MORTAR COMPOSITION COMPRISING COCONUT SHELL ASH

Abstract

ABSTRACT The present invention relates to a mortar composition suitable for use in construction. The mortar composition comprises ordinary Portland cement, fine aggregate, water, and coconut shell ash (CSA). The CSA partially substitutes the cement, enhancing the composition's environmental sustainability.

Specification

Description:MORTAR COMPOSITION COMPRISING COCONUT SHELL ASH

FIELD OF THE INVENTION

The present invention relates to environmentally friendly building materials. More particularly, the present invention relates to a mortar composition that has enhanced compressive strength and can be used in building materials.

BACKGROUND OF THE INVENTION

In the construction industry, mortar is critical as a binding material for bricks, stones, and other building blocks. Traditional mortar compositions predominantly include Portland cement, fine aggregates (such as sand), and water. Despite its widespread use due to excellent binding properties and durability, Portland cement poses significant environmental issues. It is estimated that cement production accounts for approximately 8% of global CO2 emissions, contributing markedly to climate change. The environmental impact of cement production has driven research into alternative materials that can replace cement in mortar and concrete. Various industrial byproducts, such as fly ash, silica fume, and slag, have been used as partial replacements for cement. These materials help reduce the construction materials' carbon footprint but also improve certain properties of the concrete, such as durability and resistance to sulfates.

However, the use of these byproducts presents limitations. The availability of these materials can be geographically and seasonally dependent, and their properties can vary significantly, which may affect the consistency and predictability of concrete performance. Moreover, most of these byproducts still require significant energy for production and processing, which only partially mitigates the environmental issues.

One of the key challenges is to develop a mortar composition that substantially reduces the environmental impact of cement usage while at least maintaining, if not improving, the mechanical and operational properties of the mortar. Additionally, there is a need for a sustainable and consistently available alternative that can be sourced from widely available waste materials, reducing dependency on industrial byproducts and minimizing the overall environmental footprint of the construction industry.

Few prior arts teach the use of various agricultural wastes as supplementary cementitious materials. Such as rice husk ash and sugarcane bagasse ash, which have been tested in limited contexts. These materials show promise due to their silica content, but their performance can be inconsistent, and they are not widely available globally.

Thus, there is a need for a mortar composition that utilizes address environmental issues and enhance the material properties of traditional mortar, fulfilling the demand for more sustainable construction practices.

OBJECT OF THE INVENTION

The principal object of the present invention is to provide a mortar composition with improved compressive strength.

Another object of the present invention is to provide a mortar composition with coconut shell ash (CSA).

Another object of the present invention is to provide an environment friendly mortar composition.

Yet another object of the present invention is to provide a mortar composition for enhanced structural longevity.

Summary of the Invention
The following presents a simplified summary of the invention to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later.
Accordingly, the present invention aims to provide an environment-friendly mortar composition comprising of cement, fine aggregate, coconut shell ash, and water.

In another aspect, the mortar composition comprises coconut shell ash, which is present in an amount ranging from 12% to 16% by weight based on the total weight of the cement.

In yet another aspect, the mortar composition comprises coconut shell ash, which is present in an amount ranging from 13% to 15% by weight based on the total weight of the cement.

In yet another aspect, the mortar composition comprises coconut shell ash, which is present in an amount of 14% by weight based on the total weight of the cement.

In another aspect, the mortar composition comprises coconut shell ash, which is present in an amount of 16% by weight based on the total weight of the cement.

In another aspect, the mortar composition comprises cement, which is present in an amount in an amount ranging from 25 to 32% by weight of the total weight of the solid particles in the composition.

In another aspect, the mortar composition comprises cement, which is present in an amount in an amount ranging from 27 to 30% by weight of the total weight of the solid particles in the composition.

In yet another aspect, the present invention provide a method of preparing mortar composition, the method comprises the step:
providing cement, fine aggregate, water and coconut shell ash;
mixing the cement, fine aggregate, water, and coconut shell ash to form a mortar mixture and
curing the mortar mixture.

In a preferred aspect of the present invention, the method comprises the step:
providing cement, fine aggregate, water and coconut shell ash;
mixing the cement, fine aggregate, water, and coconut shell ash to form a mortar mixture, wherein the coconut shell ash substitutes for cement and constitutes between 12% and 16% by weight based on the total weight of the cement; and
curing the mortar mixture.

