COMPOSIÇÃO DE CONCRETO PARA PISO GRAMA E PROCESSO DE PRODUÇÃO DA MESMA

Abstract

CONCRETE COMPOSITION FOR GRASS PAVING AND ITS PRODUCTION PROCESS. The present invention discloses a concrete composition and its production process. Additionally, the production of hollow paving blocks from said concrete composition, for application in permeable areas, is disclosed. Said concrete composition comprises cement, fine sand, Beige Bahia marble aggregate, traditional aggregate, water and additive.

Description

1 / 14 Concrete composition for grass pavers and its production process. Field of application.

[0001] The present invention relates to the field of materials, more specifically to the field of materials applied to civil construction. The present invention discloses a concrete composition and its production process. Additionally, the production of hollow paving blocks from said concrete composition, with application in permeable areas, is disclosed. FUNDAMENTALS OF THE INVENTION

[0002] Ornamental rocks are materials widely used in the construction industry, mainly as finishing materials for buildings and decorative artifacts. Brazil is one of the largest producers and exporters of this type of rock. In this field, the Ourolândia region in Bahia holds a position of national importance regarding rock extraction.

[0003] In recent years, the Brazilian ornamental stone industry has shown significant growth within the context of the national economy. However, this type of industry operates with a high rate of material loss due to the nature of its extraction and trade, and this is no different when it comes to Beige Bahia marble, extracted mainly in the municipality of Ourolândia. Figures provided by ASSOBEGE (2009) reveal a loss in the range of 65 to 75% in the extraction of all material in its natural state.

[0004] Since the 2000s, companies have been developing methods to reduce this amount of Petition 870260055180, dated 08 / 06 / 2026, page 11 / 28 2 / 14 of the remaining extraction waste. However, these initiatives are still not enough to meet this demand since, in addition to the waste currently produced during current extractions, there is also the waste that has accumulated over the years. Reuse is the most correct way to reduce the stock of accumulated material that could not be used in the traditional processing method.

[0005] Currently, studies in the area of ​​industrial waste reuse are being developed, in search of solutions that mitigate the impacts related to industrial activities, whether due to the high extraction of natural raw materials or the high generation of solid waste.

[0006] The incorporation of recycled coarse aggregate originating from construction waste is one example (DE MELO SILVA et al. 2020). Reincorporating waste into the production chain itself is an urgent and current concern, given that natural resources are finite and will inevitably become scarce. Studies on the incorporation of other recycled materials in concrete, such as tire rubber residue, can also be found (DA SILVA JÚNIOR, FA et al. 2016).

[0007] The complexity involved in modifying the already known composition of concrete (cement, sand, water, and traditional crushed stone, which can be granite or basalt) is related to the behavior of the material when incorporated into the mixture. This material, generically known as recycled aggregate, in this case being Beige Bahia marble crushed stone, needs to have characteristics similar to traditional granite or basalt crushed stone, that is, to have Petition 870260055180, dated 08 / 06 / 2026, page 12 / 28 3 / 14 mechanical strength and not absorb too much water from the mixture.

[0008] The macro-theme known as "recycled aggregate" is broad and already known in the literature; however, the incorporation of leftover Beige Bahia marble aggregate as recycled aggregate in concrete is still unknown. This incorporation mitigates the waste produced by the mining and processing of Beige Bahia marble and aims to reduce the cost involved in acquiring the aggregates essential for concrete.

[0009] The present invention provides a solution for a concrete composition and its production process, wherein said concrete composition comprises cement, fine sand, Beige Bahia marble aggregate, traditional aggregate, water and additive. Additionally, the production of hollow paving blocks from said concrete composition is disclosed, with application in permeable areas.

[00010] One of the advantages brought by the present invention is the reduction in the use of traditional crushed stone, which is replaced by the use of Beige Bahia marble crushed stone, which is a production process residue produced in large quantities. Currently, the Beige Bahia marble industry operates with a waste coefficient in the range of 70% (CAMPOS et al., 2009) and, given this, there is an urgent need to mitigate the remaining waste stock. The invention, therefore, comes as a solution to this problem. STATE OF THE ART

[00011] Document KR1030221 discloses a method for manufacturing a composite block made of stone slabs. Petition 870260055180, dated 08 / 06 / 2026, p. 13 / 28 4 / 14 natural and a cement mortar block fully fixed to the underside of the natural stone slab.

