Method for manufacturing interlocking pitching stones with protective coating

Abstract

The present disclosure provides a method (100) for onsite manufacturing of pitching stones (202). The method includes blending (102) stone aggregates, crushed sand, a sodium-silicate binder, polymer-based waterproofing agents, and coloured coatings to form a high-performance self-curing concrete (HPSC) composition. The method includes assembling (104) one or more molds with predefined dimensions onsite. The method includes pouring (106) the HPSC composition into the one or more molds, and molding (108) the HPSC composition for manufacturing a plurality of pitching stones (202) with uniform dimensions and optimized material properties.

Description

ENGINEERED PITCHING STONESTECHNICAL FIELD

[0001] The embodiments of the present disclosure generally relate to a field of construction and civil engineering. More specifically, the present disclosure relates to a method for manufacturing customized pitching stones directly at a construction site.BACKGROUND

[0002] The following description of the related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section is used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of the prior art.

[0003] Traditional pitching stones have been employed for decades for dam protection, providing a simple yet effective means to safeguard slopes and embankments against water erosion and wave action. These stones, manually sourced from quarries, are meticulously arranged along dam surfaces to stabilize soil and prevent its displacement. While this method has served well historically, an aging infrastructure of several dams underscores its limitations.

[0004] A significant number of dams are over 50 years old, and the pitching stones originally used have endured considerable wear and tear due to prolonged exposure to environmental factors. This degradation necessitates regular maintenance and, in severe cases, complete replacement. Furthermore, the challenges posed by evolving hydrological conditions and material deterioration demand innovative solutions to ensure long-term safety and functionality of the dams.

[0005] The reliance on quarry-sourced stones exacerbates environmental concerns. Quarrying causes habitat destruction, deforestation, and soil erosion, significantly impacting ecosystems. This unsustainable practice not only disrupts local biodiversity but also contributes to environmental degradation, raising questions about the long-term viability of traditional pitching methods. Moreover, the irregular sizes of these stones often fail to accommodate natural undulations of dam surfaces, resulting in gaps and inconsistent coverage that compromise the system's overall effectiveness.

[0006] Additional challenges include unstable slopes due to improper stone placement, which increases a risk of landslides, and an ongoing issue of soil and stone erosion that weakensthe dam structure over time. Coupled with high replacement costs for materials, transportation, and labour, these disadvantages highlight a pressing need for modem solutions.

[0007] There is, therefore, a need in the art to provide an improved method to address the limitations of traditional methods of producing the pitching stones while promoting environmental conservation and long-term efficiency.OBJECTS OF THE PRESENT DISCLOSURE

[0008] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are listed herein below.

[0009] It is an object of the present disclosure to provide a method for onsite manufacturing of pitching stones in a cost-effective manner.

[0010] It is an object of the present disclosure to provide a method to blend stone aggregates, crushed sand, a sodium-silicate binder, polymer-based waterproofing agents, and coloured coatings to form a high-performance self-curing concrete (HPSC) composition.

[0011] Another object of the present disclosure is to provide a method to assemble one or more molds with predefined dimensions onsite, and mold the HPSC composition into the pitching stones by pouring the HPSC composition into the one or more molds.

[0012] Another object of the present disclosure is to provide a method to manufacture the pitching stones with uniform dimensions and optimized material properties.

[0013] Yet another object of the present disclosure is to provide a method for curing the pitching stones within the molds to achieve desired mechanical properties.

[0014] Yet another object of the present disclosure is to provide a method for applying an Ultra-Violet (UV) resistant coloured coating onto a surface of the cured pitching stones to enhance weather resistance, provide UV protection, and improve aesthetics of the pitching stones.SUMMARY

[0015] This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.

[0016] In an aspect, the present disclosure relates to a method for onsite manufacturing of pitching stones. The method includes blending stone aggregates, crushed sand, a sodiumsilicate binder, polymer-based waterproofing agents, and coloured coatings to form a high-performance self-curing concrete (HPSC) composition. The method includes assembling one or more molds with predefined dimensions onsite, and pouring the HPSC composition into the one or more molds. Further, the method includes molding the HPSC composition for manufacturing a plurality of pitching stones with uniform dimensions and optimized material properties.

[0017] In an embodiment, the method may include curing the plurality of pitching stones within the one or more molds to attain optimal structural characteristics of the plurality of pitching stones.

