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    05 - Synthetic Aggregate For Use in Concrete - US8921463B1

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    TRAN Viet Cuong

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    «2 United States Patent Algahtani et al. 892146381 (10) Patent No. 4s) Date of Patent: US 8,921,463 BI Dec. 30, 2014 (34) SYNTHETIC AGGREGATE FOR USE IN CONCRETE, (71) Applicants:Fahad Khshim Algahtant, Riyadh (SA); Mohammad Iqbal Khan, Riyadh (SA), Gurmel Ghataora, Birmingham (cB) (72) Inveators: Fahad Khshim Algahtanf, Riyadh (SA); Mohammad Iqbal Khan, Riyadh (SA), Gurmel Ghataora, Birmingham (GB) (73) Assignee: ‘King Saud University, Riyadh (SA) (*) Notice: Suibjoct to any disclaimer, the term of this patent is extended or adjusted under 38 USC. 154(b) by O days. (21) Appl. Nos 14280881 (22) Filed: May 16, 2014 6) Inc. Coan 29008 (2006.01) CosB 28726 (200501), (2) US.CL uspC 52478; 524/482 (58) Fi 5248, 442 ‘See pplication ile for complete search history. 36) References Cited USS. PSTENT DOCUMENTS 6749.99 BL 62004. Vow Fay otal. Tat B2 12009 Repent 20080068082 AI* 42003. Blinken et soon dogwo1os191 AL $2006 Lo Pret et on awh FOREIGN PATENT DOCUMENTS ow or976663 A 32013 ” anooiask2 92009 Wo wo3msor3660 * + 22005 roc 4788 OTHER PUBLICATIONS Asad, Semi, Cengie Daran Ati. Kubilay Akgadzofa “an lmestigation on the Use of Shredded Waste PET Bots as Agarepcte tv Lightweight Concrete” Waste Management 30.2 (Goto) 288-200, ‘Asange Soul tal. “Low Desi Polshove s Addie to Flex thle Fosemen” Corona turn of Science ® Technology, vol No. oct 2012. Ratan, Md Mostfou, Md ARbarl Isla, & Main Abed “Reeseling of Waste Polymeric Materials ax Patel Replacement Jor Aggregate Concrete” International Confrence 08 Chemica "Envisonmeat Biological Sciences (CCEB'2012) Penna, Malay” sit pp 9-102. * cited by examiner Primary Examiner — John Uselding (14) Attorney, Agent, or Firm — Richard C. Litman 6 ABSTRACT The synthetic aggregate for use in concrete is a componite smateral of reeyeled plastic having a filer encapsulate inthe plastic. The synthetic aggregate includes between 30% and 50% reeyeled shredded plastic, the balance being filler. The plastic may be linear low-density polyethylene (LLDPE). The filer can include red sand, fly ash and quarry fines. The symtetic aggregate is best used to make concrete with a ‘Waterto-cement rato oft least 0.5, A method of making the thetic agaregate incl the steps of mixing plastic with filer to form a homogenized mixture, compressing. the homogenized mixture in a mold, melting the plastic in the homogenized mixture to form a composite sheet or slab, and shredding the composite set or sla a form either coarse oF fine aggregates for use in making concrete, 6 Claims, 7 Drawing Sheets fs U.S. Patent Dec. 30, 2014 Sheet 1 of 7 US 8,921,463 B1 1 Fig. 7-8 9 10 1) 12 13 14 15 16 17 18 19 20 2 22 23 2% 2 26 2 2 29 US 8,921,463 BL Sheet 2 of 7 Dec. 30, 2014 U.S, Patent ge buy OOlddY S'OOLddy VOOM SOOT 9°00N SOON | 2 e681 ceSZ6Lsygzoz aaiate Srylez — SBOLEZ oor— ool 009 OOLL 0091 001Z 0092 gu/By Aysueg ysesy US 8,921,463 BI Sheet 3 of 7 Dec. 30, 2014 US. Patent 8 “bu (shog) poreg Buling go0ididy [ll S00lsidd (2dW) UsBued4s US 8,921,463 BI Sheet 4 of 7 Dec. 30, 2014 US. Patent bbq (shoq) poled Bung Bz vi g001 side [I] sooisled = GOON SOON goon] soon [i (Pdn) usbueys US 8,921,463 BI Sheet 5 of 7 Dec. 30, 2014 US. Patent S ‘bu (shog) poweg Buying vb goomf) goon som SONA (Pdn) yjBueds U.S. Patent Dee. 30, 2014 Sheet 6 of 7 US 8,921,463 B1 5532 5532 T RPIFICO.5 6279 + LWC0.6 Fig. 6 5811.33 t Lweo.5, 5682 7 NCO.6 8673 ¢ NCO. T T T 28 8 8 5200 4 5000 6400 6200 + (squiojnog) pessog e6s0y9 U.S. Patent Dec. 30,2014 Sheet 7 of 7 US 8,921,463 BI US 8,921,463 BI 1 SYNTHETIC AGGREGATE FOR USE IN ‘CONCRETE, BACKGROUND OF THE INVENTION 1. Pield of the Invention The present invention relates generally to conerete, and Particularly to a synthetic aggregate for we in eonerete, the ‘aggregate being a composite of recycle plastic witha filler ‘encapsulated in the plastic 2, Description ofthe Related Art CConerete is oe ofthe most important and frequeatly used ‘materials in civil enginecring. such asin high-low buildings, bridges, infrastructure and environmental protection Tail