CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the priority of Indian Provisional Patent

Application No. 3423/MUM/2014, filed on October 29, 2014, with the tile, "A chemical composition for concreting with sea water", and the content of which is incorporated herein by reference in its entirely. BACKGROUND

Technical field

[0002] The present invention generally relates to a cementatious material and particularly relates to a concrete composition. The present invention more particularly relates to a concrete composition comprising fly ash and sodium silicate. The present invention also relates to a concrete composition preparation with naturally available salty water or hard water or sea water.

Description of the Related Art

[0003] Concrete is a composite material composed of water, cement and coarse granular material (fine and coarse aggregate or filler) embedded in a hard matrix of material where cement fills the space among the aggregate particles and glues them together. In modern times, the researchers have experimented with an addition of other materials like water based cross linking polymers to create a concrete composition with improved properties such as higher strength, electrical conductivity or resistance to damages through spillage.

[0004] Concrete consists of aggregate, such as sand, granite chips, cement

(generally Portland cement is used), water, chemical admixtures, reinforcement agents, mineral admixtures etc. The water is combined in an admixture material to form a cement paste by a process of hydration. The aggregate comprises of sand, natural gravel and crushed stone. The reinforcement agent comprises steel bars, steel fibers, glass fiber etc. The chemical admixtures are materials in the form of powder or fluids which are added to the concrete to give it certain characteristics that are not obtainable with plain concrete mixes.

[0005] The water is combined with a cementitious material to form a cement paste by the process of hydration. The process of hydration involves many different reactions. As the reactions proceed, the products of the cement hydration process gradually bond the individual sand and gravel particles and other components together of the concrete to form a solid and homogenous mass. The cement paste glues the aggregate together to fill the voids within it to make it flow more freely. A lower water to cement ratio yields a stronger and more durable concrete whereas more water give a free flowing concrete with a higher slump. Hence optimum water cement ratio as per standard concrete mix design, strikes balance between strength and workability of concrete. Impure water used for mixing concrete causes problems during a setting of concrete or causes a premature failure of the concrete structure.

[0006] Water used for the activity of concreting is required to be of potable quality, as concrete cannot be manufactured without water of potable quality. Water other than that of potable quality contains salts which can affect a durability of concrete and can cause the corrosion of reinforcement in the concrete. The earth contains 75% water and 25% area of land. Majority of the 75% of water is in sea, which is highly saline. The potable water is just 1% and it must be saved. The world is growing and developing at an extra-ordinary pace. These growth measures extensively need concrete and the prime requirement for concreting, brickwork, plastering and flooring is water. As per the records, about 2 billion ton of concrete is produced in world every year. If development of world continues at this speed and acceleration in the coming years, it will consume huge quantum of potable water and as a result, there may not be drinkable water available for public. According to the standards followed across the all world, water to be used for concreting should inevitably be of potable quality. All these facts together indicate that the mankind consumes potable quality water at a very high rate for all purposes including developmental activities. Further it becomes inevitable to save water. Hence there is a need to take effective measure or effective steps to find an alternative resource to replace the potable water in concreting or construction work. [0007] As per the available statistical data, about 2 billion tons of concrete is manufactured all around the world every year. Two billion ton of concrete is equivalent to 2>< 10 ⁹ MT. Density of concrete is 2.4 MT/M ³ . Hence total concreting across the world equates to 2 ^χ 10 ⁹ MT/2.4MT/M ³ = 83,33,33,333.33 M ³ . Cement consumed for manufacturing a normal grade concrete is 400 Kg/M ³ equivalent to 0.4 MT/M ³ of concrete. The cement consumed for manufacturing one year worth concrete is 83, 33, 33, 333 x 0.4= 33,33,33,333 MT. The water cement ratio for manufacturing concrete of normal grade is 0.45. The water consumed for manufacturing one year worth of concrete is 33,33,33,333 x0.45=15,00,00,000 MT i.e. 15 lO Liters of water. Even if it is assumed that 30% of these constructions take place at sea shore or by consuming salty water, the total water consumed for concreting near sea shore is 3 10 Liter. The per capita consumption of potable water per year by normal standard is 150x365=54,750 or 55,000 Liter. Hence a quantity of water consumed for concreting near sea shore is worth consumption of potable water by 5, 45, 45, 454 per year all around the world.

[0008] Our earth comprises of 75% water and a majority of water is present in the sea or oceans. Sea water is the water from sea/ocean. On an average, the sea water in the world has a salinity of 3.5% (35g/L). Hence every kilogram of seawater has approximately 35 grams of dissolved salts. The sea water mainly consists of the chloride salts. The pH of seawater is in acidic range. The sea water mainly comprises oxygen, hydrogen, chloride, sodium, magnesium, sulfur, calcium, potassium, chlorine and carbon. The physio-chemical properties of these components and sea water makes the sea water unfit for consumption in concrete. The sea water or water containing high salts can be actively considered or used as an alternate for the manufacturing of the concrete, as it is present in abundance.

