Porous drainage material prepared from regenerated particles cured by composite Portland cement geopolymer adhesive

Abstract

The porous solid surface drainage material provided by the invention is high in recycled waste content, excellent in water infiltration rate, environment-friendly and sustainable. A first phase of regenerated particulate material is combined with a second composite Portland cement geopolymer phase to produce a material having a porosity of 10-25%, a water infiltration rate of at least 18,000 mm / hr, a 28 day compressive strength of at least 10 MPa, a density of less than 1,850 kg / m3. The porous solid surface drainage material can be used in highly drained areas, such as solid surface rainwater ditches and other infrastructures that allow water to pass through while preventing mosquitoes and other insects from contacting accumulated water, thereby preventing the transmission of entomophilous diseases. The material can be dyed and formed for application of various infrastructures, so that the safety of roads and sidewalks is improved.

Description

Cross - reference to related applications:

[0001] This application claims the priority of U.S. Provisional Patent Application No. 63 / 602,683, filed on November 27, 2023, and the disclosure of the U.S. Provisional Patent Application is incorporated herein by reference in its entirety. Technical Field

[0002] The present invention relates to a porous solid surface drainage material with high porosity and high water throughput. This drainage material has excellent infiltration rate and strong mechanical properties. Background Art

[0003] Most urban stormwater channels use grille inlet covers, that is, the stormwater channel inlet is set on the road surface and covered with a metal grille thereon. However, the design of the metal grille brings several problems. First, although the openings between the grille bars can prevent people, vehicles, and large debris from falling into the stormwater channel, their width may still be sufficient for sediments and small objects to fall in, and the accumulation of these things may clog the drainage ditch, leading to flooding.

[0004] In addition, when the drainage flow is blocked by sediments, leaves, and other debris, waterlogging will form, becoming a breeding ground for mosquitoes and other insects. The openings of the metal grille allow adult mosquitoes to escape from the stormwater channel, not only causing the problem of mosquito breeding but also leading to the spread of mosquito - borne diseases such as dengue fever, Japanese encephalitis, and malaria, posing a threat to public health. Rodents such as rats can also use the ponded water as a water source and use the rainwater grille as an entrance to the rainwater discharge tunnel, thus becoming another disease vector affecting public health.

[0005] The above - mentioned metal grille may pose risks to pedestrians, cyclists, and small - wheeled vehicles. Objects, shoes, or bicycle tires may get stuck in the gaps, leading to accidents. The grille itself, especially when wet, becomes a slippery surface, posing a safety threat to pedestrians. In addition, the grille bars are easily corroded or damaged after long - term use, resulting in expensive repair or replacement costs. The appearance is also marred by the presence of metal grilles on roads or sidewalks.

[0006] To cope with extreme weather conditions, the concept of "sponge city" has gradually emerged. Sponge cities use porous road surfaces and building materials, which can effectively absorb and manage excess rainwater and prevent flooding. By absorbing or diverting rainwater into a network of drainage tunnels, the resilience of cities after heavy rainfall can be enhanced, and flooding can be prevented during increasingly frequent severe weather events and extended typhoon seasons.

[0007] However, existing porous materials generally lack sufficient mechanical strength for structural applications. Therefore, existing porous materials cannot adequately support the daily use of pedestrians or vehicles and are not suitable for large-scale implementation to create a sponge city.

[0008] Accordingly, there is a need in the art for improved porous materials that can absorb and divert rainwater during severe weather events with high rainfall rates in a short period of time. Such materials need to be robust and porous in addition to being low-cost and capable of being integrated into existing infrastructure. The present invention addresses this need. Summary of the Invention

[0009] In response to the above challenges and needs, as described below, the present invention provides a porous solid surface drainage material that not only has a high water infiltration rate and high mechanical strength but also has a high content of recycled materials, meeting both the need for improved drainage materials and the high demand for waste recycling.