ties. Concrete is a composition of an aggregate and a binder substance. The hinder substance and the aggregate are com- bined hy a moistening agent to allow the binder substance 10 Tink with aggregate particles and form a solid block. Gener- ally theauaregate orauprepates make upabout Moto 7P%of the total concrete volume. Since the properties ofthe agare- ates used in concrete significantly impact the quality ofthe ‘concrete, the selection andthe proportion ofthe agarepates is very important and should be given earefl tention. Por ‘example, air-cooled sage is used to replace coarse aggregate ‘materials and fly ash is used to replace fine aggregate mate- rials. Furthermore, sggreyates such a silica fume and tice husk ash have been used as supplementary cementing mate- rials, Natural aggregates, such as those mentioned, give con- ‘rete certain physical, chemical, aad mechanical properties, However, a8 result of environmental concems, there has been a growing trend forthe use of recycled plastic waste as ficial agaregate instead of natural aggregate in the produc- tion of concrete, Overthe last 90 years, wordsvide production ‘of plastic grew by more than SO0%6, Cument ann global production is estimated at over 100 milion tons and is ‘expected to increase by 3% a year Inthe UK, 7% of pasties ave recycled each Year, which i small vanity when com pared (0 the 275 million tons of natural aggregate used ia ‘conerete applications. About 80% of the plastic wastes are ther let in stockpiles, as landfill material, or i legally ‘dumped, Most importantly, much of the non-decaying wastes ‘vill remain inthe environment for hundreds, perhaps thou sands of years. The non-dccaying waste will not nly cause @ Waste disposal crisis, but also contribute to significant exv ronmental problems. As such, the possibilty of wsing a sya- thetic anpregate, such as a cycled plastic as aggregate, instead of a natural aggregate in concrete has received ‘increasing stention in recent years as a solution to the esea- lating sold waste problem, However, currently, synthetic aggregate, such as recycled plastic aggregate, does aot allow for the same physical, ‘chemical, or even mechanical properties of natural aggre= ates Thus, a synthetic aggregate for use in conerete soli sforementioned problems is desired, SUMMARY OF THE INVENTION ‘The synthetic agareyate for use in concrete isa componite material of recycled plastic havinga filer encapsulated inthe plastic, The synthetic aggregate includes between 30% and 50M reeyeled plastic, thebalance being ile. The plastic may be linear low-density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene (HDPE). polypropylene or other type of plastic. The filer ean inelude 0 o 2 sed sand, fly ash, quar fines, and silica fume. The synthetic ‘aggregate is best used 10 make concrete with a Wateeto- ‘ementrtio of atleast 0S ‘A method of making synthetic aggregate includes the steps ofshredding plastic, mixing the shredded plastic with filer to {forma homogenized mixture, compressing the homogenized rixture in a mold, melting the plastic inthe homogenized mixture to form a composite sheet or slab, and shredding the composite sheet or slab to form either coarse or fine aggre- gates for use in making concrete These and other features of the present invention will become realy apparent upon further review ofthe following specification and drawings, BRIEF DESCRIPTION OF THE DRAWINGS. FIG. 1 isan environmental perspective view of samples of «a symthetie aggregate for use in concrete according to the present invention, showing synthetie aggregates of cifferent particle sizes. FIG. 2s graph illustrating a comparison of Fresh Conerete Densities at different waterto-cemeat ratios for different ‘cementitious eomposiions, including concrete samples made roma synthetic aggrezate forusein concrete according tothe resent invention. FIG. 3is chat illustrating @ comparison of Compression Strengths a funetion of euring time for normal, ightweight jeoncreie and conerete having a synthetic aggrevite for use in sconerete acconting to the present invention with different FIG. 4 is a chart illustrating a comparison of Tensile Strength as a funetion of euring time for normal, ightweight jeoncret and conerete having a synthetic aggreyate