Reinforced Earth Retaining Wall Block Using Artificial Aggregate Mixed with Stone Powder and Soil Dust, and Manufacturing Method Thereof
Patent Information
- Application Number
- KR1020260053601
- Authority / Receiving Office
- KR · KR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2026-03-25
- Publication Date
- 2026-10-21
- Estimated Expiration
- 2046-03-25
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Figure 112026036161582-PAT00002_ABST
Abstract
Description
Technology Field
[0001] The present invention relates to a reinforced earth retaining wall block and a method for manufacturing the same, wherein artificial aggregate produced by hardening stone powder and soil powder generated during the stone extraction process with a hardening agent is utilized in concrete mixing. More specifically, the invention relates to a reinforced earth retaining wall block and a method for manufacturing the same, wherein artificial fine aggregate is produced by fluidizing a mixed sludge of stone powder and soil powder, which is difficult to process due to its high moisture content, and then hardening and crushing it with a hardening agent, and the artificial fine aggregate is replaced with a portion of natural aggregate to secure a predetermined compressive strength. Background Technology
[0002] Large amounts of stone dust and soil dust are inevitably generated at stone quarrying and processing sites. These stone dust and soil dust are natural soil materials in which fine stone dust and sludge are mixed; although they are not contaminated by heavy metals or organic substances, they cause environmental pollution by floating in the atmosphere in a finely pulverized state.
[0004] Clay dust generated at stone processing plants typically has a moisture content of about 70%, making drying and aggregation very difficult. Specifically, when drying finely pulverized clay dust, surface particles rapidly lose moisture and aggregate during the drying process. The moisture in the sludge clumps trapped inside these aggregated particles blocks the surface moisture pathways, causing a delay in drying. Consequently, the amount of heat required to dry the internal moisture increases, and as a result, the drying energy is significantly higher compared to general coarse aggregate, which has the disadvantage of being a heavy economic burden.
[0006] Meanwhile, regarding stone powder recycling technology, conventional methods have proposed directly incorporating stone powder containing polymer coagulant components from water treatment processes into the cement or concrete mixing process. However, this approach causes a problem where the fluidity of the concrete mixture drastically decreases due to the polymer coagulant components. This sharp decline in fluidity prevents the meeting of the water-binder ratio and working conditions required in actual field conditions, thereby causing difficulties in applying it to mass production processes.
[0008] In addition, while high-temperature treatment is known as a method to remove coagulant components from stone powder, it has the disadvantage of being economically unfeasible due to excessive treatment costs and difficult to apply in actual field conditions.
[0010] Regarding the manufacture of reinforced earth retaining wall blocks, conventional reinforced earth retaining wall blocks have been manufactured using concrete made solely of general natural aggregates, and no technology has been disclosed for utilizing stone powder or soil powder, which are by-products generated at stone processing sites, as artificial aggregates. Consequently, stone powder or soil powder has been treated as industrial waste, which has been a cause of resource waste and environmental burden.
[0012] Therefore, there is a need to develop a new technology that can economically and efficiently process stone or soil powder with high moisture content while simultaneously recycling it as aggregate for concrete products. Prior art literature
[0013] Republic of Korea Registered Patent KR10-1339716B1 (2013.12.04) Republic of Korea Registered Patent KR10-2041892B1 (2019.11.01) The problem to be solved
[0014] The present invention was devised to solve the problems of the aforementioned prior art and aims to reduce the environmental burden by efficiently recycling stone dust or soil dust generated at stone extraction and processing sites.
[0016] In addition, the present invention aims to provide a method for manufacturing artificial fine aggregate by adding water to make it fluidized, adding a solidifying agent to harden it, and crushing it, so that stone powder or clay powder sludge with a moisture content of about 70% can be processed economically without high heat treatment.
[0018] In addition, the present invention aims to solve the problem of reduced fluidity during the concrete mixing process by using manufactured artificial fine aggregate in place of a portion of natural aggregate, and to provide a reinforced earth retaining wall block that secures an equivalent level of compressive strength.
