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    Date Palm Cement Composition US

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    Rahul Patwal

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    © All Rights Reserved
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    (2) ay a my ow wo ay @ Gn 658) 36) 2n1dionesion AL United States Patent Al-Kutti et al. DATE PALM ASH BAS COMPOSITIONS EDC NT Applicant: Imam Abdulrahmen Bin Faisal University, Darumain (SA) Inventors: Walid AFKuti, Dammam (SA); A. B. M. Saiful Islam, Dammam (SA). Muhammad Nasir, Dasma (SA) Assignee: Imam Abdulrahman Bin Faisal University, Dammam (SA) Notice: Subject to any disclaimer, the term ofthis tended or adjusted under 35, Appl. Now 15/690,890 Filed: Aug. 30, 2017 Im. Cl, cose 1404 (2005.01) Cae 1406; (2005.01) cost 2804 (2006.01), ia ore (CO4B 28704 (2013.01); COB 14041 (2013.01): Cogs L406 2013.01): Coa 2201/52 (2013.01) Field of Classification Search CPC ..... COB 28/04; COMB 14/041; CO4B 14/06 CoaB 2201/52 ‘See application file for complete search history. References Cited USS. PATENT DOCUMENTS. 4105459 481978 Mentn 92014 Waters 1US010221097B1 US 10,221,097 B1 Mar. 5, 2019 (10) Patent No.: (4s) Date of Patent: FOREIGN PATENT DOCUMENTS oN torsieMo B 82015 Wo 201211500 AL 2012 Wo orsoision al 32013 OTHER PUBLICATIONS Al-Kuti We al, “Potential Use of Date Palm Ash in Cement sed Materials, ural of King Sand University Engineering Seienses (2017), pido ny 10.1016 jhe 2017.01.08, pp 16s Awang. He al, “Stongth of Sieve Oaly Ol Palm Ash Farmed Concrete Intrational Journal of Engineering and Technolog, ol 8, No, Supp. 384-357, (Ost. 2016) AlMulali, M.Z. etal, “The Incomporaton of Oil Palm Ash in CConstte sa Mens of Recycling: A Review”. Cement & Concrete Composites, vol 88, pp 129-138, (2015). Karim, MR, etal, "Strength of Conretea Infvened by Palm Oi Fuel Ash, Austaian Journal of Basic and Applied Sciences, vo S.No. 5, pp 990493, 201 * cited by examiner Primary Esaminer — Aathouy 3 Gree. (74) Attorney, Agent, ar Firm —Obloa, MoClelland, Maier & Neustadt, LIP on A conerete or mortar composition including @ a cement ‘ious binder material that comains Poriand cement and 1-50 ‘wt % date palm ash relative to the total weight of the cementitious binder material, (i) a coarse aggregate, (ii) a fine aggregate, and (iv) water, wherein the cementitious binder material is preseat at 200-800 kg perm of the ‘or mortar compesition, ABSTRACT 20 Claims, 6 Drawing Sheets U.S. Patent Mar. 5, 2019 Sheet 1 of 6 US 10,221,097 B1 | Raw Material (date palm waste) Grinding and compressing ——— | Wood production L Burning in oven Fire coal production Residue left Date palm ash formation Fig. 1 U.S. Patent Mar. 5, 2019 Sheet 2 of 6 US 10,221,097 B1 Percent passing (96) os 4 15 2 25 3 35 4 45 Sieve size (mm) Fig. 2 U.S. Patent Mar. 5, 2019 Sheet 3 of 6 US 10,221,097 B1 90 ze 80 = 7 ei) & 2 co 350 3 “eo £0 yk (KOC 5 a sommes 10% PA 030 OL = = 20% PA Zz 020% PA 2 er. eT Age (days) Fig. 3 US 10,221,097 BI Sheet 4 of 6 Mar. 5, 2019 U.S. Patent B Secondary ra N {urw) eo" @ 4 Se eS uopdosqy wnwxeyw 10% PA 20% PA 30% PA aPC U.S. Patent Mar. 5, 2019 Sheet 5 of 6 US 10,221,097 B1 orc. 10% PA 20% PA 30% PA Mixture Fig. 5 U.S. Patent Mar. 5, 2019 Sheet 6 of 6 US 10,221,097 B1 ee PY 100 | 99 98 7 96 95 94 93 92 + a1 ~ : 7 — : o 100 = 200 «300 400-500 G70 Temperature (°C} Fig. 6 TGA (%) US 10,221,097 BI 1 DATE PALM ASH BASED CEMENT ‘COMPOSITIONS STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTORS, Aspects of this technology are deseribed in an article “Potential use of date palm ash in cement-based materials” by Walid AL-Kurti, A.B M.S. Islam, and Muhammad Nasir, in Journal of King Saud University-- Engineering Sciences, 2017, hpsf/do.omy/10-1016)ksues.2017.01.008, which is inconporated herein by reference in its entity BACKGROUND OP THE DISCLOSURE. ‘Technical Pile ‘The present disclosure relates to conerete andlor morta ‘compositions that include cementitious binder material that contains date palm ash, and conerete andlor mortar products made theretiom. Description of the Related Art Te “background” description provided herein i forthe purpose of generally presenting the context of the diselo- sure, Work of the presently named inventors, to the extent it js described inthis background section, as well as aspects of the description which may not otherwise qualify as prior at at the time of filing, are neither expressly or impliedly fdmitted as prior art against the present diselosure Infrastructure development fs resulted in a boom of ‘constriction inthe last few decades around th globe. In this be, cement consumption has become excessive [Gartner E,, 2004, Industral interesting approaches to “low-CO." ‘cements, Cem, Coaer, Res. 34, 1489-1498, incorporated herein by reference in its entity) and the process of producing cement is highly energy consuming and more Importantly it causes excessive emission of greenhouse pases (GHG) into the envizonment [Mo, K. H., Alengaram, ULI, Jumaat, M.Z., Yap, S. B, Lee, 8. C., 2016, Groen ‘concrete partially comprised of farming waste residues: a review. J. Cleaner Product. 117, 122-138. and Blaszezynski ,, Krol, M., 2015, Usage of green concrete technology in ‘iv engineering. Proc. Eng. 122, 296-301. each incorpo- Fatod heroin by reference in its entry) 1s estimated that the manufacturing of | ton of conventional cement releases ‘almost the same amount of carbon dioxide (CO) imo the ‘atmosphere. It is estimated that about 40% ofthe total CO, ‘emitted is emitted during combustion of fossil fuels in the kiln operation the production process accounts for 50% a the CO, emission, and the remaining 10% of CO, emissions results from the tramsportation of cement [Imbabi, M.S. ‘Carrigan, C MeKenna, S., 2012. Trends and developments jn groon cement and concrete technology. Int. 1. Susiain. Built Environ. 1, 194-216. and Huda, M.N., Jumat, M. Z. 1B, Isham, A. B. M.S. 2016. Flexural performance of reinforced oil palm shell & palm oiLelinker concrete (PSCC) beam, Coasts Build, Mater, 127, 18-28,—each incorporated herein by reference in its entirety. In addition, every year nillions of fons of industrial wastes are generated and the majority ofthese wastes are not wllizad, These wastes often ‘euse environmental issues due to storage problems and pollution, For example, local Saud palm waste capacity has ‘exceeded more than 400 million kg with a majority of firmers burning the waste. The anal growth of this waste js estimated to increate a rate of 1.38%, 0 o 2 Using waste materials in concrete as le to considerable cahancements in concrete perormance, polltion reduction, consrtion savings and working conditions [Ahmad R Sumast,M-7. Bal, SIs, ABMS. 20143. Daeg rerformance of lightweight concrete element coming fassive palm sell clinker Const ul Mater 63, 234+ 241; Abmmad, R. Jamaal, M.Z., Babi, S, Islam, A.B. M 8. 2014h, Elect of watercemeat ratios on oil pal sbell (Ges) lightweight concrete for ccotiendly consirition, Int SAdv- Comput Se. Appl. 4 (3), 246-240; Jumaat, MZ Alenuaram,U. 1. Ahmad, R, Babs. S, Islam. A-B.N.S. 2015. Charactrsis of pal il elinker as replaceseat for oil palm sellin Tightwefght conrete subjected to elevated temperature. Const, Build. Mater 1 101, 942.981 Amadh ALA, Ost, A'S, 2016 feet of euring time on steenath development in black coitonsoil—quary tines composite stabilized with cement kin dst (CKD). J. King Sad Univ. Eng. Sci in press): and Ikponmwosa, A. Fapohunda, © Koso, 0., £30, 0. 