AGGREGATES

FIELD OF INVENTION

The present invention is related with the field of construction technology. In particular, to the area of manufacturing tiles/ blocks as construction material. The product of the present invention named as Plastone blocks finds application as structural material in the Construction Industry. Particularly the present invention comprises an improvement/modification of the invention claimed in Indian Patent Application Numbered 201721031514 dated September 06, 2017 titled “A PROCESS AND A SYSTEM FOR MANUFACTURING OF TIEES/BEOCKS FROM WASTE PLASTICS” to which a Complete Specification was filed on August 06, 2018 and granted on 20 ^th August, 2020 with a Patent number IN344670. The present invention relates to a composition for manufacturing Plastone blocks to be used as paver blocks, bricks, table tops, work tops, prefabricated wall structures and hollow blocks from waste material which includes aggregates and waste plastic.

BACKGROUND ART

The main patent or the parent patent application IN344670 discloses process and system for manufacturing of tiles/blocks from waste plastics.

Cement concrete blocks are the extensively used construction materials today for the construction of floor structure. The cement concrete blocks are used as path way blocks, bricks and mainly as interlocking concrete blocks. Present day growth in infrastructure development requires an enormous amount of cement concrete blocks structures for flooring constructions. This in turn increases the requirement of cement for this purpose. The cement manufacturing industry is one of the major contributors for the release of the greenhouse gases like CO2 and others. Contributing to a major environmental problem - global warming (Darius et al., 2012, Proc, of Int. Conf, on Advances in Civil Engineering). Hence there is an urge in finding a suitable substitute/replacement for the cement material in the preparation of cement concrete blocks. Problems related environment does not end here, another major problem raised due to the non-scientific disposal of waste plastics. Today much research is being carried out on using the waste plastics in construction industries. Moreover, use of waste plastics as binder in the construction of pavements is a well-established technology in combination with Bitumen, but usage of only waste plastic with aggregates for preparation of construction blocks is a product yet to be developed and possibility to be evaluated.

IN201621026010 pertains to recycling system for waste plastics for manufacture of pavement and kerb blocks, slabs, bricks and other objects of use. The present invention more specifically takes plastic from disposed off solid waste in dumping grounds or garbage and melts it in a melting unit. This melting unit melts all types and grades of plastic in one molten mass. The present invention categorically makes a composite mixture by mixing the said melted plastic along with sand and crushed stone. Said composite mixture also contains not limiting to ash, gravel, stones, steel scrap, solid plastic scrap, shredded rubber, shredded plastic, coloring agents and other performance, strength, life and quality enhancing elements in various proportions and ratios. The present invention pertains to using the said composite mixture generated for moulding not limited to various shapes and sizes of pavement blocks, kerb blocks, slabs, bricks, and other objects which can be used for household and industrial purpose. The various shapes and objects manufactured from the composite mixture do not pose any health hazard to the consumer and are recyclable as and when desired after use.

US5422051 discloses solid waste plastics incorporated into cementitious building materials containing a binder, of portland cement, said filler is selected from the group consisting of sand, gravel, stone and combinations thereof, said solid plastic materials consist essentially of a mixture of crystalline and amorphous plastic, and said binder and filler are in a volume ratio of between 1:4 and 1:8, binder to filler.

Waste plastics packaging film like PE, PP, PS, mono layer and multi-layer packing materials shows a softening character when the materials are heated around 110° C to 140° C, on getting softened the polymer changes its physical nature from hard into a soft paste like material. The soft, sticky paste behaves as a binder. This process is a novel research finding developed by the inventor and was granted the parent application, Indian Patent No: IN198254. Present invention when higher percentage of waste plastics is used, the molten plastic behaves like a strong binder to keep the aggregates together. The structure formed after compacting the mixture of waste plastics and aggregate at hot condition is called as “Plastone blocks”. Other waste materials like ceramic waste, PET bottles, granite waste and construction debris were also used as a replacement for aggregates either in part or in full quantity. The detailed process is described in parent patent.

Accordingly, the present invention relates to a composition of construction blocks or “Plastone blocks” as a structural material, prepared using the process disclosed in the parent application. The above cited prior art documents, do not however give a detailed study about the products prepared using waste plastics and aggregates - Plastone Blocks

OBJECTS OF INVENTION

Accordingly, it is the primary object of the present invention to provide a composition for making Construction blocks comprising aggregates or conventional aggregates and other raw materials.

It is another object of the present invention to provide a composition for Construction blocks using waste plastics, wherein the construction blocks comprise Paver blocks, bricks, table tops, work tops, prefabricated wall structured and hollow blocks prepared using waste plastics.

It is another object of the present invention to provide a composition for construction blocks, wherein the Paver blocks, bricks, table tops, work tops, prefabricated wall structured and hollow blocks are termed as “Plastone blocks” and prepared from waste plastics and aggregates.