[0020] Furthermore, the present invention aims to reduce the amount of natural aggregate used by utilizing industrial by-products such as stone powder or soil powder, and to provide an eco-friendly and economical reinforced soil retaining wall block and a method for manufacturing the same. means of solving the problem
[0021] The present invention, for solving the above problem, provides a method for manufacturing a reinforced soil retaining wall block using artificial aggregate mixed with clay powder, comprising the steps of: adding water to a mixed soil in which stone powder and clay powder are mixed in a weight ratio of 1:1 to produce a fluid soil with a moisture content of 120%; adding a solidifying agent to the fluid soil at 5% by weight relative to the total dry weight of the fluid soil and stirring to harden it; crushing the hardened product to a maximum particle size of 5mm or less and drying it to a moisture content of 10% or less to produce artificial fine aggregate; and replacing the artificial fine aggregate in the range of 10 to 30% by weight relative to the total weight of natural fine aggregate to mix and mold concrete.
[0023] At this time, the artificial fine aggregate is characterized by having a specific gravity of 2.0 and an absorption rate of 16%.
[0025] In addition, when the replacement ratio of the artificial fine aggregate is 30% by weight relative to the total weight of the natural fine aggregate, a compressive strength equivalent to that of using only natural aggregate can be secured, and if it exceeds this, the compressive strength is significantly reduced, so it is desirable to keep the replacement ratio at 30% by weight or less.
[0027] In addition, the above concrete mix is characterized by having a compressive strength of 29.5 MPa to 35.0 MPa at 28 days of age. Specifically, when the replacement ratio of artificial fine aggregate is 10 weight%, the compressive strength at 28 days of age is 33.8 MPa, when it is 20 weight%, it is 32.2 MPa, and when it is 30 weight%, it is 29.5 MPa, which is a compressive strength equivalent to 35.0 MPa when only natural aggregate is used.
[0029] Another present invention provides a reinforced soil retaining wall block using artificial aggregate mixed with clay, which is formed by replacing the artificial fine aggregate, manufactured by adding moisture to a mixed soil of stone powder and clay powder in a weight ratio of 1:1 to produce a fluid soil with a moisture content of 120%, adding a solidifying agent at 5% by weight relative to the total dry weight of the fluid soil, hardening and crushing the fluid soil, and then drying it, in a range of 10 to 30% by weight relative to the total weight of natural fine aggregate.
[0031] At this time, the reinforced earth retaining wall block is characterized by having a compressive strength of 29.5 MPa to 35.0 MPa at 28 days of age. Effects of the invention
[0032] The reinforced earth retaining wall block using artificial aggregate mixed with clay according to the present invention and the method for manufacturing the same provide the following excellent effects.
[0033] 100% resource utilization of industrial by-products and prevention of environmental pollution: Stone powder and soil powder, which are hazardous by-products with a high moisture content (approx. 70%) that were previously left to be discarded entirely as airborne particles or sludge at stone extraction and processing sites, are entirely recycled into high-value artificial fine aggregates. Through this, an eco-friendly circular economy can be realized that drastically reduces environmental burdens, such as soil and air pollution caused by waste landfilling.
[0034] Carbon emission reduction through low-energy, room-temperature processes: Artificial aggregates are manufactured solely through room-temperature-based hardening and crushing processes, which involve fluidization via the addition of water and hydration reactions of solidifying agents, by completely eliminating conventional high-temperature treatment or hot-air drying methods for moisture removal. This 혁신적으로 reduces drying energy and fundamentally prevents the use of fossil fuels and greenhouse gas emissions during the manufacturing process.
[0035] Minimization of natural aggregate extraction and protection of natural ecosystems: By using manufactured eco-friendly artificial fine aggregate to replace up to 30% by weight of natural fine aggregate in concrete mixing, it is effective in preventing the destruction of natural ecosystems by reducing the indiscriminate extraction of river sand and forest aggregates.