[0009] There are problems posed by the sea water, when the sea water is used in the manufacture of concrete. The sea water primarily contains chloride salts. Further a pH of the sea water is different from that of the potable water. The sea water reacts with the metals because of its chemical characteristics. When the sea water is used in the preparation of the concrete, the sea water reacts with the iron or steel rods or reinforcements. Further the chlorides present in the sea water leads to a corrosion of the steel rods or iron rods. The concrete ages fast and the structure become weak over a period of time. Hence the sea water cannot be directly used for the concrete preparation.

[0010] Fly ash is also known as flue ash. It is one of the residues generated in combustion and comprises fine particles that rise with the flue gases. Fly ash is an industrial waste produced after the combustion of coal. The disposal of fly ash is a challenge. Fly ash mainly consists of aluminum oxide (Α1 ₂ 0 ₃ ), Iron oxide (Fe ₂ 0 ₃ ), titanium dioxide (Ti0 ₂ ), silicon dioxide (Si0 ₂ ) and calcium oxide (CaO). Fly ash also consists of arsenic, beryllium, boron, cadmium, chromium, cobalt, lead, manganese, mercury, selenium, strontium, thallium and vanadium. Fly ash further contains dioxins and PAH compounds. These heavy metals make the fly ash, toxic. Earlier the fly ash was generally released into atmosphere, but a pollution control requirement mandates the capture of fly ash prior to release. In the present day scenario, the fly ash is used to produce hydraulic cement or hydraulic plaster or partial replacement for Portland cement in concrete production. The use of fly ash in the concrete production solves two purposes. The use of fly ash in the concrete production reduces the fly ash in nature, and hence solves the problem of pollution. Further the use of fly ash reduces the cost of cement or concrete production.

[001 1] Sodium silicate is the common name for compounds with the formula Na ₂ (Si0 ₃ )n. Sodium silicate is also known as water glass or liquid glass. Sodium silicate is available in aqueous solution and in solid form. Sodium silicate is also an industrial by product or waste. Sodium silicate is a white powder and it is readily soluble in water and produces an alkaline solution. Sodium silicate finds its applications in many areas, but the application of sodium silicate for treating concrete is well known. Concrete treated with a sodium silicate solution helps to significantly reduce porosity in most masonary products such as concrete, plasters etc. The chemical reaction of cement with sodium silicate binds the silicates with the surface and makes the concrete more durable with water resistance. Sodium silicate is alkaline in nature and hence it increases alkalinity in concrete mass. Also the inert value of sodium silicate is high. The inclusion of sodium silicate in concrete mix increases the alkalinity around the reinforcement steel bars placed inside the concrete. This result's in the protection of the steel bars from corrosion as the reaction from sea water.

[0012] Hence there is a need to develop a chemical composition for utilizing the sea water for concrete production. Also there is a need for a chemical composition utilizing industrial waste i.e. fly ash which has serious disposal problem for concreting with sea water.

[0013] The above mentioned shortcomings, disadvantages and problems are addressed herein and which will be understood by reading and studying the following specification.

OBJECTIVES OF THE EMBODIMENTS

[0014] The primary objective of the present invention is to provide a chemical composition comprising fly ash and sodium silicate for the preparation of concrete mix with sea water or water containing high salts.

[0015] Another objective of the present invention is to provide a chemical composition for making concrete mixture prepared with sea water without changing the basic properties of concrete.

[0016] Yet another objective of the present invention is to provide a chemical composition for preparing concrete mixture with sea water without changing the durability and the property of corrosion resistance to the reinforcement.

[0017] Yet another objective of the present invention is to provide a chemical composition for preparing concrete mixture with sea water with less cost. [0018] Yet another objective of the present invention is to provide a chemical composition for preparing concrete mixture with sea water to save potable water.

[0019] Yet another objective of the present invention is to provide a chemical composition for preparing concrete mixture with sea water to utilize industrial waste.

[0020] Yet another objective of the present invention is to provide a chemical composition for preparing concrete mixture with sea water which is environmental friendly.

[0021] Yet another objective of the present invention is to provide a chemical composition for preparing concrete mixture with naturally available salt water or hard water or sea water which is environmental friendly.

[0022] These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. SUMMARY

[0023] The various embodiments of the present invention provide a chemical composition for preparing concrete mixture with sea water. The chemical composition comprises fly ash and sodium silicate. The chemical composition when added to the concrete mixture makes the concrete and the reinforcement to withstand the reactions of sea water. [0024] According to one embodiment of the present invention, the chloride salts are mainly present in the sea water. The chloride salts have high affinity towards compounds such as A1 ₂ 0 ₃ . The A1 ₂ 0 ₃ is also present in cement which is mainly responsible for its main property of binding aggregates to form a homogenous concrete mass upon its hydration. The chlorides salts present in sea water react with alumina. The reaction decreases the durability of concrete and adversely affects the corrosion process of the steel reinforcements.

[0025] According to one embodiment of the present invention, a chemical composition for preparing concrete mixture with sea water comprises of the following coarse aggregate, fine aggregate, cement, sea water and anti-corrosive and salinity neutralizing agent. The anti-corrosive and salinity neutralizing agent is a physical mixture of a fly ash and a sodium silicate, and wherein the coarse aggregate contributes compressive strength and metal reinforcement contributes tensile strength.

