Waste-added, green composite concrete paving stones, curbs and subbase materials

Abstract

The invention relates to a paving stone and / or curb stone made from a green composite concrete with waste additives, a bedding material made from these paving stones and / or curb stones, and their production method. The invention focuses on developing a composite construction material that aims to reduce environmental issues through a recycling-oriented approach. These products comply with both national and international standards, offering a low carbon footprint, energy efficiency, and cost advantages. Furthermore, they provide innovative solutions for waste management by establishing a sustainable infrastructure for environmental landscaping.

Description

[0001] WASTE-ADDED, GREEN COMPOSITE CONCRETE PAVING STONES, CURBS AND SUBBASE MATERIALS

[0002] Technical Field to which the Invention Relates

[0003] The invention relates to environmentally friendly concrete paving stones, curbs and subbase material and a method of manufacturing the same using cement, natural aggregates and waste materials (marble dust, colemanite, bottom ash, rubber waste and preferably fly ash and / or slag, construction waste, paving waste).

[0004] Known State of the Art

[0005] Traditional concrete and natural stone-based construction materials are the most commonly used applications in the construction industry. However, the production of these materials requires the consumption of large amounts of natural resources and significant energy use, which increases their environmental impact. In particular, the high energy consumption and carbon emissions associated with cement production stand out as critical issues in terms of sustainability.

[0006] Concrete pavers, curbs, and subbase materials are traditionally produced by mixing components such as cement and natural aggregates in specific proportions. Although these production methods offer advantages in terms of durability and cost, their environmental impacts are significant and cannot be overlooked. In particular, environmental degradation, noise, and vibration pollution caused during the extraction of aggregate materials harm natural habitats and negatively affect sustainable production processes.

[0007] The limitations and shortcomings of current solutions, such as the negative environmental impacts and high costs of construction materials like concrete pavers, curbs, and subbase materials, have made it necessary to develop advancements in the field of concrete and natural stone-based construction materials.Brief Description and Objectives of the Invention

[0008] The invention relates to an environmentally friendly cement containing natural aggregate and waste materials (marble dust, colemanite, bottom ash, rubber waste and preferably fly ash and / or slag, construction waste, paving waste), concrete paving stones, curbs and subbase materials produced with this cement and their production method.

[0009] The aim of this invention is to develop a composite concrete paving stone, curb, and subbase material by utilizing waste materials, thereby contributing to the circular economy. This approach addresses environmental challenges posed by difficult-to-manage waste by incorporating them into the production of construction materials, promoting recycling and valorization. Specifically, the invention enables the reuse of wastes such as marble dust, colemanite, bottom ash, and rubber waste, as well as, optionally, fly ash, slag, construction waste, and paving waste in industrial processes. Moreover, considering the significant environmental impact of cement production, the invention seeks to minimize energy consumption and greenhouse gas emissions by reducing the use of raw materials.

[0010] Another object of the invention is to obtain a composite concrete paving stone, curb and subbase material that saves cost and energy. Cost advantages are achieved by using waste materials instead of expensive natural raw materials used in traditional production processes. The energy savings resulting from the reuse of waste makes production processes more efficient and provides economic gains.

[0011] Explanation of Shapes

[0012] Figure 1. Paving stones, curbstones and subbase material produced with waste reinforced green composite concrete

[0013] Reference Numbers

[0014] 1. Paving stones2. Curbstone

[0015] 3. Mattress material

[0016] Detailed Description of the Invention

[0017] The invention pertains to a paving stones (1) and / or curbstone (2) manufactured from a green composite concrete incorporating waste additives, a subbase material (3) produced from this paving stones (1) and / or curbstone (2), and the production method thereof. The paving stones (1 ) and / or curbstone (2) described in the invention contains, by volume, %6-15 cement, %6.5-30 water, %30-75 sand, % 0.3-3.5 marble powder, %0.2-1.8 colemanite, %25-33 bottom ash, and %1.6-4 rubber waste materials.

[0018] In one application of the invention, the paving stones (1) and / or curbstone (2) incorporate %5-14 cement, %0.5-7 fly ash and / or slag, %6.5-30 water, %30-75 sand, %0.3-3.5 marble powder, %0.2-1.8 colemanite, %25-33 bottom ash, %1.6-4 rubber waste materials by volume.