2015, Stuctural behsviout of bamboo. reinforced” foamed concree slab containing. polyvinyl teases (PW) a6 partial replacement of fine aggregate. King Saud Univ. Eng. Sei. (in press) —each incorporated bercin by reference in its entity. To avoid minimize pollution emused by the use of ordinary Portland cement {0RC) in eoneree and to produce environmental friendly cementitious consiiction materials for sustainable devel ‘pment, atypical cementitious hinder, named “geopoky- ts been developed for OPC substitution which muy require alkali-sctveted palm ol fos ash (POEA), The erm *geopolymer™ wos fist inoxeed by Davidovis etal which is an inorganic matenal having an sbondance of silicon (S aux aluminum (A) [Dovidovis, J, 2011. Geopolymer Chemistry and. applications. Insite Ciéapoiymére, Sai Quentin, Trance incorporated herein by reference in is catirety]. Acconding to the United States Portland Comeat Association, dileent ype of cement production emits CO, in the following order based on tons of cement per tons of Co, emissions (1) Portland coment-1.02, 2) Geo-polymer cesint by slag manulictunng 0308, (3) Geo-polymer cement by-product of slag-0.208 and (4) Fly saad cement-00014 tnten, respectively (Blasezynai, T, Kral M., 2014. Concrete and peablem of carbon dioxide emission reduction, Insultions 3, 28-30, incorporated herein by ‘efeenoe in its entirety}. Further, slam ea. computed the estan ecociency of POPA by varying dosage up to 2586 to OPC concrete and concluded that POFA based concrete performs better than tional OPC concrete with 10% POFA inclusion providing the highest cos and eco- eficieney [slam M-M.U., Mo, K. 11, Alenzaram, U3 Sumsat, M. Z., 2016. Mechanical and ftesh properties of ‘nfainable il palin sell lightweight concrete incoeporsting palm oil fel ash. J Cleaner Product 115, 307-314 Jncorported eren by reference in its entre) ‘Several researchers also. demonstrate that ash-basod cementitious materials prove the same or eter concrete hamiteristies as compared to onfinary Portland cement concrete, in aiion to thir environmental advantages IMujah, D, 2016. Compressive stength and chloride res tance of grout containing ground palm oil fuel ash J CCleaner Product. 112, 712-722 and Ozerkan, N.G., Asan, 1, Mansour, 8, Iyeuga, 8. R, 2013. Mechanical perfor mince and durability of tent! pam fe reinforeed mor tars It. J Sustain, Built Environ. 2, 131-142.—eac incor porad herein by reference in its entirety). For instance, Islam et std the effet of POFA replacement (025%) an i palm shel (OPS) oes and iccanialpropetics of lightweight conerete. They reported highest workability US 10,221,097 BI 3 and compressive strength of concrete prepared with 10% POFA due to packing effect and pozzolanie reactivity, ‘although there was reduction in the pulse velocity, split tensile strength, flexural strength and modulus of elasticity “duet the weak interfacial zone beoween the POFA pariles In tems of durability, Muja etal. evaluated the chloride jon penetration in grounded POFA based grout obtained from fruit bunches and kemels at replacement lovel of (0-409, which cause a eduction of about 30% and 60% in ‘charges passed through those gous, respectively, dv to the ‘ler eet. Previous studies involving palm tes have relied upon waste praduets POFA or OPS sourced osty from Malaysia and Nigeria, with Malaysia being the largest palm il producing country generating. millions of tons of solid ‘wastes knowin as palm ol fuel ash (POF) which is disposed ‘of anaually by pal oil mills all over the couate. Tis a by-product obtained from buming the remaining of ‘exacted palm il fers and shells inthe pal oi mill. This fash, which docs no have suficient nutrients to be usd as 2 ferilizer is dumped in open fields in the viinity ofthe palm cil mils and this bas become a significant pollutant Even though the Kingdom of Saudi Arabia cultivates ‘more than 300 types ef Date Palm tees [Assirey, E. ALR. 2015, Nutitional composition of fruit of 10: date palm (Phoenix dactyliferaL.} cultivars grown in Saudi Arabia. J “Taibah Univ. Sei, 9, 75-79.—incoeporated hercin by refer ‘ence in its entirety], no research has been cari out by the Jocal or international researchers in the atea of construction and building infrastructure using date palm ash (PA). In view of the forgoing, one object ofthe present dsclo- sure isto provide concrete andlor mortar compositions that include a ‘cementitious binder material that contains date tnd concrete and/or mortar prodets made there- irom with advantageous properties, BRIBE SUMMARY OF THE DISCLOSURE According to a fist aspoct, the present disclosure relates to a concrete of mortar composition that inchudes (i) @ ‘cementitious binder material comprising Portland cement and 1-50 w1 % date palm ash relative tothe total weight of the cementitious binder material, (i) a coarse aggregate, il) ‘fine agaregate, and (v) water, wherein the cemeatious binder material is present at 200-500 kg per ay? of the ‘concrete or mionae Composition In one embodiment, the cementitious binder material ‘contains 5-15 wt % ofthe date palm ash relative tothe total ‘weight ofthe cementitious binder materia In one embodiment, the date palm ash contains 30-40 wt éla SiO, relative to the total weight ofthe date pal ash, In one embodiment, the date palm ash contains 10-15 wt % of CaO relative to the total weight of the date palm ash, TInone embodiment, the date palm ash contains 0.1-1.0 1 % of Fe,0, reatve to the total weight of the date palm as, none embodiment, the date palm ash contains 5-10 wt % ‘of MgO relative to the total weight ofthe date palm ash Inone embodiment, te date palm ash contains 0.1-1.0 wt % of ALO, relative to the total weight ofthe date pale a, In one embodiment, the date palm ash has a specific anwvity of 20-25, Tn one embodiment, the date palm ash has @ maximam panicle sizeof less than 0.2 mm. Tn one embodiment, the Portland cement is Ordinary Portland cement (OPC) Type I Tn onc embodiment, the weight rato of the Fine aggregate to the coarse aggregate is in a range of 05-08. 4 In one emboxtiment, the coarse aggregate has particle si ‘of 3-25 mm, and the fine aggregate has a particle size of less than 0.5 mm. Tn one embodiment, the courte aggregate is crushed limestone and the fine aggregate is dune sand. Tn one embodiment, the weight ratio of the water to the ‘cementitious binder material is 0.2.0.6. In one embodiment, the cementitious binder material contains 5-15 wt % ofthe date palm ash relative to the foal ‘eight ofthe cementitious binder material, and has at least ‘one selected from the group consisting of a) a 3 day compressive strength of 35-50 MPa after setting, (b) 8 28 day compressive strength of $6.60 MPa after scting nd (c) 11360 day compressive strength of 83-90 MPa afte setting, In one embodiment, the cementitious binder material ‘contains 5-15 wt % ofthe date palm ash relative to the total ‘weight ofthe cementitious binder material, and has atleast ‘one of (a) @ maximum inital rate of water absomption of (0.25.0.72 mms afer setting and (b) a maximum secondary rae of water absorption of 1,75-2.25 mis after setting, Tn one embodiment, the cementitious binder material contains 5-15 1 % ofthe date palm ash relative to the total weight of the cementitious binder material, and hay aa average eliloride permeability of 2,000.3,500 coulombs aller setting According (0 second aspect, the present disclosure relates toa cured conerete or mortie product containing the ‘composition disclosed herein, in one or more of its embod seals, in cured form, ‘In one embodiment, the cementitious binder materi contains 5-15 wt % ofthe date palm ash relative to the total ‘weight ofthe cementitious binder material, and has atleast fone of (a) 13 day compressive strength of 35-50 MPa, (b) 428 day compressive strength of 5660 MPa, and (c) 2 360 day compressive strength of 83-90 MPa In one embodiment, the cementitious binder material contains 5-15 wt % ofthe date palm ash relative to the total ‘weight ofthe cementitious binder material, and has atleast ‘one of (a) 4 maximum inital rate of water absomption of 025.0.72 mas, (b) & maximum secondary rate of water sasorpion of 1.75-2.25 mums, and (c) un average chloride permeability of 2,000-3,500 coulombs. ‘The foregoing paragraphs have been provided by way of genera introduction, and are not intended to limit the scope Of the following claims. ‘The described embod together with farler advantages, wll be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS A more complete apprevition ofthe disclosure aod many of te altendant advantages thereof will be readily obtained fas the same becomes better understood by reference to the following detailed description when considered in eonnee- ‘ion with the aceompanying drawings, wherein: FIG. 1 isa flow diagram showing the stages of production of date palm ash (PA), wood and coal