Title of Invention

PROCESS OF MANUFACTURING A LOW POROSITY, ULTRA HIGH DENSITY, CEMENTITIOUS COMPOSITE

Abstract

The invention relates to a process of manufacturing a synergistic homogenous formulation for use in manufacture of rapid setting low porosity ultra high density cementitious composite .The process consists of preparing an homogenous admixture by dry mixing 10 to 60 % crushed inert or reactive aggregates containing alumina; 10 - 80 % water soluble alitic and/or non alitic cement; 5 - 50 % of one or more varieties of crushed, sieved, wet ground and pulverized silicious material as filler; 10 - 60 % organic and/ or inorganic fibers; 5 - 40% of ultra fine metallic particles; optionally adding 0-5 % of pigment dye to give color to composite . A moisture free homogenous mass is prepared by adding to admixture, water reducing aqueous solution of super plasticizers capable of eliminating locking forces between admixture particles, to obtain desired consistency and air drying me same. A light, fluid, uniform, plastic consistency homogenous formulation is prepared by adding water to the homogenous mass, such that it can be poured on predressed substrate and subsequently spread and leveled , to have a void ratio of less than 30 %. Optionally an external skid resistant layer may be applied, and the entire mass is compacted to remove air pockets, and cured at ambient temperature to form a ultra high density, cementitious composite.

Full Text

FORM-2 THE PATENTS ACT 1970 COMPLETE SPECIFICATION SECTION 10 TITLE:' Process of manufacturing a low porosity, ultra high density, cementitious composite' APPLICANTS: The ASSOCIATED CEMENT COMPANIES LIMITED, and Indian company having its registered address at .Cement House, 121, Maharshi Karve Road, Churchgate, Mumbai 400 020, Maharashtra, India. The following specification particularly describes and ascertains the nature of this invention and the manner in which it is performed: 06-12-2004 GRANTED This invention relates to " Process of manufacturing a low porosity, ultra high density, cementitious composite". More particularly this invention relates to process of manufacturing and laying a layer of ultra high density cementitious composite filled and spread over predressed pot holes and top asphalt / concrete / cobble stone surface layer coated with a layer of cationic or anionic emulsion covered by a layer of metallised polymer coated aggregates in herein after stated manner and cured in open air at ambient temperature for 4 hours to 1 day and extending up to 28 or more days to attain rock hard wear resistant top layer surface having herein below stated TABLE - 1 of product characteristics. BACKGROUND The porous microstructure of concrete is responsible for failure of concrete to achieve even 2-5% of yield strength of steel. Many attempts have been made to reduce the porosity of concrete thereby enhancing its strength. Dense packing is known to be an essential feature of ultra high strength of concrete material. It has also been known that the influence of small percentage of reactive fine particles on the strength gain is very significant. In an attempt to provide a theoretical basis, PC (Personal Comput¬er) based computer models have been developed which can be used to predict the dry packing behaviour of the components in cementitious systems. The concept of efficient particle packing leading to elimination of voids and thereby giving a pNo of superior structural strength is theoretically estab¬lished. The resultant product has high compressive and flexural strength, high fracture toughness and low perme¬ability. WEAR PROTECTION APPLICATIONS In transportation of heavy materials by transport vehicles on asphalt, concrete or cobble stone road surface is the main cause of erosive abrasion. This wear results in frequent interruption of vehicular traffic by transport industry resulting in financial losses leading to the loss of competitiveness and heavy repairs and maintenance costs. A variety of materials have been tried and used for wear protection of road topped surface including alloy steel, metal filings and/or hard faced cage with welded rods. Use of ceramics is an alternative candidate for wear applications because of their high temperature strength and hardness, chemical inertness in severe corrosive and oxidiz¬ing atmosphere, and having high contact fatigue resistance and low inertia. The major disadvantage of ceramics is their brittleness. The wear resistant ceramic materials used include oxides of ceramics, silicon carbide (SiC) based cer¬amics, metal composites, fused cast materials and ceramic filled polymers, elastomers or adhesives. Although a great deal of information exists on the wear resistance testing of ceramics by a variety of standard methods and means of interpreting results are yet to be established. This stems from the fact that wear resistance is not a material property of ceramics but a system response or system dependent. It is not unusual for one class of materials to behave differently in different type of wear tests. The factors generally affecting wear and abrasive-ness of road top layer include: 1. size, shape, density, hardness