The ECO-friendly three-layer concrete slab

Abstract

The eco-friendly three-layer concrete slab for advanced filtration of urban polluted water and flood resilience provides a transformative solution to pressing urban challenges, including rainwater runoff and soil pollution. Unlike traditional impermeable concrete, which exacerbates flooding, or permeable alternatives that struggle with clogging and pollutant removal, this innovative design optimally enhances filtration and drainage. The top layer captures larger pollutants, while the middle layer employs additives like activated carbon, graphite, carbon nanofibers, and specialized aggregates (garnet, silica, basalt, granite, and dolomite) to effectively eliminate heavy metals, nitrates, arsenic, pharmaceuticals, and microplastics. The robust bottom layer, reinforced with polypropylene fibers, ensures structural integrity and durability, executing final filtration even in harsh environments. Designed for use as precast slabs and concrete covers for water channels, this advanced porous concrete facilitates efficient rainwater management and supports safe irrigation practices, thereby promoting sustainable agriculture and contributing to healthier ecosystems and resilient urban infrastructure.

Description

THE ECO-FRIENDLY THREE-LAYER CONCRETE SLAB

[0001] The technical field of this invention includes environmental engineering and specifically focuses on innovative concrete technologies designed for sustainable urban development. This invention falls within the domain of water management systems and emphasizes the treatment of contaminated runoff water in urban areas.

[0002] Key aspects of this field include the formulation and design of permeable concrete materials that aid in the infiltration and filtration of polluted water, thereby improving water quality. This invention integrates multiple layers of aggregates and specialized additives, enhancing the concrete's ability to remove harmful pollutants such as heavy metals, nitrates, and pathogens from contaminated water through a specific concrete mix design.

[0003] Moreover, the invention addresses pressing urban challenges such as flood prevention and soil protection, providing effective drainage solutions that manage excess water during heavy rainfall. The use of this advanced concrete also supports agricultural practices, enabling the safe use of treated water for irrigation, contributing to sustainable agriculture and environmental responsibility.

[0004] This innovative approach represents a significant advancement in both building materials and environmental remediation, helping to create healthier urban ecosystems and more resilient infrastructures.

[0005] In recent years, growing concerns about urban flooding and soil pollution have driven the development of innovative materials and technologies. One significant advancement ispermeable concrete, also known as porous concrete, which allows water to pass through its structure, reducing surface runoff and improving groundwater recharge. Patents such asUS Patent 6,506,252highlight the use of specific aggregates, additives, and porous structures to increase water infiltration while maintaining strength and durability. This approach helps mitigate urban flooding by allowing rainwater to penetrate the ground rather than overloading drainage systems.

[0006] Another critical invention involvesfiltration-enhanced concrete, which integrates activated carbon and other absorbent materials into its mixture to capture pollutants like heavy metals, nutrients, and pathogens from water. As described inUS Patent 8,157,928, this innovation enables concrete to serve both as a structural element and a water purification solution, enhancing its environmental performance by removing contaminants from runoff.

[0007] The use ofrecycled aggregatesin concrete represents a further step toward sustainability. By incorporating waste materials like crushed glass, rubber, and industrial by-products, new formulations of concrete have been developed with improved filtration properties.US Patent 7,517,697discusses how these recycled materials can effectively reduce the presence of contaminants in runoff while also reducing the environmental footprint of concrete production.

[0008] Finally, the integration ofsmart systems and sensorsinto concrete technology has opened the door to real-time environmental monitoring.US Patent 9,811,649details smart concrete capable of detecting water pollutants and providing immediate data to urban planners and environmental agencies, enabling prompt action when contamination is detected. This innovation combines structural durability with technological advancement, offering a dual solution for both construction and environmental management.

[0009] The eco-friendly three-layer concrete slab for advanced filtration of urban polluted water and flood resilience addresses significant challenges in urban areas related to rainwater runoff, soil pollution, and the failure to treat contaminated water. Traditional impermeable concrete often exacerbates flooding and water pollution, while existing solutions such as permeable concrete face issues like clogging and an inability to remove pollutants, failing to effectively address the complexities of urban runoff.

