Ready Mix Composition Using Waste Foundry Sand
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Solution Overview
Problem
Conventional ready mix compositions for construction have high water demand, poor open time, less pot life, low shear strength, low tensile strength, and poor trafficable time, and rely on natural sand, which is scarce and environmentally harmful to extract, while waste foundry sand is often discarded and poses environmental hazards.
Innovation Solution
A ready mix composition comprising dry waste foundry sand in the range of 20-90% with a binding agent (10-40%), and optionally a polymer (0.1-3%) and filler (2-60%), which is prepared by drying waste foundry sand and mixing it with a binding agent and filler, then adding a polymer to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If natural sand is used in conventional ready mix compositions, then the composition achieves basic workability, but water demand increases and environmental harm occurs due to sand mining
Solution Approach 1:
The patent changes the physical and chemical parameters of the sand by using waste foundry sand instead of natural sand. This substitution alters the composition properties, reducing water demand while eliminating environmental harm associated with natural sand mining operations
Solution Approach 2:
The patent converts waste foundry sand, which is a harmful environmental pollutant from metal casting industries, into a beneficial construction material. This transforms the waste disposal problem into a solution that reduces both environmental harm and water demand in ready mix compositions
2Duration of action of moving object
If conventional ready mix composition is used, then basic construction functionality is achieved, but open time and pot life are poor
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating specific ratios of binding agents (10-40%) and polymers (0.1-3%). These parameter changes extend the open time and pot life while maintaining reliable workability consistency throughout the working period
3Strength
If conventional ready mix composition is used, then basic binding is achieved, but shear strength and tensile strength are low
Solution Approach 1:
The patent creates a composite material system combining waste foundry sand, binding agents, polymers, and optional fillers. This composite approach enhances shear strength and tensile strength by leveraging the synergistic properties of each component while managing composition complexity through defined ratios
Solution Approach 2:
The patent optimizes strength parameters by adjusting the proportions of binding agents (10-40%) and polymers (0.1-3%). These parameter changes directly improve shear and tensile strength while maintaining manageable composition complexity
4Duration of action of stationary object
If conventional ready mix composition is used, then basic application is achieved, but trafficable time is poor
Solution Approach 1:
The patent modifies the time-related parameters by incorporating polymers and binding agents in optimized ratios. These changes extend the trafficable time, allowing more time for construction activities before the mixture sets, thereby reducing construction delays
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition provides improved bond fixing time, trafficable time, tensile strength, shear strength, and longer pot life, while being eco-friendly and reducing the need for natural sand, thus addressing the environmental and performance issues of conventional mixes.
Implementation Method 1
at least one polymer in an amount in the range of 0.1 mass % to 3 mass % with respect to the total mass of the composition
Data Source
AI summary
The present disclosure relates to a ready mix composition. The ready mix composition comprises a dry waste foundry sand, at least one binding agent, at least one polymer, and optionally at least one filler. The present disclosure further relates to a process for the preparation of a ready mix composition and a kit comprising the ready mix composition. The ready mix composition of the present disclosure does not require water for curing, has improved bond fixing time and trafficable time. The composition provides an improved appearance and is eco-friendly.