A LOW-CARBON SUSTAINABLE CONCRETE BRICK AND PREPARATION METHOD THEREOF

Abstract

The present invention relates to a low-carbon sustainable concrete brick using biochar as filler material for sustainable construction. The low-carbon sustainable concrete brick comprises of: a binder for the concrete mix consists of Portland cement or a blended cement mix; 10-15% by weight biochar, a carbon-rich by-product of biomass pyrolysis to reduce the density and thermal conductivity of the concrete, enhancing energy efficiency; aggregates are used to provide volume, stability, and structural integrity; and superplasticizers, water-reducing agents, and air-entraining admixtures may be added to enhance workability, improve setting time, and ensure a uniform dispersion of biochar throughout the concrete matrix. The adding biochar reduces the density of the concrete to 1700 kg/m³ and decreases its thermal conductivity by approximately 20%. This innovation offers a low-carbon alternative to traditional concrete, ideal for sustainable construction applications focused on energy efficiency and environmental impact reduction.

Specification

Description:Field of the Invention
The present invention relates to building materials, more particular to a low-carbon sustainable concrete brick using biochar as filler material for sustainable construction.
Background of the Invention
The construction industry faces growing pressure to reduce its carbon footprint, and sustainable materials are critical to achieving this goal. Traditional cement-based concrete has a high environmental impact due to its energy-intensive production and substantial CO2 emissions. This invention focuses on low-carbon concrete bricks by incorporating biochar as a filler, which reduces the material's weight and thermal conductivity while maintaining its strength. Biochar, produced from biomass pyrolysis, is a carbon-rich material that not only lowers the density of concrete but also helps sequester carbon, making it an ideal component for sustainable construction.
By adding biochar in proportions of 10-15% by weight, the resulting concrete bricks achieve reduced density (1700 kg/m³) and 20% lower thermal conductivity. These properties make the bricks particularly suitable for energy-efficient buildings where insulation is essential, aligning with sustainable building practices.
Object of the Invention
• The primary objective of the present invention is to develop low-carbon concrete bricks that incorporate biochar as a filler material to reduce density and enhance thermal insulation.
• Another objective of the present invention is to reduce the thermal conductivity of concrete bricks by 20% through the addition of biochar, improving energy efficiency in buildings.
• The further objective of the present invention is to maintain the compressive strength of concrete while using biochar, ensuring that the material meets structural standards..
Detailed Description of the Invention
The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
In any embodiment described herein, the open-ended terms "comprising," "comprises," and the like (which are synonymous with "including," "having" and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like. As used herein, the singular forms "a", "an", and "the" designate both the singular and the plural, unless expressly stated to designate the singular only.
The present invention developed a low-carbon concrete brick by incorporating biochar as a filler, which reduces the material's weight and thermal conductivity while maintaining its strength. The low-carbon sustainable concrete brick comprises of:
a) Cementitious Binder: The binder for the concrete mix consists of Portland cement or a blended cement mix. The binder ensures a strong, cohesive structure for the concrete while providing the necessary compressive strength for load-bearing applications.
b) Biochar (10-15%): Biochar, derived from the pyrolysis of organic biomass, is used as a filler material in the concrete mix at 10-15% of the total weight. Biochar's porous structure and carbon content lower the density and thermal conductivity of the concrete while also helping to sequester carbon.
c) Fine and Coarse Aggregates: Aggregates are used to provide volume, stability, and structural integrity. Fine aggregates, such as sand, and coarse aggregates, such as crushed stone, are included to create a balanced, workable mix.
d) Additional Admixtures: Superplasticizers, water-reducing agents, and air-entraining admixtures may be added to enhance workability, improve setting time, and ensure a uniform dispersion of biochar throughout the concrete matrix.
The process of manufacturing low-carbon concrete bricks using biochar as a filler material follows these steps:
• Mixing: The cementitious binder, biochar, fine and coarse aggregates, and admixtures are mixed thoroughly to form a homogeneous mixture. Ensuring even distribution of biochar within the matrix is critical for achieving uniform density and thermal properties.
• Moulding: The concrete mix is poured into brick moulds, compacted, and shaped. This step ensures that the biochar particles are evenly embedded within the matrix, which is important for structural integrity and thermal performance.
• Curing: The concrete bricks are cured over a period of 28 days at controlled ambient conditions. Proper curing is essential for the development of the concrete's compressive strength and durability.
In preferred embodiment, incorporating 10-15% biochar in the concrete mix lowers the density of the material to approximately 1700 kg/m³. This reduced density provides several advantages, including easier handling, reduced load on structural elements, and suitability for applications where lighter materials are preferred, such as multi-story buildings.
In preferred embodiment, the addition of biochar improves the thermal insulation of the concrete. Initial results show that the thermal conductivity of the concrete bricks is reduced by approximately 20% compared to standard concrete. This enhanced insulation reduces heat transfer, promoting energy efficiency in buildings by helping maintain stable indoor temperatures and reducing reliance on heating and cooling systems.
Advantages of the Invention
1. Reduced Density for Lightweight Construction
The inclusion of biochar lowers the density of the concrete to approximately 1700 kg/m³, providing a lightweight alternative that is easier to handle and reduces the load on structural elements. This lightweight characteristic is particularly advantageous in multi-story buildings where reduced weight is beneficial.
2. Improved Thermal Insulation
Biochar's porous structure improves thermal insulation, reducing the thermal conductivity of the concrete by 20%. This enhanced insulation contributes to energy savings by stabilizing indoor temperatures, reducing the need for heating and cooling, and improving the energy efficiency of buildings.
3. Structural Integrity and Compressive Strength
Despite the incorporation of biochar, the concrete maintains compressive strength, making it suitable for a wide range of structural applications, including load-bearing walls and foundations. This strength retention ensures that the material meets standard construction requirements.
4. Environmental Sustainability
By integrating biochar, a carbon-rich and renewable material, this invention supports sustainable building practices. Biochar's carbon-negative properties help sequester CO2, while its inclusion in concrete reduces the amount of cement required, further lowering the carbon footprint of the material.
Applications
These low-carbon concrete bricks are suitable for various construction applications, especially in projects prioritizing energy efficiency and environmental responsibility:
1. Residential and Commercial Buildings: Ideal for both residential and commercial projects, offering improved insulation and reduced weight.
2. Energy-Efficient Construction: Suitable for buildings requiring enhanced insulation, as the reduced thermal conductivity contributes to lower energy consumption.
3. Sustainable Building Projects: These bricks are an excellent choice for green building projects seeking LEED certification or other sustainability standards due to their reduced environmental impact.
Comparative Analysis with Standard Concrete Bricks
Feature Standard Concrete Bricks Low-Carbon Concrete Bricks with Biochar
Density 2400 kg/m³ Approximately 1700 kg/m³
Thermal Conductivity Standard Reduced by 20%
Compressive Strength Standard Maintained
Carbon Sequestration None High, with long-term CO2 storage
Environmental Impact High Reduced through biochar integration
This invention presents a sustainable approach to concrete production by developing low-carbon concrete bricks that incorporate biochar as a filler material. The addition of biochar enhances the environmental profile of concrete, contributing to carbon sequestration, reducing density, and improving thermal insulation. These properties align with the objectives of sustainable and energy-efficient construction, offering a viable alternative to conventional concrete.
The reduced thermal conductivity and density, combined with retained compressive strength, make these concrete bricks suitable for a wide range of applications in both residential and commercial buildings. By integrating biochar, a renewable and carbon-negative material, this invention contributes to sustainable building practices and provides a practical solution for low-carbon construction.
This innovation meets the demands of modern green construction, offering an eco-friendly alternative that supports global efforts to reduce carbon emissions and promote energy efficiency in building materials.