[0010] In other words, the porous drainage material of the present invention is specially formulated to effectively drain surface rainwater to the underground drainage and flood control system under heavy rain (such as rainfall of up to hundreds of millimeters per hour) brought about by extreme weather events that occur during monsoons, typhoons, and tropical depressions. In a first aspect, the present invention provides a porous solid surface drainage material having a first phase of a mixture of recycled particles bound to a second-phase cementitious binder, which first phase can be recycled waste concrete aggregates, recycled waste glass, recycled plastics, recycled tire rubber crumbs, and mixtures thereof. The second-phase cementitious binder is a novel geopolymer / silicate cement binding phase. The mixed binder of portland cement (OPC) and geopolymer-forming materials is selected from ground granulated blast-furnace slag (GGBS), fly ash, metakaolin, or mixtures thereof. The portion of portland cement that produces calcium silicate hydrate bonds is used to bind to the first-phase recycled particle mixture to strengthen the porous solid surface drainage material, and a portion of the second-phase secondary rapid hardening part of the cementitious binder reacts with the calcium hydroxide portion produced by the hydration of portland cement to produce calcium aluminosilicate hydrate, wherein the ratio of portland cement to geopolymer in the second-phase cementitious binder is 3:1 or higher. The first phase accounts for about 70% to about 80% of the weight of the material, and the second phase accounts for about 15% to about 25% of the weight of the material. It should be noted that these figures are for the dry mixed material of the second-phase binder, which reacts with water and hydrates the raw materials of portland cement and geopolymer binders. Generally, 5 to 10% by weight of water is applied to the dry mixed material for mixing and hydration. The porosity of the porous solid surface drainage material is 10 - 25%, the water infiltration rate is at least 18,000 m / hr, the 28-day compressive strength is at least 10 MPa, and the density is less than 1,850 kg / m 3 .

[0011] In an embodiment of the first aspect, the porous drainage material further includes a metal fixing frame surrounding the porous solid surface drainage material block.

[0012] In another embodiment, the solid content of the water with debris in the porous solid surface drainage material is less than 1 wt% of the total debris content in the water with debris.

[0013] In another embodiment, the skid resistance value (SRV) of the porous solid surface drainage material is at least 60.

[0014] In another embodiment, the second phase further contains silica fume in an amount of about 1 to 5 wt% of the second phase.

[0015] In yet another embodiment, the porous solid surface drainage material further includes a high-range water reducer selected from polycarboxylic acid amines (PCA), polycarboxylic acid ethers (PCE), modified lignosulfonates, vinyl copolymers, acrylic superplasticizers, or combinations thereof.

[0016] In another embodiment, the porous solid surface drainage material further includes a concrete pigment in a weight content of less than 10% relative to the second phase of the material.

[0017] In addition, the present invention also provides a method for preparing the porous solid surface drainage material. The steps include: dry mixing portland cement, geopolymer material, and recycled particles in a concrete mixer to obtain a first mixture; adding water and a superplasticizer to the first solid mixture and mixing to obtain a second mixture; transferring the second wet mixture into a fixing frame while ensuring uniform distribution of the second mixture within the fixing frame, and finally compacting and flattening its surface to obtain a modular unit composed of the porous solid surface drainage material, or a drainage cover block as Figure 1A and 1B shown. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Embodiments of the present invention are described in more detail below with reference to the accompanying drawings, in which:

[0019] Figure 1A and 1B respectively show the porous solid surface drainage material of the present invention without staining and with added concrete pigment;

[0020] Figure 2 shows the size of the recycled aggregate used in the example.

[0021] Figure 3 shows the recycled rubber tire chips used in the formulation of the example.

[0022] Figure 4Shows the raw materials for preparing porous solid surface drainage materials, including recycled rubber tire chips and plastic aggregates.

[0023] Figure 5 Shows an example of a frame for fixing the porous drainage material. Detailed implementation mode

[0024] The present invention relates to a porous solid material designed for surface drainage, providing a sustainable and high-performance solution for urban and infrastructure applications. This material integrates recycled waste particles into a composite cementitious binder to form a durable porous structure with excellent drainage and load-bearing properties. The porous drainage material provides safety and accessibility as the solid surface eliminates the gaps in traditional grates, reducing risks for pedestrians, cyclists, and vehicles. The use of recycled particles reduces resource consumption and diverts waste from landfills. Since there are no open gaps, the possibility of mosquitoes coming into contact with underground water accumulation is limited, thus minimizing mosquito breeding. The disclosed porous solid material is highly suitable for urban drainage systems, sidewalks, parking lots, and other infrastructure that requires both sustainable and high-performance drainage solutions.