for use in feoncrete acconting to the present iavention with different ‘waterto-conerete ratios FIG. $ is a chart illustrating a comparison of Flexural Strength s a funetion of euring time for normal, ightweight jeoncrete and conerete having a synthetic agareyite for use in ‘concrete acconting to the present invention with different wwaterto-conerete ratios FIG. 6 is a chart illostrating a comparison of chloride permeability for normal, lightweight concrete and concrete ‘ontiningasyntheticaggrepate foruse in conerste according to the present invention. FIG. 7 is a Scanning Flectron Mierogmph (SEM) of 3 synthetic agpreyate for use in concrete aeconting w the present invention, showing particles of fille encapsulated in matrix of recycled plastic Unless otherwise indicated, similar reference charscters denote corresponding features consistently throughout the attached drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS, “The synthetic aggregate for use in concrete is composite material of reeyeed plastic having a filer encapsulate inthe plastie. The synthetic aggregate incindes between 30% and 50% recycled plastic, the balance being filler The plastic may be linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polypropylene, or other recyclable plastics. The filler can include red sand, ly ash, quarry fines, and sti fame, The synthetic aggregate is best used to make eonerete with a Waterfo-cement ratio of at least 05, A method of making symllietic aggregate includes the steps of shredding plastic ing the shredded plastic with llr to forma homogenized US 8,921,463 BI 3 mixture, compressing the homogenized mixture in a mold, melting the plastic inthe homogenized mixture to form & ‘composite sheet or lab, and shredding the eompositesheet or slab to form either coarse or fine aggregates for use in making Tnorder totes the use of recycled plastic as an agaregatein ‘concrete, different samples ofthe synthetic aguregate were prepared. The synthetic aggregate includes filer and plastic. The filler used in the synthetic agaregate is granular wast, such as re sand. fly ash or quarry fines. The particles ofthe filer, suchas red sand particles, should havea panicle sizeof 0.13 mm, for example, One manner in which this ean be accomplished is by passing the filer, such as red sand, through a sieve. After obtaining the particles ofthe desired size the filler should be dried at room temperature. The fille shouldbe fee from any contamination. 4 ‘obtained by this process are then separated into diferent sizes to be mixed with cement and make conerete As diseussed herein, the properties of the materials use in concrete have a great role in detemnining the quality of the ‘concrete, so tis important to determine the physical, chemi cal and mechanical properties af the materials used Forills- tration purposes only, tests were conducted comparing the various properties of ordinary concrete lightweight concrete, and concrete comprising a synthetic ageregate prepared as described above. A lightweight concrete is produced a a control using local lightweight agareyate, which isa typeof voleanie rock collected from the westem region of Sandi Arabia. The properties ofthis local lightweight aggregate are ‘abulated i Table 2. Anexample of the type of recycled plastic tested is Linear TABLE 2 Lom Dany Tubeblen (DPE) The planter — fenges nev bjt to ch the one porate os Saco a Tale Tr tshows weed FEDPE aed 20 Te ent ihe iin Kin fier onto ict poe | — ‘centages, leading to six different compositions. Juik Specie Grnsy SSD Basi) te ory sera Coe HBR SO RBS! B30 payee plate wasusdo replace conse opgents or be SG $ mang spac of cme vita sme are Hire HeIRar" Gp Testa guregats weve mulled i eat HBR BRAN RB Massanshown in G1 The properties of ese sy ‘Once the filler, suc as red sand, i sieved and the faction ith the desired particle size such as 0.15 mm) is selected, it js dried at room temperature ‘The recycled plastic is collected and either sorted into sifforent polymer groups, sch as LLDPE, o used “as 8" in f mixed stream. Regardless of the type of plastic used, the recycled plastic stream should be separated from non-paly= mer products (such as wood, plass, oF metal) and then shred- ‘ded and processed by grinding to obtain particles with