AN ECO-FRIENDLY, ENERGY-EFFICIENT AND LIGHTWEIGHT GEOPOLYMER BRICK AND PREPARATION METHOD THEREOF

Abstract

The present invention relates to an eco-friendly, energy-efficient and lightweight geopolymer brick incorporating bagasse as a construction material. These geopolymer bricks consist of industrial by-products such as fly ash or slag, activated by alkaline solutions to form a sustainable binding matrix, along with bagasse ash (a by-product of sugarcane processing), fine aggregates, and superplasticizers to ensure proper consistency, workability, and structural integrity of the bricks. The present invention achieves a lightweight and thermally insulating brick suitable for energy-efficient construction. Initial testing demonstrates a 25% reduction in weight and a 15% improvement in thermal insulation over conventional bricks. This invention offers a sustainable, low-carbon alternative for building materials, ideal for both residential and commercial construction.

Specification

Description:Field of the Invention
The present invention relates to the technical field of building materials, more particular to an eco-friendly, energy-efficient and lightweight geopolymer bricks incorporating bagasse as a construction material.
Background of the Invention
With the global construction sector focusing on reducing the environmental impact of building materials, there is a strong need for sustainable alternatives to traditional cement-based products. Traditional bricks, made from clay or cement, are energy-intensive to produce, rely heavily on natural resources, and have a significant carbon footprint. Geopolymer technology provides an eco-friendly alternative by using aluminosilicate sources, which, when activated by alkaline solutions, form a durable, low-carbon binding matrix.
Traditional bricks rely on clay and cement, both of which contribute to high CO2 emissions and significant energy consumption during production. In contrast, geopolymer bricks use aluminosilicate materials (like fly ash or slag) and are activated under lower temperatures, reducing energy requirements and emissions. By incorporating bagasse ash, a waste material from sugarcane, the invention further reduces environmental impact, as bagasse ash is often disposed of in landfills.
In Chinese patent np. CN107352865A, discloses a geopolymer permeable brick, which comprises a base layer and a decorative layer. The base layer comprises aggregate A, a gelling material A, and an exciting agent. The decorative layer comprises aggregate B, a gelling material B, and an exciting agent. The invention further provides a preparation method of the geopolymer permeable brick.
In Japanese Patent no. JP2015145608A, provide a building material having a temperature and humidity controlling function and a high aging degradation durability. The building material combines brick and geopolymer concrete.
None of the prior art indicated above either alone or in combination with one another disclose what the present invention has disclosed.
This invention focuses on developing lightweight geopolymer bricks that incorporate bagasse ash, a by-product of sugarcane processing. Bagasse ash not only lightens the brick, reducing structural load, but also enhances thermal insulation. This dual benefit makes the bricks an ideal material for energy-efficient construction, where insulation and sustainability are key.
Bagasse ash provides additional benefits, such as reducing the weight of the bricks and enhancing their insulating properties, thus contributing to energy-efficient buildings. The inclusion of bagasse ash makes these bricks functional and environmentally friendly, suitable for modern green construction projects.
Object of the Invention
• The primary objective of the present invention is to develop lightweight geopolymer bricks that reduce structural loads while maintaining high strength and durability.
• Another objective of the present invention is to improve the thermal insulation of bricks by incorporating bagasse ash, enhancing building energy efficiency.
• The further objective of the present invention is to create a low-carbon alternative to traditional bricks that minimizes waste and utilizes sustainable resources.
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 lightweight and thermally insulating brick suitable for energy-efficient construction. The geopolymer brick comprises:
• Geopolymer Binder: The binder is formed by activating aluminosilicate materials, such as fly ash or slag, with an alkaline solution, typically sodium or potassium hydroxide. This process creates a robust, low-carbon binding matrix that effectively encapsulates bagasse ash.
• Bagasse Ash: Derived from the combustion of sugarcane bagasse, bagasse ash is added to the mix in proportions of 15-25% of the total brick weight. Bagasse ash serves both as a lightweight aggregate and an insulating component, enhancing the thermal efficiency of the brick.
• Additional Aggregates and Admixtures: Fine aggregates and superplasticizers may be used to ensure proper consistency, workability, and structural integrity of the bricks.
In preferred embodiment, the geopolymer bricks are manufactured through the following steps:
• Mixing: The geopolymer binder, bagasse ash, fine aggregates, and necessary admixtures are mixed in specified proportions to form a homogeneous mixture. Consistency in mixing is critical to achieving an even distribution of the bagasse ash and the desired lightweight and insulating properties.
• Moulding: The mix is poured into moulds that shape the bricks. Compaction techniques are used during moulding to remove air pockets and create a dense, uniform structure.
• Curing: Curing is conducted at ambient or slightly elevated temperatures over a period of 28 days, allowing the geopolymer reaction to strengthen the matrix and optimize thermal properties.
In preferred embodiment, the incorporation of 20% bagasse ash by weight into the geopolymer matrix reduces the brick's overall weight by approximately 25%. This reduction in weight lowers structural loads, making these bricks especially suitable for multi-story buildings and other applications where load reduction is critical.