[0025] I. Overview of drainage materials

[0026] The porous drainage material consists of two main phases:

[0027] 1. Recycled particle mixture: The first phase consists of recycled materials selected from waste concrete aggregates, waste glass, waste plastics, tire rubber chips, or mixtures thereof. This phase accounts for approximately 70 - 80% of the total weight of the material. The recycled particles provide structural porosity and environmental sustainability by reusing materials that would otherwise be discarded and become part of the waste stream.

[0028] 2. Cementitious binder phase: The second phase is a composite binder formed by mixing ordinary Portland cement (OPC) with geopolmer-forming materials (such as ground granulated blast furnace slag (GGBS), fly ash, or metakaolin). The Portland cement contributes to the development of early strength through rapid hydration and the formation of calcium silicate hydrate (C - S - H) bonds, while the geopolmer-forming materials enable rapid hardening and long-term strength. In the binder, the Portland cement accounts for at least 75% by weight, and the remainder is the geopolmer material. This mixing ratio helps enhance mechanical properties and chemical resistance.

[0029] The porous drainage material obtained by combining the above achieves the following properties:

[0030] 1. Porosity: In the range of 10 - 25% by volume, providing high water permeability. The interconnected pores form numerous tiny channels that allow water to pass through while being sufficient to block debris and insects. Thus, the surface drainage channels covered by the porous material do not provide breeding grounds for disease - carrying mosquitoes, thereby protecting the community and promoting public health.

[0031] 2. Infiltration rate: The minimum water infiltration rate is 18,000 mm / hour, ensuring effective surface water drainage.

[0032] 3. Mechanical strength: The 28 - day compressive strength of at least 10 MPa is sufficient to withstand pedestrian and light vehicle loads.

[0033] 4. Density: Less than 1,850 kg / m 3 , achieving a balance between lightness and durability.

[0034] To optimize workability and performance, the cementitious binder may include high - range water reducers. Examples include polycarboxylic amine (PCA), polycarboxylic ether (PCE), modified lignosulfonate, vinyl copolymer, or acrylic - type high - range water reducers. These additives reduce the water demand and improve the workability of the material, enabling it to be shaped into forms such as paving bricks and drain covers. For example, the workability imparted by high - range water reducers can optimize the mechanical properties of the post - treatment of porous drainage materials, including skid resistance and load - bearing capacity, while maintaining its significant water infiltration rate. The addition of high - range water reducers also helps to disperse the cementitious materials more evenly in the mixture, improving the overall quality and strength of the matrix and ensuring the interconnected porous channels required for drainage.

[0035] Concrete pigments that make up less than 10% of the binder can be selectively added, enabling aesthetic customization to be favorably incorporated into the urban landscape. This includes matching the color of sidewalks or roads, or matching the greening environment. The porous drainage material can be flexibly customized both functionally and aesthetically, and thus has a wide range of applications, from road surfaces and drainage to sports facilities, bicycle lanes, housing estates, and school playgrounds.

[0036] Although the porous solid material is self - supporting, it can optionally be incorporated into a fixed frame to form a modular unit or a drain cover unit. The frame ensures structural stability (especially in high - traffic or load - bearing scenarios) while also making it easy to install.

[0037] The novel composite binder of the present invention achieves a synergistic interaction between the hydration of portland cement (OPC) and geopolymerization to produce a strong bond with the particulate filler. During the hydration process of portland cement, the components of portland cement react with water to form C - S - H gel and calcium hydroxide, thereby providing the initial bond strength.

[0038] Geopolymerization of Granular Blast Furnace Slag / Fly Ash / Metakaolin: Calcium hydroxide from Portland cement activates the geopolymerization reaction to form calcium silicate hydrate (C-A-S-H). This secondary binding phase enhances the long-term durability and chemical resistance of the finished product.