[0018] In an embodiment, the method may include applying an Ultra-Violet (UV) resistant coloured coating onto a surface of the plurality of cured pitching stones to enhance weather resistance, provide UV protection, and improve aesthetics of the plurality of pitching stones.

[0019] In an embodiment, prior to molding the HPSC composition, the method may include vibrating the one or more molds to expel air voids from the HPSC composition and compact the HPSC composition.

[0020] In an embodiment, the plurality of pitching stones may be manufactured with an interlocking structure. The interlocking structure may include one or more bottom teeth-like projections to facilitate secure anchorage into underlying soil, enhance slope stability, and mitigate a risk of displacement under dynamic conditions.

[0021] In an embodiment, the plurality of pitching stones may be manufactured with a cavity between adjacent stones. The cavity may be formed of predefined geometry to facilitate efficient stormwater management and surface runoff drainage, thereby preventing water stagnation and erosion on a dam surface.

[0022] In an embodiment, the plurality of pitching stones may be integrated with a hydro-pressure regulator including thrust head sections. The thrust head sections may be configured to reduce an impact of hydrological forces and stabilize the plurality of pitching stones under dynamic conditions.

[0023] In an embodiment, the plurality of pitching stones may be manufactured from the HPSC composition to exhibit resistance to erosion, water penetration, and weathering, and ensure structural integrity of a dam surface.

[0024] In an embodiment, the HPSC composition may include 20 mm retaining aggregate, 4.5-4.7 mm sand, sodium silicate binder, Polyethylene Glycol (PEG)-400, and Ordinary Portland Cement (OPC) 53 grade cement.

[0025] In an embodiment, the UV resistant coloured coating may be at least a silicate-based formulation.BRIEF DESCRIPTION OF DRAWINGS

[0026] The accompanying drawings, which are incorporated herein, and constitute a part of this disclosure, illustrate exemplary embodiments of the disclosed methods and systems which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that disclosure of such drawings includes the disclosure of electrical components, electronic components, or circuitry commonly used to implement such components.

[0027] FIG. 1 illustrates a flow chart of an example method for onsite manufacturing of pitching stones, in accordance with an embodiment of the present disclosure.

[0028] FIGs. 2A and 2B illustrate example schematic representations depicting an arrangement of the pitching stones along a dam slope, in accordance with an embodiment of the present disclosure.

[0029] FIG. 3 illustrates example isometric views of the pitching stones with different lengths, in accordance with an embodiment of the present disclosure.

[0030] FIGs. 4A-4C illustrate elevation views of the pitching stones, in accordance with embodiments of the present disclosure.

[0031] The foregoing shall be more apparent from the following more detailed description of the disclosure.DETAILED DESCRIPTION

[0032] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of theproblems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.

[0033] The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.

[0034] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail to avoid obscuring the embodiments.

[0035] Also, it is noted that individual embodiments may be described as a process that is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.

[0036] The word “exemplary” and / or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and / or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similarto the term “comprising” as an open transition word without precluding any additional or other elements.

[0037] Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0038] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0039] The present disclosure relates to a method for onsite manufacturing of pitching stones. The method which is sustainable and user-friendly enables onsite manufacturing of engineered pitching stones with uniform dimensions, minimizing natural resource exploitation and environmental impact. The method enhances soil stability, protects dam structures, and prevents vegetation growth. The method is cost-effective, durable, and easy to perform in a construction site, thereby reducing transportation costs and eliminating a need for skilled labour during installation.

[0040] The pitching stones are designed for applications such as slope stabilization, erosion control, and water flow management in infrastructure projects, including dams, embankments, and waterways. The present disclosure focuses on a high-performance, cost-effective, and environmentally adaptive process for producing customized pitching stones directly at the construction site.

[0041] The proposed method focuses on a cutting-edge zero-waste technology to produce the engineered pitching stones entirely from recycled materials. The proposed methodis sustainable and repurposes pre-existing pitching stones from the construction site into durable construction products, eliminating a need for quarrying, minimizing carbon emissions, and advancing eco-friendly practices within the construction site. The proposed method minimizes environmental impact, aligns with global climate change initiatives, and ensures that all leftover materials from the production process are recycled, resulting in zero waste. The zero-waste technology is a step towards a greener, more sustainable future. By recycling and repurposing waste materials, the proposed method addresses environmental concerns, reduces costs, and delivers high-performance construction products. Further, the proposed method ensures a balance between development and environmental preservation, benefiting current and future generations.