a ‘maximus size of I mim. Aller Ihe plastic andthe filler are dried, they are mixed together within @ mixing machine to produce a homogenized mixture. “The homogenized mixture is then poured into a at mold Alerts poured into the flat mold, the homogenized mixture js compressed. To compress the homogenized mixture, the ‘mold containing the polymer-filler mixtare i placed between ‘0 heated plates in a compression molding machine. The ‘compression molding machine is heated to temperature of about 175° C., and the polymer filler mixture is compressed With about 25 tons of foree Tor about 1S minutes. After flly melting the polymer and the subsequent eneapsulation of ‘ler, the resulting sl i slowly cooled in the mold through an automatic cooling system in the machine and Tater removed from the compression molding machine, to be ‘cooled slowly inairt oom temperature for about I hour AS shown by the SEM mierograph of the suraee ofthe sab in FIG. 7, the process rests ina composite material with filler particles embedded ina matrix of recycled plate. Utilizing a screen created to mest certain specifications, the polymer ‘ler sold slab is shredded ina plastic shredding machine 10 orm coarse aggregate o fine aggregate atthe desired grada- tion, As illustrated in EIG. 1, the synthetic agaregates 0 o ‘ageregates arc tabulate in Table’. The samplesae identified by a sample name of the format RP,P,A, where RP, isthe ‘number identifying the recycled plastic type and percentage F isthe umber identifying the fillertype and percentage, and Ais aggregate TABLE 3, Tet ROE A RAE A RMF A RFA REF A Bukspeae 12 Os toes nD Grain 0D Bai) Skee 1a ON S189 aL Grain SSD Bs) ope Seite 12s oss snes Atsoption | 35s ei 596 a7 9a Borkwsahe on SHE sins?” iu ois (ease ere ogi san gn Type Cased Cl Cried Coihed Cried Maimmsie om 0mm oom orm 1omm For those mixes containing synthetic aggregate andlor Jocal lightweight aggregate, the quantity ofthe couse aggre- agate is calculated by wing the specific wrvity ofthe synthetic fageregateand/or local lightweight aggregate as areplacement for the specific gravity of natural coarse aggregates. The resultant mix proportions ae ilustratedin Table 4. In Table 4, the sample designation “NC” means normal concrete, the ‘designation “LW” means concrete made with the lea! vol- canie Hghtweight agaregate described above, and the desig- US 8,921 5 nation “RP,F,C” means synthetic aggregate with exyeled plastic 1 (50% recycled LLDPE) and filler 1 (50% sand) TABLE 4 463 BI 6 jconerete ad the highest stenuth at all the ages of curing, ‘whereas the lowest strength was observed in RP, FC. a ee Fae Coane Ligewsigt "Plie WiC Wares Ceneyr Agueases Algmies Afuepes Atuses SNo___Rato_Kum' Kum’ “Kom “Kem Kum’ Kom ‘Conerete mix design can also be wsed for conerete contain= ing synthetic recycled plastic coarse aggregate by sh ing natural coarse aggregate with synthetic recycled plastic ‘course agereyate based on required replacement percentage "The methods in which the tests were conducted are dis ‘cussed herein and the results of the tesis referenced herein ithastrate the effect that an specific aggregate ean have on certain concrete properies. Specifically, the tests illustrate > the relation between uit weight, compressive strength, fex- ‘ural strength, and tensile strength fr all specimens at differ ‘ent water cement ratios Comparison of Concrete Densities » FIG. 2 illustrates « comparison of the fresh demsitis of various conerete mixes done in this study. As shown in FIG. 2, the ondinary concrete had achieved a density of 2370 kya’ ‘witha water-to-cement ratio of 0, (NCO.3), a8 compared 10 the concrete with the synthedc ageregite, which hada density ‘of 1880 ky/m® with a water-to-coment ratio of 0.6, (RP\F iC 0.6), meaning that at a difference of 0.1 waterio-cemeat ratio, the density of the material used was reduced around 21%, Referring to FIG. 2, in the 05 water-to-eement category, the lowest density was seen with RP\F,C 0.5. I had the density of 1925 kg/m, This isa substantial redaction of 19%. This reduction sdue to the lightweight nature ofthesymthetic agaregate. By comparison, the lightweight concrete with 0.5 waterfo-cement ratio hus attained a density 14.5% less than Neos. ‘Compressive Strength Test 0 FIG. 3 illwsrates