from the raw material FIG. 2 is & graph ilustrating the sieve analysis of date pal ash and sand, FIG. 3 is a graph illus vavious mortar mixtures FIG. 4 is @ graph illestrating maximum initial and sec ondary rates of water absorption in concrete samples FIG. Sisa graph illustrating the number of charges passed ‘through various conerete mixtures using RCPT ing compressive strength in US 10,221,097 BI FIG, 6 sa graph illustrating the TGA curve of OPC and PA pastes at 90 days DETAILED DESCRIPTION OF THE EMBODIMENTS, Embodiments of the present disclosure will now be described more fully hereinafter with relerence 10 the accompanying drawings, in which some, but not all of the ‘embodiments of the disclosure are show. ‘As used herein, the woeds “a” and “an and the ike cary the meaning of “one or more”. Additionally, within the description of this disclosure, wiiere @ numerical limit oF range is stated, the endpoints are included unless stated ‘otherwise. Also all valves and subranges within a numerical for range’ are specifically included as if explicitly ‘As used herein, the terms “optional” or “optionally” means thatthe subsequently described event(s) ean or can- not occur or the subsequently described eomponent(s) may ‘or may not be present (eg. 0 wt %). ‘The term “comprising” is considered an open-ended term. synonymous with terms such as including, containing oF having and is used herein to describe aspocts ofthe invention ‘which may include additional components, functionality ‘andor stricture, Terms such as “eorsisting essentially af” are used to identily aspects ofthe invention which exclude particular components that are not explicitly recited in the ‘laim but would othersvise havea material eect onthe basic and novel properties ofthe conerete or mortar composition in cithera dry, wet or cured form. Basic and novel properties ‘of the present dislosure include the strength such a8 come pressive sirongth, curing time, slump time, and viscosity. The term “consisting of” describes aspects of the invention in which oaly those features explicitly recited in the claims are included and thus other components not explicitly oF ‘inherently included in the claim are excluded. ‘As used herein, the tem of phrase “cement” of “cement binder” refers to composition or substance with one oF more constituents that is capable of binding. materials together, once set. Generally, cement can include a number ‘of dry constituents chosen based on the deste ratio oF lass ‘of cemeat to be prodiced. Thus, cement refers to the dey. pre-tet composition unless the context clearly dictates oth- ‘eovite. The phrase “cemenitious binder material” refers to materials oF mixtures of materials that are “ements” of materials that are capable of fo ‘capable oF sition (eg, calcium hydroxide) at ordina Tom compounds possessing cemetitions properties. For ‘example, pozzolans (eg. fly ash, silica fame from silicon ‘melting, highly resctive meiakoolin) and bumed organic matter residues e.g date pal ash) fll in tis estegory, and temperature to ‘are therefore considered to be components of the vet tious binder material of the present disclosure. That sy pozvolans andor some burned organic matter (eg. date palm ash) are not considered “ements” in tho. present ‘disclosure, but can be mixed with cements to form “Cemen= titiows binder materials” ‘A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the Tormulation or composition ia Which the component is 0 o Uundestoud at this pereenage is in relation to @ wal tonal percentage of HX Further with respect 0 cementitious binder material the dry weight basis sed, the wt Yedacs aot include any water add os the cementitious binder material. With respect othe total con- Crete of mortar composition, the content of various compo- Dents may be expressed in forms ke of Sai component per ‘of th toll concrete Or mortar composition, and hecase te concrete or mortar composition includes water, the content recited as kgin™ isin tenms of w wet bast (he mount of water is ineluded) "According to ist spect, the preseat disclosure relates to.aconerete or mortar composition that comprises, consists essentially of, or consists of (i) a eementitonsbinde Fal comprising Porland cement and date palm ash ours agarose, (it) ine agaregate, and (x) wate The cementitious binder material herein includes at least one cement For example, tie cement muy inlade hydraulic coment, non-hyaralis eoment ra combination threo. In {prefered embodiment, the cement comprises Portland ment basic ingredient of concrete, mortar tic, ad onspecalty grout which isa fine powder, produced by heating limestone and clay minerals in kilt Form clinker, arinding the efinker, and adding small amounts of other materials. Several iypes of Portland cement. may be employed herein, for example, Onlnary Pordand Cement (OFC) wpe, Wpe Tl pe Til, ype IV or ype Voor a combination thereof (ia azeorlance with the ASTM C150 Stundard)-Porand Cement ype la, type Il, andor type Ila ‘may lt be used, which have the same composition a iypex [VIL snl excep that an ai-otmising agent i ground nto the ain (also in accord withthe ASTM. C150 standaed), Adina cement types inlule hydrulic cements, nox lydealie cement, Pordand fly ash cement, Poland Poze olan cement, Portland silica fume cement, masonry Cements, morars, FMC cements, stceos, plastic coments, expansive cements, W line ements, sloglime cements, supesulate coment, calcium minute cements, calcium sblfoluminste cements, geo polymer cements, Rosendale cements, polymer cement mor far. lime morur, andor Pozzolana momar. In one emiboie ‘nt, the cement comprises a cement blend of to er moze ‘ypes of cemest for example a bead comprising Prd cement and non-Portand hydraulic cement. In further embodiment, the eement sn the dry form I nceded 0 se ‘waters typically added afer the cement is mixed withthe ter componentsingrediats, for example, the date pln as, and the coarse and fine aggregete, and iis then ready to be hardened oF st Any amount of cement may be incorporate into the concrete or mar compositions herein, however type mounts range, from 200-400 kyl or 310-380 kat, oF 220-360 kim, oF 230-340 kgm’, or 240-320 Kyla or 245.315 kgm, or 260-310 kal ofthe conerete or mortar eompositon oe 1030 wt 12-28 Wt, 14-26 We, 15-24 ‘W196, 16-2 wt %, 17-20 wt % based onthe oa weight oF te eonerete or mortar composition depending onthe par ticular application (eg. light ¥s. normal conetete) (wet basi), Ta the most profere embodiment, thecament is Oia Portland cement (OPC) Type “The cementitious binder material, in adit to at lest fe cement, also inches date pal ash, Date palm ash sa ‘terial produced from the process of recycling local pan cr from fuming Jead pat fronds refered to heally as US 10,221,097 BI 1 “Taban" from palm plants sueh as those located in the ‘eastem province of Saudi Arabia, Ia these regions, local palm reeyeling produces two commercial products: palm- based firewood and coal. The process of manufeturing palm firewood and coal includes several stages such as 1) btain- fing the row palm plant/frond material 2) initial grinding 3) final grinding 4) drying 5) pressing to form fiewoos! 