[0019] The production method of a paving stone (1) and / or curbstone (2) made from the composite concrete subject to the invention;

[0020] a. For bottom ash and marble powder, size reduction processes are carried out in a way that they pass through at least a 1 mm sieve after a natural and devicebased drying at at least 60 °C and at least 12 hours,

[0021] b. Mixing the mortar composition containing, %25-33 bottom ash, %0.3-3.5 marble powder, %0.2-1.8 colemanite, %1.6-4 rubber waste, %30-75 sand, %6-15 cement and %6.5-30 water by volume for 30 seconds to 3 minutes with a mixer, c. Filling the mortar mixture into the molds for paving stones (1 ) and / or curbstones (2),

[0022] d. Applying a pressure of at least 10 kg and a vibration value of at least 1.96 kN to the mortar mixture in the mold using the machine for at least 5 seconds, e. Completing the volumetric deficiencies in the mold and performing at least two smoothing applications using manual and / or automatic surface leveling equipment to smooth the surface,

[0023] f. The process includes curing the paving stone (1) and / or curbstone (2) molded in the machine for at least 7 days, while maintaining a constant air temperature and relative humidity using natural and / or mechanical equipment.In one embodiment of the invention, a method of manufacturing a paving stone (1) and / or a curb stone (2) made of composite concrete subject to the invention;

[0024] a. size reduction processes for bottom ash, marble dust to pass through at least 1 mm sieve after drying at least 60 °C and at least 12 hours with natural and device,

[0025] b. Mixing the mortar content containing %25-33 bottom ash, %0.5-7 fly ash and / or slag, %0.3-3.5 marble powder, %0.2-1.8 colemanite, %1.6-4 rubber waste, %30-75 sand, %5-14 cement ve %6.5-30 water with a mixer for 30 seconds - 3 minutes,

[0026] c. Filling the prepared mortar mixture into the paving stone (1) and / or curb stone (2) molds,

[0027] d. Applying a pressure of at least 10 kg and vibration values of at least 1.96 kN for a minimum of 5 seconds using the machine to the mortar mixture in the mold, e. Completing the volumetric deficiencies in the mold and performing at least two smoothing operations using manual and / or automatic surface leveling equipment to smooth the surface,

[0028] f. The process steps include curing the paving stone (1) and / or curb stone (2) molded in the machine for at least 7 days, while maintaining a constant air temperature and relative humidity using natural and / or mechanical equipment.

[0029] A subbase material (3) made of paving stone (1) and / or curb stone (2) which is the subject of the invention includes construction waste, paving stone waste, sand and composite concrete paving stone (1) and / or curb stone (2) waste.

[0030] In one application of the invention, a subbase material (3) made from the paving stone (1) and / or curb stone (2) incorporates, by volume, 2.5-20% construction waste, 2.5-50% paving waste, 30-95% sand and 2.5-50% composite concrete paving stone (1) and / or curb stone (2).

[0031] In one embodiment of the invention, a method of manufacturing a subbase material (3) made of the inventive cobblestone (1) and / or curbstone (2);a. Construction waste, paving stone waste, sand and composite concrete paving stone (1 ) and / or curb stone (2) waste are reduced to at least 0.2 mm in size and foreign materials such as metal, glass, plastic are cleaned manually and / or with equipment and / or reinforcement,

[0032] b. Mixing of 2.5-20% construction waste, 2.5-50% paving waste, 30-95% sand and 2.5-50% composite concrete paving stone (1) and / or curbstone (2) waste by volume for 30 seconds - 5 minutes,

[0033] c. Sifting of the mixed composition,

[0034] d. Storing of the mixture are included in the process steps.

[0035] Some properties of all concrete paving stone (1) and curb samples obtained in the invention were tested by experimental methods. The ranges of experimental data for these properties are given in Table 1.

[0036] Table 1. properties of cobblestone (1) and curbstone (2)

[0037] Definition of the Feature Values

[0038] Compressive Strength, MPa 16 <

[0039] Water Absorption, % 2,00-6,00

[0040] Dry Unit Weight, g / cm3< 2,30

[0041] Splitting Tensile Strength, MPa 3,60 <

[0042] Abrasion Resistance, mm < 20,00

[0043] < 23mm (H class) *

[0044] < 20 mm (I class) *

[0045] Weight Change After 50 Freeze-Thaw < 20

[0046] Cycles, %

[0047] Compressive Strength After 50 Freeze- 12 <

[0048]

[0049] Thaw Cycles, MPa

[0050] *These are the limit values specified in TS 2824 EN 1338 standard.