[0042] Various embodiments of the present disclosure will be explained in detail with reference to FIGs. 1-4C.

[0043] FIG. 1 illustrates a flow chart of an example method (100) for onsite manufacturing of pitching stones, in accordance with an embodiment of the present disclosure.

[0044] With reference to FIG. 1, the method (100) for onsite manufacturing of pitching stones may include one or more steps as explained below. At step 102, the method (100) may include blending stone aggregates, crushed sand, a sodium-silicate binder, polymer-based waterproofing agents, and coloured coatings to form a high-performance self-curing concrete (HPSC) composition. The HPSC composition may exhibit resistance to erosion, water penetration, and weathering, and ensure structural integrity of a dam surface. The HPSC composition may include, but not limited to, 20 mm retaining aggregate, 4.5-4.7 mm sand, sodium silicate binder, Polyethylene Glycol (PEG)-400, and Ordinary Portland Cement (OPC) 53 grade cement.

[0045] The 20 mm retaining aggregate may provide structural strength and resistance to dynamic loads. 4.5 -4.7 mm sand may ensure optimal gradation and surface quality of the pitching stones. Sodium silicate binder may enhance durability and resistance to chemical exposure. The PEG-400 may impart self-curing properties, maintaining internal moisture and reducing shrinkage cracks. The OPC 53 grade cement may provide superior compressive strength for critical applications. The HPSC composition, supplemented with waterproofing agents and epoxy coatings, may ensure resistance to hydraulic forces, freeze-thaw effects, and long-term degradation.

[0046] At step 104, the method (100) may include assembling one or more molds with predefined dimensions onsite. At step 106, the method (100) may include pouring the HPSCcomposition into the one or more molds. At step 108, the method (100) may include molding the HPSC composition into a plurality of pitching stones, thereby manufacturing the plurality of pitching stones with uniform dimensions and optimized material properties.

[0047] In an embodiment, prior to molding the HPSC composition, the method (100) may include vibrating the one or more molds to expel air voids from the HPSC composition and compact the HPSC composition.

[0048] Further, the method (100) may include curing the plurality of pitching stones within the one or more molds to achieve desired mechanical properties or to attain optimal structural characteristics of the plurality of pitching stones. The method (100) may include applying an Ultra-Violet (UV) resistant coloured coating onto a surface of the plurality of cured pitching stones to enhance weather resistance, provide UV protection, and improve aesthetics of the plurality of pitching stones. The UV resistant coloured coating may be, for example, a silicate-based formulation.

[0049] In an embodiment, the plurality of pitching stones may be manufactured with an interlocking structure. The interlocking structure may include one or more bottom teeth-like projections. The one or more bottom teeth-like projections may be configured to facilitate secure anchorage into underlying soil, enhance slope stability, and mitigate a risk of displacement under dynamic conditions.

[0050] FIGs. 2A and 2B illustrate example schematic representations (200A, 200B) depicting an arrangement of the pitching stones along a dam slope, in accordance with an embodiment of the present disclosure.

[0051] With reference to FIGs. 2A and 2B, the pitching stones (202) may be depicted in a uniform and systematic arrangement along the dam slope. Each pitching stone (202) may be precisely aligned to ensure full surface coverage, leaving minimal gaps between the pitching stones (202). The uniform placement of the pitching stones (202) may distribute the load evenly across the dam slope, thereby reducing stress concentrations and preventing localized failures. The localized failures may include, but not limited to, stone displacement caused by insufficient interlocking, poor placement, or strong water currents, gap formation between the pitching stones (202) caused by non-uniform stone sizes, irregular placement, or soil subsidence beneath the stones (202), surface erosion, stone fracture, and drainage blockage caused due to accumulation of debris in designed cavities or drainage paths.

[0052] In an embodiment, the pitching stones (202) may be manufactured with the interlocking structure. That is, the pitching stones (202) may be interlocked with theirneighbour stones, thereby enhancing slope stability and mitigating displacement due to water pressure or wave action.

[0053] FIG. 3 illustrates example isometric views (300) of the pitching stones (202) with different lengths, in accordance with an embodiment of the present disclosure.