[00012] The difference between this document and the present invention is that the latter consists of a concrete composition containing natural Beige Bahia marble in its crushed form with cement, water and superplasticizer, therefore not using the rock slab, and that said composition can be used for the production of hollow paving blocks or grass pavers.

[00013] Document US20070044685 discloses a type of marble floor comprising a base, a vapor barrier, a concrete slab, mortar composed of Portland cement and marble pieces and marble pieces around the mortar.

[00014] The difference between this document and the present invention is that the latter is a concrete composition containing natural Beige Bahia marble in its crushed form with cement, water and superplasticizer, therefore not using the rock slab, and that said composition can be used for the production of hollow paving blocks or grass pavers.

[00015] Document CN106145771 discloses a decorative building material and a method for producing it. The decorative building material is prepared from waste, plastic, cellosilk and an additive. The production method comprises the following steps: preparation of a powder from waste; obtaining a plastic powder; mixing the plastic powder with the waste powder; adding the additive and cellosilk, stirring uniformly, granulating and performing extrusion molding to obtain a finished product. Petition 870260055180, dated 08 / 06 / 2026, page 14 / 28 5 / 14

[00016] The difference between this document and the present invention is the type of waste used, which, in the case of the present invention, is Beige Bahia marble gravel. SUMMARY OF THE INVENTION

[00017] In order to achieve the objectives described above, the present invention describes a concrete composition and its production process. Additionally, the production of hollow paving blocks for application in permeable areas is disclosed. The said concrete composition comprises cement, fine sand, Beige Bahia marble aggregate, traditional aggregate, water, and an additive. BRIEF DESCRIPTION OF THE FIGURES

[00018] Figure 1 shows a hollow paving block produced from the concrete composition of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[00019] The present invention discloses a concrete composition and its production process. Additionally, the production of hollow paving blocks from said concrete composition, with application in permeable areas, is disclosed.

[00020] The aforementioned concrete composition for grass pavers comprises cement, fine sand, Beige Bahia marble aggregate, traditional aggregate, water, and a superplasticizing additive.

[00021] Portland cement CP-II F-32 should be used.

[00022] Fine sand with a diameter between 0.075 mm and 0.6 mm.

[00023] Beige Bahia marble aggregate with a diameter between 2.36 mm and 12.5 mm should be used.

[00024] Traditional granite aggregate should be used or Petition 870260055180, dated 08 / 06 / 2026, p. 15 / 28 6 / 14 basaltic with a diameter between 2.36 mm and 12.5 mm.

[00025] Public water supply must be used.

[00026] A superplasticizer additive selected from the group comprising polycarboxylate ether compound additives must be used.

[00027] The concrete composition comprises between 14% and 15% by weight of cement; 31% to 33% by weight of fine sand; 6.5% to 7.0% by weight of Beige Bahia marble aggregate; 39% to 41% by weight of traditional aggregate; 7.0% to 7.2% by weight of water and 0.5% to 0.7% in relation to the mass of cement by weight of superplasticizing additive.

[00028] The production process for concrete mix for grass pavers comprises the following steps:

[00029] (a) weigh the cement, fine sand, Beige Bahia marble gravel, traditional gravel, water and superplasticizer additive;

[00030] (b) mix the fine sand, the Beige Bahia marble aggregate, the traditional aggregate and the superplasticizer additive for 60 to 90 seconds, in a concrete mixer, at a speed in the range of 25 to 30 revolutions per minute (RPM);

[00031] (c) add half of the heavy water in step (a) and mix the materials for 60 to 90 seconds, at a speed range of 25 to 30 RPM;

[00032] (d) add the cement and mix for 30 to 40 seconds, at a speed range of 25 to 30 RPM;

[00033] (e) add half of the heavy water in step (a) and mix the materials for 120 to 160 seconds, at a speed range of 25 to 30 RPM; Petition 870260055180, dated 08 / 06 / 2026, p. 16 / 28 7 / 14

[00034] (f) add the superplasticizer additive and mix for 120 to 160 seconds, at a speed range of 25 to 30 RPM.