comparison of the compressive strengths ofeach specimen that was prepared by casting the res coneretein two layers in stel cubic molds with dimen- sions of $0050 mi, Fach layersvas subjected to vibration {or3 seconds. After twenty-four (24) hours the cubic 5 mens were demolded and cured in water ats temperature of 20° C.22° C. for 7, 14 and 28 days, respectively. After the ‘curing process, the cubes were tested by a compressive Sreaatl machine to measure the compressive load ad eo pressive strenath at which the cubes wil fl Referring 10 FIG. 3, the eompression strengths of normal, lightweight and conerete containing « synthetic ageregate (RP,F,C) with differnt water-cement ratios of 0 and 06 illustrated. The general trend s that increase in the water- to-cemeat rato eases reetion in compressive strength for all mixes. However, the compression strength ofall mixes increases with the curing period. Furthermore, the control o Inthecaseof 0.5 waterto-coment rato, at the age of seven «days, the strength ofthe control conerete ws 622% higher than the lest RPC. The lightweight concrete was 30% lswer than the control concrete. At the age of fourteen days, the control concrete attained 37.22 MPa, which is 29% and 64% higher in comparison with lightweight and RP,F\C eon croes, respectively. "Nevertheless, the same tend is continued st the later stage of the test. AU this age, the lowest strength was seen ia RP\F,C, which was 64% lower than the contol, The same tnend bias observed at 06 waterto-cement ratio, as contol ‘concrete achieved the highest strength amongst the restof the recycle plastic eonerete (RP,F,C), respectively, regardless fof the rethiction amount due 10 the increase in waterto- ‘cement ratio. However. the reduction incompression strength {duet water 1o-cenient ratio inerease inthe conerete contain: ing RPA was oout 19% and was feted by curing pero. ‘Tn fac, the reduction in compression strength duet ‘weakness in the bonding between cement mortar and thetic agarezte particles, This weakness is due to differen in surface texture and size of synthetic plastic aggregate pa ticles Tensile Strength Test ‘The tensile strength of eonerete was calculated using the tension machine test, riguette specimens were made to be tested at twenty-eight days according to BS EN 123906: 2009(E). Comparison of tensile siengths for the concrete ‘mixes made with recycled plastics with diferent waterto- ‘cement ratiosare presented in FIG. 4, The general tend sthat ‘increase in the waterto-cement ratio. decreases. tensile strength forall mixes. However, the tensile strength of all ‘mixes inereases with the euring perio Ta the case of a 0.5 walerlo-cemeat ratio, the contol ‘concrete reached a maximum of 3.28 MPa at twenty-eight days, showing a 30% increase from seven to fourteen days, fan then # 13% inercase fom fourteen to twenty-eight days. ‘This was followed by the lighweight concrete, whose strength was 6.5% higher a the early age of seven days ‘Conegete containing syuthetic aggregate (RP,F,C) had 42%, $5% and $7% lower tensile strength than the contol fourteen, and twenty-eight days, respec i ile strength was 45%, 38% and 37% less than the tensile strength of lightweight conerete at seven, fourteen, and twenty-eight days respectively. The same trend was observed at 06 water-o-cement rato, as control conerete achieved the highest strength amongst the rest followed by lightweight concrete and the synthetic reveled plastic con- US 8,921,463 BI 1 crete (RP,F,C), respectively, regardless of the reducto famount due to increase in the waterto-cement ratio. Hom= ‘ever, the reduction in tensile strength de wo watero-cement ratio inerease inthe RPA concrete was around 319%, ‘The feetors causing reduction in the tensile strength in ‘concrete containing synthetic plastic aggregate are the same asthat which eause reduction in compeessve strength, stated previously. In addition, the increase in porosity due to the ‘ding of plastic aggregate causes more voids and makes the bonding weaker Flexural Strength Test ‘Using a simple beam (Prism) with one point loading. che flexural strength specimens were prepared by casting the Jesh conerete in two layers in steel prism beam molds with

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