[0054] With reference to FIG. 3, the isometric views (300) of the pitching stones (202) with different lengths illustrate design and structural variations tailored to specific engineering and environmental needs. FIG. 3 illustrates a three-dimensional representation of the pitching stones (202), showcasing their geometry, dimensions, and features that contribute to their functionality in dam slope protection.

[0055] The pitching stones (202) may be designed with varying lengths to accommodate diverse requirements of the dam's slope. Longer pitching stones (202) may be used for areas requiring enhanced stability or coverage, while shorter stones may address undulations or tight spaces. This modularity may ensure that the pitching stones (202) fit seamlessly, reducing gaps and improving overall slope protection.

[0056] Despite the variation in lengths, the cross-section of the pitching stones (202) may remain consistent, ensuring uniform load distribution and compatibility with adjacent stones. This consistency may simplify the installation process and enhance the structural integrity of the arrangement of the pitching stones (202).

[0057] The varying lengths of the pitching stones (202) may allow for tailored solutions to accommodate uneven dam slopes, ensuring proper coverage and stability. By optimizing the stone design for specific conditions, the risk of failure due to gaps, erosion, or displacement may be minimized. The modular design of the pitching stones (202) may simplify replacement and repair, reducing long-term maintenance costs.

[0058] FIGs. 4A-4C illustrate elevation views (400A-400C) of the pitching stones (202), in accordance with embodiments of the present disclosure.

[0059] With reference to FIGs. 4A-4C, in an embodiment, the pitching stones (202) may be manufactured with a cavity (402) between adjacent stones, as illustrated in FIG. 4C. The cavity (402) may be formed of a predefined geometry to facilitate efficient stormwater management and surface runoff drainage, thereby preventing water stagnation and erosion on a dam surface. The cavity (402) may be, for example, a trapezoidal cavity between adjacent stones for efficient management of stormwater and runoff. The cavity (402) may be formed of a bottom width of 100 mm, a top width of 125 mm, a height of 100 mm, and a length of 900mm, 600 mm, and 300 mm. The engineered cavity (402) may minimize hydraulic pressures by channelling runoff, mitigating erosion, and maintaining substrate stability.

[0060] By incorporating the cavity (402) between the adjacent stones to channel runoff, the risk of flooding and soil degradation may be reduced, while enhancing water conservation and contributing to an overall stability and longevity of the dam structure. Surface runoff harvesting in the dam pitching stone system may help to manage excess water flow, preventing erosion and soil instability.

[0061] In an embodiment, the pitching stones (202) may be designed and manufactured with handling hooks (404) (as illustrated in FIG. 4B) to facilitate efficient transportation, placement, and installation during dam slope protection operations. The handling hooks (404) may be incorporated in sides of the pitching stones (202), thereby enhancing their utility and ease of use while minimizing the risk of damage during handling. By enabling the handling hooks (404), the reliance on manual labour may be reduced, leading to faster installation and lower labour costs. This may also reduce the risk of workplace injuries associated with manually lifting heavy stones. The handling hooks (404) may eliminate the need for direct contact with the stone surfaces during lifting and placement, preventing chipping or cracking, thereby ensuring that a structural integrity of the pitching stones (202) is maintained throughout the handling process.

[0062] In an embodiment, the pitching stones (202) may be manufactured with a soil stabilizing mechanism (406). The soil stabilizing mechanism (406) in the pitching stones (202) may improve the structural stability and durability of dam slopes. The soil stabilizing mechanism (406) not only addresses common challenges like soil erosion and displacement but also enhances the overall efficiency, sustainability, and cost-effectiveness of dam protection systems.

[0063] In an embodiment, the pitching stones (202) may be integrated with a hydropressure regulator (408) with thrust head sections. The hydro-pressure regulator (408) may be integrated in the pitching stones (202) to manage water flow and pressure along the dam slope effectively. This integration may address challenges related to water pressure buildup, turbulence, and erosion, ensuring long-term stability and functionality of a dam structure. The hydro-pressure regulator (408) may be designed to dissipate or redirect water pressure exerted on the pitching stones (202) due to wave action, rainfall, or runoff. By reducing localized water pressure, the hydro-pressure regulator (408) may prevent damage to the pitching stones (202)and mitigate the risk of displacement. The hydro-pressure regulator (408) may be integrated with thrust head sections.