[0039] Adhesion to Recycled Aggregates: The calcium-based products of Portland cement hydration improve the adhesion to the irregular surfaces of recycled particles, producing a viscous matrix.

[0040] Finished Product Process

[0041] This preparation method ensures uniformity and optimal performance through a combination of dry mixing and wet mixing. In dry mixing, Portland cement, geopolymer materials, and recycled particles are mixed for 3 - 7 minutes to obtain a homogeneous initial mixture. In wet mixing, water and a high-range water reducer are added, and the mixture is processed for 8 - 12 minutes to ensure uniform distribution.

[0042] Frame Loading and Compaction: The mixture is poured into a frame (such as a plastic or metal frame), placed on a vibrating table, and compacted for a few seconds to strengthen the links between the particles in the first phase.

[0043] Finishing: The surface is leveled to form modular units, such as drain covers.

[0044] II. Detailed Explanation of Porous Solid Material Composition

[0045] 1. Recycled Waste

[0046] The recycled waste used for the first phase of the composite porous material is mainly used as aggregate in the concrete composition, that is, they are more used for mechanical properties rather than based on a specific chemical composition. Therefore, the specific chemical composition of the recycled waste is not important. The waste materials such as tire chips, glass particles, or recycled concrete aggregates are mainly classified according to particle size. The typical particle size range is from 1 mm to 7 mm, more specifically, from 2 mm to 5 mm. The smaller particle size provides a larger total surface area for binder adhesion and can increase the adhesion strength, thus producing a stronger final product. The details of the particles used in each composition are elaborated in the following examples.

[0047] 2. Composite Binder

[0048] The composite binder includes a first component of Portland cement (OPC). Portland cement is a hydraulic cement that typically contains varying proportions of calcium oxide, silica, and alumina. The composition of Portland cement can include calcium oxide in the range of 61 - 67%, silica in the range of 19 - 23%, alumina in the range of 2.5 - 6%, iron oxide in the range of 0 - 6%, and sulfate in the range of 1.5 - 4.5%. The various components of Portland cement are described in ASTM C150 / C150M - 16e1, "Standard Specification for Portland Cement", available from ASTM International, West Conshohocken, PA, 2016, the disclosure of which is incorporated herein by reference. Any of these compositions can be used in the Portland cement binder portion of the present invention.

[0049] Geopolymer is an inorganic aluminosilicate - based material formed by the reaction of aluminosilicate precursors with an alkali activator under controlled conditions. Geopolymers are synthesized through a process called geopolymerization, in which silicate and aluminate monomers polymerize to form a three - dimensional network of aluminosilicate or calcium aluminosilicate bonds. The starting materials for geopolymer manufacture are mainly industrial by - products or natural minerals containing reactive silica and alumina. Common raw materials include ground granulated blast - furnace slag (GGBS), fly ash, metakaolin, silica fume, natural pozzolans, and rice husk ash.

[0050] Slag is the material left behind when metals are separated from their respective metal ores (e.g., smelting). Granulated blast - furnace slag is produced by quenching molten iron slag from a blast furnace (a by - product of steel production) and then grinding it. The main components of granulated blast - furnace slag are calcium oxide (30 - 50%), silica (28 - 38%), alumina (8 - 24%), and magnesia (1 - 18%). Unless otherwise stated, all percentages given in the specification are by weight. Specific example compositions of granulated blast - furnace slag are used in the examples and are described below.

[0051] Fly ash is a fine - powdered residue produced from the combustion of coal in power plants. Class F fly ash is rich in silica and alumina, while Class C fly ash also contains a significant calcium content.

[0052] Metakaolin is a thermally activated clay (calcined kaolin) that has high reactivity due to its amorphous aluminosilicate structure.

[0053] Silica fume is a byproduct of silicon or ferrosilicon alloy production and is typically an ultrafine powder with a high silicon dioxide content. Silica fume is added in amounts of 1-5% by weight to help improve density and durability. The addition of silica fume promotes a pozzolanic reaction between silica fume and calcium hydroxide (produced during cement hydration) to form additional calcium silicate hydrate (CSH). Silica fume also increases the degree of hydration of the cementitious binder. This not only increases the strength of the concrete mix, but also improves its durability by reducing water infiltration. The extent of these changes depends on the amount of silica fume used and the design of the overall mix formulation.