[0010] This innovative invention features a unique three-layer design that significantly improves filtration and drainage. The top layer captures larger pollutants, while the middle layer incorporates special additives like activated carbon, graphite, carbon nanofibers, and specific aggregates such as garnet, silica, basalt, granite, and dolomite. This layer is designed to remove heavy metals, nitrates, arsenic, pharmaceuticals, microplastics and other pollutants from the air and road surfaces. Additionally, the use of polypropylene fibers and filtering materials in the bottom layer ensures structural integrity and durability, even in harsh environments, while performing the final filtration.

[0011] This advanced water-purifying porous concrete, used as precast slabs and concrete covers for water channels, not only provides effective rainwater management and extensive urban drainage but also enables the safe use of treated water for irrigation, contributing to sustainable agriculture. By integrating multiple functions, this invention comprehensively addresses urgent urban challenges and contributes to healthier ecosystems and more resilient infrastructure.

[0012] Despite advancements in concrete technology and environmental engineering, several persistent issues remain unaddressed in the field of sustainable urban development and water management. One significant problem is the inadequacy of traditional concrete in managing stormwater runoff, which can lead to urban flooding, especially in areas with high rainfall. Standard concrete surfaces are impermeable, causing water to accumulate and overwhelm drainage systems, resulting in street flooding, property damage, and increased maintenance costs for municipal infrastructure. Although permeable concrete solutions have been introduced, many of these options still struggle with clogging and require regular maintenance, limiting their effectiveness over time.

[0013] Additionally, the pollution of soil and water resources due to urban runoff continues to be a critical concern. Rainwater often picks up contaminants such as heavy metals, nutrients, and pathogens from road surfaces, which then flow into nearby water bodies, leading to degraded water quality and harming aquatic ecosystems. While various filtration methods have been proposed, many existing products do not adequately capture and treat the wide range of pollutants found in urban runoff. The complexity of urban environments makes it challenging for traditional filtration systems to address diverse contaminants effectively, leading to ongoing environmental degradation.

[0014] Another persistent issue is the limited effectiveness of conventional wastewater treatment methods in removing certain hazardous substances, such as pharmaceuticals and microplastics. These contaminants are not only detrimental to aquatic life but can also pose risks to human health when they enter the food chain. Although advancements in filtration technology exist, many treatment systems are either too costly for widespread implementation or not robust enough to handle the fluctuating compositions of urban wastewater.

[0015] Furthermore, the structural integrity and longevity of existing concrete solutions often come into question, especially when exposed to harsh environmental conditions and pollutants. Traditional concrete can deteriorate over time, particularly in areas where it interacts with corrosive substances, leading to costly repairs and replacements. While some innovative materials have been developed to enhance durability, many still do not offer the necessary combination of strength, permeability, and pollutant removal capabilities, leaving a gap in the market for a more effective solution.

[0016] Urban areas are also facing challenges related to resource scarcity and environmental sustainability. As cities grow, the demand for clean water and fertile soil increases, but the existing systems for managing these resources are often outdated or insufficient. Many innovations in the field have focused on one aspect—be it drainage, filtration, or structural integrity—without integrating these functions into a cohesive solution. This lack of holistic approaches limits the potential for advancements that could simultaneously address multiple urban environmental issues.

[0017] Moreover, the implementation of green infrastructure solutions, such as green roofs and bio-retention systems, while beneficial, often requires significant upfront investments and space, which may not be feasible in densely populated urban areas. The challenge lies in finding economically viable and spatially efficient solutions that can be seamlessly integrated into existing urban landscapes.

[0018] Additionally, challenges related to manholes and canal covers exacerbate the problem of urban flooding and water pollution. Traditional materials used in these structures are often impermeable and ineffective at filtering pollutants, contributing to the accumulation of contaminants in the drainage systems. Manholes frequently become clogged, leading to overflow situations during heavy rainfall, where pollutants are not adequately filtered before entering larger drainage systems. Existing filtration solutions in these areas are insufficient to prevent these issues, as current products designed for filtration are often limited in performance, prone to clogging, or not practical for large-scale urban implementation. This highlights the urgent need for high-performance filtration solutions that can effectively capture and treat pollutants before they enter larger drainage systems, addressing the challenges posed by manholes and flooded pathways in urban environments.