[0036] Ensuring excellent quality and maximizing economic efficiency: Even when artificial fine aggregate is mixed, the mixing water (based on a water-to-cement ratio of 45%) and fluidity are stably maintained, and excellent compressive strength (29.5 MPa to 35.0 MPa at 28 days of age) equivalent to that of natural aggregate mixes is exhibited. This enables the mass supply of highly reliable green materials while significantly reducing the cost of various concrete secondary products requiring structural stability, such as reinforced earth retaining wall blocks and slope protection blocks. Brief explanation of the drawing
[0037] Figure 1 is a flowchart showing the overall manufacturing process of a reinforced soil retaining wall block using artificial aggregate mixed with clay according to the present invention. FIG. 2 is a block diagram showing the device configuration of an artificial fine aggregate manufacturing system according to the present invention. FIG. 3 is a mixing composition diagram showing the substitution ratio of natural fine aggregate and artificial fine aggregate and the composition of each material in the concrete mixing step according to the present invention. Figure 4 is a graph showing the change in compressive strength at ages 3, 7, and 28 days according to the replacement ratio of artificial fine aggregate manufactured according to the present invention. FIG. 5 is a perspective view showing the structure of a reinforced earth retaining wall block molded using concrete containing artificial fine aggregate manufactured according to the present invention. FIG. 6 is a conceptual diagram that intuitively illustrates the entire concept of the invention, from stone powder or soil powder generated at a stone processing site being reborn as artificial fine aggregate, manufactured into reinforced soil retaining wall blocks, and applied to a retaining wall construction site. Specific details for implementing the invention
[0038] Hereinafter, specific details for implementing the present invention will be described in more detail with reference to the attached drawings. The present invention can be more clearly understood by the following examples, which are for illustrative purposes only and are not intended to limit the scope of protection defined by the appended claims.
[0040] Figure 1 is a flowchart showing the overall manufacturing process of a reinforced soil retaining wall block using artificial aggregate mixed with clay according to the present invention.
[0042] Referring to FIG. 1, the method for manufacturing reinforced soil retaining wall blocks of the present invention consists of a total of 10 steps, starting from the stone powder and soil powder collection step (S100) to the reinforced soil retaining wall block molding step (S190).
[0044] First, in the stone dust and soil dust collection step (S100), stone dust and soil dust generated at the stone extraction or processing site are collected. These stone dust and soil dust are naturally derived materials that are not contaminated by heavy metals or organic substances, but are industrial by-products that are difficult to process by conventional methods because their moisture content reaches about 70%.
[0046] Next, in the mixed soil manufacturing step (S110), the collected stone powder and soil powder are mixed in a weight ratio of 1:1 to produce mixed soil. Mixing the stone powder and soil powder in equal proportions is intended to reflect the physical and chemical properties of each component in a balanced manner, thereby obtaining artificial fine aggregate of uniform quality in the subsequent solidification process.
[0048] In the fluidized soil manufacturing step (S120), water is added to the mixed soil to produce fluidized soil with a moisture content of 120%. This is intended to fundamentally resolve the phenomenon of sludge aggregation or delayed drying that was a problem in the prior art, and paradoxically, the key is to create a completely fluidized state by adding more water. Since internal moisture is not trapped when the solidifying agent is uniformly dispersed and reacted in the fluidized state, energy consumption can be significantly reduced compared to the conventional direct drying method.
[0050] For example, if the dry weight of the mixed soil is 100 kg, additional water is added in addition to the existing moisture content of 70% to adjust the final moisture content to 120%. That is, a fluid soil is produced by mixing 120 kg of water based on a dry weight of 100 kg.
[0052] In the step of adding and stirring the solidifying agent (S130), 5% by weight of the solidifying agent is added to the fluidized soil relative to the total dry weight of the fluidized soil, and the mixture is stirred for about 1 minute and 30 seconds in a twin mixer (130 in FIG. 2). The solidifying agent reacts with the mixed soil in a slurry state to cause a hardening reaction, and since it is added in a fluid state, it has the advantage that the solidifying agent is uniformly dispersed throughout the entire mixture.
[0054] In the curing and hardening stage (S140), the mixture that has been stirred is discharged into an external space and cured for 28 days. By undergoing a sufficient curing period, the hydration reaction of the hardening agent is fully carried out to form a hardened body having a predetermined strength.
[0056] In the crushing step (S150), the hardened product is fed into a concrete crusher and crushed into fine aggregate with a maximum particle size of 5 mm or less. Limiting the crushed particle size to 5 mm or less is intended to ensure an appropriate particle size distribution to perform the role of fine aggregate when mixing concrete.
[0058] In the drying step (S160), the crushed artificial fine aggregate is dried to a moisture content of 10% or less. Since the artificial fine aggregate, which has undergone the solidification and crushing processes after fluidization, has an open surface structure, the drying energy is significantly reduced compared to the conventional direct sludge drying method.
