An apparatus for casting a coarse aggregate mixture using thermosetting polymer and waste materials

Abstract

An Apparatus for Casting a Coarse Aggregate Mixture Using Thermosetting Polymer and Waste Materials The present disclosure proposes an apparatus for casting a coarse aggregate mixture using thermosetting polymer and waste materials. The apparatus (100) of casting a contrived coarse aggregate composition. The apparatus (100) is specially designed apparatus is prepared using tin smithy and gas welding processes. The apparatus (100) comprises an elongated shaft (102) having a base plate (104) and a handle (106), a removable perforated mould box (108), and a base frame (110). The apparatus (100) does not require any energy intensive procedures such as agglomeration, curing and sintering thereof for preparing a coarse aggregate composition for concrete. The apparatus (100) can cast a coarse aggregate with desired strength and minimum effect on the environment through minimal mining of natural resources.

Description

An Apparatus for Casting a Coarse Aggregate Mixture Using Thermosetting Polymer and Waste MaterialsDESCRIPTION:Field of the invention:

[0001] The present disclosure generally relates to the technical field of equipment for preparation of concrete composition, and in specific relates to an equipment for preparation of contrived aggregate composition that utilizes thermosetting polymer and disposed waste material such as fly ash to thereby reduce the consumption of natural resources involved in making concrete.Background of the invention:

[0002] According to statistical data, cement is the second most consumed material in the world. The cement manufacturing industries contribute around 5 to 8% of the world's manmade greenhouse gas emissions. Since cement is mostly utilized in construction, the usage of other related materials is also huge. When concrete is considered, the global consumption of natural coarse aggregate and fine aggregate such as sand is very high. There is a constant need for construction material in the developed countries as well as in the developing countries. In this scenario, developing countries face a shortage of quality aggregates.

[0003] Concrete is referred to as a building material made from a mixture of broken stone or gravel, sand, cement, and water, that when spread or poured into moulds, forms a mass resembling stone upon hardening. Concrete blocks are intended to serve as paving units (e.g., pavers, paving tiles, etc.), wall construction units (e.g., masonry units, retaining wall units, etc.), ornamental blocks, steps, and other landscaping elements.

[0004] Artificial aggregates are aggregates that are produced from industrial waste materials or other by-products. They are an alternative to natural aggregates, which are becoming increasingly scarce and expensive. The production of artificial aggregates typically involves mixing of raw materials, agglomeration, and hardening or binding of the particles. The raw materials are typically mixed in a batch mixer. The mix design will vary depending on the desired properties of the artificial aggregate. Some common raw materials used to produceartificial aggregates include fly ash, blast furnace slag, and recycled concrete. Then, the mixed raw materials are then agglomerated, which means that they are formed into small clumps. This can be done using a variety of methods, such as pelletizing, briquetting, or granulation. Once the raw materials have been agglomerated, they need to be hardened or bound together. This can be done using a variety of methods, such as sintering, autoclaving, or cold bonding. The hardened or bound artificial aggregates may then undergo further processing, such as curing or sizing.

[0005] There are three main methods for producing artificial aggregates: sintering, autoclaving, and cold bonding. However, conventional concrete composition needs mining of raw materials which leads to depletion of natural resources. Hence, it is necessary to look for alternative ways to prepare concrete that is eco-friendly and does not need exploitation of natural resources such as water, rocks and thereof.

[0006] Therefore, there is a need for an indigenous equipment to prepare the coarse aggregate composition using thermosetting polymer and waste materials such as fly ash. There is a need for an equipment that can cast a coarse aggregate with desired strength and minimum effect on the environment through minimal mining of natural resources.Objectives of the invention:

[0007] The primary objective of the invention is to provide an indigenous equipment to prepare the coarse aggregate composition using thermosetting polymer and waste materials such as fly ash.

[0008] Another objective of the invention is to provide an equipment that utilizes thermosetting polymer and disposed waste material such as fly ash and with best workability to prepare a coarse aggregate composition for concrete.

[0009] Further objective of the invention is to provide a simple equipment that does not require any energy intensive procedures such as agglomeration, curing and sintering thereof for preparing a coarse aggregate composition for concrete.

[0010] Yet another objective of the invention is to provide an apparatus that can cast a coarse aggregate with desired strength and minimum effect on the environment through minimal mining of natural resources.Summary of the invention:

[0011] The present disclosure proposes an apparatus for casting a coarse aggregate mixture using thermosetting polymer and waste materials. The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview. It is not intended to identify key / critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0012] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide an equipment for preparation of contrived aggregate composition that utilizes thermosetting polymer and disposed waste material such as fly ash to thereby reduce the consumption of natural resources involved in making concrete.