[0064] The thrust head sections may be configured to reduce an impact of hydrological forces and stabilize the pitching stones (202) under dynamic conditions. The thrust head sections may be formed of 150 mm width and 100 mm length, that projects out at an interval of 50 mm across three different lengths of 900 mm, 600 mm, and 300 mm. The thrust head sections may reduce the impact load and vibrations created by the hydrological pressures, help in dissipation of energy of waves, and create friction between the stone surface and water / wind since designed at a regular interval which helps in stabilization process.

[0065] In an embodiment, a UV resistant coloured coating (410) may be applied onto a surface of the pitching stones (202) to enhance weather resistance, provide UV protection, and improve aesthetics of the pitching stones (202). The pitching stones (202) may exhibit textured or coated surfaces designed to enhance friction with the soil or adjacent stones. Coatings, such as silicate-based waterproofing layers, may be used to improve weather resistance and longevity. The silicate-based UV resistant coating may introduce a visually pleasing design, promoting the dam's appeal as a tourist attraction.

[0066] In an embodiment, the pitching stones (202) may be integrated with interlocking structure (412), as illustrated in FIG. 4A. The interlocking structure (412) may include teethlike projections or grooves at a bottom to enhance an anchorage of the pitching stones (202) to the underlying soil. The interlocking structure (412) may prevent displacement under dynamic conditions like water flow or soil movement, ensuring stability. The interlocking teeth-like projections may ensure a secure fit with the underlying soil and adjacent stones, enhancing resistance to displacement caused by dynamic forces like water flow or soil movement. The teeth-like projections may enhance frictional engagement of the pitching stones (202) with a substrate, ensuring superior resistance against sliding and slope instability.

[0067] The interlocking structure (412) may improve structural integrity of the pitching stones (202) and reduce maintenance needs by preventing stone movement over time. The arrangement of the interlocking structure (412) may adapt to undulations in the dam slope, ensuring consistent coverage even on irregular surfaces.

[0068] The geometrical configuration of the interlocking structure (412) may facilitate precise alignment and eliminate voids, thereby minimizing pathways for seepage or vegetative intrusion, and enhancing lateral resistance against hydraulic forces. The interlocking structure(412) may ensure resistance against sliding and displacement under hydrodynamic and geodynamic pressures.

[0069] The pitching stone (202) may be formed of, for example, 400 mm width, 350 mm height, and uniform 50 mm of edge thickness for superior modular fitment. Therefore, the onsite manufacturing of the pitching stone (202) may minimize transportation costs and environmental impact. The onsite manufacturing process may be user-friendly, requiring no skilled labour for installation. The pitching stone (202) may have enhanced performance, durability, sustainability, and aesthetic value for long-term dam protection.

[0070] While considerable emphasis has been placed herein on the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be implemented merely as illustrative of the disclosure and not as a limitation.ADVANTAGES OF THE PRESENT DISCLOSURE

[0071] The present disclosure provides a cost-effective method for onsite manufacturing of engineered pitching stones.

[0072] The present disclosure ensures precise customization and adaptation of the stones, minimizing transportation and material costs, while maintaining consistent quality control.

[0073] The present disclosure minimizes carbon footprints and wastes, and manufactures stones that may be tailored to specific site conditions.

[0074] The present disclosure accelerates project timelines with faster production and installation, ensures uniformity and consistent quality through onsite production, and requires less skilled labour for manufacturing and installation.

[0075] The present disclosure manufactures stones that are optimized for local environmental conditions.

[0076] The present disclosure applies customizable coatings to the stones that enhance the dam’s visual appeal and improves tourist attraction.

[0077] The present disclosure lowers dependence on external suppliers and storage needs, and creates jobs and supports local industries.

[0078] The present disclosure ensures superior durability of the stones, enabled by high-performance self-curing concrete (HPSC) composition and protective coatings, and directly contributes to long-term performance and reduced maintenance needs of the dam, making it a reliable solution for flood and erosion control.

[0079] The present disclosure eliminates dependency on natural stone quarrying, reducing environmental degradation and resource depletion. Onsite manufacturing minimizes waste and promotes the use of eco-friendly materials, aligning with sustainable development goals.

[0080] The present disclosure offers simplicity in manufacturing and installation. The process is designed to be easily operable, requiring minimal training, making it accessible to a wider range of users.