It is another objective of the present invention to provide Construction blocks or Plastone blocks, wherein the waste plastics acts as a binder in the Plastone blocks

It is another object of the present invention to provide Construction blocks termed Plastone blocks made without using bitumen, sand, cement and water.

It is another object of the present invention to provide Construction blocks termed Plastone blocks made up of waste plastics and other solid waste materials only.

It is another object of the present invention to provide a composition of the Plastone blocks comprising of a specific composition of aggregates and waste plastics in a ratio of 100:35 respectively. It is another objective of the present invention to provide Construction blocks or plastone blocks, wherein the Plastone blocks of the present invention can be used as a substitute for cement blocks used in the construction industry.

It is another objective of the present invention to provide Plastone blocks, wherein the Plastone blocks of the present invention reduce the pollution.

It is another objective of the present invention to provide Plastone blocks, wherein the Plastone blocks comprises of usage of waste plastics which and contributes to effective disposal of waste plastics in an eco-friendly way.

It is another objective of the present invention to provide Plastone blocks, wherein the Plastone blocks comprises of high compression strength, bending strength, low water absorption and properties like malleability and ductility.

SUMMARY OF INVENTION

The basic aspect of the present invention is directed to provide a composition for making Construction Block, composition comprising: aggregates or conventional aggregate or other raw materials and waste plastics as binder and other raw materials.

It is another aspect of the present invention to provide a composition for making Construction Block, wherein the composition for making Construction Blocks, wherein the ratio of aggregates to waste plastic is 100: 25-35 by % weight.

It is another aspect of the present invention to provide a composition for making Construction Block, wherein the aggregates comprise of one or more of aggregate stones, crushed rocks granite aggregates, gravel aggregates, limestone aggregates, quarries stones and the like.

It is another aspect of the present invention to provide a composition for making Construction Blocks, wherein the waste plastic comprises of films comprising mono layered, multi layered and MLP’s shredded to average size of 2mm to 4 mm and of Thickness less than 80 microns. It is another aspect of the present invention to provide a composition for making Construction Blocks, wherein the other raw material comprises ceramic waste, PET bottles, and granite waste, lime stone, Bakelite and construction debris.

It is another aspect of the present invention to provide a composition for making Construction Blocks, wherein the aggregates comprise of average particle size of 6 mm to 13 mm.

It is another aspect of the present invention to provide a composition for making Construction Blocks, wherein the blocks comprises paver blocks, bricks, table tops, work tops, prefabricated wall structures and hollow blocks.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FIGURES

The present invention is thus directed to an improvemen t/modification of the invention claimed in Indian Patent Application Numbered 201721031514 dated September 06, 2017 titled “A PROCESS AND SYSTEM FOR MANUFACTURING OF TILES/BLOCKS FROM WASTE PLASTICS” to which a Complete Specification was filed on August 06, 2018 and granted on 20 ^th August, 2020 with a Patent number IN344670.

The terms Construction block and Plastone block are used synonymously in the present invention. Embodiments of the present invention disclose a composition of construction blocks. The construction blocks according to embodiments of the present invention comprises Paver blocks, bricks, table tops, work tops, prefabricated wall structured and hollow blocks prepared from waste plastics and aggregates. Particularly the embodiments of the present invention disclose the composition for Construction blocks which is termed as “Plastone blocks” as it is made up of plastic waste, aggregates comprising conventional aggregates and other raw materials. The blocks derived or prepared by the composition of the present invention are termed as “Plastone” Blocks. Plastone blocks as referred in the embodiments of the present invention are used as construction materials which includes paver blocks, bricks, table tops, work tops, prefabricated wall structures and hollow blocks, prepared from conventional aggregates and waste plastic by a method described in the parent application. The construction blocks or “Plastone blocks”, according to embodiments of the present invention falls under the category of construction materials which includes paver blocks, bricks, table tops, work tops, prefabricated wall structures and hollow blocks, like structural materials developed using waste plastics, aggregates and other waste materials like ceramic waste, PET bottles, and granite waste, lime stone, Bakelite and construction debris. Use of waste plastics as a binder to produce the construction blocks or Plastone blocks was conceived to reduce the use of cement and other binding materials. It is also an object of the present invention to put the waste plastic to a good use.

An embodiment of the present invention discloses a composition for construction blocks comprising aggregates and waste plastics. The present invention discloses a composition for construction blocks comprising aggregates, waste plastics and other raw materials. The other raw materials according to embodiment of the present invention comprises ceramic waste, PET bottles, and granite waste, lime stone, Bakelite and construction debris.

Particular embodiment of the present invention discloses a composition for construction blocks termed as “Plastone blocks”, comprising aggregates and waste plastics in the ratio of 100: 25-35% by weight.