[0013] According to an aspect, the invention provides an apparatus utilized to cast a coarse aggregate composition. The specially designed apparatus is prepared using tin smithy and gas welding processes. The apparatus comprises an elongated shaft having a base plate and a handle, a removable perforated mould box, and a base frame. The elongated shaft is a mild steel (M.S) rod and having a diameter of at least 20 mm. The handle is a mild steel (M.S) handle with a diameter of at least 10 mm. The elongated shaft having plurality of threads rotatably supported by a frame member. In specific, the handle is configured for enabling a user to rotate the elongated shaft.

[0014] The base plate is adapted to secure to one end of the elongated shaft. In specific, the base plate is a sandwiched mild steel (M.S) plate and having a thickness of at least 2 mm. The elongated shaft is fixed to at a height of 330 mm above the base frame. The base plate is disposed at one distal end of the elongated shaft, and the handle is disposed at other distal end of the elongated shaft.

[0015] The removable perforated mould box is disposed underneath the base plate. The removable perforated mould box is configured to store a mixture of coarse aggregates. The base plate is configured to press the mixture of coarse aggregates stored in the removable perforated mould box upon rotation of the elongated shaft, thereby applying pressure on the mixture to perform a cold pressing process.

[0016] The removable perforated mould box is prepared with plurality of M.S plates of 2 mm. The removable perforated mould box having a top opening and plurality of holes on a bottom surface of the removable perforated mould box. The holes are configured for allowing the mixture out of the removable perforated mould box when the base plate presses the mixture of coarse aggregates.

[0017] The base frame is configured to securely support the removable perforated mould box in a position during the use. The base frame is made of plurality of a hollow sections, wherein dimension of each hollow section is 30 mm x 30 mm x 3 mm confirming to IS: 4923-1997, for holding the removable perforated mould box. The base frame has overall dimensions of 300 mm x 220 mm x 320 mm.

[0018] In an embodiment, the contrived coarse aggregate composition is formed by placing the mixture of thermosetting polymer in the removable perforated mould box and performing cold pressing by twisting the elongated shaft through the handle, and enabling the base plate to press the mixture of thermosetting polymer.

[0019] Further, objects and advantages of the present invention will be apparent from a study of the following portion of the specification, the claims, and the attached drawings.Detailed description of drawings:

[0020] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, explain the principles of the invention.

[0021] FIG. 1 illustrates a schematic view of an apparatus of casting a contrived coarse aggregate composition, in accordance to an exemplary embodiment of the invention.

[0022] FIG. 2A illustrates a perspective top view of a removable perforated mould box of the apparatus, in accordance to an exemplary embodiment of the invention.

[0023] FIG. 2B illustrates a perspective bottom view of the removable perforated mould box of the apparatus, in accordance to an exemplary embodiment of the invention.

[0024] FIG. 3A illustrates a perspective view of an elongated shaft having a base plate and a handle of the apparatus, in accordance to an exemplary embodiment of the invention.

[0025] FIG. 3B illustrates a perspective view of a base frame of the apparatus, in accordance to an exemplary embodiment of the invention.

[0026] FIG. 4 illustrates a schematic view depicting rotation of the elongated shaft having the base plate and the handle, in accordance to an exemplary embodiment of the invention.Detailed invention disclosure:

[0027] Various embodiments of the present invention will be described in reference to the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.

[0028] The present disclosure has been made with a view towards solving the problem with the prior art described above, and it is an object of the present invention to provide an equipment for preparation of contrived aggregate composition that utilizes thermosetting polymer and disposed waste material such as fly ash to thereby reduce the consumption of natural resources involved in making concrete.

[0029] According to an exemplary embodiment of the invention, FIG. 1 refers to a schematic view of an apparatus 100 of casting a contrived coarse aggregate composition. The apparatus 100 is specially designed apparatus is prepared using tin smithy and gas welding processes. The apparatus 100 comprises an elongated shaft 102 having a base plate 104 and a handle 106, a removable perforated mould box 108, and a base frame 110.

