BIOCHAR-ENHANCED CONCRETE COMPOSITION FOR SUSTAINABLECONSTRUCTION

Abstract

This invention introduces a low-carbon geopolymer concrete composition that combines recycled aggregates and polypropylene fibers for enhanced structural durability and sustainability. By replacing traditional cement with an alkali-activated binder derived from industrial byproducts like fly ash and slag, this concrete significantly reduces carbon emissions. The use of recycled aggregates further supports environmental goals by reducing reliance on natural resources. Polypropylene fibers improve mechanical performance by reducing crack formation and increasing resilience to thermal and mechanical stresses, thus extending the concrete's lifespan. This durable, sustainable geopolymer concrete is ideal for high-performance structural applications requiring minimal maintenance, such as pavements, structural beams, precast elements, and infrastructure components. By promoting reduced life cycle costs through greater durability, this composition provides a practical solution for sustainable construction, aligning with efforts to reduce environmental impact and enhance structural resilience.

Specification

Description:I/We Claim 1 (Independent Claim)
A low-carbon geopolymer concrete composition comprising:
An alkali-activated binder,
Recycled concrete aggregate,
An alkali solution of sodium hydroxide and sodium silicate,
Polypropylene fibers (0.1% to 1% by weight),
where the composition improves structural durability and reduces carbon emissions.
I/We Claim 2 (Dependent Claim)
The composition as claimed in Claim 1, wherein the binder includes industrial byproducts such as fly ash or ground granulated blast-furnace slag (GGBFS).
I/We Claim 3 (Dependent Claim)
The composition as claimed in Claim 1, wherein the recycled aggregates are derived from processed construction and demolition waste.
I/We Claim 4 (Dependent Claim)
The composition as claimed in Claim 1, wherein the polypropylene fibers have a length between 6 mm and 12 mm to enhance the tensile properties of the concrete.
I/We Claim 5 (Dependent Claim)
The composition as claimed in Claim 1, wherein the polypropylene fibers reduce shrinkage and improve the concrete's resistance to crack formation during curing.
I/We Claim 6 (Dependent Claim)
The composition as claimed in Claim 1, wherein the geopolymer matrix provides enhanced chemical resistance to sulfates, chlorides, and acidic environments.
I/We Claim 7 (Dependent Claim)
The composition as claimed in Claim 1, wherein the alkali solution consists of a sodium hydroxide and sodium silicate mixture in a weight ratio of
1:1 to 1:2.
I/We Claim 8 (Dependent Claim)
The composition as claimed in Claim 1, where the recycled aggregate content ranges from 30% to 70% by weight of the total aggregate to optimize strength and workability.
I/We Claim 9 (Dependent Claim)
The composition as claimed in Claim 1, wherein the geopolymer concrete exhibits enhanced compressive strength, making it suitable for load-bearing structures. Adding polypropylene fibers, Curing the mixture to form the low-carbon geopolymer concrete.
, C , Claims:BACKGROUND
Field of the invention Title: LOW-CARBON GEOPOLYMER CONCRETE WITH RECYCLED AGGREGATE AND POLYPROPYLENE FIBERS FOR ENHANCED STRUCTURAL DURABILITY
DESCRIPTION:
Field of the Invention:
The invention relates to sustainable construction materials, specifically a low-carbon geopolymer concrete composition. This concrete incorporates recycled aggregates and polypropylene fibers to improve the structural durability and sustainability of concrete structures. The field of invention covers construction engineering and material science, focusing on advanced, eco-friendly materials designed to reduce the environmental impact of traditional concrete while enhancing performance properties like durability and crack resistance.
BACKGROUND:
Traditional concrete production has a major environmental impact due to the high carbon emissions associated with cement manufacturing, which is responsible for approximately 8% of global CO₂ emissions. Cement production requires energy-intensive processes, including heating limestone at high temperatures, releasing significant CO₂. As an alternative, geopolymer concrete drastically reduces the carbon footprint by using industrial byproducts like fly ash and slag. This type of concrete is made through alkali activation, which involves a low-temperature chemical reaction that forms a solid, durable binder. By using these byproducts, geopolymer concrete not only reduces emissions but also repurposes waste materials, creating a sustainable binder that rivals the strength of traditional Portland cement. Further enhancing sustainability, recycled aggregates replace natural aggregates, decreasing reliance on mined resources and aligning with circular economy principles. Recycled aggregates repurpose construction waste and reduce environmental impacts associated with natural aggregate mining, contributing to a more resource-efficient concrete mix.
To improve durability, polypropylene fibers are added to the geopolymer concrete, enhancing its mechanical properties and crack resistance. Polypropylene fibers are resistant to chemical attacks and provide additional tensile strength, effectively bridging and controlling cracks under load or temperature changes. This crack-bridging ability prevents crack propagation and improves the long-term durability of the concrete, making it suitable for infrastructure and structural applications demanding high resilience. Together, the geopolymer binder, recycled aggregates, and polypropylene fibers produce a low-carbon, sustainable concrete that meets performance requirements and is better suited for long-lasting structures. This approach not only addresses environmental concerns in construction but also offers a robust, eco-friendly concrete solution ideal for resilient and sustainable construction projects.
DETAILED DESCRIPTION:
Composition:
The invention includes the following key components:
1. Geopolymer Binder: The binder consists of a mix of aluminosilicate precursors, such as fly ash, slag, or metakaolin, activated with an alkali solution, typically sodium or potassium hydroxide/silicate solution. This combination allows for a sustainable binder with low CO₂ emissions.
2. Recycled Aggregates: Recycled concrete aggregates (RCA) are introduced to replace a percentage of the natural aggregates in the mix. This reduces dependency on natural aggregates, minimizes landfill waste, and conserves natural resources.
3. Polypropylene Fibers: Polypropylene fibers are included in the mix to improve crack resistance and structural durability. The fibers mitigate crack propagation by providing additional tensile strength and bridging cracks that form due to mechanical or thermal stress.
4. Mix Design and Ratios: The geopolymer concrete mix uses optimized proportions of each component to balance mechanical performance and sustainability. Specific mix ratios of geopolymer binder, recycled aggregate, and fiber content are defined to achieve desired compressive strength, durability, and crack resistance.
Proportions
• Binder to Aggregate Ratio: The binder material ranges from 20% to 40% of the total concrete mix by weight.
• Alkali Solution: Sodium hydroxide and sodium silicate solutions in a ratio of 1:1 to 1:2.
• Polypropylene Fibers: Incorporated at 0.1% to 1% by weight of the total concrete mix for optimal improvement in mechanical properties.
Advantages
1. Environmental Sustainability: Utilizes industrial byproducts and recycled aggregates, significantly reducing the carbon footprint compared to conventional cement-based concrete.
2. Improved Durability: Polypropylene fibers increase resistance to cracking, shrinkage, and harsh environmental conditions.
3. Enhanced Structural Performance: The composite exhibits higher compressive and flexural strength, making it ideal for load-bearing applications.
4. Resource Efficiency: Reduces the need for virgin aggregates and conventional cement, promoting a circular economy approach in construction.