[0060] In the artificial fine aggregate quality verification step (S170), the quality is verified by measuring the specific gravity or water absorption rate of the manufactured artificial fine aggregate. The artificial fine aggregate manufactured according to the present invention exhibits physical properties of a specific gravity of 2.0 and a water absorption rate of 16%.
[0062] FIG. 2 is a block diagram showing the device configuration of an artificial fine aggregate manufacturing system (100) according to the present invention.
[0064] Referring to FIG. 2, the artificial fine aggregate manufacturing system (100) comprises a raw material input section (110), a moisture control section (120), a twin mixer (130), a solidifying agent input section (140), a curing section (150), a crushing section (160), a drying section (170), a quality inspection section (180), and an artificial fine aggregate storage section (190).
[0066] The raw material input section (110) measures stone powder and soil powder collected at the stone processing site in a 1:1 weight ratio and supplies them to the twin mixer (130). The moisture control section (120) measures and supplies moisture to control the moisture content of the mixed soil to 120%. The twin mixer (130) mixes the materials supplied from the raw material input section (110) and the moisture control section (120) for about 1 minute and 30 seconds to produce uniform fluid soil. The solidifying agent input section (140) measures 5% by weight of the solidifying agent relative to the total dry weight of the fluidized soil and feeds it into the twin mixer (130). The curing section (150) discharges the mixed mixture into an external space and cures it for 28 days. The crushing section (160) crushes the hardened body, including a concrete crusher, to a maximum particle size of 5 mm or less, and the drying section (170) dries the crushed artificial fine aggregate to a moisture content of 10% or less. The quality inspection unit (180) verifies the quality of artificial fine aggregate by measuring the specific gravity or absorption rate, and the artificial fine aggregate that passes is stored in the artificial fine aggregate storage unit (190).
[0068] FIG. 3 is a concrete mix composition diagram according to the present invention, showing the composition or ratio of each material in the concrete mix step (S180).
[0070] Referring to FIG. 3, natural fine aggregate (210), artificial fine aggregate (220), cement (230), water (240), and admixture (250) are introduced into the concrete mixing section (200) to produce a finished concrete mixture (260). At this time, the artificial fine aggregate (220) is used to replace 10 to 30 weight percent of the natural fine aggregate (210). Since the compressive strength is significantly reduced when the replacement ratio exceeds 30 weight percent, as shown in the experimental results described later, it is preferable to keep the replacement ratio at 30 weight percent or less.
[0072] For specific mix design, refer to the attached mix design document (Seonjin Enterprise Co., Ltd., October 28, 2024), and the mix is made based on a water-cement ratio of 45% and a fine aggregate ratio of 45.1% under conditions of a design standard strength of 35 MPa, a maximum coarse aggregate size of 25 mm, a slump of 100 mm, and an air content of 4.5%.
[0073] Figure 4 is a graph showing the compressive strength by age according to the replacement ratio of artificial fine aggregate.
[0074] Examples and comparative examples are described with reference to FIG. 4 and Table 1 below.
[0075] [Table 1] Compressive strength by age according to artificial fine aggregate replacement ratio (Unit: MPa)
[0076]
[0077] [Example 1]
[0079] As a standard mix using 100% natural fine aggregate, the compressive strengths at ages 3, 7, and 28 were 16.5 MPa, 25.2 MPa, and 35.0 MPa, respectively. This satisfies the design standard strength of 35 MPa and serves as a comparative standard for the present invention.
[0081] [Example 2]
[0083] In a mixture in which 10 parts by weight of artificial fine aggregate were substituted for 90 parts by weight of natural fine aggregate, the compressive strengths at 3, 7, and 28 days of age were 16.0 MPa, 24.2 MPa, and 33.8 MPa, respectively. Compared to Example 1, the compressive strength at 28 days of age decreased by only about 3.4%, showing virtually equivalent compressive strength.
[0085] [Example 3]
[0087] The mixture used by substituting 20 parts by weight of artificial fine aggregate with 80 parts by weight of natural fine aggregate had compressive strengths of 15.4 MPa, 23.4 MPa, and 32.2 MPa at 3, 7, and 28 days of age, respectively. The reduction rate of compressive strength at 28 days of age compared to Example 1 was approximately 8.0%, maintaining sufficient strength as a structural material.
