Patent AU-2020104412-A4 (AU)
Title: Manufacture of green concrete by partial replacement of ferrock powder as an alternative to conventional cement
Inventor: Vijayan D S
IPC: C04B18/08
Filed: 2020-12-31
Granted: 2021-04-15
Abstract: Manufacture of Green concrete by partial replacement of Ferrock 
powder as an alternative to Conventional cement 
ABSTRACT 
In modem era, achieving sustainability in the field of construction was deliberating as a 
prime factor, because the field of construction becomes as a major pioneer of environmental 
pollution and it was estimated about 40 % of pollution was generated only during the construction 
activities. For manufacturing of cement and other materials related to construction, nearly 60% of 
earth resources were utilized and by continuous extraction of these materials leads to rapid depletion 
of natural resources at very soon. In worldwide, it was assessed that during the manufacturing of 
cement alone emit nearly 7% of carbon dioxide and it was directly induce the greenhouse effect and 
create pollution such as acid rain, depletion of ozone etc. On other side, the industrial wastes are 
available in vast quantity and that may be utilized in the concrete either directly or by the 
combination of industrial waste with different bonding additives. The industrial wastes are 
constituent of heavy pollutants, during the dumping it may cause harmful health effects to living 
organisms and it may also act as carcinogenic agent. For this study, the combination of industrial 
waste are taken to form a new novel material called "Ferrock" and it was usually the mixture of 
Lime stone, Iron dust, Fly ash, Metakaolin and Loose sand at different proportion. The main aim of 
this study is to enhance the engineering property of concrete by adding ferrock, instead of cement in 
the form of powder at different proportion of 0, 5,10,15 and 20 percentage. For initial study, the 
compressive strength of various proportions are examined by casting cement mortar and allow them 
to curing for the different periods of 7 days, 14 days and 28 days. Further, the cured cement mortar 
cubes were subjected to compressive stress and the property was examined. From the result it was 
found that, the compressive strength obtained during addition of Ferrock powder at the proportion of 
5 and 10 percentage can provides higher strength than conventional cement mortar. In other side, the 
higher proportions such as 15 and 20 percentage of ferrock may decline the strength of cement 
mortar by way of increasing the plasticity nature of cement paste. Hence it was advisable that higher 
proportion of ferrock in cement concrete was not recommended.  
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43.51 44.59 44.87 
45 
39.38 
40 
35 30.4 .  
30 25.63 
25 20.56 
20 17-4 15.6 ] 163. 79 
15 10.2 
10 
5 
0 
Pure cement 95% Cement + 90% Cement + 85% Cement + 80% Cement + 
[PPC] 5% Ferrock 10% Ferrock 15% Ferrock 20% Ferrock 
Powder Powder Powder Powder 
* 7 Days compressive Strength 0 14 Days compressive Strength 
28 Days compressive Strength 
Fig. 1: Compressive strength [N/mm 2 ] of Conventional and Ferrock Replaced cement Mortar at 
different curing periods 
Fig. 2: Weighing of industrial byproducts and lime stone for Ferrock 
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Fig. 3: Mixing and casting of Cube mortar specimen 
Fig. 4: Physical properties of conventional cement and Ferrock cement 
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Fig. 5: Curing of Cubical cement mortar specimen 
Fig. 6: Testing of Cubical mortar specimens 
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