and velocity con¬centration, impact angle, load and corrosivity affect the wear factor; 2. nature of wear material in terms of fracture toughness, corrosion resistance, porosity, friction co¬efficient, grain size and hardness affecting the wear factor. The increase in the wear resistance capacity of "ACCMarg' composite is possible when mixed with the addition of various types of fibers. Fiber reinforcement is one ofr,. the most cost effective ways of improving the strength and toughness of "ACCMarg' composite wherein the amount of strength increase depends on the type of fibre and the fibre cement matrix interaction. There are various types of available fibres are : 1. Carbon fibres which are inert, medically stable than glass. These fibres are low in density but their strength;to density ratio is higher and possesses high electrical conductivity. The tensile and flexural strength increases with addition of carbon fibres. Increase of tensile strength is to the extent of 28% and flexural strength is 55 % • 2. Steel and stainless steel fibres mixed in a cement matrix provides a useful way for enhancing the tensile strength and tou9hness to brittle matrix. Addition of stainless steel fibres to cement causes high densities, strength and lower porosity. 3. Addition of 3 volume percent of 'Kavelar' fiber to cement matrix increases modulus of rupture four fold over ordinary cement. As most of its strength is lost at temperature above 300 deg. C. its use needs to be limited to applications "SELFIL" which looks like a white cotton fibre to cement matrix increases >2 fold tensile strength and MOR increases 5. Addition of commercially available ^.; y Fiber' when mixed with water attains unique property to expand along one plane like an accordion and its fibers get entan¬gled with each other and attain greater compression and tensile strength wherein an addition of small 1.5 % volume of said fibres to the cement matrix 'increases impact resist¬ance four times and compressive strength two times. Pot holes are usually formed in asphalt / concrete /cobble stone top layer by the piercing hydraulic jet impact of rain water digging into asphalt road top and enlarging the pot hole size and depth and also by the rolling of heavy transport vehicles which frequently interrupts the smooth flow of vehicular traffic and calls for expensive filling up of said pot holes and supervision by road inspectors. DEFINITIONS: For brevity sake the following expressions used throughout this specification mean and include the meaning set against each expression: ~ACCMarg composite' - includes rapid setting water soluble highly densified rock hard cementitious mass prepared from selective combination of herein stated ingre¬dients prepared according to the process of this invention for filling / topping/ relaying, in herein described man¬ner, pre-dressed pot holes / top surface of old asphalt / concrete roads forming rock hard / jointless / smooth top layer having herein stated TABLE- 1 of product characteris¬tics. "Source of quartz and the like ' - include crushed sieved and wet ground pulverised mass of quartz, sand, slag, alumina, calcium carbonate, dolomite, calcite, metakaoline, metal powders alone or selective combination thereof. 'Source of inorganic fibers' - include fibers of metal, stainless steel, glass, high alpha alumina, micro silica obtained as byproduct from ferrosilicon industry, polycrystal1ine alumina and the like alone or any combina¬tion thereof having particle size varying from 1 to 100 microns alone or a selective combination thereof for being used as filler mass for maintaining the selective lime to silica ratio in the product mix. "Source of organic fibers' - include organic fibers commercially marketted under trade mark 'KAVELAR' having unique properties of expanding along one plane like an accordion along one plane and get entangled with matrix of "ACCMarg' composite give more than double compression strength and more than four times the impact resistance and includes source of lime, processed fly ash, carbon black alone or combination thereof having particle size varying from 1 to 100 micron, Source of water soluble cement1 - includes OPC (Ordinary Portland Cement), High Early Strength Cement, Sulphate Resistant Cement, Low Alkali Cement, Low Heat Cement, Portland Blast Furnace Slag Cement, and/or Portland Pozzolona Cement, White Portland Cement, Calcium Sulpho-aluminate cement, High Alumina Cement alone or a selective combination thereof having specific area having 4500-5000 Cm. Sq. particle size. "Source of ultra fine particles' - include ultra-fine particles varying from 50 A to 0.5 micron of any one o selective combination of alumina, calcium carbonate, hydrox ide, ash of rice husk, metakaoline, 'oxides such as AV 04, SiO , ZrO , and TiO , ground sieved fly ash, quartz, slag and micro silica i.e silica rich ultrafine dust obtained as byproduct in the production of ferro-si1iciurn or elmental silicon for.yielding superior strength of 8-9 MoH to said ultra fine particles. "Source of silica' - include quartz, agate, quartzite, garnet, sandstone, amorphous silica, colloidal silica, alone or selective combination thereof depending on the product specifications laid down by end user. 