[0081] The present disclosure, by manufacturing engineered stones onsite, prevents the overuse of soil, rocks, and natural stones, thereby conserving ecosystems and protecting biodiversity in quarrying areas.

[0082] The present disclosure supports soil stability, minimizes erosion, and prevents vegetation growth that can weaken dam surfaces, contributing to overall environmental conservation.

[0083] The present disclosure ensures consistent size and shape of the stones, which is crucial for effective coverage and stability of dam slopes. Uniform stones may improve soil stability, protect dam structures, and address issues such as soil displacement and structural damage caused by vegetation growth.

[0084] The present disclosure customizes engineered stones with visually appealing patterns and colours, enhancing the appearance of dams. This beautification aspect not only improves public perception but also promotes tourism by creating visually attractive landmarks.

[0085] The present disclosure preserves natural resources by eliminating the need for quarrying, reduces carbon emissions from material extraction, transportation, and processing, and prevents waste by repurposing materials.

[0086] The present disclosure lowers manufacturing costs of the pitching stones by using recycled materials, and reduces expenses related to transportation, storage, and disposal.

[0087] The present disclosure produces the engineered pitching stones that are strong, durable, and weather-resistant, and suitable for a variety of construction and infrastructure applications.

[0088] The present disclosure reduces carbon footprint, and supports global efforts to combat climate change by lowering emissions associated with traditional methods.

[0089] The present disclosure promotes sustainable development by turning waste into a valuable resource.

[0090] The present disclosure provides cost-effective, high-quality materials for construction projects, benefiting both industry and society.

Claims

We Claim:

1. A method (100) for onsite manufacturing of pitching stones (202), the method comprising:blending (102) at least stone aggregates, crushed sand, a sodium-silicate binder, polymer-based waterproofing agents, and coloured coatings to form a high- performance self-curing concrete (HPSC) composition;assembling (104) one or more molds with predefined dimensions onsite; pouring (106) the HPSC composition into the one or more molds; and molding (108) the HPSC composition for manufacturing a plurality of pitching stones (202) with uniform dimensions and optimized material properties.

2. The method (100) as claimed in claim 1, comprising curing the plurality of pitching stones (202) within the one or more molds to attain optimal structural characteristics of the plurality of pitching stones (202).

3. The method ( 100) as claimed in claim 2, comprising applying an Ultra-Violet (UV) resistant coloured coating (410) onto a surface of the plurality of cured pitching stones (202) to enhance weather resistance, provide UV protection, and improve aesthetics of the plurality of pitching stones (202).

4. The method (100) as claimed in claim 1, wherein prior to molding the HPSC composition, the method comprises vibrating the one or more molds to expel air voids from the HPSC composition and compact the HPSC composition.

5. The method (100) as claimed in claim 1, wherein the plurality of pitching stones (202) is manufactured with an interlocking structure, and wherein the interlocking structure comprises one or more bottom teeth-like projections to facilitate secure anchorage into underlying soil, enhance slope stability, and mitigate a risk of displacement under dynamic conditions.

6. The method (100) as claimed in claim 1, wherein the plurality of pitching stones (202) is manufactured with a cavity (402) between adjacent stones, and wherein the cavity (402) is formed of predefined geometry to facilitate efficient stormwater management and surface runoff drainage, thereby preventing water stagnation and erosion on a dam surface.

7. The method (100) as claimed in claim 1, wherein the plurality of pitching stones (202) is integrated with a hydro-pressure regulator (408) comprising thrust head sections, wherein the thrust head sections are configured to reduce an impact of hydrological forces and stabilize the plurality of pitching stones (202) under dynamic conditions.

8. The method (100) as claimed in claim 1, wherein the plurality of pitching stones (202) is manufactured from the HPSC composition to exhibit resistance to erosion, water penetration, and weathering, and ensure structural integrity of a dam surface.

9. The method (100) as claimed in claim 1, wherein the HPSC composition comprises 20 mm retaining aggregate, 4.5-4.7 mm sand, sodium silicate binder, Polyethylene Glycol (PEG)-400, and Ordinary Portland Cement (OPC) 53 grade cement.

10. The method (100) as claimed in claim 3, wherein the UV resistant coloured coating (410) is at least a silicate-based formulation.

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