[0054] Although geopolymerization is usually initiated by an alkaline activator (such as sodium silicate, sodium hydroxide or potassium hydroxide), in the composite binder of the present invention, calcium hydroxide produced during the hydration of Portland cement can activate the geopolymerization process, thereby eliminating the need for an additional alkaline activator.

[0055] Using geopolymer materials can optimize packing density, fill voids and enhance bonding between recycled tire rubber crumbs, aggregates or other recycled waste materials. Shrinkage compensators can also be added to offset drying shrinkage during the geopolymer curing process, thereby reducing the potential for cracking in porous materials.

[0056] 3. Characteristics of porous materials

[0057] By using a composite Portland cement / geopolymer binder composition, a recycled particulate first phase, combined with rapid hardening geopolymerization technology and cement hydration, the monolithic material exhibits high performance on multiple parameters.

[0058] The density of the porous drainage material is maintained at 1,850 kg / m 3 This density level indicates that the particles in the material are packed tightly enough while still allowing a high infiltration rate of water through the material.

[0059] Tests conducted using simulated rainwater (e.g., with debris present in typical stormwater runoff) through the porous drainage material of the present invention have shown that the output water contains less than 1% solids by weight. This means that the porous drainage material, while having a high water infiltration rate, has a small average pore size, so that not only larger debris, but also sediment and small objects are blocked from entering the stormwater drain pipe located below the material. This effectively prevents any blockage or obstruction of the stormwater drain pipe, as continuous water flow is essential, especially during storms.

[0060] Importantly, the porous material exhibits high anti-slip properties. Anti-slip properties are essential for both road applications and sidewalk applications. This is a measurement of surface slipperiness - whether it is a floor or a road surface. The Pendulum Test Value (PTV) can also be used to calculate anti-slip properties. The PTV is measured using a pendulum device that simulates shoes or bare feet on the surface. The measured anti-slip properties of the materials in the following examples are at least 60. Anti-slip properties (PTV) are measured on a 100-point scale, with higher values indicating higher anti-slip properties.

[0061] In an embodiment of the present invention, the porous drainage material is formed within a support frame to form various shapes, such as drainage covers, paving bricks, and gutters for sidewalks, runways, or parking lots. The support frame can be made of metal or high-strength polymer. By forming the porous drainage material within the frame, discrete structures are cast, which can be transported to the construction site for installation in substantially the same manner as conventional concrete paving bricks or blocks. The frame also imparts additional strength to the porous drainage material. The frame includes a side region and a porous bottom. Mechanical features such as keyholes can be formed to facilitate handling by drainage material installers. After mechanically fixing the frame, the drainage cover blocks can achieve a load-bearing capacity of Class A or above as defined by FACTA.

[0062] Specific compositions and their properties are set forth in the following examples:

[0063] Examples

[0064] Example 1 - Starting material composition of the porous drainage material

[0065] The Portland cement used in the examples is formulated according to the CEM I 52.5 standard.

[0066] The ground granulated blast furnace slag (GGBS) used is of grade S95, with a minimum specific surface area of 400 m 2 / kg.

[0067] In addition, silica fume with a specific surface area greater than 15,000 m 2 / kg and a 7-day accelerated pozzolanic activity index higher than 105% is added to improve durability and performance.

[0068] The chemical compositions of the above Portland cement, ground granulated blast furnace slag, and silica fume are shown in Table 1 below.

[0069] Table 1: Chemical Compositions of Raw Materials

[0070] The porous drainage material of the present invention uses recycled aggregates, which has the advantage of low carbon emissions. The size range of the recycled aggregates is between 2.36 mm and 5 mm, as Figure 2 shown.

[0071] The formulation of the present invention uses recycled rubber tire granules with a size between 2.36 mm and 5 mm, such as Figure 3 shown. The tire granule rubber is visually inspected and free of impurities to ensure its suitability for use.

[0072] Recycled plastic with a size between 2.36 mm and 5 mm is used, such as Figure 4 shown. Similar to the recycled rubber tire granules, the recycled plastic is visually inspected before use to ensure it is free of impurities.

