NEXT GEN AGGREGATE FOR STRUCTURAL CONCRETE

Abstract

NEXT GEN AGGREGATE FOR STRUCTUAL CONCRETE ABSTRACT OF THE INVENTION The invention utilizes copper slag as a sustainable alternative to conventional coarse aggregates by grinding and pelletizing it into new aggregate (NGA) under controlled conditions. As industrial waste; copper slag poses significant environmental challenges when improperly disposed of. Its advantageous mechanical properties and chemical composition make it valuable in the construction industry. Previous studies have explored its use in cement manufacturing and as a replacement for fine aggregates. This research focuses on developing coarse aggregates from copper slag and assessing their suitability according to Indian Standards for coarse aggregates. The mechanical properties of these copper slag aggregates are compared with natural coarse aggregates, highlighting their potential for structural concrete applications. Unlike existing lightweight aggregates from fly ash and pond ash, the angular shape of the copper slag aggregates enhances bonding, setting them apart as a promising option for construction. Total Number of Words in Abstract: 150 words SIGNATURE OF THE APPLICANT Dated this 26th of October 2024 PRINCIPAL EASWARI ENGINEERING COLLEGE (Autonomous) Bharathi Salai, Ramapuram, Chennai, Pin Code-600089.

Specification

FORM 2
THE PATENT ACT 1970 (39 OF 1970)
&
The Patent Rules, 2003
RROV4SIONAUCOMPLETE SPECIFICATION (See Section 10 and rule 13)

1. TITLE OF THE INVENTION:
NEXT GEN AGGREGATE FOR STRUCTUAL CONCRETE
2. APPLICANTS (S)
(a) NAME: 1. Easwari Engineering College
(b) NATIONALITY: INDIAN
(c) ADDRESS: 1. Easwari Engineering College, BharathiSalai, Ramapuram, Chennai - 600089

3.
PREAMBLE TO THE DESCRIPTION:
PROVISIONAL
r IXV VTVIvIlriL
The-following-specifigation-describes-the inverrtien
28-Oct-2024/130838/202441082224/Form 2(Title Page)
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.
4. DESCRIPTION (Description shall start from next page.)
ATTACHED
5. CLAIMS (not-appliGable-foH "I/we claim" on separate page)
iork Claims should start with the preamble
ATTACHED
6. DATE AND SIGNATURE (to be given at the end of last page of specification)
ATTACHED
7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page)
ATTACHED
Note:
*Repeat boxes in case of more than one entry.
*To be signed by the applicant(s) or by authorized registered patent agent
*Name of the applicant should be given in full, family name in the beginning.
*Complete address of the applicant should be given stating the postal index no./code, state and country.
*Strike out the column which is/are not applicable

DESCRIPTION:
[0001] Aggregates, which account for 60 to 75 percent of concrete volume and are the most affordable material in concrete production, have significant economic and environmental impacts. The rising demand for stones and sand for concrete has led to environmental concerns, making it essential to control their extraction. With increasing infrastructure needs, alternatives to traditional coarse aggregates are crucial to prevent mineral depletion.

[0002] Excessive extraction causes environmental damage, including impaired water quality, harm to aquifers, reduced lake levels, and disruption of wetlands. Additionally, large amounts of industrial waste, often toxic, are dumped in landfills, causing land fertility loss and environmental damage.

[0003] Copper slag, a by-product of copper refining, offers a viable alternative to natural aggregates. Produced in large quantities, copper slag can replace natural aggregates in concrete. Testing shows that Next Gen aggregates have comparable or better strength properties compared to conventional aggregates, making them a sustainable option for concrete production.

PRIOR ART AND BACKGROUND:
20 [0004] US 2008/0168928A1 the invention relates to a concrete composition that
incorporates atomized steelmaking slag balls (PS balls) as a substitute for sand. Specifically, the composition replaces part or all of the sand with PS balls. The concrete mixture consists of water, cement, coarse aggregates with particle sizes greater than 5 mm, fine aggregates with particle sizes less than 5 mm, optional additives, and other unavoidable impurities. In this composition, more than 30% of the fine aggregates by volume are composed of atomized steelmaking slag balls.

[0005] CN-110845163-A The invention relates to the preparation and application of copper slag aggregate, addressing the comprehensive utilization of non-ferrous 30 metallurgy solid wastes. The method involves mixing 65-80 wt% of converter copper smelting water-quenched slag, 15-25 wt% ferrosilicon, and 5-20 wt% lime, followed by grinding to achieve an 80% pass rate through a 2mm sieve. The mixture is melted at 1120-1150°C in a submerged arc furnace for 3 hours, and after discharging molten iron, the residual slag is water-quenched. The resulting tailings are ground, magnetically separated, and classified into copper slag aggregates of different sizes, providing a sustainable solution for large-scale copper slag utilization.