[0019] The invention of the eco-friendly three-layer concrete slab for advanced filtration of urban polluted water and flood resilience presents a comprehensive solution to the myriad challenges faced in urban water management and environmental sustainability. This innovative concrete is prepared by mixing highly water-permeable mortar with coarse aggregate in a carefully controlled mixing plan, ensuring optimal material performance. The mixture undergoes a curing process for 28 days, achieving 95% of its pressure resistance, which enhances the structural durability and efficiency of the slab. By leveraging innovative materials and a thoughtful design approach, this invention effectively addresses critical issues related to stormwater runoff, soil and water pollution, resource efficiency, and community engagement.

[0020] This innovative invention features a unique three-layer design that significantly improves filtration and drainage. The top layer captures larger pollutants, utilizing larger aggregates such asdolomite (maximum size 4.75 mm)andsilica (maximum size 4.75 mm)to act as a sturdy barrier against larger debris like leaves, soil, and litter. This initial filter prevents clogging in the subsequent layers, thereby enhancing the overall efficiency of the system. The permeability of this layer is crucial, as it allows rainwater to pass through, reducing surface runoff that could lead to urban flooding. By effectively managing the initial influx of rainwater, this layer ensures that water accumulates in a controlled manner and is directed toward designated drainage systems or canals. The design of this top layer also incorporates a rough texture that increases the surface area for pollutant capture. This roughness helps trap particles more effectively while simultaneously promoting airflow and water movement, which are essential for the hydration of underlying layers. Additionally, the use of recycled aggregates in this layer contributes to sustainability by minimizing waste and reducing the carbon footprint associated with traditional concrete production, featuring a mix of300 kg / m³ of cementand2% micro silicawith awater-to-cement (W / C) ratio of 30%.

[0021] Moving to the second layer, this is the core of the filtration system, designed with a special mixture plan that minimizes cement usage while maximizing filtration efficiency and structural integrity. This layer incorporates a unique blend of additives such asactivated carbon granules (size 2.36 mm),graphite powder (2%),carbon nanofibers (1%),garnet (size 2.36 mm),silica (size 2.36 mm),basalt (size 4.75 mm), anddolomite (size 4.75 mm). The innovative mixture significantly enhances the filtration capabilities, allowing for a high degree of pollutant removal while maintaining the necessary resistance to tensile forces. By using this strategic combination, we ensure that the concrete remains robust yet highly effective in filtering pollutants.

[0022] The activated carbon is renowned for its exceptional adsorption properties, effectively capturing hazardous substances like heavy metals (including lead and mercury), nitrates, and pharmaceuticals. The incorporation of garnet, known for its hardness and angular shape, facilitates effective mechanical filtration of particulate matter, while silica enhances the strength of the matrix and contributes to overall durability. The addition of carbon nanofibers improves the interconnectivity of the layer, allowing for better flow dynamics and enhancing the filtration process.

[0023] This layer is specifically designed to target and remove microplastics and other fine pollutants, ensuring that almost all contaminants are eliminated from wastewater as it passes through. Importantly, this layer's special mixture plan optimizes the balance between filtration performance and mechanical strength, creating a concrete product that can withstand the rigors of urban environments while performing at an elevated filtration capacity. The mix utilizes200 kg / m³ of cementwith awater-to-cement (W / C) ratio of 25%and incorporates2% micro silicato enhance overall performance.

[0024] it provides structural support while also performing the final filtration of any remaining contaminants. This layer featurespolypropylene fibers (2%)that contribute to the tensile strength and resilience of the slabs, ensuring that they can withstand harsh environmental conditions and mechanical stresses. The polypropylene fibers are strategically distributed throughout the matrix to enhance crack resistance and flexibility, which are crucial for maintaining structural integrity under dynamic loading conditions.

[0025] Additionally, the filtering materials used in this layer includefine aggregatessuch as dolomite (size 4.75 mm) and silica (size 4.75 mm), which enhance its ability to capture any residual pollutants that may have passed through the first two layers. The mix utilizes300 kg / m³ of cement, incorporates2% micro silica, and maintains a water-to-cement (W / C) ratio of 30% to improve overall performance.

[0026] Furthermore, this layer containsaluminum silicate powder (2%), which significantly boosts the slab's filtration capacity. Known for its high surface area and adsorptive properties, aluminum silicate enhances pollutant capture, effectively trapping fine particulates and absorbing heavy metals that may have bypassed previous layers. This feature ensures a thorough final filtration process, contributing to a more comprehensive purification of urban water.