[0026] According to one embodiment of the present invention, the composition comprises of the coarse aggregates in a quantity of 1200 Kg, the cement with a quantity of 400 Kg, the fine aggregates with a quantity of 600 Kg, the sea water with a quantity of 160 Litre and the an anti-corrosive and salinity neutralizing agent with a quantity of 45 Kg.

[0027] According to one embodiment of the present invention, the fly ash comprises of alumina A1 ₂ 0 ₃ (26%), iron in the form of Fe ₂ 0 ₃ (5%), silica Si0 ₂ (55%), Titanium in the form of Ti0 ₂ (1.5%), carbon, calcium in the form of CaO (2%) and magnesium in the form of MgO (1.5%).

[0028] According to one embodiment of the present invention, the anti- corrosive and salinity neutralizing agent comprises of fly ash and sodium silicate mixed in a ratio of 25 :3 , and preferably in a ratio of 90: 10.

[0029] According to one embodiment of the present invention, the fly ash and the sodium silicate are industrial waste. The fly ash is collected from electrostatic precipitator (ESP) of coal fired boilers. Sodium silicate is the industrial by-product.

[0030] According to one embodiment of the present invention, the fly ash resists the chloride attack from sea water on metal reinforcement.

[0031] According to one embodiment of the present invention, the sodium silicate increases the alkalinity of the concrete mass. The sodium silicate protects the metal reinforcement from getting corroded for a long time.

[0032] According to one embodiment of the present invention, a method of preparing concrete mixture with sea water comprises the following steps. The first step is preparing a dry concrete mixture. Further a mixture of an anti-corrosive and salinity neutralizing agent and the sea water is prepared. The next step is mixing the concrete mixture and the mixture of the anti-corrosive and salinity neutralizing agent and the sea water to obtain a homogeneous concrete mixture with sea water. The concrete mixture is casted into a plurality of structures and the strength is analyzed. [0033] According to one embodiment of the present invention, the method of preparing dry concrete mixture comprising the following steps. The first step is mixing cement, coarse mixture and fine aggregate in a pre defined proportion. The cement, the coarse aggregate and the fine aggregate is dry mixed. The amount of coarse aggregate used is 1200 Kg. The amount of cement used is400 Kg. The amount of fine aggregate mixed is 600 Kg. With change in ultimate requirement of strength, this proportion varies accordingly.

[0034] According to one embodiment of the present invention, the method of preparing an anti-corrosive agent and salinity neutralizing agent mixture comprising the following steps. The anti-corrosive agent and salinity neutralizing agent with sea water are mixed in a pre-determined proportion. The anti-corrosive agent and salinity neutralizing agent is a physical mixture of a fly ash and a sodium silicate. The fly ash and the sodium silicate are mixed in a ratio of 25:3, and preferably in a ratio of 90: 10. The anti-corrosive agent and salinity neutralizing agent and the sea water are preferably mixed for 30 minutes.

[0035] The amount of anti-corrosive and salinity neutralizing agent used is 45 Kg in the amount of sea water of 160 Liters. The mixture of the anti-corrosive and salinity neutralizing agent and the sea water is preferably warmed/heated to a temperature of 40°C. The warming/heating removes the limitation of concrete reinforcement corrosion. [0036] The dry concrete mixture and the mixture of an anti-corrosive and salinity neutralizing agent and the sea water are mixed in a rotating concrete mixer for obtaining a homogeneous mixture.

[0037] The 1M ³ of M-20 grade concrete with the anti-corrosive and salinity neutralizing agent and the sea water has a strength of 200 Kg/Cm ² after 28 days.

[0038] The concrete with an anti-corrosive and salinity neutralizing agent and the sea water is casted into plurality of structures. The structures are selected from a group consisting of cubes, pillars and wall.

[0039] According to one embodiment of the present invention, the dry fly ash comprises of alumina as A1 ₂ 0 ₃ (26%), silica as Si0 ₂ (55%), Iron as Fe ₂ 0 ₃ (5%), calcium as CaO (2%), magnesium as MgO (1.5%) and Titanium as Ti0 ₂ (1.5%). Sodium silicate is a single element in the form of Na ₂ Si0 ₃ . Sodium silicate increases the alkalinity of the concrete mass. With higher alkalinity, the corrosion protection for reinforcement bars is increased and the reinforcement bars are effectively protected against their corrosion, which can otherwise be induced with a chloride attack of the sea water. Dry fly ash resists the chloride attack which can affect the durability of concrete with deteriorated hydration of cement in the absence of alumina and sodium silicate improves the alkalinity of the concrete mass and effectively protects reinforcement bars from getting corroded for a long time.

[0040] According to one embodiment of the present invention, the other ingredients of dry fly ash like CaO, MgO and Ti0 ₂ also react with the salts present in the sea water. Ti0 ₂ is having a high molecular weight and hence it contributes more in nullifying the determined effects of salts present in the sea water.