Claims

CLAIMS1. A paving stone (1 ) and / or curb stone (2) made from a green composite concrete with waste additives, characterized by containing, by volume, %6-15 cement, %6.5-30 water, %30-75 sand, %0.3-3.5 marble powder, %0.2-1.8 colemanite, %25-33 bottom ash, %1.6-4 rubber waste.

2. A Paving stone (1) and / or curb stone (2) made from a composite concrete according to claim 1, characterized by containing, by volume, %5-14 cement, %0.5-7 fly ash and / or slag, %6.5-30 water, %30-75 sand, %0.3-3.5 marble powder, %0.2-1.8 colemanite, %25-33 bottom ash, %1.6-4 rubber waste.

3. A method of manufacturing a paving stone (1) and / or curb stone (2) made of composite concrete according to claim 1 and characterized in that;a. size reduction processes for bottom ash, marble dust to pass through at least 1 mm sieve after drying at least 60 °C and at least 12 hours with natural and device,b. Mixing the mortar content containing %25-33 bottom ash, %0.5-7 fly ash and / or slag, %0.3-3.5 5 marble powder, %0.2-1.8 colemanite, %1.6-4 rubber waste, %30-75 sand, %5-14 cement ve %6.5-30 water with a mixer for 30 seconds - 3 minutes,c. Filling the prepared mortar mixture into the paving stone (1) and / or curb stone (2) molds,d. Applying a pressure of at least 10 kg and vibration values of at least 1.96 kN for a minimum of 5 seconds using the machine to the mortar mixture in the mold,e. Completing the volumetric deficiencies in the mold and performing at least two smoothing operations using manual and / or automatic surface leveling equipment to smooth the surfacef. The process steps include curing the paving stone (1 ) and / or curb stone (2) molded in the machine for at least 7 days, while maintaining a constant air temperature and relative humidity using natural and / or mechanical equipment.

4. A production method for a paving stone (1) and / or curb stone (2) made from composite concrete according to claim 2, characterized by;a. size reduction processes for bottom ash, marble dust to pass through at least 1 mm sieve after drying at least 60 °C and at least 12 hours with natural and device,b. Mixing the mortar content containing %25-33 bottom ash, %0.5-7 fly ash and / or slag, %0.3-3.5 marble powder, %0.2-1.8 colemanite, %1.6-4 rubber waste, %30-75 sand, %5-14 cement ve %6.5-30 water with a mixer for 30 seconds - 3 minutes,c. Filling the prepared mortar mixture into the paving stone (1 ) and / or curb stone (2) molds,d. Applying a pressure of at least 10 kg and vibration values of at least 1.96 kN for a minimum of 5 seconds using the machine to the mortar mixture in the mold ,e. Completing the volumetric deficiencies in the mold and performing at least two smoothing operations using manual and / or automatic surface leveling equipment to smooth the surface,f. process steps include curing the paving stone (1) and / or curb stone (2) molded in the machine for at least 7 days, while maintaining a constant air temperature and relative humidity using natural and / or mechanical equipment.

5. A subbase material (3) made from a paving stone (1) and / or curb stone (2) according to claim 1 , characterized by containing construction waste, paving stone waste, sand, and waste from composite concrete paving stones (1) and / or curb stones (2).

6. According to claim 5, it is a subbase material (3) made of a paving stone (1) and / or curb stone (2) and its feature is that it contains 2.5-20% construction waste, 2.5-50% paving waste, 30-95% sand and 2.5-50% composite concrete paving stone (1) and / or curb stone (2) waste by volume..

7. A production method for a bedding material (3) made from a paving stone (1) and / or curb stone (2) according to claim 6, characterized by;a. Construction waste, paving stone waste, sand and composite concrete paving stone (1) and / or curb stone (2) waste are reduced to at least 0.2 mm in size and foreign materials such as metal, glass, plastic are cleaned manually and / or with equipment and / or reinforcement,b. Mixing of 2.5-20% construction waste, 2.5-50% paving waste, 30-95% sand and 2.5-50% composite concrete paving stone (1) and / or curbstone (2) waste by volume for 30 seconds - 5 minutes,c. Sifting of the mixed composition,d. Storing of the mixture are included in the process steps.

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