A concrete composition system with nanosilica, RGO and industrial waste

Abstract

Concrete composition system with nanosilica, RGO and industrial waste, comprising: an ordinary Portland cement (OPC) that serves as the primary binder in the mixture, with part of the OPC partially replaced by a combination of industrial waste and nanomaterials, including: Copper waste, which is contained in a proportion of 5 to 60 wt% of the cement content and serves as additional cement material from mining waste; Nanosilica, which is present in a proportion of 2 to 6 wt% of the cement and has a high pozzolanic reactivity to improve hydration and microstructural compaction; and reduced graphene oxide (rGO), which is present in trace amounts of 0.03 to 0.08% by weight of the cement and serves as a nano-reinforcing agent to improve crack resistance and tensile behavior; Granite powder, added as a filler in a proportion of 5 to 30 percent by weight of the total mixture, contributing to improved particle packing and reduced porosity; Fine and coarse aggregates in standardized proportions that form the granular structure of the concrete; Water added in a controlled water-binder ratio suitable to initiate cement hydration and maintain the workability of the fresh mix; a superplasticizer additive included in appropriate dosage to reduce water requirements and maintain fluidity without compromising mechanical performance.

Description

[0001] The present invention relates to the field of sustainable building materials, in particular to innovative concrete mixes. Specifically, it is a novel concrete mix containing industrial waste such as copper waste and granite powder, as well as nanosilica and reduced graphene oxide (rGO) to partially replace cement.

[0002] Concrete is one of the world's most widely used construction materials due to its strength, versatility, and availability. However, the production of cement—the main binding agent in concrete—is energy-intensive and contributes significantly to global carbon dioxide (CO2) emissions, accounting for approximately 7-8% of total emissions. This has led to growing environmental concerns and the need for more sustainable construction alternatives. Conventional concrete mixes consist of cement, fine and coarse aggregates, water, and, in some cases, chemical additives. While structurally sound, these formulations offer limited opportunities for sustainability and performance improvements. In recent years, the incorporation of industrial by-products and advanced nanomaterials into concrete has been explored.However, these efforts have often been hampered by poor material compatibility, inconsistent performance, or limited industrial acceptance. Furthermore, while admixtures such as fly ash, silica fume, and natural pozzolans show promise, many formulations are not optimized or do not result in consistent improvements in mechanical properties and durability. Therefore, there remains a significant need for a concrete mix that not only reduces the environmental impact of cement production but also improves strength, durability, and resistance to environmental stress.

[0003] To solve the problem, the present invention provides a concrete mixing system with nanosilica, rGO and industrial waste.

[0004] The system uses industrial waste and nanomaterials to reduce the environmental impact of conventional cement concrete.

[0005] The system contains copper waste and granite powder as partial cement replacement and fillers, thus minimizing the consumption of natural resources.

[0006] The system improves the mechanical properties of concrete, including compressive and tensile strength, through the use of nanosilica and reduced graphene oxide (rGO).

[0007] The system improves the durability, water absorption and acid resistance of concrete through a ternary mixture of cementitious and reinforcing materials.

[0008] The aim of the system is to develop a sustainable, economically viable concrete formulation that is compatible with existing techniques for mixing, pouring and curing concrete.

[0009] The system can reduce cement consumption by up to 27% while maintaining or improving the overall performance of the concrete, contributing to low-carbon construction.

[0010] In one embodiment, the present invention provides a concrete composition system comprising nanosilica, rGO, and industrial waste. The present invention provides a novel and sustainable concrete mix that integrates industrial waste and nanomaterials to reduce environmental impact while improving the mechanical properties and durability of the concrete. The proposed system comprises a partial replacement of ordinary Portland cement (OPC) with copper waste in the range of 5% to 60%, combined with granite powder as a filler in the range of 5% to 30%. To further enhance pozzolanic activity and reinforce the microstructure, the mix contains nanosilica (2%-6%) and traces of reduced graphene oxide (rGO) (0.03%-0.08%).This ternary mix formulation significantly reduces cement content—by up to 27%—and improves key performance indicators such as compressive strength, splitting tensile strength, water absorption resistance, and acid resistance. The formulation is tested and optimized through a series of mechanical and durability tests. The unique combination of these materials in specific ratios results in a concrete mix that is both high-performance and environmentally friendly. The invention addresses the dual challenge of environmental sustainability and structural reliability by providing a composition that is compatible with existing construction practices, cost-effective, and suitable for industrial production.

[0011] The invention is explained again below.

