 -a.
Table 1-a
Comparison of concrete strengths with and without ALCCOFINE-1203... 10% replacement of cement content when cement quantity is 300 Kgs (column I), 350 Kgs (column II) and 450 Kgs (column III).

I II III
1. Cement content in concrete.( Kgs) 300 270 350 315 450 405
2. ALCCOFINE 1203 (Kgs) 0 30 0 35 0 45
3. STRENGTH
ID MPa 10.42 13.38 12.01 14.04 20.21 24.60
3D MPa 10.26 21.26 20.12 22.42 31.80 35.91
7D MPa 24.26 27.19 27.33 29.26 40.21 45.43
28D MPa 35.66 38.85 36.43 41.96 46.26 50.62
Columns I, II and III give strengths with 10% ALCCOFINE 1203 replacing equal quantity weight by weight of cement in concrete, using 300, 350 and 450 Kgs cement.

(I) Gives strength with 300 kg cement and no ALCCOFINE 1203 on left hand side and 270 kg cement & 30 kg ALCCOFINE 1203 which is 10% replacement of 300 kg cement on right hand side.
(II) Gives strength with 350 kg cement and no ALCCOFINE 1203 on left hand
side and 315 kg cement & 35 kg ALCCOFINE 1203 which is 10% replacement of
350 kg cement on right hand side.
(III) Gives strength with 350 kg cement and no ALCCOFINE 1203 on left hand
side and 405 kg cement & 45 kg ALCCOFINE 1203 which is 10% replacement of
450 kg cement on right hand side.
Example of different percentages of ALCCOFINE 1203 in concrete with 450 kg/m3 cementitious content at replacsement levels of 0, 10, 20, 30 and 40 percent are given in Table 1-b, which gives the slump at various times and concrete strengths at 1, 3, 7, 28, 56 & 90 days. ALCCOFINE 1203 improves concrete strength at the different percentages.
Table 1-b

CEMENTITIOUS CONTENT OF 450 kg /m3 40%
Replacement % 0% (OPC) 10% 20% 30%

CEMENT 450 405 360 315 270
ALCCOFINE 1203 0 45 90 135 180
FINE SAND 334 334 334 334 334
COARSE SAND 506 506 506 506 506
10 MM 492 492 492 492 492
20 MM 494 494 494 494 494
WATER 160 160 160 160 160
ADMIXTURE 2.25 2.25 2.25 2.25 2.25
% OF ADMIXTURE 0.50% 0.50% 0.50% 0.50% 0.50%
ADMIXTURE TYPE PCE PCE PCE PCE PCE
SLUMP IN MM
INITIAL 190 mm collapse collapse collapse Collapse

30MIN 130 mm collapse collapse collapse Collapse
60MIN — 180 mm 175 mm collapse 190 mm
90MIN — 160 mm 150 mm 180 mm 140 mm
120 MIN — 120 mm 120 mm 155 mm 130 mm
150 MIN — — — 120 mm —
COMPRESSIVE
STRENGTH
1DAY 25.99 29.02 31.47 32.81 33.01
3DAY 36.02 39.41 43.61 42.02 47.98
7 DAY 44.78 48.07 54.43 57.08 59.19
28 DAY 56.96 62.21 66.04 68.97 70.22
56 DAY 60.01 67.11 71.96 73.45 74.05
90 DAY
\ 63.98 71.96 72.93 74.77 77.78
Example 2:
This relates to the addition of ALCCOFINE 1203 into concrete to achieve higher Slag absorption.
Table 2:
Increasing the quantity of Slag that can be incorporated into concrete as an SCM
TRIAL WITH INCREASED GGBS

MATERIAL REFERENCE MIX ALCCOFINE 1203
Ordinary Portland Cement 188 126
GGBS 126 179
ALCCOFINE 1203 0 9
Water Content 160 160

W/ binder Ratio
0.4 0.51
Admixture(SNF base) 1.00% 1.00%
SIump(mm) Initial 130 140
30 min 80 85
60 min - -
COMPRESSIVE STRENGTH (MPa)
24 Hours 8.64 8.94
3 Days 16.56 16.49
7 Days 22.02 24.43
28 Days 25.42 29.07
Thus it is evident that more amount of slag can be incorporated when ALCCOFINE 1203 of the present invention is used compared to known reference mixes.

We claim.
1. A supplementary cementitious material having an average particle size of 4 to 5 microns and fineness ranging from 6000 to 20000 sq.cm/gm and adapted to be incorporated into material selected from cement, concrete and mortar.
2. The supplementary cementitious material as claimed in claim 1, wherein said supplementary cementitious material is preferably adapted to be incorporated into portland slag cement.
3. The supplementary cementitious material as claimed in any of the preceding claims, wherein said supplementary cementitious material has fineness preferably in the range of 8000 to 16000 sq/cm gm.
4. The supplementary cementitious material as claimed in any of the preceding claims comprises
30 to 40% by weight CaO,
30 to 35% by weight Si02,
15 to 22% by weight A1203,
1 to 3% by weight Fe203,
8 to 10% by weight MgO,
0 to 4% by weight S03,
0.23 - 0.26% by weight Mn203,
0.08 to 0.12% by weight Na20,
0.02 to 0.22% by weight K20; such that glass content is minimum 90%.
5. The supplementary cementitious material as claimed in claim 3, wherein
said supplementary cementitious material is further processed with 0 to

35% by weight fibrous glass, 0 to 10% by weight gypsum, 0 to 5% by weight Potassium aluminium silicate, 0 to 5% by weight nano silica, and 0 to 5% by weight poly carboxylate ether.
6. The supplementary cementitious material as claimed in any of the preceding claims, wherein said supplementary cementitious material improves concrete strength.
7. The supplementary cementitious material as claimed in any of the preceding claims, wherein said supplementary cementitious material imparts higher slag absorption.
8. A supplementary cementitious material as herein substantially described and illustrated with reference examples.