[0027] The use of permeable materials in this layer ensures that the final filtration does not impede the movement of water, allowing for efficient drainage and reducing the risk of surface flooding. The combination of these features ensures that the concrete maintains its structural integrity over time while effectively removing any lingering contaminants. Moreover, this layer's design incorporatesdrainage channelsthat direct filtered water efficiently toward collection points, making the system not only functional but also easy to integrate into existing urban drainage infrastructure.

[0028] Together, these three layers work synergistically to provide a holistic solution to urban water management challenges. The unique mixture plan for each layer is critical in achieving optimal performance. The top layer effectively traps larger debris, preventing blockages; the second layer focuses on high-efficiency filtration, reducing cement usage while ensuring strength and pollutant removal; and the third layer guarantees structural durability while finalizing the purification process. This multifaceted approach not only addresses issues related to stormwater runoff and soil and water pollution but also enables the safe reuse of treated water for irrigation, contributing to sustainable agricultural practices and reducing reliance on freshwater resources.

[0029] Furthermore, this invention can be utilized as precast slabs and concrete covers for water channels, providing effective rainwater management and extensive urban drainage. By integrating multiple functions into one cohesive design, this invention comprehensively addresses urgent urban challenges and promotes healthier ecosystems and more resilient infrastructure.

[0030] In conclusion, the invention serves as a multifaceted solution to the myriad problems faced in urban water management and environmental protection. By leveraging innovative materials and a thoughtful design approach, it effectively addresses issues related to stormwater runoff, soil and water pollution, structural durability, resource efficiency, and community engagement. This invention exemplifies the potential for concrete technology to evolve and contribute positively to sustainable urban development.

[0031] Enhanced Filtration: The multi-layer design effectively removes a wide range of pollutants, including heavy metals, nitrates, and pathogens.

[0032] Stormwater Management: The permeable structure reduces surface runoff, mitigating urban flooding and promoting groundwater recharge.

[0033] Soil Protection: Prevents contaminants from infiltrating the soil, thereby preserving soil health and fertility.

[0034] Safe Agricultural Water: Allows for the safe reuse of treated wastewater for irrigation, supporting sustainable farming practices.

[0035] Structural Integrity: Incorporates polypropylene fibers in the bottom layer to enhance durability and resilience against harsh environmental conditions.

[0036] Reduced Maintenance Needs: The clog-resistant design minimizes the need for frequent maintenance compared to traditional permeable concrete.

[0037] Sustainable Urban Development: Contributes to greener urban environments by improving water management and quality.

[0038] Adaptability: Can be integrated into various urban infrastructure projects, including roads, sidewalks, and green roofs.

[0039] Cost-Effective: Reduces long-term infrastructure repair and maintenance costs associated with traditional concrete.

[0040] Public Health Benefits: Helps improve overall water quality in urban areas, reducing health risks associated with contaminated water sources.

[0041] Resource Efficiency: Utilizes recycled materials in its formulation, contributing to a lower environmental footprint.

[0042] Enhanced Aesthetic Value: Can be designed to blend into urban landscapes while providing functional benefits.

[0043] Real-Time Monitoring Potential: Can integrate smart technology for monitoring water quality, enhancing urban planning and environmental management.

[0044] Resilience to Climate Change: Helps cities adapt to extreme weather conditions by managing excess water effectively.

[0045] Increased Biodiversity: Supports healthier ecosystems by preventing pollutants from entering water bodies, thus protecting aquatic life.

[0046] The complete structure of the designed slab system, illustrating its integrated layers and detailing the arrangement of each component.

[0047] Specifications of the middle layer structure.

[0048] The structure of the top and bottom layers.

[0049] Theeco-friendly three-layer concrete slabfor advanced filtration of urban polluted water and flood resilience addresses urban water management challenges while promoting environmental sustainability.

[0050] Top Layer (1): This layer captures larger pollutants and debris, constructed from recycled aggregates like basalt and granite for durability. Its textured surface maximizes surface area for debris capture and allows rainwater to percolate through, reducing surface runoff and mitigating urban flooding risks.

[0051] Middle Layer (2): The core of the filtration system, this layer minimizes cement use while ensuring structural integrity. It incorporates amix of cement and carbon nanofibers (2-1)for enhanced connectivity,activated carbon granules (2-2)for contaminant adsorption, and ablend of dolomite, basalt, garnet, and silica (2-3)for mechanical filtration. Additionally,graphite powder (2-4)further aids in pollutant capture, targeting heavy metals, nitrates, and pharmaceuticals for near-complete contaminant removal.