6) ‘converting. firewood into coal through environmentally {iendly oven heating and 7) cooling to provide the coal (see FIG. 1). Date palm ash (PA) (aso called “palm ash") is produced as wastage during the production of these palm Frevood and coal produets during oven deying/heating steps foe $-10 hours, oF 5-9 hours oF 6-8 hones, o¢ 7 hours from the raw materials or from the conversion of firewood into eos. This date palm ashis used herein as partial replacement of cement (@ Portland cement) as the cementitious binder The process for producing date palm ash therefore differs from methods used to mike oil palm shell (OPS), which is a waste product from the palm il extraction process using fresh fruit bunches (FFB), and palm vil fuel ash (POFA), also refered to as oil palm ash (OPA), which involves burning palm oil shel and husk (palm oil empty fruit bunch) sfc! ina palm ol mill boiler inorder to prodice steam to generate electricity for the palm oil extraction process Instead of using conventional fuels. ‘The cementitious binder material ofthe present disclosure ‘contains 1-50 wt %, preferably 2-45 w 9%, preferably 4-40. wt %, preferably 5-35 wt %, preferably 6-30 w %, prefer ably 7-25 w1%, preferably 8-20 wt %,proferably 9-18 wt 9%, preferably 10-15 wt % date palm ash relative to the toal ‘weight ofthe cementitious binder material (dry hass) Ina preferred embodiment, the cementitious binder material ‘Contains §-15 wt Ma the date palm ash relative tothe total ‘weight ofthe cementitious binder material, This equates to fn amouat of date palm ash of 20-150 kg/m’, or 20-150 ulm’, or 20-150 ky/an' oF 20-150 ky’, or 20-150 ky’, ‘oF 20-150 kg/m’, of 20-150 kg/m’ ofthe conerete or mortar ‘composition (et basis) “The componition of date palm ash can vary depending on the source of date palms, and the conditions under which the date palms were growa, for example, the types and amount ‘of fenilzers can affect the chemical make-up (eg. the amount of K,0). However, in a preferred embodiment, date palm ash suitable for use in the present diselosure comprises ‘least one ofthe following chemical constituents, prefer- ably thee or more ofall ofthe following chemical consti ‘ents, most preferably all ofthe following chemical eonstit- ‘ents as determined by well-aecepted standard ASTM C114, ‘each by weight relative tothe total weight of the date palm ah: 30-40 wt % SiO, preferably 31-40 wt % SiO,, preferably 32-40 wt % SiO., preferably 33-0 w % SiOx preferably 34-40 wt % SiO, preferably 35-40 wi % SiO, or most preferably about 3593 wt % SiO: 0.1-1.0 wt % of Fe,O,, preferably 02.0.95 wt % of Fe,0,, preferably 03-09 wt % of FeO, preferably 0.4- (O85 wr % of Fe,0y, preferably 0.5-0.8 wi % of Fe,Oy, oF most preferably about 0.79 wt % of Fe,Ox: 10-15 w.% of CaO, preferably 10.5-145 wt % of C20, preferably 11-14 wi %of CaO, preferably 115-13.9 wt % oF CaO, preferably 12-13.7 w1 96 of Ca, preferably 12.5-13.5, swt Yo of CaO, preferably 13-134 wt % of CaO, oF most proferably about 133 wt % of CaO; (0.1-1,0 wt Y6 of AlzOs, preferably 02-0.9 wt % of ALLO, preferably 03-0.8 wt % of ALO,, preferably 0.4-0.7 wt % of ALO, preferably 05-068 wi % of Al:Os, oF most preferably about 0.65 wi % of ALO,: 0 o 8 5-10 wl % of MgO, preferably 54-9 wt % of MgO, preferably 5.6.8 wt % of MgO, preferably 58.7.5 wt % of MgO, prelerably 6.07.0 wt % of MgO, preferably 6.2-6.5 ‘wt % of MgO, or most preferably about 6.36 wt % of MgO: 210 Wt% of K,O, proferbly 3-9.5 wt % of KO, preferably 4.9 wt % af KO, preferably S-8.5 wt 9% of K.0, preferably 6-8 wt % of KO, preferably 7-7.5 wt % of KO, for most preferably about 7.4wt % of KO: and 1-5 wt % of Na,O, preferably 15-45 wt % of Na,O, preferably 2-4 wt % of Na,O, preferably 2.5.3.0 wi % of 1Na,O, preferably 33.8 wt % of Na,0, preferably 3.5:3.7 wt %% of Na,O, oF most preferably about 3.6 wt % of No.0. In an alternative emboctiment, the date palm ash com- prises at least one of the following chemical constituents preferably three or more of all of the following chemical constituents, most preferably all of the following ehemieal ccnstituents as determined by well-accepted standard ASTM C114, each by weight relative to the vtal weight of the date poly ash 40-55 wt % SiO,. preferably 41-54 w % SiO,, preferably 42-53 wt % SiO, preferably 44-52 wt % SiO, proferably 46-51 wt % SiO, preferably 48.50 wt % SiO,, or most preferably about 48.04 wt 9 SiO. 1.5.3.0 1% of FeO, preferably 1.7-2.9 wt % of Fe,Oy, preferably 1,-2.8 wi % of Fe,Oy, preferably 2.1-2.7 wt % Of Fe.Oy, preferably 23-26 wt % of Fe,O,, oF most preferably about 2.51 wt % of Fe,O,3, 10-15 «1% of CaO, preferably 105-149 wt % of CaO, preferably 115-148 wt % of Ca, preferably 12-14.7 wt % of CaO, preferably 125-146 wi % of CaO, preferably 13-145 wt % of CaO, preferably 13.5-14.4 wt % of CaO, or most preferably about 14.2 wt % of CaO: ‘55-7 wt % of AL,Os, preferably 5.6-6:8 wt % oF ALO, preferably 57-6.6 wt % of AL,O,, preferably 58-64 wt % Of Al,O,, preferably $.9-6.2 wt % of ALO,, oF most pref erly aout 6.12 W196 oF ALO: 4-6 wt % of MgO, preferably 42-58 wt % of MgO, preferably 43.5.6 wt % of MgO, preferably 4.45.4 wt % of MgO, preferably 45-52 wt % of MgO, preferably 4.6-5.0 ‘WI % af MgO, of most preferably about 488 w1 % of MgO; Let wt % of KO, prefembly 153.6 wt % of KO, preferably 23.2 wi % of K.O, preferably 22-3.1 wt % of KO, preferably 2.43.0 wt % of KO, preferably 2.6-2.9 wt ‘of KO, of most preferably about 2.8 wt % of KO, and 05-3 wt % of Na,O, preferably 1-28 we % of No.0, preferably 1.2-2.6 wt eof Na,O, preferably 14-2.4 wt % of 1Na,O, preferably 1.6-2.2 wt % of NaO, preferably 1.7-2.0 ‘W186 oF NagO, oF most preferably about 81 wt % of NAO, ‘The loss on ignition (LOM) of the date palm ash used Jperein is less than 10%, preferably less than 9%, preferably Jess than 8% by weight based on a total weight ofthe date palm ash, and thus is generally considered acceptable for use fn the cementitious binder material, ‘The date palm ash employed inthe present concrete and mortar composition therefore differ. considerably Irom other products prodaced fom palm-based plants, such as palm oil products, palm oil fuel ash (POFA) and oil palma ‘hell (OPS), as well as other conventional pozzolanie mate- Fials such as fly ash, in teams of type and amounts of chemical constituents (Michael Yong. ing Liu, Choon Peng Chua, U, Johnson Alengsram, and Mohd Zamin Jumact, “Utilization of Palm Oil Fuel Ash as Binder in Lightweight Ci Palm Shell Goopolymer Concrete.” Advances in Mate- rials Science and Enginccring, vol. 2014, Ancle ID 610274, 6 pages, 2014; H. Awang and M. Z. Al-Mulali “Strength of Sieved Only Oil Palm Ash Poamed Concrete” Interational Journal of Engineering and Techoolowy, Vol. 8, No. 5, 2016; US 10,221,097 BI 9 Mohammed Zabear Almulali, Hanizam Awana, H. B.S [Abdal Khlil, Zaid Shaker Aloumlly "he incorporation ‘il palm sh in concrete a a means of reyclng: A review Cement & Concrete Composites 55 (2015) 129-138; and Mai Rezaul Karim: M. FM. Zain: M. Jamil; Md, Nozml Islas “Strength of Cnercte a Infcaced by Palm Oil Fel Ash" Ausizalian Joumal of asic and Applied Sciences, 5 (5): 90.997, 2011 cach ncorporte herein by reference in its enizety) in particular, the amounts of each of SiO. CaO, Fe,O,, MgO, ad Al,Oy none embodiment, the date palm ash as a pectic sri (he mati of density of date palm as to the density ‘of water at am and 4° C.) of 20-25, preferably 2.1-2.49, preferably 22.248, preferably 23-2147, most preferably 242.46, rts: the date palm ash used inthe conerete and mortar ‘composition described herein ass through a 425 um sieve, preferably throug a 40 un sieve, preferably though a 380 Jum sieve, preferably through a 300 um sieve, preferably through 8 200 yn seve, preferably though a 180 um sieve, and therfore have a maxims pats sie of less than $25 jum, es then 400 in, fess tha 380g ens tha 3080 jon, fess than 200 jus, preferably est than 150 un, of most preferably less than about 149 pm. “After forming the date palm ash or obtaining the date palm sh from te process vutined eae, the date pal ash may be chemically mex! o. change its properties or “oetivate it binding properties, For example the dat pam ash may be teat with a hydroxide bse sch as sim or potassium hydoxide, tated with mineral aid seh as FCI, sulfa ci, andlor nite sci, rated with an organic id sich as citi aid, omic aid, aetc seid oxalic sci fn the like, or oxidived with a strong oxidant sich 98 2 peroxide, ozone ae coro discharge applications Tn aikiion to the coment and the uate pana, other pozolaie materials may optionally be included in the ‘csmentitiows binder material inchuding Timeston, iy ash (Ge. silicoons fly ash or ealeareous AY ash), ground blast frase slag (GOBES oF GGRS), silica fase, etki, carbon nanofibers and carbon pro's. Such additional Pozolani materials may optionally be added 9s 9 pail Feplacemeat ofthe coment component upto about SOW %, up to 40 wt %, up © 30 We %, up 0-20 wt %,up Wo 10Wi 26, up to Sw 2 up wo Lt Me eelative fo the total weight of he coment (eg Pordanal cemeat). ‘hen the cement (eg. Porland cement) and the date palm ssh ae mixed together, slong with any’ other optional Ingredient to form the comentitous binder material, ssid ‘eementtions binder materials present at 200-500 kg perm? of the cogerete or mortar composition, preferably 200-500 ke perm preferably 225-475 hy por preferably 250- 450 kg por m’, preferably 275-425 kg per m’, peferbly 300-400 ks pers", prelerably 325-375 ky perm’ oF most proferably about 380 kg perm? ofthe coneste or morte ‘omposiion Ta one embodiment, the cementitious binder material ‘consists of cement (eg. Ontinary Portland cement type 1) fnd the date palm ash. Inone embodiment, the cementitions binder material and therefore the eonerete or morte positions, ae few of other products produced from date Pali plants icloding pale fel ash POFA) and ol pln Shell (OPS) “The use of date palm ash as a patil replacement of coment (i. Portland coment) in accordance withthe meth- ‘ods and compositions of the present disclosure not only Provides concrete ad mortar compositions and eure cone ‘rete and mortar prodoct (cured peel ors) with advan 0 o 10 tagcous properties as discussed later, but the use of date palm ast abo redvees the high CO, emissions generated during. manufacture of cement and enables recycling of byproduct with otherwise limited uty (date pal ash. “The concrete oF mortar composition of the present di closure includes a coarse aggregate. Coarse aggregates are ‘used to influence the conetete's freshly mixed and hardened properties, mixture proportions, nx exonomy of proucing. ‘The types and amounts of coarse aggregate can be varied depending on the application, For example the type and amount of coarse aggregate can be varied (0 produce a lightweight eoncrete with bulk density commonly less than about 1480 kg/m, a normal weight concrete with a bulk density of about 1500-2400 kg/at® (ASTM. C33), or a heavyweight conerete with a bulk density of grenter than 2400 ka/m® (ASTM C637 ane C638). Typically, the coarse ‘aggregate has patcle size 3-25 mm, preferably 5-24 mm, preferably 7-23 mm, preferably 10-22 mm, preferably 13-21 am, preferably 16-20 mm, preferably about 17-19 mum, although coarse agaveuats wih parle size slghly above for below these values (4/-2 mm) may also function as intended. The grading of coarse agaregate employed herein preferably conforms to the standard ASTM C33 witha Size No 56. ‘Exemplary course aggregates include crushed recycled concrete gravel, rocks, natural soil, quarried erushed min- «ral aggregates from igneous (granite, syenite, dort, gab- bm periotite peamatite, voleanie glass, felsite, basalt), metamorphic (marble, metaquarte, slate, pyle, shi amphibolite, horafels, gneiss, serentte) or sedimentary rocks (conglomerate, sandstone, elaystone, siltstone, ang ite, shale, limestone, dolomite, mar, chalk, cher) include ing unused and waste aggregates from quarry operations, dredged aggregates, china clay stent, china lay wastes, natural stone, recycled bituminous pavements, reeled eon- cree pavements, reclaimed rad base and subbase material, crushed bricks, consttion and demolition wastes, was recycled flve gas ashes, crushed glass, sate waste, waste plastics, eug shells, seashells, barte, Himonite, magnetite AImenite, hematite, ion, see, including reveled or serap steel, and mixtures thereof. In one embodiment, the coarse ‘garegate js limestone, preferably enusbed limestone. The crushed limestone van be made by crushing, arinding pulverizing, etc. any natural limestone oF reeycled. lime: Stone. The amounts of coarse aggregate deployed herein ay vary, at typieal values range Between 600-1500 kx per ‘of the coneete or morar composition, preferably 610- 1,400 kg perm, preferably 620-1,300 kg perm’, preferably 630-1,200 kg perm’. preferably 680-1,100 kg per m preferably 650-1,100ke perm, preferably 660-1,110ke per ‘n° of the concrete or morar composition, or 3-80 Wt" preferably 36-75 wt 9%, preferably 37-70 wt %, preferably 53868 wt %, preferably 39-60 wt So, preferably 40-80 wt ‘or most preferably 41-46 w %, relative to the total weight of the conerete and mortar composition. The conerete and mortar compositions of the present disclosure include a fine agaregate, The fine agaregates herein may be sand, blast furnace granulated slg, andlor crushed/pulverized stone or rock made from, materia Aeserbed for use as the coarse aggregate. In the event & coarse agarezate and a fine aggregate are used in the concrete of mortar composition thats sourced fom the same material, for example, crushed limestone, then the parle size will dictate whether i is defined as coarse oF fine aggrevat. in a preferred embeiment, the course and US 10,221,097 BI uw the fine aggregates employed are diferent material, for ‘example, the course agarepate is crushed limestone, and the fine aggregate is sand, Inne embodiment, the ine aggregate has a panicle size ‘of les than 0.5 mm, preferably less than 0.48 mm, prefer ably less than 0.46 mam, preferably less than 0.44 mm, preferably less than 0.42 mm, preferably less than 0.40 mm. In some embodiments, the fine agaregate may be passed through sieve No. 100 to provide fine aggregates with panicle siz of no more than 149 um, no more than 130 pa. no more than 120 um, or no more than 100 pn. In one ‘embodiment, and the fine aggrepate is dune sand. ‘The amounts of fine aggregate deployed herein may vary, but typical values range between 400-700 kg per m’ of the ‘concrete of mortar composition, preferably $10-695 kx per 1m, preferably 420-690 kg per 0", preferably 4304685 kg per m’, preferably 40-680 kg per m", preferably 450.675 kg per m’, preferably 460-673 kz per m’, prelerably 448- 672 ke per m" of the concrete or mortar composition, of 20-40 wi %, preferably 22-38 wt %, preferdbly 24-36 wi proferably 26-34 wt %, proforably 27-32 wt ®%, oF most preferably 28.31 wt &%, relative 10 the total weight of the [Conerste ad mortar composition, Inone embodiment, a weight ratio ofthe fine apgregate to the coarse aggregate is in a range of 05.0.8, preferably (0,55-0.76, preferably 0.60.72, preferably 0.65.07, or most preferably about 0.667 “The conerete and mortar compewition als includes water. Jn one embodiment, the weight ratio of the water to the ‘cementitious binder material (wiem) is 02.0.6, preferably (025-055, preferably 03.0.5, preferably 0.35-0.45, prefer- ably about 0.4. However, a person of ordinary skill ean adjust the water content of the conerste oF mortar compo- sitions as needed (© suit the application or workability Fesjirements, and the w/em weight ratio may therefore fall ‘outside of these described ranges, Suitable water sources inchide fresh water, potable water, seawater, and the like. In some embodiments, the disclosed concrete of moetae ‘compositions optionally comprise at least one additional Ingredient, such as an accelerator, a retarder, a plasticizer, 9 superplasticizer, a pigment, cormsion inhibitor. and bonding agent, including mixtures thereof. The additional Ingredien(s), when present, may be present in an amount up to 10. %, preferably up to 8 wt %, preferably up to 6 wt %, preferably up to 4 Wt %, preferably up to 2 wt %, preferably up to 1 w %, preferably up to 0.5 wt % based on the total weight of the cementitious binder material. For ‘example, if 100 kg of cementitious binder material is pres ‘ent, for 3.5 wt%or the addtional ingredients), 3.5 kgof the ditional ingredient(s) is present regardless of the other ‘components. In still a Jurther embodiment, the disclosed ‘conerete oF mortar compositions further comprise & rein Toreing component, suchas, for example, steel reinforce rent bars, ste] mesh, ste! fibers, glass fibers, earbon fibers, ‘or plat fibers, and the Tike As used herein, the term or phrase “accelerator” “cement ‘eceleaton” oF “concrete accelerator” reers 10 a chemical ‘capable of accelerating, the hardening (ealy strength devel- ‘opment) of cement or concrete. For example, a “a ‘chloride cement aecelerator” refers toa chloride-free chem) ‘al capable of accelerating the ealy strength development of ‘cement or concrete, The disclosed conerete or mortar om= Positions may optionally comprise & coment accelerator Solectod from calcium nitrite, calcium niteat, caleium for- mate, caleium ehloride, oe sodium nitrate, or a combination thereat. Ina preferred embodiment, the cement accelerator ‘comprises calcium chloride, calcium nitrate, or sodium 0 o 12 rte, ora combination thereof, Ia some embodiments, the ‘cement accelerator comprises non-chloride cement accel- erator, which includes calcium nite, or calcium formate, oF ‘combination thereof. “The retanler may be selected from a borate salt such as of sodium pentaborte (NazBj,O;q), sodium tetraborate (Na,B,0,) and borie acid (1,80,); an organophosphonste Jncluding sodium or caleium salts of elhylenediaminetetra (methylenephosphonic acid) (EDTMP), hexamethylened aminetetra (melhylenephosphonic atid), and dietlenetri- ‘aminepenta (methylenephiosphonic seid); copolymers Tormed from 2-aerylamido-2-methylpropane-3-sulphonic acid (AMPS) and @ monomer selected fom the group ‘consisting of acrylic acid, aerylamide: metal sulfates such as erous sulfate: gypsum; sugar; sucrose, sodium gluconate; lucose: citric acid; tartaric acd; and the like Broadly, a plasticizer is a material that when added t0 another yields a mixture which is easier to handle or has ‘teater utility. The plasticizer as used herein means an ‘onganie compound which is usually non-volatile at standard room temperature and pressure (25° C., 1 atm.) and which bas no specific chemical reactivity, As such, the plasticizer js incr towards the cementitious binder material and merely serves as medium in which that cementitious hinder ‘material may be suspended or otherwise dispersed. Suitable plasticizers may be selected from polyalkyleneglyeols and ‘ther polyethers, sulfonated or phosphorylated organie com pounds, alkyl or aryl esters of organic acids, ols Irom ‘atural or synthetic nature, «varity of vinyl polymers, and polyesters or silicones, Suitable polyalkyleneglycols include polyethylene glycal, blends with polypropylene glycol or bother eo-plasticizers to make it liquid, polypropylene glycol land other liquid polyethers in general, eg. copolymers of ethylene oxide, propylene oxide and/or butylene oxide Suitable sulfonated or phosphorylated organic compounds include alky! sulfonic acid ester of phenol and eresol (Tor ‘example available as Mesamoll) snd aromatie sulfonamides Suitable alkyl or ary] esters of organic acids inelude benzie facid esters of glycols and their oligomers (for example available as Bensoflex), esters of 1,2 diarboxy eyelohexane (ydrogenated phthalates, Hexamoll DINCH),phthalie acid esters, terephthalic acid estes, timellitaes, adipic acid esters, sebasic acid esters, tartrate esters, citric acid esters fand sucrose esters, Suitable ols from natural or synthetic ‘ature include vegetable oils and thee derivatives including fatty acid esters and epoxidised vegetable oils, organic liquids derived from wood and other forest products like Tiquid osin esters and hydrocarbon fluids such as mineral ol ‘or parallinie igus. Suitable vinyl polymers inlude poly jsobutene, liguid polybutadiene and liquid polyacrylates LLiguid polyesters and silicone Muids ae also suitable and available to the skilled person. The above mentioned plas- ticizer ean be wsed in combination. "The superplasticizers that may be employed in accordance with the present disclosure include palyalkylaryl sulfonate superplasticizers, melamine/formalin resin sulfonate super plasticizers, sulfonated copolymer superplasticizers, and polymers obtained by the copolymerization of (methacrylic acids, maleie anhydride, maleke acids or their salts wi polyonyethiylene (methacrylic esters or adducts of polyeth ylene derivatives to vinyl monomers (commonly known as Saerylic supemplasticizers", “vinyl superplasticizers™ and “polycarboxylates superplastcizers” according to the type ‘of monomers wsed for their production). However, any plasticizers not composed of the above components but exhibiting string tackiness and non-bloeding prapertics may be employed as the superplasticizer of the present disclo- US 10,221,097 BI 13 sure, The polyalkylaryl sulfonate type superplastiizer includes «condensation product of naphthalene sulfonic ‘cid with formalin oa salt thereof, a condensation product ‘of methylnaphthalene sulfonie acid with formalin or a salt thereof, and a condensation product of anthracene sulfonic ‘id with formalin of a salt thereof. The polyalkylaryt sulfonate type superplasticizers are marketed under the trade names of “MIGHTY 100°, “MIGHTY 150° and “MIGHTY 200" by KAO Comporation; “SELFLOW-110P" by Daiichi Kogyo Seiyaku Co., Lid: “POLFINE S10N” by Takemoto (Oiland Fat Co, Lid; “SANFLO-PS" and “SANFLO-PSR™ by Sanyo-Kokusakts Pulp Co, Lud and “PT-S00" by Deak Kagtk Kogyo KK. The melamine’ formalin resin sulfonate type superpasticizers are marketed under the trade names of “MELMENT F-10" and “MELMENT F-20" by Showa Denko KK. and "NL-4000” by Nisso Master Builders Co, Ld. Exemplary sulfonated copolymers include styrene-c- mmethylstyrene copolymers containing 2 mole ratio of from 90:10 to 10:90, preferably 30:70 w 70:30, of styrene 10 ‘cmeihylstyrene. Polyearboxylate polymers are preferably ‘obtained by polymerization of acrylic acid and methacrylic fd or their mixtures, optionally in combination with other monomers capable to reaet sith serylic and methacrylic ‘acid. Typical examples of such monomers are maleic any dride, maleic acid, styrene, vinyl sulfonic acid, 2-aery~ Jamido-2-methyl-1-propanesulfonic acid (AMPS) and vinyl scotate Pigments may optionally be included in the eouerete oF mortar composition to form colored cured concrete or mor tar products. Exemplary pigments include, but are not fim- ited to ion oxide, satiral burst umber, carbon black, chro- ‘ium oxide, ultra-marine blue and titanium dioxide and are ‘commercially available from Harcross Pigmenls, Inc. Bayer ‘Comporation, Reckits Colour Ltd, and DuPont Comp. ‘Other optional additional ingredients in the eonerete oF ‘mortar compositions diselosed erein include corrosion Inhibitors such as nitrites (eg. caleium nitrite, see JP. B, 2-28532), chromates, phosphate, benotrazoles or akano- Jamines (€g. N.Neiethyl-ethanolamine, N-methyl-etha- nolamine, monoethanloamine, diethanloamine, ithan- Joamine and the like, sce JP. A, 17-173650) and bonding agents which comprises a blend of aluminum solate and 20 ‘alkali metal silicate comprising, for example, sodium andlor potassium silieate. Tnone embodiment, the cemeatitious binder material e ‘cement and date palm ash), the coarse aggregate, and the fine ‘aggregate are placed ina conercte mixer/mixing vessel and ‘dry mixed in a mechanical mixer or by hand for any time period suitable for forming a workable mixture wherein all ‘components are uniformly dispersediisributed, typically this time period is around 30 seconds-10 minutes, 4S sec- ‘onds-8 minutes, of $0 seeonls-S minutes. The cementitious binder material may be pre-formed andor pre-packaged prior to mixing with the other components (e.g. the coarse! fine aggregates), or alternatively the cement, date palm ash and any other optional pozzolanie material may be added as ‘cparate components o The mixerimixing vessel to form the cementitious binder material in situ. Following the dry mixing process, water is added, preferably by slow adit into the mixer while tuning the resulting concrete and mortar composition fora time period generally in the range ‘of 1-10 minutes, 2-8 minutes, or 3-6 minutes, although time periods outside ofthese ranges may also be acceptable, The Felative amounts of the components may he adjusted t0 ‘achieve concrete or mortar compositions having the desired properties, for example the shimp may be tested and adjusted 1 be within desired ypecifiations by adjusting the 0 o 14 relative amounts ofthe cementitions binder material (eg. the ‘eement andor the date pal ash, the corseine ayeregates, the water, and/or any optional additional ingredients. Any esired adktional ingredient(s) (eg. the accelerator, the retarder the plasticizer the superplasticizer, the pigment, the corrosion inhibitor, and the bonding agent) may be added during the dry mixing step or after the addition of water Preferably, all desired components are weighed in suitable ‘amounts and mixed in a mechanical electronic mixer accord- 1x fo ASTM C192 and ASTM C305, Slump is term of art relating to a standard test for determining