'Source of super plasticizer': include water soluble lignosulphonate, sulphonated naphthalene, formaldehyde condensate or sulphonated naphthalene, formaldehyde condensate, modified carboxylic ether alone or any selective combination thereof capable of acting as water reducing agent wherein said selected agents are capable of eliminating locking forces between the particles in the product mix and has no negative effect with respect to quality and rock hard wear resistance of the laid composite. 'Source of Bauxite and the like' - includes calcined bauxite, white / brown tabular alumina, fused alumina and the like inert or reactive aggregates alone or in any selective combination thereof. 'Pigment /dye' - includes any known pigment / dye of any desired colour or selective combination of colours for being impregnated with composite for giving eye pleasing colour to top composite' surface layer on asphalt / concrete / pebbled roads and floorings. 'Cationic emulsion' includes Polyacrilate water emulsion or Bitumen emulsion the like alone or in any selective combination thereof forming, a binder sandwiched between base of predressed pot holes and polymer coated metallised compound, known by generic name 'METAL - I' before spreading / laying composite. 'Anionic emulsion' includes Polyacrylamides Anionic emulsion or Asphalt emulsion and the like alone or any desired combination thereof forming a binder sandwiched between base of predressed pot holes and polymer coated metallised compound known by generic name 'METAL-I'. 'Polymer aggregates coated with commerci¬ally available 'METAL-I' metallised binder 'formi ng a bi nder'. 'Pot holes and the like' - include pot holes formed in old asphalt / concrete roads for being dressed with cationic / anionic emulsion. 'Lime reactive materials' - include fly ash or slag alone or any selective combination thereof. 'Inert inorganic particles' include dolomite, calcite, metakaoline, metal powders, metal fibers glass fibers alone or any selective combination thereof; 'Organic fibers' commercially known as Kavelar fibers'. Fibers of polycrystalline alumina or high alpha alumina, and/or polymer fibers , alone or selective combination thereof having unique properties of expanding along accordion like one plane and adapted to get entangled with cement matrix to attain tensile strength two times and increase impact and compression resistance four times; 'dispersing agents' include lignosulphonate, sulphonated melamine, formaldehyde condensate or modified carboxylic ether alone or any selective combination thereof forming a water reducing agent or high performance water reducing agent capable of substantially eliminating locking forces between the particles in the product mix. STATEMENT OF INVENTION: According to this invention , a rapid setting, homogenous composition is prepared and set to form a low porosity ultra high density cementitious composite. The process comprises amongst others of : a. Preparing an homogenous admixture by dry mixing the following: i) 10 to 60 % crushed inert or reactive aggregates containing alumina; ii) 10 - 80 % water soluble alitic and/or non alitic cement; iii) 5 - 50 % of one or more varieties of crushed, sieved, wet ground and pulverized silicious material as filler; iv) 10 - 60 % f organic and/ or inorganic fibers ; v) 5 - 40% of ultra fine metallic parti cles; vi) optionally adding 0-5 % of pigment dye to give color to composite The above mixing may be done in a high intensive or planetary mixer for 4-5 minutes a b) A moisture free homogenous mass is prepared by adding to admixture, while mixing is continued, water reducing aqueous solution of super plasticizers.The super plasticiser is added in two installments . First 75% is added, and mixed thoroughly and then the balance is added. The super plasticisers are capable of eliminating locking forces between admixture particles, so that a desired consistency is obtained , and the resultant is air dried to remove any residual moisture. c) a light, fluid, uniform, plastic consistency homogenous composition is prepared by adding water to the homogenous mass . This homogenous composition is set by pouring it on predressed substrate and subsequently spread and leveled. The substrate may range from pot holes, old worn out asphalt, tar, cement, cobble stone or concrete roads and such other road surfaces that need to be repaired. The substrate is usually predressed with a cationic or anionic emulsion, and covered with a coat of 1 to 5 % metlised polymer coated aggregates such as Metal -I, to form a binder composition sandwiched between the base of the pothole and base of said predressed road top surface which is covered by the grout which is the homogeneous composition. Optionally a skid resistant layer may be added over the composition that has been poured in to the substrate. The entirety is compacted to remove ai r pockets and to have a void ratio of less than 30 % . The same is cured at ambient temperature, by exposing to air to form a ultra high density, cementitious composite. The composite so formed has the characteristics, as set out in TABLE -1 as herein given: TABLE- 1 a Compressive strength : 1000-A 3000 Kg/Cm. -Sq. b) Hardness after 1 day : ... 