[0052] Bottom Layer (3): Serving as structural support and final filtration, this layer featurespolypropylene fibers (3-1)for tensile strength andaluminum silicate powder (3-2)to enhance fine particulate capture and heavy metal absorption. Additional filtering materials, including fine aggregates and specialized polymers, boost efficiency. Drainage channels direct filtered water to collection points, combining structural durability with effective filtration.

[0053] The overall design of these three layers enables advanced filtration of urban polluted water while ensuring flood resilience, making this invention a practical solution for urban environments facing water management challenges.

[0054] Urban Infrastructure Development:The eco-friendly three-layer concrete slab can be widely applied in urban development projects, particularly in constructing roads, pavements, and drainage systems that require effective stormwater management and pollution control.

[0055] Agricultural Use:This invention enables the safe reuse of treated water for irrigation, promoting sustainable agricultural practices and contributing to food security while reducing the dependency on freshwater resources.

[0056] Environmental Remediation:The advanced filtration capabilities make this concrete slab suitable for installation in areas prone to flooding and pollution, effectively capturing and treating contaminants to restore and protect local ecosystems.

Claims

A three-layer concrete slab for advanced filtration of polluted water and flood resilience, comprising:(a) a top layer made of dolomite and silica aggregates with a maximum size ranging from 4 mm to 10 mm, featuring a rough texture to trap larger pollutants;(b) a second layer consisting of a mixture of activated carbon granules (1% to 4%), graphite powder (2% to 4%), carbon nanofibers (1% to 3%), and a special mix of garnet, silica, basalt, and dolomite aggregates with sizes between 3 mm and 8 mm, designed for enhanced filtration;(c) a third layer providing structural support and final filtration, incorporating polypropylene fibers (1% to 3%) in sponge concrete, aluminum silicate powder (1% to 2.5%), and fine aggregates such as dolomite and silica;(d) a curing process for the special type of sponge concrete mixture that achieves 95% of its pressure resistance within 28 days.The three-layer concrete slab according to claim 1, wherein the top layer's rough texture increases the surface area for pollutant capture and promotes airflow and water movement.According to claim 1 and claim 2, the top layer is characterized by a water-to-cement (W / C) ratio of (25% to 30%) and includes a mixture of 300 kg / m³ of cement and (1% to 3%) micro silica.According to claim 1, the second layer is designed to maximize filtration efficiency while minimizing cement usage, utilizing 200 kg / m³ of cement with a W / C ratio of (25% to 30%).According to claim 1 and claim 4, the second layer includes carbon nanofibers at a concentration of (1% to 3%) to improve interconnectivity and flow dynamics within the filtration matrix.According to claim 1, the third layer features a cement mixture of 300 kg / m³ and incorporates between (1% to 3%) micro silica, aluminum silicate powder between (1% to 2.5%), and a W / C ratio between (25% to 30%).According to claim 1 and claim 6, the third layer utilizes polypropylene fibers in special sponge concrete at a concentration of (1% to 3%) to enhance tensile strength and resilience against mechanical stresses.According to claim 1, the drainage channels in the third layer direct filtered water efficiently toward collection points, facilitating integration into existing urban drainage infrastructure.According to claim 1, the second layer utilizes garnet for mechanical filtration of particulate matter, enhancing the overall pollutant removal capability.According to claim 1 and claim 3, the combination of dolomite, basalt, and silica in the top layer ensures effective capture of larger debris while allowing rainwater to pass through for controlled drainage.According to claim 1 and claim 5, the activated carbon granules in the second layer effectively capture heavy metals and hazardous substances, enhancing the environmental benefits of the filtration system.According to claim 1, the design of the three-layer concrete slab allows for its use as precast slabs and concrete covers for water channels, providing effective rainwater management.The three-layer concrete slab according to claim 1, wherein the aluminum silicate powder in the third layer increases the filtration capacity by enhancing pollutant capture and particle retention.According to claim 1, claim 5, and claim 13, the combined use of graphite powder in the second layer and aluminum silicate powder in the third layer optimizes pollutant filtration and improves overall water purification efficiency across the slab structure.

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