the ease of movement of an unset cement ‘composition, The slump test measures the amount of settle- ‘ment of flow a shaped cement charge hus once under ‘unsupported conditions. cemient composition is workable, i.e. moldable, shapable, et. while the coment exhibits some degree of shump or flow characteristics. Advantagoous eon- ‘rete oF mortar compositions deseribet herein typically will have a slump of 30-105 mam as determined by the ASTM C143 standaed After forming the desired conerete or mortar composition, said composition may be molded, casted, placed, com- pocted, finished, andor eured (set) as needed to suit the Applicaton. For example, the conerete of mortar compos ‘ion may'be fad into 4 meld to ereate any desired shape, Tor ‘example in the shape of a masonry block for application in ‘eonsiuetion materials, The concrete or morta composition ‘may be east in a mold to produce a cast or precast compo- sition oF product. In various embodiments, the casting process comprises any typical cement or conerete casting process, In one embodiment, The casting process is carried fut in multiple steps, for example a vibration step may be utilized by vibrating the filled mold, for example, to remove air and/or minimize segregation. none embodisneat, a top ‘teface ofthe filled mold is removed and fresh mixture is ‘added to fill the mold, In another embodiment, the vibration and filing steps are repested as necessary t produce the ‘sired composition or product, The molding, casing, ct ing steps may be carried out in a controlled environment to form a precast, of performed on site in standard concrete processes. In one embodiment, the eonerete or mortar com- Position is cured by submenging the specimens into a water ‘tank per the provisions of ASTM CSI. The eure times may vary from 1 day to 400 days, for example. 3,7, 14, 28, 90, 180, and 360 days and any’time in between those stated values, preferably 28-360 days. ‘The conerete and mortar composition herein provides ceed products having advantageous compressive strength \water absorption, chloride permeability, water loss, creep, leaching, aad thermal properties. Moreover, such advant _geous properties are obtainable at a lower cost than standard feoncrees due at least partially tothe inclusion of date pala ash as described. "The present conerete andl mortar composition provides, after curing/settng, «high early compressive strongth, with 41-5 day compressive strength ranging from 20-55 MPa, preferably 22-50 MPa, preferably 24-47 MPa, preferably 26-46 MPa, preferably 28-45 MPa. In a prefered embod ‘meat, the cementitious binder material contains 5-15 wt %, 7-12 wt %, of about 10 wt 8 ofthe date palm ash relative 10 the total weight of the cementitious binder material, and hhas.a3 day compressive strength of 35-50 MPa, 40-48 MPa, 42-46 MPa, 35-45 MPa, 43-44 MPa afer setting. This compressive strength is superior to that obtained from a ‘material having no date palm ash (cement only cementitious binder material) at 26.6 MPa US 10,221,097 BI 15, The present concrete and mortar composition also pro- vides, alter curingstting, a 10-40 day compressive stent ranging from 40.65 MPa, preferably 45-64 MPa, preferably 50-63 MPa, preferably 55-62 MPs, preferably 56-61 MPa. Ina preferred embodiment, dhe cemealitious binder material contains 5-15 wt %, 7-12 wt %, or about 10 wt % ofthe date palm ash relative to the total weight of the cementitious binder material, and has @ 28 day compressive strength of 56:60 MPa, 56.2-59 MPa, 56.458 MPa, 56.6:57 MPa after setting, “The present concrete and mortar composition also pro- Vides, after curin/seting, a 30 oF more day compressive streagth ranging from 50-100 MPa, preferably 60-95 MPa, preferably 65-90 MPa, preferably 70-88 MPa, preferably 75-86 MPa. In a preferred embodiment, the cementitious binder material contains 5-15 wt %, 7-12 w %, oF about 10 ‘wt % of the date palm ash relative to the total weight of the ‘cementitious binder material and as a 360 day compressive strength of 83.90 MPa, 84:89 MPa, 85-88 MPa, 85.5-87 MPa alter seting ‘All compressive strength tests may be tested using cubed ‘mortar samples via a compression testing machine per ASTM C109, ‘Water absorption isa measure of concrete permeability. A, Jow water absorption rate equates fo reduced permeability of deleterious substances into concrete and therefore a longer Jife span, panicularly when applied w aquatic settings. CCaleulatons for determining both the inital rate of water absomption and the secondary rate of water absorption as ‘well as the testing procedure wsed are deseribed in ASTM. C1s8s. ‘The present concrete and mortar composition provides, ‘er euring/setting, alow rate of initial water absorption and alow rate of secondary water absomption, with a maximum ‘nial water absorption rate of 0.4-1.0 mum’, 0.42-0.9 mu 044-038 mmis, 0.46-0.7 mm/s, 0.48-0.6 mmis, and a maxi mum secondary water absorption rate of 1.5.3.0 mms, 162.5 men's, 17-20 mais, L8-1.95 mins, 19-194 mis Ina preferred embodiment, the cementitious binder mate- Fial contains 5-15 w1 9%, 7-12 ¥1 %, oF about 10 wt 9% ofthe date palm ash relative tothe total weight of the cementitious binder material, and has a maximum initial rate of water absomption of 0.25-0.72 munis, 030-0.70 mum's, 035-065, munis, 04-0.6 mm/s, 0.48-0.58 munis, 05-0.56 muw’s aller setting. Such an initial water permeability rate is about 30-40% lower than that obtained from a material having no ‘date palm ash (cement only cementitious binder materia. ‘Ina preferred embodiment, the cementitious binder mate- Fial contains 5-15 wt %, 7-12 w %, oF about 10 wt % of the date palm ash relative tothe total weight of the cementitious binder material, and has a maximum secondary rate of Water absomption of 175-2.25 mums, 18.2.1 mm/s, 1.85.20 mmi, 1.9-1.98 mms, 1.92-1.95 mis alter setting Such a sec= ‘ondary water permeability rate is about 15-25% lower than that obtained from # material having mo date palm ash (cement only cementitious binder material), ike water absorption, the permeability to chloride and ‘ther dauressive agents (ie. Cr, $0, ar CO.) ean be measured through changes passed into eonerete samples ‘Advantageous conerete or mortar materials therefore have low chloride permeability (cowlombs passed), and thus ‘advantageous “durability, particularly when applied 10 fguatie settings as determined by a rapid chloride perme- ability test (RCPT) according to the standard ASTM C1202, "The present concrete and mortar composition provides, after curing/setting, a resistance 10 the permeability of 0 o 16 chloride anions with an average charges passed (coulombs) ‘through the concrete of 3,000-8,500, 3,100-6,000, 3.20044, (00, 3,250-3,500. Tina preferad embodiment, the comeontitious binder mate ial contains 5-15 wt %, 7-12 w %, oe about 10 wt % ofthe date palm ash relative tothe total weight ofthe cementtons binder material, and has an erage chloride permeability of 2,000-3,500,2,200-3,400, 2.400-3,300, 2,600-3,200, 2,800- 3.260, 3,000-3,250 eoulombs ater seting. ‘According to a second aspect, the present disclosure relates toa cured conerete or more product eoataining the composition disclosed herein, in one or more of its embod- ‘meals, in cured foem, Tn one embodiment, the cementitious binder material ‘contains 5-15 wt % of te date palm ash relative to the total ‘eight ofthe cementitious binder material, and has at least ‘one of (a) 23 day compressive strength of 35-50 MPa, (b) 28 day compressive strength of 56-60 MPa, and (c) 2'360 day compressive strength of 83-90 MPa. Tn one embodimenl, the cementitious binder material ccontins 5-15 wt % ofthe date palm ash relative to the foal ‘eight ofthe cementitious binder material, and has atleast fone of (a) @ maximum initial rate of water absorption of 0.25.0.72 mmis, (b) a maximum secondary rate of water absorption of 1.75-2.25 mmis, and (c) an average chloride permeability of 2,000-3,500 coulombs. ‘he disclosed concrete or mortar compositions are wef in the manufacture of various end use articles or peclues. la ‘one embodiment, various cured comerete or mortar products are formed from setting uring the disclosed conerete or ‘mortar composition. In