[00035] The dosage of the concrete composition used in the grass paver was established according to the EPUSP / IPT method, presented in the Concrete Dosage and Control Manual (HELENE; TERZIAN, 1992) as an update made at the Polytechnic School of USP - University of São Paulo, based on the method initially developed at IPT - Technological Research Institute of the State of São Paulo, using the Abrams curve. The production of the concrete composition, the sequence and the mixing time were determined as established in the two-stage mixing process (TSMA) described by Tam et al. (2005). According to Leite and Monteiro (2016), this process proved to be efficient in the production of concretes with recycled aggregate.

[00036] The aforementioned concrete mix production process is described in detail below. This process begins, in step (a), where the cement, fine sand, Beige Bahia marble aggregate, traditional aggregate, water and superplasticizer additive are weighed. Preferably, 373.88 kg of cement per 1 m3 of mix, 837.49 kg of fine sand per 1 m3 of mix, 183.20 kg of Beige Bahia marble aggregate per 1 m3 of mix, 1031.91 kg of traditional aggregate per 1 m3 of mix, 186.94 kg of water per 1 m3 of mix and 1.87 kg of superplasticizer additive per 1 m3 of mix are weighed.

[00037] In step (b), the fine sand, the Beige Bahia marble gravel, the traditional gravel and the superplasticizer additive are mixed for 60 to 90 seconds in a Petition 870260055180, dated 08 / 06 / 2026, p. 17 / 28 8 / 14 concrete mixer, with a speed in the range of 25 to 30 revolutions per minute (RPM). Optionally, the concrete mixer has a capacity of 150 liters. Preferably, 837.49 kg of fine sand are added per 1 m³ of composition, 183.20 kg of Beige Bahia marble gravel per 1 m³ of composition, 1031.91 kg of traditional gravel per 1 m³ of composition, and 1.87 kg of superplasticizer additive per 1 m³ of composition.

[00038] In step (c), half of the heavy water from step (a) is added and the materials are mixed for 60 to 90 seconds, at a speed range of 25 to 30 RPM.

[00039] In step (d), add the cement and mix for 30 to 40 seconds, at a speed range of 25 to 30 RPM. Preferably, add 373.88 kg of cement per 1 m3 of mix.

[00040] In step (e), the remaining half of the water is added and mixed for 120 to 160 seconds, at a speed range of 25 to 30 RPM.

[00041] In step (f), add the superplasticizer additive and mix for 120 to 160 seconds, at a speed range of 25 to 30 RPM. Preferably, add 1.87 kg of superplasticizer additive per 1 m3 of composition.

[00042] The production process for grass flooring comprises the following steps: (a) apply release agent to the molds; (b) mold the concrete composition for grass pavers to the molds in at least 3 layers; (c) dry; (d) remove the grass floor from the molds after 24 hours. Petition 870260055180, dated 08 / 06 / 2026, page 18 / 28 9 / 14

[00043] The aforementioned concrete composition is used for the production of hollow paving blocks or grass pavers for application in permeable areas, as shown in figure 1.

[00044] The aforementioned grass flooring production process is described in detail below. This process begins with step (a), in which the emulsified mineral oil release agent is applied to the molds.

[00045] In step (b), the concrete mix is ​​added to the molds in at least 3 layers. Preferably, the molds have equal dimensions, are cylindrical and have a height equal to twice the diameter, which varies between 10 cm and 15 cm. Preferably, each added layer is struck 15 times with the Slump Test rod to be uniformly compacted.

[00046] In step (c), the concrete composition is air-dried in the mold for 23 to 25 hours, obtaining hardened concrete test specimens with dimensions similar to the cylindrical molds.

[00047] In step (d), the concrete test specimens are removed from the molds, after 24 hours counted from the start of step (b).

[00048] The resulting grass tiles must be stored in a saturated calcium hydroxide solution at (23 ± 2) °C or in a humid chamber at a temperature of (23 ± 2) °C and relative humidity above 95%, during the curing time of 27 to 29 days from the date of production. The test specimens must not be exposed to dripping or the action of moving water. Example 1 - Characterization tests of crushed stone raw material Petition 870260055180, dated 08 / 06 / 2026, p. 19 / 28 10 / 14 Beige Bahia Marble

[00049] Tests were carried out to characterize the raw materials used for the production of the concrete composition of the present invention, and the raw material tested was: Beige Bahia marble aggregate with a maximum diameter of 12.5 mm.

