Environment friendly composite construction materials

Abstract

Disclosed are a system, a method and/or composition of environment friendly composite construction material. In one aspect, a method includes providing a mixture of a pozzolanic material and/or a kaolin clay with an activator solution to form an alumino-silicate cementitious material through a resulting geo-polymerization process. The alumino-silicate cementitious material is in the form of a paste. The method also includes processing the alumino-silicate cementitious material to transform the alumino-silicate cementitious material that is in the form of the paste to a form of a powder of the alumino-silicate cementitious material. The method further includes mixing the alumino-silicate cementitious material which is in the form of the powder with water to control a workability of the alumino-silicate cementitious material. Furthermore the method includes combining a mixture of the alumino-silicate cementitious material and water with a coarse aggregate, a fine aggregate and/or a plasticizer to form a composite construction material.

What is claimed is: 
     
         1 . A composite construction material composition comprising:
 an alumino-silicate cementitious material that is formed through mixing a pozzolanic material, kaolin clay and sodium silicate in at least one of a dried and pulverized form in a solution of alkali hydroxide to form the alumino-silicate cementitious material through a process of geopolymerization resulting from mixing the pozzolanic material, kaolin clay and sodium silicate in at least one of a dried and pulverized form in a solution of alkali hydroxide; wherein the alumino-silicate cementitious material that is in the form of a paste is processed to transform the alumino-silicate cementitious material that is in the form of a paste to a the form of a powder;   water mixed with the alumino-silicate cementitious material that is in the form of a powder to control a workability of the alumino-silicate cementitious material;   a fine aggregate to increase a compressive strength of the composite construction material when mixed with the mixture of alumino-silicate cementitious material and water; and   a coarse aggregate to increase a compressive strength of the composite construction material when mixed with the mixture of alumino-silicate cementitious material and water.   
     
     
         2 . The composition of  claim 1 :
 wherein a weight of the mixture of the pozzolanic material and the kaolin clay that is used to form the alumino-silicate cementitious material ranges between 350 kilograms and 400 kilograms,   wherein the weight of the sodium hyroxide that is used to form the aluminosilicate cementitious material ranges between 30 kilograms and 60 kilograms, wherein the weight of the sodium silicate that is used to form the alumino-silicate cementitious material ranges between 100 kilograms and 150 kilograms,   wherein the weight of the fine aggregate used to form the concrete ranges between 500 kilograms and 600 kilograms,   wherein the weight of the coarse aggregate used to form the concrete ranges between 1200 kilograms and 1400 kilograms, and   wherein the weight of the water used to form the concrete ranges between 60 kilograms and 400 kilograms.   
     
     
         3 . The composition of  claim 1 , further comprising at least one of a plasticizer, a super plasticizer and polymeric additive to make the composite construction material self-consolidating. 
     
     
         4 . The composition of  claim 1 :
 wherein the alumino-silicate cementitious material that is in the form of a paste is dried at a temperature ranging between 40° C. and 100° C. through a normal drying process, and   wherein the dried alumino-silicate cementitious material reduced to the powder form through at least one of a grinding and pulverizing the dried aluminosilicate cementitious material when the alumino-silicate cementitious material is dried through a normal drying process at a temperature ranging between 40° C. and 100° C.   
     
     
         5 . The composition of  claim 1 :
 wherein the alumino silicate cementitious material that is in the form of a paste is transformed to the form of the powder through a spray drying,   wherein the alumino silicate cementitious material that is in the form of a paste is sprayed through a nozzle into an environment that has at a temperature ranging between 40° C. and 100° C. to transform the alumino silicate cementitious material that is in the form of a paste to the form of powder,   wherein the environment that has at a temperature ranging between 40° C. and 100° C. to which the alumino silicate cementitious material is sprayed to dry the sprayed alumino silicate cementitious material, and   wherein the density of the composite construction material formed from the powdered alumino silicate cementitious material that is transformed to the form of powder through at least one of the spray drying and the normal drying the paste form of the alumino silicate cementitious material is based on the plasticizer that is added to the alumino silicate cementitious material to form the composite construction material.   
     
     
         6 . The composition of  claim 1 :
 wherein the composite construction material is cured through at least one of a curing process at a room temperature and a heat curing at a temperature ranging between 40° C. and 120° C.,   wherein a resistance of the composite construction material to an acidic environment is increased through mixing the alkali hydroxide as activator with the pozzolanic material to form a crystalline alumino silicate cementitious material that is used to produce the composite construction material,   wherein the koalin clay to reinforce a strength of the composite construction material, and   wherein at least one of the fine aggregates and coarse aggregates to increase a compressive strength of the concrete.