further embodiment, the disclosed cured eonerete or mortar products are in the form ofa useful shape, formed hy a variety of means sich as, for example, using mokis, cass, or forms, or the ike, in aecord with their intended use. Any typical process of forming cement or ‘goncrete can be used herein, Therefore, the cured concrete oF rmonar preuct may refer to a molded article. Pxemplary cured conerete or mortar products of the present disclosure fnclude, but are not limited o, slabs, panes, precast panels, wall boards, hollow blocks, floor and roo! tiles, beams, columas, posts, conduits and pipes, gravestones, insulators, extemal cladding, slate, concrete decking, eg. swimming pools, surfaces and surrounds, ceramie style products ‘marble Tike produets, sink tops, bar tops, bathroom tops, table tops, replace tiles, fire proof walls, building bloe (eg. masonry blocks); both reinforced and not reinforced by steel, depending on the use and purpose for which the ‘manufactured products are fabricated "As described herein, the disclosed compositions can, ia various embodiments, advantageously exhibit early com- pressive strength development. Thus, ia one embodiment, the disclosed concrete and mortar compositions ate useful in castin-place or poured-in-place applications, where sul cient early compressive strength ean be important, In @ Trther embodiment, the disclosed cured eonerete or morar compositions are useful in precast applications such as, for ccxample, precast structural products. The disclosed cured concrete oF mortar product may provide economic advantages. Inone embodiment, the cured ‘concrete or mortar products sre useful i thin pat applica ‘ions sue a8, roof slabs o road slabs, and high temperate ‘or sunny environments that can accelerate excessive blesd- ing (i.e. loss of water and cemeat binder slowly overtime). As described above, articles and products formed from the isclosed concrete or mortar compositions exhibit improved ‘wearing guaity: As such, articles snd products fonmed from the disclosed compositions can require less frequent replace- US 10,221,097 BI 17 ment or repair. In a further embodiment, the improved surface quality of articles and products formed from the ‘disclosed compositions generate less surface dust in hot ‘environments did less mud in rainy environments. Having generally described this disclosure, a furer S understanding can be obtained by reference to certain spe- Cif examples which are provided herein for purposes of illustration only and are not intended w be fimiting unless cothenvise specified, The examples below are intended t0 Jurther illustrate protocols for preparing and characterizing the conerete and mortar compositions. They are not intended to limit the seope of the claims. Example 1 ‘Gooeral Materials and Methods ‘Cement is mixture of various ehemsieal compounds. AIL ingredients have their own speci (OPC) conforming to ASTM C 1: ‘nal “different properties 10 concrete pee eeereareee sss De a : ‘material produced from the process of recycling local palm ‘or from burning local palm dead fronds so-alled leslly Tabanh which is obtained fom a reyeling palm plant 25 located in the easter province of Saudi Arabi. The heal alm reyeting roves two products daily: (1) 1.5 tons of ‘oa sd (2) 3 tons of firewood while pa ash is produced from wastage during the prodtion ofthese poets by @ process of heating the raw mera in an oven for 7 hous. %? ‘The local palm firewood is first prodoced which is tamed into local palin coal aad after baring the wastage the local palm ash is obtains. The process of mansfactaring foal firewood and coal consists of seven stages incding fn grinding, drying pressing, converting 0 coal through environmental friendly oven an cooling Palm ash pssng 425 pm sieve i used. 109%, 20%, and 30% of pam ‘sh (PA) was incorporated a replacement of OPC. IG. 1 shows the pitoral palm ash proces of producing dsb ea) fan firewood fom the raw materials il final prodvct at plant, “The coarse and fine aggregates wed wore crashed Hime stone and dune sand. respectively fom local quaris. The trading of coarse aggregates was conforming 19 ASTM C33 4s {Size No, 56). Sieve analysis of both PA and sand was ‘atid out with sive size No.4, 10, 40, 100 and 200. FIG. 2 shows the percentage passing of boll materials, Fuster, the fine wo course agaregate ratio of 0.667 by mass and the ‘cementitious materials content of 380 kgim* were kept 5 ‘constant in all the conercte mixtures, Moreover, all the ‘conerste and mors specimens were prepared foto of 0.4 and potable water was used for mixing and uring the specimens. Table 1 shows the physical properties ‘of OPC, PA, sand and agaregate TABLE 1 skal asses of ons o Pepe orc PA Sent Assos Specie et ia fe fee eran) Se ae Misiuen pile sie (nen) 07S 0800S 18 Example 2 Specimen Preparation and Curing Four eonerste and for morte mixtures were prepared in the laboratory employing neat ordinary Portland cement (OPC) and three percentage replacement levels (10%, 20% ‘nd 30%) of date palm ash (PA) to OPC. The eonerete and ‘mortar constituents were weighted in the required propor ‘ions and mixed in an eleetonie mixer in accordance With ASTM C 192 and ASTM C 305. The concrete slump was ‘measured in accordance wit the provisions of ASTM C 1 fad superplasticizr vas nsed to ensure 4 constant sump. ‘After the casting. placing. compacting and finishing ‘operations were performed all ypevintens were covered with laste sheet until demolding, Thereafter, specimens were feured by submenging them into a water tank as per the provisions of ASTM C SIT, Once the desired period was Completed, the specimens were removed from the ering fank and prepared for further analysis in the test program: ‘The effet of date palm ash dosage on mortar and concrete specimens was assessed by measuring mechanical and duri- bility properties including, but not limited to, compressive strength, rate of water absorption, rapid chloride permeabi ity and thermogravimetrc analysis (TGA). Example 3 (Chemical Composition Analysis Tn ofder to determine the mineralogical content of date palm ash (PA), a chemical composition analysis for PA was performed for determination of silica, Ca, K, Mg. Na, Al. and Fe. Loss on ignition was done at 950° C. as per a ‘Standaed method. Table 2 shows the results chemical analy- sis results for date palm ash (PA) and Type T ordinary Portland cement used in the mortar and concrete specimens. was observed thatthe content of SiO, of date palm ash radioed in this stody was around 36%. The second major Portion Was found to be eaeite material showing about 13% in amount which is followed by sodium oxide at 8.47%. Alkaline substances, such as, for example K,O were the ‘main foreign particles in date palm ash (PA) having a content of 7.40%, According 10 Zain et al. (2011), KO ccontent depends on types sid amount of fertilizers used uring growing period of the plant [Zain, M. F. M., Islam, MLN, Mahmud, P, Jamil, M..2011. Production of rice husk ash for use in concrete as & supplementary cementitious pateial. Constr, Build, Mater, 25, 798-803], Content of foreign panicles like F203 and Ai,O, was less than 19%, LLosson ignition (Ol) of PA obtained using combustion was 8.419%, Thos fire duration, sr supply duration and chilling process followed were reasonably appropriate TABLE 2 ‘Conical compotion of dt palm ah PA) ant Tus Ponand cane Tae {OPC fe, id 3 co she io. ass Mo oe Ko a No. va NiO + 0688 KO) ae Towon leiton Tom 00a ‘Table 3 shows the differences in chemical constitution between different sources of date palms ash (PA) and differ ent types of POFA, US 10,221,097 BI 19 TABLE 3 20 rm Is) 3) snare MR ronnie ee So, Te AM we a an aT 3, te ae SS SS Si Miso" 636 ay Mpa eo ss rae MiB aseKo, tr - a Meron lnmoe Nar ie iss 2, S mop urs ie, = 5 ee ne ees See SS Referenoes [1] W. Al-kutti, A. B. M.S. Islam, and M. Nasir, “Potential ‘use of date palm ash in cement-based materials,” J. King Saud Univ.” Eng. Sei, pp. 0, 2017. [2]A. Khellou, A. Kriker, A. Hafisi, K. Belbarka, and K. Dali, “Effect of the adition of by-product ash of date pals on the mechanical characteristics of gypsum-

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