In further aspect the present invention provides a method for preparing a coconut shell ash, comprising the steps of
collecting and cleaning coconut shells;
drying the cleaned coconut shells at a temperature of 100°C - 110°C for 12 to 24 hours;
combusting the dried coconut shells at a temperature between 500°C and 800°C for 4 to 6 hours;
cooling and processing the combusted shells to obtain ash; and
sieving the ash through a fine mesh to obtain fine ash.

Brief Description of the Drawings:

Figure 1: illustrates the cube under a compressive strength test.

Figure 2: illustrates the different cubes after the compressive strength test.

Detailed Description of the Invention
The exemplary embodiments described herein detail for illustrative purposes are subject to many variations in the structure and design. It should be emphasized, however, that the present invention is not limited to a particular improved heat resistant mortar as described herein. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.

Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The use of terms "including," "comprising," or "having" and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

Further, the terms, "an" and "a" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

As used herein, the term "and/or" means that either all or only one of the elements of said group may be present. For example, "A and/or B" shall mean "only A, or only B, or both A and B". In the case of "only A", the term also covers the possibility that B is absent, i.e. "only A, but not B".

As used herein, "relative to" refers to calculating the proportion or percentage of a component or ingredient in the context of another specified component's quantity or the context of the total composition's quantity, as explicitly stated. This term is used to express the dependency of one measurement on another as a basis for comparison. For example, when stating that a component is present in an amount "relative to the total weight of the cement" or "relative to the total weight of solid particles in the composition", or "total weight of the cement"the percentage or ratio is calculated by:
Determining the absolute weight of the referenced component (e.g., cement or solid particles).
Calculating the weight of the component in question (e.g., coconut shell ash, water, or any additives) as a percentage of the weight of the referenced component.

The present invention aims to provide a mortar composition comprising of coconut shell ash (CSA) with improved compressive strength. The composition comprises of cement, fine aggregate, coconut shell ash, and water.

In an embodiment, the mortar composition comprises coconut shell ash (CSA) in the range of 12% to 16% by weight based on the total weight of the cement in the composition.

In another embodiment, the mortar composition comprises coconut shell ash (CSA) in the range of 13% to 15% by weight based on the total weight of the cement in the composition.
In an embodiment of the present invention, the mortar composition comprises cement in an amount of 25 to 32% by weigh of the total weight of the solid particles in the composition.

Solid particles include but are not limited to cement and fine aggregates such as clay, silt, sand, crushed gravel, crushed stone, coconut ash, or any other additive used in the composition. Further, fine aggregates include all particles other than the water used for preparing the composition.

In another embodiment, the present invention provides a method for preparing the mortar composition, the comprising the steps of:
providing cement, fine aggregate, water and coconut shell ash;
mixing the cement, fine aggregate, water, and coconut shell ash to form a mortar mixture; and
curing the mortar mixture.

In another embodiment, the method of preparing the mortar composition comprises the steps:
providing cement, fine aggregate, water and coconut shell ash;
mixing the cement, fine aggregate, water, and coconut shell ash to form a mortar mixture wherein the coconut shell ash substitutes for cement and constitutes between 12% and 16% by weight based on the total weight of the cement of the cement; and
curing the mortar mixture.

In another embodiment, the method of preparing the composition comprises:
measuring the required amount of cement, fine aggregate, water and coconut shell ash;
mixing cement, fine aggregate, water and coconut shell ash to form a mortar mixture, wherein the coconut shell ash substitutes for cement and constitutes 12% by weight based on the total weight of the cement; and
curing the mortar mixture.

In another embodiment, the method of preparing the composition comprises:
measuring the required amount of cement, fine aggregate, water and coconut shell ash;
mixing cement, fine aggregate, water and coconut shell ash to form a mortar mixture, wherein the coconut shell ash substitutes for cement and constitutes 14% by weight based on the total weight of the cement; and
curing the mortar mixture.

In another embodiment, the method of preparing the composition comprises:
measuring the required amount of cement, fine aggregate, water and coconut shell ash;
mixing cement, fine aggregate, water and coconut shell ash to form a mortar mixture, wherein the coconut shell ash substitutes for cement and constitutes 16% by weight based on the total weight of the cement; and
curing the mortar mixture.