[0006] KR-102393545-B1 This invention pertains to a mortar composition for producing recycled aggregate concrete by blending recycled fine aggregate with copper slag fine powder. The composition utilizes copper slag fine powder with a particle size of 1.2 mm or less, a by-product of industrial processes, combined with recycled fine aggregate. This mixture prevents the re-hardening of recycled aggregate, increases density, and reduces absorption, ensuring adequate concrete strength. Additionally, it enhances fluidity and workability, making it suitable for various applications. The mortar composition consists of cement, water, an expansive admixture, an AE agent, natural fine aggregate, recycled fine aggregate, and copper slag fine powder.

[0007] KR-20030080270-AThe concrete is distinguished by the partial or complete replacement of fine aggregates with copper slag derived from copper refining processes. Specifically, the copper slag is used in a range of 30 to 100% by volume. Additionally, the concrete is mixed with water at a water-to-cement ratio of 40-65%, achieving a slump of 8 to 18 ± 2 cm.

OBJECTIVE:

[0008] To make artificial coarse aggregates for replacing the natural aggregate forstructural concrete from a feasible industrial waste.

[0009] To test the suitability of the conceived NEXT GEN AGGREGATE (NGA) by performing the required tests as per IS383:2016, IS2386:1963(Part l-IV) for structural 25 concrete for a concrete strength of M20 to M80

[0010] To reduce the depletion of the natural aggregate by replacing them with NGA

SUMMARY:
[0011] The following summary is provided to facilitate a clear understanding of the new
features in the disclosed embodiment and it is not intended to be a full, detailed description. A detailed description of all the aspects of the disclosed invention can be understood by reviewing the full specification, the drawing and the claims and the abstract, as a whole. 7

[0012] In the aspect of the present invention, it is to reduce the construction cost of any building to a considerable extend. The Complete replacement of natural materials like gravel which will help to sustain the environment

[0013] In another aspect of the present invention is recycling of polluting industrial waste which will help to sustain the good Environment and it plays a major role to reduce the demands of conventional materials.

[0014] In yet another aspect of the present invention is the importance of saving and
conservation of resources, efficient development of all these solid industrial wastes towards newer applications and maximizing use of existing technologies for a sustainable and environmentally sound management

DETAILED TECHNICAL DESCRIPTION:

[0015] The materials required for making coarse aggregate are identified and study for its physical and chemical characteristics.Based on their characteristics the methodology adopted for pelletizing the coarse aggregate has to be finalized.Curing of the NGA to obtain sufficient strength equivalent to normal coarse aggregate.

[0016] The Next GenAggregates thus made is to confirm to the standards specified in IS
2386 (Part l-IV) and IS 383:2016
The following test were carried out on NGA confirm to the IS standards
Crushing strength
Impact strength
Specific gravity
Abrasion test
Water absorption
Flakiness index
Elongation index

[0017] Comparative analysis of NGA with IS Code:
SI. No.
Properties
Artificial Coarse
aggregate
Permissible Limits (As per IS Codes)
1.
Flakiness Index
Nil
< 30 %
2.
Elongation Index
17.81 %
< 45 %
3.
Specific Gravity
2.58
2.5 to 3.0
4.
Water Absorption
0.42 %
< 0.6 %
5.
Crushing Value
18%
< 30 %
6.
Impact Value
27 %
< 45 %
7.
Abrasion Value
37.50%
< 60 %

CLAIM:
WE Claim,
1 Artificial Course Aggregate is developed for structural concrete of concrete strength of M20 to M80, system comprising

a. Wherein developed from of industrial waste such as Copper slag, Fly ash and silica fume.
b. Wherein gives a solution for the disposal of the copper slag
c. Wherein gives an alternate solution for replacing the gravel derived from the rocks.
d. Wherein saves the depletion of the natural resource which has a high impact in climatic change.

2. The aggregate as claimed in claim 1, for structural concrete with a mix ratio Copper
slag : Cement: Flyash : Silica fume 1:0.24:0.30:0.05

3. The aggregate as claimed in claim 1, has the Specific Gravity 2.58, Water absorption 0.42%.

4. The aggregate as claimed in claim 1, has the Specific Gravity 2.58, Water absorption 0.42%.
The aggregate as claimed in claim 1, has crushing value 18%, Impact value 27% and abrasion value 37.5%.

5. The aggregate as claimed in claim 1, are angular in shape for better bonding which
makes it stand out from the other developed artificial aggregate.

SIGNATURE OF THE APPLICANT

Dated this 26th of October 2024

PRINCIPAL
EASWARI ENGINEERING COLLEGE
(Autonomous)
Bharathi Salai, Ramapuram, Chennai, Pin Code-600089.

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