[0089] [Example 4]
[0091] The mixture was prepared by substituting 30 parts by weight of artificial fine aggregate with 70 parts by weight of natural fine aggregate, and the compressive strengths at 3, 7, and 28 days were 14.5 MPa, 21.8 MPa, and 29.5 MPa, respectively. Although the compressive strength at 28 days was 29.5 MPa, which is about 15.7% lower than that of Example 1, it was confirmed that this is a sufficient strength level to perform the structural function of a reinforced earth retaining wall block.
[0093] [Comparative Example 1]
[0095] In a mixture in which 40 parts by weight of artificial fine aggregate were substituted for 60 parts by weight of natural fine aggregate, the compressive strength at 28 days of age was 26.8 MPa, which was a decrease of about 23.4% compared to Example 1. This was an additional decrease of about 9.2% compared to Example 4, confirming that the decrease in compressive strength accelerates when the substitution rate exceeds 30% by weight.
[0097] [Comparative Example 2]
[0099] With a mix using equal amounts of natural fine aggregate and artificial fine aggregate in a 50:50 ratio, the 28-day compressive strength was 23.5 MPa, which is about 32.9% lower than that of Example 1. This is a strength level that is difficult to satisfy the structural requirements of reinforced earth retaining wall blocks, and serves as the basis for limiting the upper limit of the replacement ratio of artificial fine aggregate to 30 weight%.
[0100] As can be seen from the compressive strength graph (300), the compressive strength curve at 3 days (310), the compressive strength curve at 7 days (320), and the compressive strength curve at 28 days (330) all show a tendency to gradually decrease as the artificial fine aggregate replacement rate increases. In particular, in the example section (340) (replacement rate 0 to 30%), a gradual decrease is observed, whereas in the comparative example section (350) (replacement rate 40 to 50%), the decrease in strength is accelerated. Based on the reference strength line (360) of 29.5 MPa, it can be seen that the above standard is satisfied at an artificial fine aggregate replacement rate of 30 weight% or less.
[0102] FIG. 5 is a perspective view of a reinforced soil retaining wall block (400) manufactured according to the present invention.
[0104] Referring to FIG. 5, the reinforced soil retaining wall block (400) is composed of a front wall (410), a rear wall (420), a side wall (430), an internal filling space (440), and a concrete body (450) containing artificial fine aggregate. The front wall (410) and the rear wall (420) form the front and rear surfaces of the retaining wall, and the side wall (430) connects the front wall (410) and the rear wall (420) on both sides to form a rectangular pipe-shaped block exterior. Reinforced soil is filled into the internal filling space (440) to ensure the stability of the retaining wall block. The artificial fine aggregate-containing concrete body (450) is formed by mixing artificial fine aggregate manufactured according to the present invention with 10 to 30 weight percent of natural fine aggregate, and exhibits a predetermined structural strength in the range of 29.5 MPa to 35.0 MPa compressive strength at 28 days of age.
[0106] FIG. 6 is a cartoon concept diagram that intuitively illustrates the overall concept of the present invention.
[0108] Referring to FIG. 6, the sludge from the stone powder / soil powder generation section (510) generated at the stone extraction / processing site (500) is fluidized in a twin mixer (520), and after a solidifying agent is injected as in the solidifying agent injection scene (530), it passes through the curing / crushing treatment section (540) and is reborn as an artificial fine aggregate finished product (550). The manufactured artificial fine aggregate is replaced and mixed with a portion of natural aggregate in the concrete mixing scene (560), molded into a reinforced soil retaining wall block finished product (570), and then stacked and constructed at the retaining wall construction site (580). In this way, the present invention implements an eco-friendly circular resource conversion technology that converts stone powder or soil powder, which was conventionally treated as industrial waste, into high-value-added construction materials.