[0073] Example 2 - Development of the mixing ratio

[0074] 2.1 General overview and specified values of porous drainage materials

[0075] As shown in Table 2, a total of 12 formulations of porous drainage materials were selected. These formulations were cast in cubic molds for compressive strength testing; and another part was cast in the Figure 5 metal holding frame shown for mechanical testing and performance testing such as water permeability, anti-slip, load-bearing capacity, and debris barrier. Among them, the test of water permeability performance, that is, the evaluation method of infiltration rate, is carried out according to the standard of ASTM C1701 / C1701M-09.

[0076] Table 2: Formulations of selected porous solid surface drainage materials

[0077] Table 3: General properties of selected formulations

[0078] Preparation of samples for mechanical testing:

[0079] The composite binder material of binder phase 2 and the recycled material of particle phase 1 are mixed in a concrete mixer for 3 - 7 minutes to obtain a first mixture.

[0080] Then water and a high-range water reducer are added to the first mixture and mixed for 8 - 12 minutes to obtain a second mixture.

[0081] The second mixture is transferred to a fixed frame while ensuring that the second mixture is evenly distributed within the fixed frame.

[0082] The carrier rack filled with the second mixture is placed on a vibrating table and vibrated for 8 - 15 seconds and compacted.

[0083] After the vibration compaction is completed, the surface is leveled to allow the mixture to solidify. The resulting solidified product is the porous drainage material.

[0084] Perfection of the composition:

[0085] Formulations 1-4 are comparative examples of binder phases consisting only of Portland cement. These are the base compositions used to determine the optimal base ratios for further improvement and are used to demonstrate the technical effects of the composite Portland cement / geopolymer binder of the present invention on porous drainage materials compared to prior art Portland cement binders.

[0086] Formulations 5-12 incorporate geopolymer components of ground granulated blast-furnace slag (GGBS) or ground granulated blast-furnace slag plus silica fume.

[0087] As can be seen from Formulations 3, 5, 6, and 7, by adjusting the ratio of Portland cement (OPC) and ground granulated blast-furnace slag, as the replacement amount of ground granulated blast-furnace slag increases from 34.5 kg / m 3 to 103.4 kg / m 3 (refer to Table 2 above), the compressive strength of the porous solid surface drainage material increases to as high as 11.4 MPa (refer to Table 3 above). Although the infiltration rate decreases slightly with the increase in the content of ground granulated blast-furnace slag, this decrease is attributed to the enhanced workability and fluidity of the fresh mixture, and the presence of ground granulated blast-furnace slag has a relatively insignificant effect on the infiltration rate of the porous solid surface drainage material.

[0088] Among the three formulations, Formulation 5 was selected for further adjustment and testing because of its further improved compressive strength (10.9 MPa) while maintaining a relatively high infiltration rate (22,500 mm / hr).

[0089] The addition of silica fume further increases the degree of hydration of the cementitious binder, which in turn improves the strength and durability of the porous solid surface drainage material by reducing water seepage. This can be observed in Formulations 5, 8, 9, and 10, where the silica fume content gradually increases from 0 kg / m 3 to 12.1 kg / m 3 , and the compressive strength of the porous material also increases from 11.9 MPa to 12.2 MPa.

[0090] However, the degree of change brought about by the addition of silica fume also depends on the amount of silica fume used and the overall mixing design. For example, in Formulation 10, although the compressive strength of the porous material reaches a high level of 12.2 MPa, its infiltration rate drops to 21,300 mm / hr.

[0091] Therefore, after balancing the performance of compressive strength and infiltration rate, Formulation 9 was selected as the best mixture among the three.

[0092] In addition, coloring the cement for aesthetic purposes will greatly facilitate expanding the application potential of the porous drainage material of the present invention in more facilities and scenarios.

[0093] Pigments are generally chemically inert. Therefore, even when pigments are added, the chemical reactions within the cement matrix are not disturbed or affected. However, excessive use may affect the workability and compaction of porous materials.