[0030] The elongated shaft 102 is a 20 mm diameter mild steel (M.S) rod. The handle 106 is a mild steel (M.S) handle with a diameter of 10 mm. The base plate 104 is a 2 mm thick end sandwiched mild steel (M.S) plate of size 150 mm x 150 mm. The elongated shaft 102 is fixed to at a height of 330 mm above the base frame 110. The elongated shaft 102 is a mild steel(M.S) rod and having a diameter of at least 20 mm. The handle 106 is a mild steel (M.S) handle with a diameter of at least 10 mm. The elongated shaft 102 having plurality of threads 103 rotatably supported by a frame member 111. In specific, the handle 106 is configured for enabling a user to rotate the elongated shaft 102.

[0031] The base plate 104 is adapted to secure to one end of the elongated shaft. In specific, the base plate 102 is a sandwiched mild steel (M.S) plate and having a thickness of at least 2 mm. The elongated shaft 102 is fixed to at a height of 330 mm above the base frame 104. The base plate 104 is disposed at one distal end of the elongated shaft 102, and the handle 106 is disposed at other distal end of the elongated shaft 102.

[0032] The removable perforated mould box 108 is disposed underneath the base plate 104. The removable perforated mould box 108 is configured to store a mixture of coarse aggregates. The base plate 104 is configured to press the mixture of coarse aggregates stored in the removable perforated mould box 108 upon rotation of the elongated shaft 102, thereby applying pressure on the mixture to perform a cold pressing process.

[0033] The removable perforated mould box 108 is prepared with plurality of M.S plates of 2 mm. The removable perforated mould box 108 has dimensions of 150 x 150 x 150 mm with a top opening and plurality of holes 112 of 20 mm on the bottom surface of the removable perforated mould box 108. The holes 112 are configured for passing a homogenous mixture out of the removable perforated mould box 108 when the base plate 104 presses the mixture of thermosetting polymer.

[0034] The base frame 110 is configured to securely support the removable perforated mould box 102 in a position during the use. The base frame 110 is made of plurality of a hollow sections, wherein dimension of each hollow section is 30 mm x 30 mm x 3 mm confirming to IS: 4923-1997, for holding the removable perforated mould box 108. The base frame has overall dimensions of 300 mm x 220 mm x 320 mm.

[0035] In an embodiment, the contrived coarse aggregate composition is formed by placing the mixture of thermosetting polymer in the removable perforated mould box 108 and performing cold pressing by twisting the elongated shaft 102 through the handle 106, and enabling the base plate 104 to press the mixture of thermosetting polymer.

[0036] Table 1:

[0037] In one embodiment, FIG. 1 shows the apparatus 100 developed for casting contrived coarse aggregates using tin smithy and gas welding processes. Table 1 shows that the most economical mix of thermosetting polymer to fly ash is 25% by weight. The developed apparatus 100 is used to prepare 20 mm nominal size contrived coarse aggregates using this mix. The prepared aggregate samples are tested at an age of 3 days at room temperature according to IS standards to assess their suitability for partial and full use in concrete works.

[0038] According to another exemplary embodiment of the invention, FIG. 2A and FIG. 2B refers to the removable perforated mould box 108. The removable perforated mould box 108 is prepared with 2 mm M.S plate of size 150 mm x 150 mm x 150 mm with an opening on the top side and 20 mm random holes drilled on bottom. Also, special arrangement is made in top of the base frame 110 with ISA 30mm x 30mm x 5mm to fix the removable perforated mould box 108 for aggregate casting.

[0039] According to another exemplary embodiment of the invention, FIG. 3A refers to the elongated shaft 102 having the base plate 104 and the handle 106. FIG. 3B refers to the base frame 110 of the apparatus. The base frame 110 is designed with provisions to enable perfect fitment of the removable perforated mould box 108 and hold the mould box in position.

[0040] According to another exemplary embodiment of the invention, FIG. 4 refers to rotation of the elongated shaft 102 having the base plate 104 and the handle 106. The process of creating the contrived coarse aggregates is both fascinating and intricate. A carefully measured mixture of thermosetting polymer is first placed into the perforated mould box108. Next, the elongated shaft 102 is twisted, with the base plate 104 acting as a plunger, to cold press the mixture. This process results in the formation of the contrived coarse aggregates, which are essential for the production of high-quality products.

[0041] The elongated shaft 102 is the central element of this equipment and is made of 20 mm diameter material. The elongated shaft 102 is operated by the handle 106 made of M.S plain rod, which is 10 mm in diameter. At the bottom of the elongated shaft 102, there is the base plate 104, which is made of 2 mm thickened sandwiched mild steel (M.S) plate. The base plate 104 is 150 mm x 150 mm in size and is designed to push the matrix.