Trials were conducted with different percentage of waste plastics for the preparation of the construction blocks, or “Plastone blocks” using different percentages of waste plastics. Trials as depicted in table 1 below were conducted using % of waste plastic ranging from 5% -45% and aggregates in wt% to make up to 100% composition. Optimum % of waste plastic was chosen based on the Compression strength and bending strength values as presented in Table 3. The prepared Plastone blocks were subjected to various tests like compression strength, bending strength and others as per the IS coding. Trials are illustrated in Table 3.

Table 1. Trials comprising different percentage of plastic waste and corresponding weights of the aggregates (% wt).

From the results of the compression strength and bending strength as presented in Table 3, Trial No 5, 6, with maximum CS and BS obtained it was concluded that the optimum waste plastics percentage (to the weight of aggregate) is in the range of 25 % to 35 % that gives positive results.

The waste plastic as disclosed in embodiment of the present invention comprises of plastic bottles or other plastic goods such as carry bags, cups, thermocoles, multi and mono layered waste plastics, plastic film packaging materials of thickness below 80 microns. The waste plastics used in the present invention works a binder. Waste plastics consists of PE, PP, PS, mono layer and multi-layer packing materials are chosen as it gets soften on heating around a particular temperature range (110°C to 140°C). No toxic gas is released at this temperature and moreover when these waste plastics get softened it has a tendency to behave like a binder. This property of waste plastics is used to coat the aggregate, when then plastic waste is sprayed over the hot aggregate, at around (180°C). The structure formed after compacting the mixture of waste plastics and aggregate at hot condition to a definite shape is called as Plastone blocks. Detailed studies have been carried out in this regard and it was found that the results are positive and the product can be used commercially.

Exemplary embodiment of the present invention discloses a Plastone block comprising of the aggregates and the waste plastic.

Example 1

Weight of the plastic= 1.2 kg

Weight of aggregates = 3.0 kg

Mixed in hot condition at a temperature not more than 180°C

Moulded to square blocks of size 1ft X 1ft X 1 inch They can be used to make Plastone blocks, which can be applied to construction works like paver blocks, bricks, work tops, pre-fabricated wall structures and hollow blocks. The average Compression strength of these blocks will be around 140 N/mm ² and the bending strength is 11.42 N/mm ² .

Plastone blocks can be made in any different shapes and structure depending on the mold used for casting the Plastone blocks. The shape of the construction blocks can be designed as per its application in the construction area. The shapes may be like paver blocks, bricks, work tops, prefabricated wall structures and hollow blocks.

Characterization of the Plastone blocks

The Construction blocks according to embodiments of the present invention can be made of any size and shape.

The Construction blocks are evaluated for various physical and chemical parameters to study the strength and the suitability of the blocks to be used in various applications. Plastone blocks were made using different types of waste plastics and different percentage of waste plastics (Table 1). The prepared Plastone blocks were then subjected to different testing procedures like compression strength (Table 3), flexural strength, water absorption (Table 5) and bending strength (Table 3), to find its suitability to be used as a replacement of concrete blocks. It is observed that the Plastone blocks shows improved test results when compared with ordinary cement and concrete blocks. Observed reports on compression strength (140 N/mm2) and nil moisture absorption for the Plastone blocks are motivating. The Plastone blocks also shows improved abrasion resistance values. Chemical resistance of the Plastone blocks was also found enhanced. All the characterization tests are carried out by following the standard procedures as per IS - 15658: 2006.

TEST PROCEDURE

1. Raw Materials:

A. Aggregate

Size of the aggregate is to be found out by using standard sieves as per IS coding for sieve analysis of aggregates - IS 460 (1962)

Colour - Any colour (Blue, grey or white) - Visual observation Physical properties/ Mechanical Properties

As per IS -2386 - Part 3, 4 and 5 (1963)

B. Waste Plastics

Size of the shredded waste plastics is determined using standard sieves as per IS coding for any sieve standards

Thickness of the waste plastics found using plastic film thickness gauge/thickness meter. There are ASTM standard like D8136 is available for measuring the thickness of the films, but an indigenous thickness measuring meter is sufficient

2. In Process

• Temperature - any IR thermometer may be used for testing the temperature of the heating Cylinder and the molten mix.

• Pressure - For loading purposes, hydraulic loading should be applied with proper load measurement tool. The unit should be in tons/bars.

3. Final Product

• Binding strength - Compression strength using IS 516

• Size measurement - Any measuring scale of IS standards

• Polishing - Any hand polishing machine used for polishing or mechanical polishing

• Appearance - Visual observation

A. Physical Characteristics:

1. Stone aggregate used:

All types of aggregates like Aggregate stone / Crushed rocks / Granite aggregates / Gravel aggregates / Limestone aggregates / Quarries Stones, can be used. Ceramic tiles waste can also be used as a raw material.