[0041] According to an embodiment of the present invention, a composition is prepared referred to as "CONCARE B- 14". The CONCARE B- 14 is an anti-corrosive and salinity neutralizing agent. The CONCARE B-14 consists of dry fly ash, [collected from Electro Static Precipitator (ESP)] and sodium silicate (Na ₂ Si0 ₃ ). The CONCARE B-14 consists of fly ash and sodium silicate, both of which are industrial waste products. The disposal of fly ash and sodium silicate is difficult according to the rules laid down by the State Pollution Control Board. The dry fly ash is available from the industries having coal fired boilers. The sodium silicate is also available as the industrial by-product. This makes the availability of fly ash and sodium silicate at an economical rate. The CONCARE B-14 consists of fly ash and sodium silicate in the ratio of 25:3 respectively. The CONCARE B-14 is produced by mixing both the fly ash and sodium silicate in the desired ratios, which is at par with the cement. This makes the cost of CONCARE B-14 manufacturing and packaging low.

[0042] According to one embodiment of the present invention, the mixing of CONCARE B-14in sea water prior to its mixing with concrete mass, makes the chlorides of sea water to react with alumina present in CONCARE B-14 and hence its detrimental effects get nullified. When sea water mixed with CONCARE B-14is added in a concrete mixture, there is no detrimental effect of sea water to react with alumina of cement during hydration process. [0043] According to one embodiment of the present invention, the CON CARE B-14 is a physical mix and not a chemical mix. The fly ash in the CONCARE B-14 contains ingredients like A1 ₂ 0 ₃ , Fe ₂ 0 ₃ , Si0 ₂ , Ti0 ₂ , carbon, calcium etc. The sea water contains a majority of chloride salts. Though the chloride provides an early strength to concrete, the chloride deteriorates the reinforcement inside the concrete. Further due to the corrosion and chemical reactions by chlorides of sea water, the concrete deteriorates in the long run. The reaction products generated at the end of the reaction between sea water and CONCARE B 14 are saturated products and do not generate reversible reaction thereby leaving options open for reinforcement corrosion. The sodium silicate is of alkaline nature. The inert value of sodium silicate is high. The purpose of including the sodium silicate in CONCARE B-14 is to increase the alkalinity around the reinforcement steel bars, which are placed inside the concrete element so that the chloride attack does not corrode reinforcement steel of concrete element.

[0044] According to one embodiment of the present invention, the method of preparing concrete cubes with CONCARE B-14 comprises the following steps. The first step is preparing a concrete mixture. The concrete mixture is prepared by mixing cement, coarse aggregates and fine aggregates in a predefined proportion. The cement, coarse aggregates and fine aggregates are mixed in dry state in a container. The next step is mixing CONCARE B-14 with sea water in a predefined proportion in a separate container. The mixture of CONCARE B-14 and the sea water is mixed and preferably kept for 30 minutes. After 30 minutes the CONCARE B-14 mixed with sea water and the dry mixture of concrete mixture are mixed together. The concrete mixture and the CONCARE B-14 mixture is thoroughly mixed in a rotating concrete mixer for obtaining a homogeneous mixture. Instead of concrete aggregates the ready mixed concrete (RMC) is also used. Further when RMC is used, then CONCARE B- 14 is preferably premixed in sea water for 30 minutes. After 30 minutes the CONCARE B-14 is mixed with RMC and mixed in a mechanical stirrer or concrete mixer.

[0045] According to one embodiment of the present invention, 1M ³ of M-20 grade concrete has a strength of 200 Kg/Cm at the end of 28 days after casting with CONCARE B-14 and sea water. The CONCARE B-14 is a physical mixture of fly ash and sodium silicate. The ratio of fly ash and sodium silicate is 90:10 respectively. The amount of ingredients in the concrete mixtures is as follows: coarse aggregates (1200 Kg), cement (400 Kg), fine aggregates (600 Kg), and sea water (160 Liter). The amount of CONCARE B- 14 is taken in an amount of 45 Kg.

[0046] According to one embodiment of the present invention, for obtaining better results the mixture of sea water and CONCARE B-14 are preferably warmed to a temperature of 40°C. The warming of the mixture removes the limitation of concrete reinforcement corrosion and reduced durability on account of salts of sea water. [0047] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

[0049] FIG. 1 illustrates a flow chart explaining a method of preparing the concrete with sea water, according to one embodiment of the present invention.

[0050] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0051] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. The embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.

[0052] The various embodiments of the present invention provide a chemical composition for preparing concrete mixture with sea water or salty water. The chemical composition comprises fly ash and sodium silicate. The chemical composition when added to the concrete mixture, makes the concrete and the reinforcement to withstand the adverse reactions of sea water.

[0053] According to one embodiment of the present invention, the chloride salts are mainly present in the sea water. The chloride salts have high affinity towards compounds such as AI2O3. The Al20 ₃ (Alumina) is also present in cement which is mainly responsible for its main property of binding aggregates to form a homogenous concrete mass upon its hydration. The chloride salts present in sea water react with alumina. The reaction decreases the durability of concrete and adversely affects the corrosion process of the steel reinforcements.

[0054] According to one embodiment of the present invention, a chemical composition for preparing concrete mixture with sea water comprises of the following coarse aggregate, fine aggregate, cement, sea water and anti-corrosive and salinity neutralizing agent. The anti-corrosive and salinity neutralizing agent is a physical mixture of fly ash and a sodium silicate, and wherein the coarse aggregate contributes compressive strength and metal reinforcement contribute tensile strength.