[0042] To provide stability and support to the elongated shaft 102, a special provision is made using hollow section 30 mm x 30 mm x 30 mm, which confirms to IS: 4923-1997. This provision is attached to the base frame 110 and provides a height of 330 mm above the base frame. The base frame 110 is also made of a hollow section with dimensions 30 mm x 30 mm x 30 mm, confirming to IS: 4923-1997. The equipment is compact in size, measuring 100 mm in length, 220 mm in width, and 320 mm in height. The overall design ensures stability, durability and ease of operation.

[0043] Further, the removable perforated mould box 108 is prepared with 2mm M.S plate of size 150 mm x 150 mm x 150 mm with an opening on the top side and 20 mm random holes drilled on bottom. The removable perforated mould box 108 comprises plurality of holes 112 for passing a homogenous mixture out of the removable perforated mould box 108 when the base plate 104 presses the mixture of thermosetting polymer.

[0044] In one embodiment, the apparatus 100 is design for the production of lightweight contrived coarse aggregate using fly ash and thermosetting polymer without requiring any conventional manufacturing energy-consuming processes such as agglomeration, curing, and sintering, which consume large amounts of natural resources, thermal, mechanical, and electrical energy. The proposed method of making the aggregate with the apparatus 100 does not involve energy-intensive procedures, making it an eco-friendly method.

[0045] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, an apparatus 100 for preparation of contrived aggregate composition that utilizes thermosetting polymer and disposed wastematerial such as fly ash to thereby reduce the consumption of natural resources involved in making concrete.

[0046] The indigenous apparatus 100 is configured to prepare the coarse aggregate composition using thermosetting polymer and waste materials such as fly ash. The apparatus 100 utilizes thermosetting polymer and disposed waste material such as fly ash and with best workability to prepare a coarse aggregate composition for concrete. The apparatus 100 does not require any energy intensive procedures such as agglomeration, curing and sintering thereof for preparing a coarse aggregate composition for concrete. The apparatus 100 can cast a coarse aggregate with desired strength and minimum effect on the environment through minimal mining of natural resources. The apparatus 100 aids to provide concrete with good compressive, impact and crushing strength, also less water absorption and self-weight than concrete with conventional coarse aggregates.

[0047] It will readily be apparent that numerous modifications and alterations can be made to the processes described in the foregoing examples without departing from the principles underlying the invention, and all such modifications and alterations are intended to be embraced by this application.

Claims

CLAIMS:I / We Claim:

1. An apparatus (100) for casting a contrived coarse aggregate composition, comprising: an elongated shaft (102) having plurality of threads (103) rotatably supported by a frame member (111), wherein the elongated shaft (102) comprises a handle (106) for enabling a user to rotate the elongated shaft (102); a base plate (104) adapted to secure to one end of the shaft (102); a removable perforated mould box (108) disposed underneath the base plate (104), wherein the removable perforated mould box (108) is configured to store a mixture of coarse aggregates, the base plate (104) is configured to press the mixture of coarse aggregates stored in the removable perforated mould box (108) upon rotation of the elongated shaft (102), thereby applying pressure on the mixture to perform a cold pressing process; and a base frame (110) configured to securely support the removable perforated mould box (108) in a position during the use.

2. The apparatus (100) as claimed in claim 1, wherein the elongated shaft (102) is a mild steel (M.S) rod and having a diameter of at least 20 mm.

3. The apparatus (100) as claimed in claim 1, wherein the handle (106) is a mild steel (M.S) handle with a diameter of at least 10 mm.

4. The apparatus (100) as claimed in claim 1, wherein the base plate (104) is a sandwiched mild steel (M.S) plate and having a thickness of at least 2 mm.

5. The apparatus (100) as claimed in claim 1, wherein the elongated shaft (102) is fixed to at a height of 330 mm above the base frame (110).

6. The apparatus (100) as claimed in claim 1, wherein the removable perforated mould box (108) is prepared with plurality of M.S plates of 2 mm.

7. The apparatus (100) as claimed in claim 1, wherein the removable perforated mould box (108) having a top opening and plurality of holes (112) on a bottom surface of the removable perforated mould box (108).

8. The apparatus (100) as claimed in claim 8, wherein the plurality of holes (112) is configured for allowing the mixture out of the removable perforated mould box (108) when the base plate (104) presses the mixture of coarse aggregates.

Images