Applications
This innovative concrete composition is ideal for high-durability structural applications across a range of infrastructure and building projects that demand long-lasting, low-maintenance materials. Pavements benefit from its crack resistance and strength, providing surfaces that withstand heavy traffic and environmental stress. Structural beams and precast elements are enhanced by the material's improved tensile strength and load-bearing capacity, reducing the risk of cracking and degradation over time. Additionally, this composition is particularly suited to infrastructure projects like bridges, retaining walls, tunnels, and foundations, where resilience to mechanical stress and environmental exposure is critical. The blend of recycled aggregates and polypropylene fibers not only meets structural needs but also supports sustainability goals, making it a prime choice for projects requiring eco-friendly and durable building materials.






Conclusion
The low-carbon geopolymer concrete composition, reinforced with recycled aggregate and polypropylene fibers, offers a groundbreaking solution to sustainable construction challenges. This material demonstrates enhanced mechanical performance, exceptional durability, and reduced environmental impact, aligning with the industry's increasing focus on reducing carbon emissions. Its innovative use of recycled materials not only conserves natural resources but also diverts waste from landfills, contributing to a circular economy within construction. With its capacity for long-term structural resilience and its suitability for demanding applications, this concrete composition provides a practical pathway toward sustainable development. By minimizing the ecological footprint while maximizing durability and performance, it stands as a transformative material for future construction projects that prioritize sustainability, resilience, and environmental responsibility.

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