Size of the aggregate - sieve size 13.2 mm passing and 9.5 mm retaining.

Color - Any color (Blue, grey or white).

Physical properties- Specific Gravity - 2.0g/cc to 2.5 g/cc

2. Nature of the plastic waste used:

All packaging films (mono layered, multi layered and MLP’s) of shredded size 2mm to 4mm and of Thickness less than 80 microns.

Table 2. Process Conditions Table 3: Compression strength of the Plastone block (as per IS 516) Table 4

B. Composition of Waste plastics and Aggregate:

Waste plastic is used as a binder in the manufacturing of Plastone block.

An amount of 25 % to 35 % of waste plastics to the weight of stone aggregate is chosen after preliminary tests for the preparation of the mix (Table 3).

The composition of the mixture is 100: 25-35. 100 % aggregate and 25 % - 35 % of waste plastics.

ALL TESTS ARE DONE IN ACCORDANCE WITH STANDARD IS 15658: 2006

C. CHEMICAL SPOT TEST (8.1 SEFA 8-2010 GUIDELINES) (Table 5)

Procedure for SEFA 8/2010 Paragraph 8.1 Chemical Spot Test 12 x 12 samples,

Method A&B

Test Method A: Volatile chemicals tested by placing a saturated cotton ball with the reagent in the mouth of 1-oz bottle and inverting the bottle on the surface of the panel.

Test method B: Five drops of non-volatile chemicals of each reagent placed on sample covered with glass, convex side down. Each chemical was left for one hour then washed off with water, cleaned with detergent and naptha and rinsed with deionised water, dried and evaluated after 24 hours at 73+/- 3deg F and 50+/- 5% relative humidity.

Rating Scale: Level 0: No detectable Change

Level 1 : Slight change in colour or Gloss

Level 2: Slight surface Etching of severe staining

Level 3: Pitting, Cratering, Swelling, Erosion of coating, Obvious & Significant Deterioration.

Table 5

Test Result: Tested plastic recycled worktop no more than three (3) Level 3 conditions. Hence it is accepted as per SEFA. Results:

The Plastone blocks made using different types of waste plastics and different percentage of waste plastics were subjected to different testing procedures like compression strength, bending strength (Table 3) flexural strength, tensile strength, abrasion resistance, water absorption (Table 4), to find its suitability to be used as a replacement of concrete blocks. It is observed that the Plastone blocks shows improved test results when compared with ordinary cement and concrete blocks. Observed reports on compression strength (140 N/mm2) and nil moisture absorption for the Plastone blocks are motivating. The Plastone blocks also shows improved abrasion resistance values. The chemical study (Table 5) also shows the Plastone blocks are non-reactive to most of the corrosive chemicals.

Moreover, this process of using waste plastics as a binder is an easy method for the disposal of waste plastics in an eco-friendly way. Waste materials like ceramic reject, construction debris lime stone, Bakelite and granite rejects are used in this process for the production of Plastone blocks.

Another exemplary embodiment discloses the price incurred in manufacturing of a Plastone block of size Iftxlft. x linch

EXAMPLE 2:

Composition of a Block of size 1ft X 1ft comprising 100:25-35% by weight of aggregates and plastic waste.

Aggregate is chosen as Stone aggregate- weight 3 kgs.

Plastics 1.5 kgs

Cost Details in Rupees: Rupees

Cost of Stones 3.00kgs X 0.50 1.50

Cost of Plastics 1.50kgs X 5.0 7.50

(Including evaporation)

LPG Fuel 6.00

Electricity 1.50

Machinery Deprecation 15 Years 1.75

Labor 4X300 = 1200^200 6.0

Maintance 0.25

Contingencies 2.00

Total Rs. 26.50/per block

(when 200 blocks per day is manufactured)

Application of “Plastone Blocks”

• Plastone as Tiles

• Plastone as Table Top

• Plastone as Hollow Blocks

• Plastone as sewage tank covers • Plastone as Rail Sleepers

• Plastone as Speed Breakers

• Plastone as Erosion Prevention Blocks

• Paver blocks

• Pathway blocks

Plastone used for

Construction of Low Cost Toilet and low cost tiles

Solid Waste Management

• Lime Stone, Ceramic Waste, Cable Waste

• Brake Lining Waste, Construction Waste Other Industry Waste

Advantages of “Plastone Blocks”:

• Plastone are structural blocks manufactured using aggregates and waste plastics.

• New effective technique for the disposal of waste plastics in a large scale.

• hirst technology to utilize multi layered films of waste plastics

• Special properties of Plastone block with high compression strengths, malleability and ductility.

• The product paver blocks can be effectively used in laying pathways, parking lots and for other flooring purposes.

• The paver blocks are very strong and can withstand higher compression load, when compared with ordinary cement paver blocks.

• It can be used as replacement for cement concrete blocks.

• Reduction in cost of the product.