[0094] As observed in Formulations 9, 11, and 12, according to Formulation 9, 10.3 kg / m of pigments were added to the concrete matrix. 3 The pigments had a minimal effect on the infiltration rate (from 21,900 mm / hr to 21,800 mm / hr) and maintained a relatively high compressive strength (11.6 MPa). However, if more pigments (20.4 kg / m 3 ) were added, the infiltration rate and compressive strength further decreased, indicating that a high pigment content may have an adverse effect on the performance of porous drainage materials.

[0095] In addition, according to the BS EN 13036-4 standard and the FACTA road surface covering product specifications, the skid resistance and bearing capacity of porous drainage materials with a waste utilization rate greater than 70% of the total material weight were tested respectively. The pendulum test value (PTV; equivalent to the skid resistance value SRV) of the samples was greater than or equal to 60. With a fixed frame of 30 mm thickness, the bearing capacity was Class A; with a fixed frame of 60 mm thickness, the bearing capacity was Class C.

[0096] Example 3 - Design of the fixed frame

[0097] The porous drainage material of the present invention is supported by a fixed frame made of stainless steel or other highly durable metals, alloys, or polymers. The overall design of the fixed frame can refer to Figure 5 .

[0098] Specifically, the specific embodiments and upgraded parts of the holding frame are made of the same 304-grade stainless steel material as the original frame, with a thickness of 2 mm. Two keyhole boxes with dimensions of 50 mm × 40 mm × 26 mm were added in the middle of the 300 mm short side of the standard 300 mm × 400 mm × 30 mm holding frame. The 50 mm edge of the box is parallel to the short side of the frame. The keyhole boxes are equipped with convenient handles, allowing workers to install and remove the porous drainage material more easily, making it easier for customers to operate, install, and maintain.

[0099] It is worth noting that Figure 5The fixed frame in can be customized for drain cover applications. When used as a drain cover, thick gauge aluminum or stainless steel sheets can form specific drain cover configurations according to the type of drain cover and its location - for example, road drain covers require stronger frame materials, while pedestrian pavements do not require such strong frame materials. In some cases, additional metal connector parts can be formed on the frame to be fixed to existing drain openings by welding or by using mechanical fasteners.

[0100] While the above standard 300 mm × 400 mm × 30 mm retaining frame is used for Class A pedestrian load capacity; alternatively, the standard 300 mm × 400 mm × 60 mm size specification can also be used, with a 304 grade stainless steel material of 5 mm thickness to make the fixed frame and suitable for Class C vehicle load capacity, depending on the required application.

[0101] Example 4 - Industrial Applicability

[0102] As shown by the various tests above, the porous drainage material of the present invention combines a high level of recycled materials, while exhibiting a significant infiltration rate, being able to easily cope with heavy rain scenarios equivalent to the black rainstorm signal level in Hong Kong, China, and ensuring high usage safety, which is reflected in its high anti-slip property and core strength.

[0103] The porous drainage material of the present invention can also form different shapes and be adjusted according to the load capacity by using metal fixed frames of different designs and sizes, for installation and use in different applications.

[0104] Referring to Example 2 above, the manufacturing process of the present invention is relatively straightforward, but at the same time is suitable for large-scale manufacturing; and by appropriately selecting or customizing the fixed frame design, the porous drainage material of the present invention can be mass-produced and easily installed in different applications.

[0105] Plus, by pigment coloring and being tested to prove that it does not significantly affect the performance of the porous surface drainage material, the porous drainage material of the present invention has great design flexibility and customizability in terms of practicality and aesthetics, with a wide range of applications, including but not limited to infrastructure such as road surfaces and drain covers, bicycle lanes, various sports facilities, different facilities in schools and residential areas, etc. Therefore, it is expected that the porous drainage material of the present invention can be widely applied in a variety of scenarios on a large scale.

[0106] Several embodiments and detailed features of the present disclosure have been briefly described above. The embodiments described in the present disclosure can be easily used as a basis for designing or modifying other processes and structures to achieve the same or similar purposes and / or obtain the same or similar advantages as those introduced in the embodiments of the present disclosure. Such equivalent configurations do not depart from the spirit and scope of the present disclosure, and various changes, substitutions, and modifications can be made without departing from the spirit and scope of the present disclosure.