[0110] The invention described above has been explained with reference to an embodiment illustrated in the drawings, but this is merely illustrative, and it should be made clear to those skilled in the art that various modifications and equivalent alternative embodiments are possible therefrom. Accordingly, the true technical scope of protection of the invention should be interpreted by the appended claims, and all technical ideas within an equivalent scope should be interpreted as being included within the scope of rights of the invention. Explanation of the symbols
[0111] S100: Stone powder and clay powder collection stage S110: Mixed soil manufacturing step S130: Solidifying agent injection and stirring stage S150: Crushing stage S180: Concrete Mixing Step 100: Artificial fine aggregate manufacturing system 130 : Twinmixer 210 : Natural fine aggregate 220 : Artificial fine aggregate 400 : Reinforced soil retaining wall block 410 : Front wall 440: Internal charging space
Claims
Claim 1 A method for manufacturing a reinforced earth retaining wall block using artificial aggregate mixed with clay, comprising: a step of producing a fluidized soil with a moisture content of 120% by adding water to a mixed soil in which stone powder and clay powder are mixed in a weight ratio of 1:1; a step of adding a solidifying agent to the fluidized soil at 5% by weight relative to the total dry weight of the fluidized soil and stirring, and then discharging the mixture after stirring is completed into an external space and curing it for 28 days to harden it; a step of producing artificial fine aggregate having a specific gravity of 2.0 and an absorption rate of 16% by crushing the hardened product to a maximum particle size of 5mm or less and drying it to a moisture content of 10% or less; and a step of mixing and molding concrete by replacing the artificial fine aggregate with the natural fine aggregate in a range of 10 to 30% by weight relative to the total weight of the natural fine aggregate. Claim 2 A reinforced earth retaining wall block using artificial aggregate mixed with clay powder, characterized in that the block is formed by replacing natural fine aggregate with artificial fine aggregate having a specific gravity of 2.0 and an absorption rate of 16%, manufactured by adding moisture to a mixture of stone powder and clay powder in a weight ratio of 1:1 to produce a fluidized soil with a moisture content of 120%, adding a solidifying agent at 5% by weight relative to the total dry weight of the fluidized soil, curing for 28 days to harden, crushing the hardened product to a maximum particle size of 5mm or less and drying it to a moisture content of 10% or less, in a range of 10 to 30% by weight relative to the total weight of the natural fine aggregate, and forming the block with concrete having a compressive strength of 29.5 MPa to 35.0 MPa at 28 days of age. Claim 3 A method for manufacturing a reinforced earth retaining wall block using artificial aggregate mixed with clay, characterized in that, in claim 1, the solidification agent is added to the fluidized soil and then stirred in a twin mixer for 1 minute and 30 seconds, the artificial fine aggregate is replaced at 30% by weight relative to the total weight of the natural fine aggregate, the concrete mix is formed based on a water-cement ratio of 45% and a fine aggregate ratio of 45.1% under conditions of a design standard strength of 35 MPa, a maximum coarse aggregate size of 25 mm, a slump of 100 mm, and an air content of 4.5%, and the compressive strength of the concrete at 28 days of age is 29.5 MPa. Claim 4 A reinforced earth retaining wall block using artificial aggregate mixed with clay, characterized in that, in paragraph 2, the replacement ratio of the artificial fine aggregate is 30% by weight relative to the total weight of the natural fine aggregate, the reinforced earth retaining wall block comprises a front wall, a rear wall, a side wall, an internal filling space, and a concrete body containing artificial fine aggregate, wherein the front wall and the rear wall form the front and rear surfaces of the retaining wall, the side wall connects the front wall and the rear wall on both sides to form a rectangular tube-shaped block exterior, the internal filling space is filled with reinforced earth, and the compressive strength of the concrete body containing artificial fine aggregate at 28 days of age is 29.5 MPa. Claim 5 A method for manufacturing a reinforced earth retaining wall block using clay-mixed artificial aggregate, characterized in that, in claim 1, after the step of manufacturing the artificial fine aggregate, the specific gravity and absorption rate of the manufactured artificial fine aggregate are measured in a quality inspection unit to verify the quality of the artificial fine aggregate, and the passed artificial fine aggregate is stored in an artificial fine aggregate storage unit. Claim 6 A reinforced earth retaining wall block using clay-mixed artificial aggregate, characterized in that, in paragraph 2, the concrete comprises natural fine aggregate, the artificial fine aggregate, cement, water, and an admixture, and is mixed based on a water-cement ratio of 45% and a fine aggregate ratio of 45.1% under conditions of a design standard strength of 35 MPa, a maximum coarse aggregate size of 25 mm, a slump of 100 mm, and an air content of 4.5%.
Citation Information
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