[0012] The present invention discloses a sustainable and performance-enhancing concrete mix containing a ternary blend of industrial waste and nanomaterials to partially replace ordinary Portland cement (OPC). The composition was developed to reduce the environmental impact of conventional concretes while improving their mechanical properties and durability. The formulation contains copper waste (CT) as a cement substitute in varying proportions from 5% to 25%, nanosilica in a constant proportion of 2% for pozzolanic activity, and reduced graphene oxide (rGO) in trace amounts of 0.03% to 0.08% for nanoreinforcement. Additionally, granite powder is used as a microfiller in a fixed proportion between 5% and 30% to increase particle packing density and reduce porosity.Together, these materials work synergistically to reduce OPC content by up to 27% while maintaining or improving structural performance. The remaining ingredients include standard concrete components such as fine and coarse aggregates, clean water, and a superplasticizer admixture to ensure good workability and hydration. The mix composition and replacement strategy are described in . Fig.where ten compositions are shown in the form of pie charts. The first mix uses 100% OPC as a control, while the remaining nine show a progressive reduction in cement content, offset by increasing amounts of copper waste and constant dosages of nanosilica, rGO, and granite powder. The resulting concrete mixes were subjected to standard tests such as compressive strength, splitting tensile strength, water absorption, and acid resistance, all of which confirmed that optimal performance is achieved with approximately 10% copper waste combined with 2% nanosilica and 0.05% rGO. The improved performance is due to the pozzolanic response of nanosilica, the crack-bridging properties of rGO, and the improved microstructure provided by the addition of granite powder. The system is compatible with conventional mixing, pouring, and curing methods, making it industrially scalable and commercially viable.This innovative composition offers a high-strength, durable and environmentally friendly alternative to conventional concrete, addressing both the sustainability and performance challenges facing the modern construction industry.

Claims

[1] Concrete composition system with nanosilica, RGO and industrial waste, comprising: an ordinary Portland cement (OPC) that serves as the primary binder in the mixture, with part of the OPC partially replaced by a combination of industrial waste and nanomaterials, including: Copper waste, which is contained in a proportion of 5 to 60 wt% of the cement content and serves as additional cement material from mining waste; Nanosilica, which is present in a proportion of 2 to 6 wt% of the cement and has a high pozzolanic reactivity to improve hydration and microstructural compaction; and reduced graphene oxide (rGO), which is present in trace amounts of 0.03 to 0.08% by weight of the cement and serves as a nano-reinforcing agent to improve crack resistance and tensile behavior; Granite powder, added as a filler in a proportion of 5 to 30 percent by weight of the total mixture, contributing to improved particle packing and reduced porosity; Fine and coarse aggregates in standardized proportions that form the granular structure of the concrete; Water added in a controlled water-binder ratio suitable to initiate cement hydration and maintain the workability of the fresh mix; a superplasticizer additive included in appropriate dosage to reduce water requirements and maintain fluidity without compromising mechanical performance. [2] The system (100) of claim 1, wherein the copper residues are added in incrementally tested proportions between 5% and 25%, and wherein optimum performance is achieved with a proportion of 10% copper residues. [3] The system (100) of claim 1, wherein the nano-silica improves mechanical strength by participating in secondary hydration reactions, generating additional calcium silicate hydrate (CSH), and refining the pore structure of the cured concrete. [4] The system (100) of claim 1, wherein the reduced graphene oxide improves the microstructure by bridging microcracks, improving load transfer across cementitious phases, and contributing to the ductility and crack resistance of the concrete matrix [5] The system (100) of claim 1, wherein the granite powder serves to improve the density and packing density of the fine particles in the mixture, thereby reducing the overall void fraction and improving durability under aggressive environmental conditions. [6] The system (100) of claim 1, wherein the mechanical performance is evaluated using standard tests including compressive strength test (IS 516), splitting tensile test (IS 5816), water absorption test (ASTM C642) and acid resistance test, and wherein the mix with optimized proportions performs better than conventional 100% OPC concrete in each category. [7] The system (100) of claim 1, wherein the mixture is compatible with standard mixing, pouring and curing equipment used in commercial concrete production and does not require modifications to conventional batching equipment. [8] The system (100) of claim 1, wherein the use of copper waste reduces the environmental impact associated with the disposal of mining waste and the partial replacement of cement significantly reduces the carbon content of the final concrete product. [9] The system (100) of claim 1, wherein the reduced graphene oxide is uniformly dispersed in an aqueous solution prior to addition to the concrete mix to ensure optimal distribution and performance enhancement at the nanoscale. [10] The system (100) of claim 1, wherein the mixture is particularly suitable for use in green buildings, infrastructure projects, road surfaces, precast products and marine structures where improved durability and reduced carbon footprint are critical performance indicators.