[00050] The following characterization tests were carried out for the raw materials: specific gravity and absorption - aggregate 12; formwork index; total moisture content. - 12-inch crushed stone; particle size analysis - 12-inch crushed stone; determination of organic impurities and determination of clay content in lumps and friable materials - 12-inch crushed stone.

[00051] Table 1 below specifies the characterization test methodologies used for Beige Bahia marble aggregates with a maximum diameter of 12.5 mm. Table 1 - Characterization tests of the raw material Beige Bahia marble aggregate with a maximum diameter of 12.5 mm. Test Method - Normative Reference Specific gravity and absorption - Crushed stone 12 ABNT NBR NM 53:2009 Shape index ABNT NBR 7809:2006 Total moisture content - Crushed stone 12 ABNT NBR 9939:2011 Particle size analysis - Crushed stone 12 ABNT NBR NM 248:2003 Determination of organic impurities ABNT NBR NM 49:2001 Determination of clay content in lumps and friable materials - Crushed stone 12 ABNT NBR 7218:2010

[00052] The results are shown in Table 2 below. Petition 870260055180, dated 08 / 06 / 2026, page 20 / 28 11 / 14 obtained for the characterization tests of the aforementioned raw material carried out according to the methodologies shown in Table 1. Table 2 - Results of characterization tests of the raw material Beige Bahia marble aggregate with a maximum diameter of 12.5 mm. Test Result Specific gravity and absorption 2.64 g / cm3 Shape index 2.75 Total moisture content 0.11% Particle size analysis Maximum characteristic dimension = 12.5 mm Fineness modulus = 2.93% Determination of organic impurities Non-reactive. Determination of clay content in lumps and friable materials 0.76%

[00053] Based on the analysis of the results of the raw material characterization tests, it was possible to see that the analyzed crushed stones have a specific gravity of 2.64 g / cm3 and do not contain organic impurities. However, remnants of clay and other friable materials were found, which usually compromises mechanical strength. Example 2 - Tests performed on concrete compositions in the fresh and hardened states.

[00054] Tests were carried out to evaluate the properties of the concrete composition of the present invention in the fresh and hardened states, in which were Petition 870260055180, dated 08 / 06 / 2026, page 21 / 28 12 / 14 the following properties were evaluated: consistency determination test by slump test; water absorption, void index and specific mass and axial compression.

[00055] For these tests, a concrete mix was developed with a replacement content of traditional crushed stone with Beige Bahia marble crushed stone of 15%.

[00056] Table 3 below specifies the test methodologies for evaluating the properties of the concrete composition in the fresh and hardened states. Table 3 - Tests performed on the concrete composition of the present invention in the fresh and hardened states. Property Method - Material: composition of concrete in the fresh and hardened state. Consistency determination test by slump test ABNT NBR 16889:2020. Water absorption, void index and specific gravity NBR 9778:2005. Axial compression ABNT NBR 5739:2018.

[00057] Next, in table 4, are shown the results obtained for the properties of the concrete composition in the fresh state, carried out according to the methodologies shown in table 3. Table 4 - Results of tests evaluating the properties of the concrete composition in the fresh state. Property Result: Slump Determination Test of 70 ± 10 Petition 870260055180, dated 08 / 06 / 2026, page 22 / 28 13 / 14 consistency by slump test mm

[00058] Based on the analysis of the results of the tests evaluating the properties of the concrete composition in the fresh state, it can be seen that the concrete presented a typical value for application in pavements, precast or prefabricated elements, thus characterizing a concrete with consistency class S50, which presents a slump between 50 and 100mm (MAYOR, 2014).