In another embodiment, the present invention provides a method for preparing the coconut shell, the method comprises:

Coconut Shell Ash (CSA) preparation typically involves a controlled combustion process of coconut shells to ensure that the ash produced is suitable for various applications, such as in concrete production or as a reinforcing material. Below is the step-by-step process, along with key process parameters:

Collection and Cleaning of Coconut Shells

Collection: Dry coconut shells are collected, ensuring they are free from moisture and contaminants.
Cleaning: The shells are thoroughly cleaned to remove dirt, fibers, and organic matter that could interfere with the combustion process.

Drying: Before burning, the coconut shells are air-dried or oven-dried to remove any residual moisture.
Temperature: For oven drying, temperatures around 100-110°C for 12-24 hours may be used, depending on the moisture content of the shells. This ensures that combustion is more efficient and complete during the next step.

Combustion or Calcination Process
The dried coconut shells are then combusted in a furnace, kiln, or an open-air environment under controlled conditions.
Temperature: The combustion temperature typically ranges from 500°C to 800°C. Lower temperatures may result in incomplete combustion, while higher temperatures (above 800°C) may reduce the quality of the ash due to the loss of reactive silica.

Duration: The combustion process can take anywhere from 2 to 6 hours, depending on the amount of material and the temperature used.

Air Supply: The process can be done in an open atmosphere (which is less controlled) or in a controlled furnace where the oxygen supply can be regulated to avoid excessive oxidation of useful constituents.
Cooling and Collection of Ash
After combustion, the ash is allowed to cool down naturally.

The resulting ash is carefully collected. The cooling process is important to prevent any reaction with moisture from the air, which could alter the properties of the ash.

Sieving and Grinding
To obtain fine ash for specific applications, the ash may be sieved through a fine mesh (for example, a 90 µm sieve).

Grinding: In some cases, the ash is ground using a ball mill or other grinding equipment to achieve a finer particle size, which improves its reactivity and performance in applications such as concrete production.

Examples

Example 1: Collection of raw materials
Ordinary Portland Cement (OPC) of 43 Grade was used for preparing the mortar composition. Fine aggregates were locally procured Greater Noida, India. Coconut Shell were collected from local vegetable market and ash prepared as per the method discussed above.

Cement
Table 1: Properties of Cement
Properties Values
Type OPC 43
Specific Gravity 3.202
Consistency 28%
Initial Setting Time 46 min
Final Setting Time 400 min
fineness 5%

Fine Aggregate
Table 2: Properties of Fine Aggregate
Properties Values
Specific Gravity 2.61
Size used 2.36

Water
Table 3: Properties of Water
Properties Values
Density 1000 kg/m3
pH Level 7.5
Turbidity Nil

Coconut Shell Ash
The specific gravity of 1.344 was used in the experiment.
Example 2
Preparation of the mortar composition

Different Mortar Composition were prepared by varying the amount of cement and coconut shell ash (CSA), as depicted in below table:

Table 4: Different Mortar composition
Mix Id Cement (gm) CSA (gm) Fine Aggregate (gm) Water (ml)
CM 616.3 0 1848 246
CSA10 554.67 61.63 1848 246
CSA12 542.35 73.95 1848 246
CSA14 530 86.28 1848 246
CSA16 517.7 98.6 1848 246
CSA18 505.4 110.93 1848 246

Example 3
Standard - CM
Ordinary Portland Cement (OPC), sand (as per IS 650), potable water free from impurities were mixed using a mechanical mixer to obtain the control mortar composition free of coconut shell ash (CSA). Cubical molds of size 70.6 mm x 70.6 mm x 70.6 mm (or 50 mm cube for high-strength mortars).

The standard mortar mix is prepared in the ratio of 1:3 by mass (1 part of cement and 3 parts of standard sand) as per IS 2250:1981.

Preparation of Mortar Composition with Coconut Shell Ash
CSA10
A total of 554.67 grams of cement, 61.63 grams of coconut shell ash, 1848 grams of fine aggregate (sand), and 246 milliliters of water were measured. The cement and fine aggregate were mixed in a dry state, followed by adding water to achieve the required water-cement ratio. The mixing process continued to obtain a homogeneous mixture for 3-4 minutes.