[0055] According to one embodiment of the present invention, the composition comprises of the coarse aggregates in a quantity of 1200 Kg, the cement with a quantity of 400 Kg, the fine aggregates with a quantity of 600 Kg, the sea water with a quantity of 160 Litre and the an anti -corrosive and salinity neutralizing agent with a quantity of 45 Kg. For normal concrete having compressive strength of 200 Kg/CM ² at 28 days.

[0056] According to one embodiment of the present invention, the fly ash comprises of alumina Α1 ₂ 0 ₃ (26%), iron in the form of Fe ₂ 0 ₃ (5%), silica Si0 ₂ (55%), Titanium in the form of Ti0 ₂ (1.5%), carbon, calcium in the form of CaO (2%) and magnesium in the form of MgO (1.5%).

[0057] According to one embodiment of the present invention, the anti- corrosive and salinity neutralizing agent comprises of fly ash and sodium silicate mixed in a ratio of 25 :3, and preferably in a ratio of 90: 10. [0058] According to one embodiment of the present invention, the fly ash and the sodium silicate are industrial waste. The fly ash is collected from electrostatic precipitator (ESP) or from the coal fired boilers. Sodium silicate is the industrial byproduct.

[0059] According to one embodiment of the present invention, the fly ash resists the chloride attack from sea water on metal reinforcement.

[0060] According to one embodiment of the present invention, the sodium silicate increases the alkalinity of the concrete mass. The sodium silicate protects the metal reinforcement from getting corroded for a long time.

[0061] According to one embodiment of the present invention, a method of preparing concrete mixture with sea water comprises the following steps. The first step is preparing a dry concrete mixture. Simultaneously a mixture of an anti- corrosive and salinity neutralizing agent and the sea water is prepared. The next step is mixing the concrete mixture and the mixture of the anti-corrosive and salinity neutralizing agent and the sea water to obtain a homogeneous concrete mixture with sea water. The concrete mixture is cast into a plurality of structures and the strength is analyzed.

[0062] According to one embodiment of the present invention, the method of preparing dry concrete mixture comprising the following steps. The first step is mixing cement, coarse mixture and fine aggregate in a pre-defined proportion. The cement, the coarse aggregate and the fine aggregate is dry mixed. The amount of coarse aggregate used is 1200 Kg. The amount of cement used is 400 Kg. The amount of fine aggregate mixed is 600 Kg for normal concrete having compressive strength of 200 Kg/Cm ² at 28 days.

[0063] According to one embodiment of the present invention, the method of preparing an anti-corrosive agent and salinity neutralizing agent mixture comprising the following steps. The anti-corrosive agent and salinity neutralizing agent with sea water are mixed in a pre-determined proportion. The anti-corrosive agent and salinity neutralizing agent is a physical mixture of a fly ash and a sodium silicate. The fly ash and the sodium silicate are mixed in a ratio of 25:3, and preferably in a ratio of 90:10. The anti-corrosive agent and salinity neutralizing agent and the sea water are mixed preferably for 30 minutes.

[0064] The amount of anti-corrosive and salinity neutralizing agent used is 45 Kg and the amount of sea water used is 160 Liters. The mixture of the anti-corrosive and salinity neutralizing agent and the sea water is preferably warmed/heated to a temperature of 40°C. The warming/heating removes the limitation of concrete reinforcement corrosion.

[0065] The dry concrete mixture and the mixture of an anti-corrosive and salinity neutralizing agent and the sea water are mixed in a rotating concrete mixer for obtaining a homogeneous mixture. [0066] The 1M ³ of M-20 grade concrete with the anti-corrosive and salinity neutralizing agent and the sea water has a strength of 200 Kg/Cm ² after 28 days which is considered here.

[0067] The concrete with an anti-corrosive and salinity neutralizing agent and the sea water is casted into plurality of structures. The structures are selected from a group consisting of cubes, pillars and wall.

[0068] According to one embodiment of the present invention, the dry fly ash comprises of alumina as A1 ₂ 0 ₃ (26%), silica as Si0 ₂ (55%), Iron as Fe ₂ 0 ₃ (5%), calcium as CaO (2%), magnesium as MgO (1.5%) and Titanium as Ti0 ₂ (1.5%). Sodium silicate is a single element in the form of Na ₂ Si0 ₃ . Sodium silicate increases the alkalinity of the concrete mass. With higher alkalinity, the corrosion protection for reinforcement bars is increased and the reinforcement bars are effectively protected against their corrosion, which can otherwise be induced with a chloride attack of the sea water. The dry fly ash resists the chloride attack which can affect the durability of concrete with deteriorated hydration of cement in the absence of alumina and sodium silicate improves the alkalinity of the concrete mass and effectively protects reinforcement bars from getting corroded for a long time.