[0107] As used herein, terms such as "approximate", "substantially", "essentially", and "about" are used to describe and explain minor variations. When used in connection with an event or situation, the term can refer to the case where the event or situation occurs exactly, as well as the case where the event or situation occurs approximately. As used herein with respect to a given value or range, the term "about" generally means within ±10%, ±5%, ±1%, or ±0.5% of the given value or range. A range can be expressed herein as from one endpoint to another endpoint or between two endpoints. Unless otherwise stated, all ranges disclosed in the present disclosure include the endpoints. The term "substantially coplanar" can refer to two surfaces within a few micrometers (μm) of being located in the same plane, such as within 10 μm, 5 μm, 1 μm, or 0.5 μm of being located in the same plane. When referring to "substantially" the same numerical value or characteristic, the term can refer to a numerical value within ±10%, ±5%, ±1%, or ±0.5% of the average value.

Claims

1. A porous solid surface drainage material, characterized in that: include: a first phase comprising a recycled particulate mixture bonded to a second phase cementitious binder, the first phase being selected from recycled concrete aggregate, recycled glass, recycled plastic, recycled tire rubber crumbs, or mixtures thereof; a second phase of cementitious binder comprising a composite Portland cement geopolymer binder formed by compounding (i) Portland cement and (ii) a geopolymer forming material selected from granulated blast furnace slag (GGBS), fly ash, metakaolin or mixtures thereof, wherein the Portland cement portion produces calcium silicate hydrate bonds for bonding with the first phase regenerated granular mixture to reinforce the porous solid surface drainage material, and the geopolymer forms a secondary rapid setting portion in the second phase of the cementitious binder, reacting with calcium hydroxide produced in the hydration of the Portland cement to produce calcium aluminosilicate hydrates, wherein the ratio of Portland cement to geopolymer in the second phase of the cementitious binder is 3:1 or more; The first phase comprises 70% to 80% by weight of the material and the second phase comprises 15% to 25% by weight of the material; and The porous solid surface drainage material has a porosity of 10-25% by volume, a water infiltration rate of at least 18,000 mm / hr, a 28-day compressive strength of at least 10 MPa, and a density of less than 1,850 kg / m 3 .

2. The porous solid surface drainage material according to claim 1, characterized in that: The second phase further comprises silica fume in an amount of 1 to 5 weight percent of the second phase.

3. The porous solid surface drainage material according to claim 1, characterized in that: The invention further comprises a high-efficiency water reducing agent selected from polycarboxylic acid amine (PCA), polycarboxylic acid ether (PCE), modified lignin sulfonate, vinyl copolymer, acrylic superplasticizer or a combination thereof.

4. The porous solid surface drainage material according to claim 1, characterized in that: The invention further comprises concrete pigment in an amount less than 10% by weight relative to the second phase of the material.

5. The porous solid surface drainage material according to claim 1, characterized in that: Further included is a metal fixing frame surrounding the porous solid surface drainage material block.

6. The porous solid surface drainage material according to claim 1, characterized in that: The solids content of the debris-containing water passing through the porous solid surface drainage material is less than 1% by weight of the total debris content of the debris-containing water.

7. The porous solid surface drainage material according to claim 1, characterized in that: The material has a slip resistance value (SRV) of at least 60.

8. A drainage ditch cover comprising the porous solid surface drainage material according to claim 5 and a metal fixing frame.

9. A method for manufacturing the porous solid surface drainage material according to claim 1, characterized in that: include: dry mixing the Portland cement, the geopolymer, and the recycled granular mixture to obtain a first dry mixture; adding water and a high-range water reducer to the first dry mixture and mixing into a second wet mixture; transferring the second wet mixture into the fixed frame while ensuring that the second wet mixture is evenly distributed within the fixed frame; and The second wet mix is ​​compacted and flattened within a stationary frame.

10. The method according to claim 9, characterized in that The fixing frame is a metal fixing frame.

11. The method according to claim 10, characterized in that The metal retaining frame is a gutter cover fixing frame.

12. The method according to claim 9, characterized in that Further comprising adding a dry pigment to the dry mixture.

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