Similar to CSA 10, other mortar compositions (CSA12, CSA14, CSA16 and CSA18) were prepared by varying the amount of Cement and Coconut shell ash (CSA) as per table 1

Example 4
Mould Preparation

Clean the cube moulds and apply a thin layer of oil or grease on the internal surfaces to ensure easy removal of mortar cubes after curing. Fill the moulds with the freshly prepared mortar in two layers. Compact each layer by tamping 20-25 times using a standard rod (16 mm diameter) or a similar compacting device to eliminate air voids.

Cube moulds are clean and a thin layer of oil or grease was applied to the internal surfaces to facilitate easy removal of mortar cubes after curing. Subsequently, the moulds were filed with freshly prepared mortar in two layers. Each layer was compacted by tamping around 20-25 times using a standard rod (16 mm diameter) or a similar compacting device to eliminate air voids.

Example 5

Curing

After preparing the molds, the cubes were covered to prevent moisture loss and allowed to set for about 24 hours under ambient conditions. After 24 hours, the cubes were removed from the molds and placed in clean water for curing at 27 ± 2°C, following IS 2250 standards. The cubes were then cured for 28 days.

Example 6
After 28 days of curing, the mortar cubes were dried and placed in a compression testing machine. The cubes were carefully aligned within the machine to ensure that the load was applied uniformly on opposite faces of the cubes. The load was applied at a rate of 35 N/mm² per minute until the cubes failed, and the load at which the cube failed was recorded.

Calculation of Compressive Strength:
The compressive strength is calculated using the formula:
Compressive Strength (N/mm²) = (Maximum Load (N))/(Cross-sectional Area of Cube (mm²))

Compressive strength of the different mortar composition were subject to the compressive strength test as per Indian Standards (IS 2250: 1981 and IS 4031: 1988 Part 6), a standardized method. The procedure ensures the compressive strength of the mortar is measured accurately under controlled conditions.
Compressive strength results after 28 days
Percentage of CSA by weight of cement in the mortar Compressive strength MPa (28 days)
0 19.8
10 20.93
12 21.46
14 23.13
16 20.26
18 17.85

It is evident from the above t the compressive strength results for mortar after 28 days' for coconut shell ash (CSA), revealing that the maximum compressive strength achieved is 23.13 MPa, obtained through a 14% replacement of cement. Additionally, it is observed that for CSA, the optimal replacement level is found to be 16%. This suggests that substituting 14% of cement with CSA yields the highest compressive strength, while 16% is the most effective replacement level overall.

While the disclosure has been presented with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit and scope of the disclosure. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the disclosure.
, Claims:We Claim:

1. A mortar composition, comprising:
cement;
fine aggregate;
coconut shell ash; and
water.

2. The mortar composition as claimed in claim 1, wherein the coconut shell ash is present in an amount ranging from 12 to 16% by weight based on the total weight of the cement.

3. The mortar composition as claimed in claim 1, wherein the coconut shell ash is present in an amount ranging from 13 to 15% by weight based on the total weight of the cement.

4. The mortar composition as claimed in claim 1, wherein the cement is present in an amount in an amount ranging from 25 to 32% by weight of the total weight of the solid particles in the composition.

5. The mortar composition as claimed in claim 1, wherein the cement is present in an amount in an amount ranging from 27 to 30% by weight of the total weight of the solid particles in the composition.

6. A method for preparing a mortar composition comprising the steps of:
a. providing cement, fine aggregate, water and coconut shell ash;
b. mixing the cement, fine aggregate, water, and coconut shell ash to form a mortar mixture wherein the coconut shell ash substitutes for cement and constitutes between 12% and 16% by weight, relative to the total weight of the cement; and
c. curing the mortar mixture.

7. The method as claimed in claim 6, wherein the coconut shell ash is prepared by a process comprising:
a. collecting and cleaning coconut shells;
b. drying the cleaned coconut shells at a temperature of 100°C - 110°C for 12 to 24 hours;
c. combusting the dried coconut shells at a temperature between 500°C and 800°C for 4 to 6 hours;
d. cooling and processing the combusted shells to obtain ash; and
e. sieving the ash through a fine mesh to obtain fine ash.

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