, Claims:1. A low-carbon sustainable concrete brick, comprising of:
a) a cementitious binder as the primary structural component consists of Portland cement or a blended cement mix;
b) 10-15% by weight biochar, a carbon-rich by-product of biomass pyrolysis to reduce the density and thermal conductivity of the concrete, enhancing energy efficiency;
c) Fine aggregates, such as sand, and coarse aggregates, such as crushed stone, are included to provide volume, stability, and structural integrity or to create a balanced, workable mix; and
d) superplasticizers, water-reducing agents, and air-entraining admixtures may be added to enhance workability, improve setting time, and ensure a uniform dispersion of biochar throughout the concrete matrix.
2. The low-carbon sustainable concrete brick as claimed in the claim 1, wherein the biochar reduces the density of the concrete to approximately 1700 kg/m³.
3. The low-carbon sustainable concrete brick as claimed in the claim 1, wherein the process of manufacturing comprises the following steps:
• Step 1: The cementitious binder, biochar, fine and coarse aggregates, and admixtures are mixed thoroughly to form a homogeneous mixture;
• Step 2: The concrete mix is poured into brick moulds, compacted, and shaped. This step ensures that the biochar particles are evenly embedded within the matrix, which is important for structural integrity and thermal performance; and
• Step 3: curing the concrete bricks at ambient or slightly elevated temperatures over a period of 28 days, essential for the development of the concrete's compressive strength and durability.
4. The low-carbon sustainable concrete brick as claimed in the claim 1, wherein brick exhibit 20% reduction in thermal conductivity and enhancing the brick's insulation properties.
5. The low-carbon sustainable concrete brick as claimed in the claim 1, wherein the compressive strength of the concrete is maintained, allowing the brick to be used in load-bearing applications.

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