[0069] According to one embodiment of the present invention, the other ingredients of dry fly ash like CaO, MgO and Ti0 ₂ also react with the salts present in the sea water. Ti0 ₂ is having a high molecular weight and hence it contributes more in nullifying the determined effects of salts present in the sea water. [0070] The various embodiments of the present invention provide a chemical composition for preparing concrete mixture with sea water. The chemical composition comprises fly ash and sodium silicate. The chemical composition when added to the concrete mixture makes the concrete and the reinforcement to withstand the reactions of sea water.

[0071] According to one embodiment of the present invention, the chloride salts are mainly present in the sea water. The chloride salts have high affinity towards compounds such as A1 ₂ 0 ₃ . The A1 ₂ 0 ₃ (Alumina) is also present in cement which is mainly responsible for its main property of binding aggregates to form a homogenous concrete mass upon its hydration. The chlorides salts present in sea water react with alumina. The reaction decreases the durability of concrete and adversely affects the corrosion process of the steel reinforcements.

[0072] According to one embodiment of the present invention, a chemical composition for preparing concrete mixture with sea water comprises of the following coarse aggregate, fine aggregate, cement, sea water and anti-corrosive and salinity neutralizing agent. The anti-corrosive and salinity neutralizing agent is a physical mixture of a fly ash and a sodium silicate, and wherein the coarse aggregate comprises of metal reinforcement.

[0073] According to one embodiment of the present invention, the fly ash and the sodium silicate are industrial waste. The fly ash is collected from electrostatic precipitator (ESP) or from the coal fired boilers. Sodium silicate is the industrial byproduct.

[0074] According to one embodiment of the present invention, the fly ash resists the chloride attack from sea water on metal reinforcement.

[0075] According to one embodiment of the present invention, the sodium silicate increases the alkalinity of the concrete mass. The sodium silicate protects the metal reinforcement from getting corroded for a long time.

[0076] According to one embodiment of the present invention, a method of preparing concrete mixture with sea water comprises the following steps. The first step is preparing a dry concrete mixture. Simultaneously a mixture of an anti- corrosive and salinity neutralizing agent and the sea water is prepared. The next step is mixing the concrete mixture and the mixture of the anti-corrosive and salinity neutralizing agent and the sea water to obtain a homogeneous concrete mixture with sea water. The concrete mixture is casted into a plurality of structures and the strength is analyzed.

[0077] According to one embodiment of the present invention, the method of preparing an anti-corrosive agent and salinity neutralizing agent mixture comprising the following steps. The anti-corrosive agent and salinity neutralizing agent with sea water are mixed in a pre-determined proportion. The anti-corrosive agent and salinity neutralizing agent is a physical mixture of a fly ash and a sodium silicate. The fly ash and the sodium silicate are in a ratio of 25:3, preferably in a ratio of 90; 10. The anti- corrosive agent and salinity neutralizing agent and the sea water are preferably mixed for 30 minutes.

[0078] The dry concrete mixture and the mixture of an anti-corrosive and salinity neutralizing agent and the sea water are mixed in a rotating concrete mixer for obtaining a homogeneous mixture.

[0079] The concrete with an anti-corrosive and salinity neutralizing agent and the sea water is casted into plurality of structures. The structures are selected from a group consisting of cubes, pillars and wall.

[0080] According to an embodiment of the present invention, a composition is prepared referred to as "CONC ARE B- 14".The CONC ARE B- 14 is an anti-corrosive and salinity neutralizing agent. The CONC ARE B-14 consists of dry fly ash, [collected from Electro Static Precipitator (ESP)] and sodium silicate (Na ₂ Si0 ₃ ). The CONC ARE B-14 consists of fly ash and sodium silicate, both of which are industrial waste products. The disposal of fly ash and sodium silicate is difficult according to the rules laid down by the State Pollution Control Board. The dry fly ash is available from the industries having coal fired boilers. The sodium silicate is also available as the industrial by-product. This makes the availability of fly ash and sodium silicate at an economical rate. The CONC ARE B-14 consists of fly ash and sodium silicate in the ratio of 25:3 respectively. The CONCARE B-14 is produced by mixing both the fly ash and sodium silicate in the desired ratios, which is at par with the cement. This makes the cost of CONCARE B-14 manufacturing and packaging low. [0081] According to one embodiment of the present invention, the mixing of CONCARE B-14 in sea water prior to its mixing with concrete mass, makes the chlorides of sea water to react with alumina present in CONCARE B-14 and hence its detrimental effects get nullified and when sea water mixed with CONCARE B-14 is added in concrete mixture, there is no detrimental effect of sea water to react with alumina of cement during hydration process.