In preferred embodiment, the bagasse ash within the geopolymer matrix contributes significantly to the brick's thermal insulation properties, achieving a 15% improvement in thermal insulation compared to standard bricks. This improvement results in better temperature regulation within buildings, contributing to energy savings in both warm and cold climates. The insulating effect of bagasse ash helps retain heat in winter and reduce heat ingress in summer.
The present geopolymer brick maintain excellent compressive strength and durability due to the geopolymer binder. The bagasse ash particles, while lightweight, contribute to the matrix structure, supporting high structural integrity suitable for various building applications.
The present lightweight geopolymer bricks lower the carbon footprint of construction materials by using waste products like bagasse ash and reducing reliance on virgin materials. The geopolymer binder emits significantly less CO2 than traditional cement-based products, while bagasse ash utilization reduces landfill waste, aligning the invention with sustainable construction practices.
Advantages of the Invention
1. Lightweight Construction Material
The addition of bagasse ash reduces the weight of the brick by approximately 25%, which helps reduce the structural load on buildings. This characteristic makes the bricks ideal for lightweight construction, particularly in high-rise buildings or structures where load reduction is a priority.
2. Improved Thermal Performance
With an improvement in U-value by 15%, these bricks offer superior thermal insulation, promoting energy savings and maintaining comfortable indoor temperatures. This feature is beneficial in climates that require both heating and cooling, as it reduces reliance on HVAC systems.
3. Environmental Sustainability
By utilizing bagasse ash, a by-product of sugarcane, the invention minimizes waste, reduces reliance on virgin resources, and aligns with circular economy principles. The geopolymer binder also contributes to lower CO2 emissions compared to traditional cement, making this a sustainable alternative for construction.
4. Cost-Effective Material
Bagasse ash is an abundant, low-cost material, which can reduce the overall cost of brick production. This cost efficiency makes it feasible for large-scale applications and accessible for environmentally conscious construction projects.
Applications
These lightweight geopolymer bricks are suitable for a wide range of construction applications, especially where energy efficiency and lightweight materials are desired:
1. Residential and Commercial Buildings: Ideal for both single-family homes and multi-story buildings, offering insulation and load reduction.
2. Green Building Projects: Suitable for projects seeking LEED or other green building certifications, as the bricks meet sustainability and energy efficiency requirements.
3. Retrofit and Renovation Projects: The reduced weight of these bricks makes them suitable for retrofitting older structures that require lightweight building materials.
Comparative Analysis with Conventional Bricks
Feature Conventional Bricks Lightweight Geopolymer Bricks with Bagasse Ash
Material Clay or cement Geopolymer binder with bagasse ash
Production Temperature High (kiln-fired) Low to ambient
CO2 Emissions High Low
Weight Reduction Standard weight Reduced by approximately 25%
Thermal Insulation Moderate Improved by 15%
Environmental Impact High Low, with recycled materials
This invention introduces a sustainable approach to brick production by developing lightweight geopolymer bricks that incorporate bagasse ash. The geopolymer and bagasse ash combination creates a material that is strong, thermally efficient, and environmentally friendly. These bricks align with green building standards, making them suitable for both residential and commercial construction.
The inclusion of bagasse ash not only improves the thermal efficiency of buildings but also provides a low-cost solution for lightweight construction, thus broadening the appeal of these bricks in the global market. By reducing CO2 emissions, minimizing waste, and enhancing energy efficiency, this invention contributes to the ongoing efforts to make construction more sustainable.
In a world where sustainable building materials are increasingly valued, these lightweight geopolymer bricks offer a viable, eco-friendly alternative to traditional bricks. Their performance characteristics make them suitable for a range of applications, addressing the needs of modern, energy-efficient construction while promoting circular economy principles.
, Claims:1. An eco-friendly, energy-efficient and lightweight geopolymer brick, comprises of:
a) a geopolymer binder is formed by activating aluminosilicate materials, such as fly ash or slag, with an alkaline solution, typically sodium or potassium hydroxide;
b) 15-25 wt.% bagasse ash derived from the combustion of sugarcane bagasse; and
c) fine aggregates with superplasticizers to ensure proper consistency, workability, and structural integrity of the bricks.
2. The eco-friendly, energy-efficient and lightweight geopolymer brick as claimed in the claim 1, wherein the bagasse ash is finely ground to a particle size range of 100-500 microns to optimize weight reduction and thermal insulation.
3. The eco-friendly, energy-efficient and lightweight geopolymer brick as claimed in the claim 1, wherein the process of manufacturing comprises the following steps:
• Step 1: The geopolymer binder, bagasse ash, fine aggregates, and necessary admixtures are mixed in specified proportions to form a homogeneous mixture;
• Step 2: The mixtrure is poured into moulds that shape the bricks. Compaction techniques are used during moulding to remove air pockets and create a dense, uniform structure; and
• Step 3: curing the mixture at ambient or slightly elevated temperatures over a period of 28 days, allowing the geopolymer reaction to strengthen the matrix and optimize thermal properties.
4. The eco-friendly, energy-efficient and lightweight geopolymer brick as claimed in the claim 1, wherein brick enhanced thermal insulation with a 15% improvement in U-value.
5. The eco-friendly, energy-efficient and lightweight geopolymer brick as claimed in the claim 1, wherein the bricks exhibit a weight reduction of approximately 25% compared to conventional bricks with the inclusion of 20% bagasse ash.

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