[00059] Next, in table 5, are shown the results obtained for the properties of the concrete composition in the hardened state, carried out according to the methodologies shown in table 3. Table 5 - Results of tests evaluating the properties of the concrete composition in the hardened state. Property Result Water absorption, void ratio and specific gravity Water absorption (%) = 5.65 Void ratio (%) = 12.62 Specific gravity (g / cm3) = 2.56 Axial compression Feature Compression Known (ffck) = 28.6 ± 1.0 MPa

[00060] Based on the analysis of the results of the tests evaluating the properties of the concrete composition in its hardened state, it can be seen that the concrete composition in its hardened state presented a result superior to the minimum fck value established by NBR 12655:2015. Therefore, the grass paver is resistant to axial compression.

[00061] The present invention was disclosed in this report. Petition 870260055180, dated 08 / 06 / 2026, pages 23 / 28 14 / 14 descriptive in terms of its preferred embodiment. However, other modifications and variations are possible from the present description, and are still within the scope of the invention disclosed herein. Petition 870260055180, dated 08 / 06 / 2026, pp. 24 / 28

Claims

1 / 3 CLAIMS 1. Concrete composition for grass pavers CHARACTERIZED by the fact that it comprises a range of 14% to 15% by weight of cement; 31% to 33% by weight of fine sand; 6.5% to 7.0% by weight of Beige Bahia marble aggregate; 39% to 41% by weight of traditional aggregate; 7.0% to 7.2% by weight of water and 0.5% to 0.7% in relation to the mass of cement by weight of superplasticizing additive.

2. Composition, according to claim 1, CHARACTERIZED in that the cement is Portland cement CPII F-32.

3. Composition, according to claim 1 or 2, CHARACTERIZED in that the fine sand has a diameter between 0.075 mm and 0.6 mm.

4. Composition, according to any one of claims 1 to 3, CHARACTERIZED in that the Beige Bahia marble aggregate has a diameter between 2.36 mm and 12.5 mm.

5. Composition, according to any one of claims 1 to 4, CHARACTERIZED in that the water comes from the public water supply network.

6. Composition, according to any one of claims 1 to 5, CHARACTERIZED in that the superplasticizer additive is selected from the group comprising superplasticizer additives composed of Polycarboxylate Ether.

7. Production process for the concrete composition for grass pavers, as defined in claims 1-6, CHARACTERIZED by comprising the steps of: (a) weighing the cement, fine sand, and crushed marble. Petition 870260055180, dated 08 / 06 / 2026, page 1.8 / 28 2 / 3 Beige Bahia, traditional crushed stone, water and superplasticizer additive; (b) mix the fine sand, Beige Bahia marble crushed stone, traditional crushed stone and superplasticizer additive for 60 to 90 seconds in a concrete mixer at a speed of 25 to 30 revolutions per minute (RPM); (c) add half of the heavy water from step (a) and mix the materials for 60 to 90 seconds at a speed of 25 to 30 RPM; (d) add the cement and mix for 30 to 40 seconds at a speed of 25 to 30 RPM; (e) add half of the heavy water from step (a) and mix the materials for 120 to 160 seconds at a speed of 25 to 30 RPM; (e) and (f) add the superplasticizer additive and mix for 120 to 160 seconds, at a speed range of 25 to 30 RPM.

8. Process, according to claim 7, CHARACTERIZED in that, in step (a), 373.88 kg of cement are weighed per 1 m3 of composition, 837.49 kg of fine sand per 1 m3 of composition, 183.20 kg of Beige Bahia marble aggregate per 1 m3 of composition, 1031.91 kg of traditional aggregate per 1 m3 of composition, 186.94 kg of water per 1 m3 of composition and 1.87 kg of superplasticizer additive per 1 m3 of composition.

9. Process, according to claims 7 or 8, CHARACTERIZED in that, in step (b), the concrete mixer has a capacity of 150 liters and, preferably, 837.49 kg of fine sand are added per 1 m3 of composition, 183.20 kg of Beige Bahia marble gravel per 1 m3 of composition, 1031.91 kg of traditional gravel per 1 m3 of composition, 1.87 kg of superplasticizer additive per 1 m3 of composition.

10. Process, according to any one of claims 7 to 9, CHARACTERIZED in that, in step (d), 373.88 kg of cement is added per 1 m3 of composition.

11. Process, according to any one of claims 7 to 10, CHARACTERIZED in that, in step (f), 1.87 kg of superplasticizer additive is added per 1 m3 of composition. Petition 870260055180, dated 08 / 06 / 2026, page 10 / 28

Images