[0082] According to one embodiment of the present invention, the CONCARE B-14 is a physical mix and not a chemical mix. The fly ash in the CONCARE B-14 contains ingredients like A1 ₂ 0 ₃ , Fe ₂ 0 ₃ , Si0 ₂ , Ti0 ₂ , carbon, calcium etc. The sea water contains a majority of chloride salts. Though the chloride provides an early strength to concrete, the chloride deteriorates the reinforcement inside the concrete. Further due to the corrosion and chemical reactions by chlorides of sea water, the concrete deteriorates in the long run. The reaction products generated at the end of the reaction between sea water and CONCARE B-14 are saturated products and do not generate reversible reaction thereby leaving options open for reinforcement corrosion. The sodium silicate is of alkaline nature. The inert value of sodium silicate is high. The purpose of including the sodium silicate in CONCARE B-14 is to increase the alkalinity around the reinforcement steel bars, which are placed inside the concrete element so that the chloride attack does not corrode the reinforcement steel of concrete element. [0083] The corrosive action of sea water is mainly because of its lower pH. The pH value of 5.7 in this case corresponds to the free hydrogen ion concentration of the order of 2xlO ^"6 M. The composition of the additive has 2-5% by weight of CaO + MgO and 100% of Na ₂ Si0 ₃ . All of these components are alkaline in nature and can neutralize molar equivalent amounts of free acid present in the medium. The following reactions take place:

CaO + 2H ⁺ ^ Ca ²⁺ + H ₂ 0

MgO + 2H ⁺ - Mg ²⁺ + H ₂ 0

Na ₂ Si0 ₃ + 2H ⁺ ^ Si0 ₂ + H ₂ 0 + 2Na ⁺

[0084] The molar equivalents of the hydrogen ion, the composition takes is between 6.5x 10 ^" M to 6.6x10 ^" M. This is 1000 times more than the amount of alkali required for neutralizing the free acid present in the sea water to make it alkaline. The other oxides present, such as A1 ₂ 0 ₃ and Fe ₂ 0 ₃ are amphoteric or weakly basic. Thus the medium becomes distinctly alkaline and the corrosive action of sea water is nullified. Further, the formation of Si0 ₂ during the reaction is instantaneous and may form a fine coating on the metallic bars thus preventing corrosion.

[0085] FIG. 1 illustrates a flow chart explaining a method of preparing the concrete with sea water, according to one embodiment of the present invention. The first step is preparing a concrete mixture (101). The concrete mixture is prepared by mixing the dry components of concrete. The dry components are cement, coarse aggregate and fine aggregate. The next step is preparing a mixture of CONCARE B- 14 and sea water (102). The CONCARE B-14 is a physical mixture of fly ash and sodium silicate. The CONCARE B-14 and sea water are mixed together preferably for 30 minutes. Further the mixture of CONCARE B-14 and sea water is mixed with the dry mixture of concrete having dry components to obtain a homogenous mixture (103). Casting the homogeneous concrete mixture comprising CONCARE B-14 and sea water into concrete structure and testing for strength (104).

[0086] According to one embodiment of the present invention, it is confirmed that the end products generated after mixing CONCARE B-14 in sea water and concrete mix are not injurious to concrete throughout its functional life. Many field tests are conducted to test the effect of CONCARE B-14 on concrete mixture. Based on the field trials the quantity of the CONCARE B-14 is decided. The field tests and the findings are summarized in the table below:

n y - - - - sea 07- 07- 08- 02- water. 2 201 201 201 201

0 3 3 3 4

18. 24. 33.

88 23 68

J Concr M 25- 01- 12/ 25/ 1 1/ 07/ 12/ 25/ 1 1/ 07/ ete 01- 02- 03/ 04/ 08/ 09/ 03/ 04/ 08/ 09/ cubes 2 201 201 201 201 20 20 20 20 20 20 cast 0 4 4 4 4 14 14 14 14 14 14 with

sea 19 22 45 90 19 22 water 45 90 8 5 day day 8 5 mixed day day day day s. s. day day with s. s s s s s

CON

CAR

E B

11

with

reinfo

rceme

nt

cage

of 8

mm

dia

bars.

24. 22. - - - -

24. 23. 68 62 0.1 0.1 0.2 0.2

37 1 80 55 23 26

K Concr M 30- 06- 12/ 25/ 11/ 07/ 12/ 25/ 11/ 07/ 30/ ete 01- 02- 03/ 04/ 08/ 09/ 03/ 04/ 08/ 09/ 01/ cubes 2 201 201 201 201 20 20 20 20 20 20 20 cast 0 4 4 4 4 14 14 14 14 14 14 15 with

norm 19 22 40 85 19 22 36 al 40 85 3 0 day day 8 0 5 constr day day day day s. s. day day day uction s. s s. s s s s water

of

potabl e

qualit

y with

reinfo

rceme

nt

cage

of 8

mm

dia

bars.

29.

17. 22. 21. 91 0.1 0.1 0.1 0.1 0.1 80 3 82 90 05 91 10 91

Concr M 27- 07/ 30/ 07/ 30/ ete 05- 09/ 01/ 09/ 01/ cubes 2 201 20 201 20 20 cast 0 4 14 5 14 15 with

sea 10 248 10 24 water 3 day 3 8 mixed day s day day with s. s s

CON

CAR

E B

14

with

reinfo

rceme

nt

cage

of 8

mm

dia

bars.

19. 28. 0.1 0.1 18 80 55 91 [0087] The above mentioned table shows the compiled results of the field tests performed with the concrete cubes of standard size and cast with different permutations to check the durability and the reinforcement corrosion. Five sets of concrete cubes have been cast and tested. Five sets of concrete cubes consist of concrete cast only with sea water, concrete cast with sea water and partial CONCARE B-14, concrete cast only with normal water, concrete cast with normal water and sea water mixed in fixed proportion and reinforcement bars and concrete cast with normal water and reinforcement bars. The testing of the concrete cubes is done as per International Standards (IS). The strength of the concrete cubes is tested after 7 days, 28 days, 90 days and 180 days as per IS related to the civil engineering. Accordingly the cubes are tested at pre-defined time intervals. By virtue of the properties, the chloride salts accelerate the process of strength gain of concrete cubes initially for few days. After few days the gain strength decelerates and also starts reducing. The strength in the concrete cube reduces because of the presence of the chloride in water used for the preparation of concrete cubes. The table further illustrates that the strength of concrete cast with normal water have approximately same strength as strength of the concrete cubes cast with sea water and partial CONCARE B-14 even at 180 days. This indicates that the durability of concrete does not get affected by adding CONCARE B-14, even if concrete is cast with sea water. Further half-cell potentiometer test represents corrosion level in reinforcement bars embedded in concrete mass. The results also illustrates that a reading below -0.2 milliohms confirms that the steel is not corroded. This residing for both the cube of concrete cast water and with normal water confirms that the steel inside these cubes has not corroded in both of them.

[0088] According to one embodiment of the present invention, the method of preparing concrete cubes with CONCARE B-14 comprises the following steps. The first step is preparing a concrete mixture. The concrete mixture us prepared by mixing cement, coarse aggregates and fine aggregates in a predefined proportion. The cement, coarse aggregates and fine aggregates are mixed in dry state in a container. The next step is mixing CONCARE B-14 with sea water in a predefined proportion in a separate container. The mixture of CONCARE B-14 and the sea water is mixed preferably for 30 minutes. After 30 minutes the CONCARE B-14 mixed with sea water and the dry mixture of concrete mixture are mixed together. The concrete mixture and the CONCARE B-14 mixture is thoroughly mixed in a rotating concrete mixer for obtaining a homogeneous mixture. Instead of concrete aggregates the ready mixed concrete (RMC) is also used. Further when RMC is used, then CONCARE B- 14 is premixed in sea water preferably for 30 minutes. After 30 minutes the CONCARE B-14 is mixed with RMC and mixed in a mechanical stirrer or concrete mixer.

[0089] According to one embodiment of the present invention, 1M3 of M-20 grade concrete has a strength of 200 Kg/Cm at the end of 28 days after casting with CONCARE B-14 and sea water. The CONCARE B-14 is a physical mixture of fly ash and sodium silicate. The ration of fly ash and sodium silicate is 90: 10 respectively. The amount of ingredients in the concrete mixtures is as follows: coarse aggregates (1200 Kg), cement (400 Kg), fine aggregates (600 Kg), and sea water (160 Liter). The amount of CONCARE B-14 is taken in an amount of 45 Kg for compressive strength of concrete of 200 Kg/Cm ² at 28 days.

[0090] According to one embodiment of the present invention, for obtaining better results the mixture of sea water and CONCARE B-14 are preferably warmed to a temperature of 40°C. The warming of the mixture removes the limitation of concrete reinforcement corrosion and reduced durability on account of salts of sea water.

[0091] The products of the reactions with the additives are silica, water, calcium and magnesium ions which are otherwise also present in the cement which participate in the process of concrete setting. The calcium and magnesium ions after combining with the chloride and sulfate ions present in the sea water (responsible for its acidic character) have the same effect as adding small amounts of calcium sulfate (gypsum) or calcium chloride and similar salts of magnesium. All these reactions products have characteristic of retaining moisture. This helps in slowing down the setting process to a small extent thereby helping in improving the strength of concrete elements.

[0092] The CONCARE B-14 or an anti-corrosive and salinity neutralizing agent is a product obtained by mixing the industrial waste. The industrial wastes such as the fly ash and the sodium silicate have the disposal problem. By utilizing the fly ash and sodium silicate the problem of disposing the industrial waste is tackled.

[0093] The fly ash and the sodium silicate are used to make an anti-corrosive and salinity neutralizing agent/CONCARE B-14. Being industrial waste and abundantly available, makes the CONCARE B-14 cost affective.

[0094] Potable water is extensively consumed and wasted in concreting and other construction activities. The use of sea water as an alternate source will address the problem of potable water wastage and will preserve it for future generations to come. But sea water reacts with the concrete and the iron/steel reinforcements, thereby making the entire structure weak. By using CONCARE B-14, sea water can be used for concreting and construction projects.

[0095] With regard to the product, it is critically calculated and proved that incremental cost of adding the CONCARE B-14 to sea water for making the concrete mixture costs seven Indian rupees (INR 1.50/-) per Kg of cement used for concreting.

[0096] The concrete durability is found to be not affected when the sea water is used along with CONCARE B-14 composition. Also the reinforcement corrosion does not occur when the CONCARE B-14 is used along with sea water to prepare the concrete mix.

[0097] The composition is used effectively for preparing the concrete mixture with naturally available sea water in abundant quantities or naturally available salt water or hard water. [0098] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

[0099] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

[00100] Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims.

[00101] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the embodiments described herein and all the statements of the scope of the embodiments which as a matter of language might be said to fall there between.