35-40 Mpa c) Hardness after 28 days : >80 - 90 Mpa d) Flexural strength: 08 - 10 Mpa e) Density: 2100 Kg/m sq. f) Apparent porosity : • 000-0.02 % g) Abradibility index : . ... 010-030 and wherein the sequential order of steps (a) to (f) for carrying out said process being alterable to suit end user convenience. According to one embodiment for filling up pot¬holes and resurfacing cement concrete road tops*anionic emulsion is used as binder instead of cationic emulsion. According to this invention the smooth layer of asphalt road top is rendered skid resistant by saturating powdered quartz into top layer of ~ACCMarg' composite before allowing it to get cured at ambient temp, in open air for 4 hours to 28 days depending on rock hard wear resistant surface desired for said top layer. According to still another embodiment for giving ACCMarg smooth road top surface layer said composite is 14 sprayed with herein stated source of curing compound Ri*te cure _ AL such as and the like or combination thereof to prevent rapid drying of said "ACCMarg' composite. According to still another embodiment "ACCMarg' composite is mixed and impregnated with any desired colour fast dye while being mixed in a pan mixer to form light fluid / coherent consistency. According to still another embodiment for rehabil¬itation and extension of service life of old asphalt / concrete / cobble stone topped road surface wherein- apart from sub-grade soil properties, soil moisture in pavement thickness matters the cross sectional thickness is required to be increased and in such cases the 'ACCMarg' overlays is thinner in cross section yet having higher load bearing capacities than mere use of bituminous overlays. According to yet another embodiment the high intensive mixer comprises a high speed rotor wherein rota¬tion of pan opposite to said rotor direction generates a dense packing for said powdered mass. According to one embodiment where skid resistant surface is required said 'ACCMarg' layer after spreading on pretreated asphalt roads is saturated with pulverised quartz particles to form skid resistant top layer which on being cured attains rock hard wear resistant strength herein stated TABLE- 1 . According to another embodiment wherein the rapid drying of said "ACCMarg' laid top layer on top of predressed asphalt road is retarded by immediately spraying / sprink- Rite- qure, - .AL ling said layer with curing compound such as >:'....'.... and the like alone or selective combination thereof before allowing it to get cured at ambient temperature in open air in herein stated manner to give smooth road top. surface having product.characteristics in herein stated, TABLE- 1. According to this invention the "ACCMarg' com¬posite forms a much cheaper substitute to concrete and bitumen layered roads. The following typical working examples describe the manner in which the process of manufacturing and apply¬ing rapid setting rock hard ultra high dense cementitious compound is to be carried out: EXAMPLE- 1 Grinding separately or together: a) Dry crushed coarse ground lumps of calcined bauxite aggregates having 4 mm to 700 micron particle size mixed with fine ground calcined bauxite aggregates having 500 to 100 micron particle size in 2:1 ratio 650 gms b) Water soluble Cement such as OPC (Ordinary Portland Cement) 53 grade- with specific surface varying from 3500 to 500 cm.sq./gm. ' 750 gms. c) source of herein defined quartz and the like having d) source of herein stated Silicafume 100 gms. e) aqua sol of herein stated water soluble source of super plasticizer such as napthalene, sulphonic acid, formaldehyde condensate 100 gms. wherein the product of steps (b), (c), and (d) are dry mixed in high a intensive mixer for 4 -10 minutes before adding product mix of step (a) and slowly adding 75% of aqua sol of step (e) to said mixer and mixing is continued for further 4 -10 minutes before adding balance 25% of said aqua sol to said mixer and mixing is continued for further 20-25 minutes and air drying said powdered mass to remove thereform resid¬ual moisture to form ~ACCMarg' composite before packing in air tight plastic or like bags and which at user end is fur¬ther mixed in a pan mixer with water at factory or work site to form light fluid / coherent consistency ready for being laid and uniformly spread on predressed pot holes and top layer on asphalt or, cobble stoned road surface coated with cationic emulsion and metallised polymer coated binder and spread.with light and firm scrapping of said "ACCMarg' fluid layer with rubber scrappers and compacted by rolling a smooth roller thereover to remove any residual air pockets left in said polymer coated top layer while therein taking care to see that said "ACCMarg' layer fully covers said polymer coated layer before curing it in open air at ambient temperature for 4 hours to 1 day and extending upto 28 days depending- rock hard wear resistance required by the end user specification to be attained by said "ACCMarg' topped layer having hereinbefore stated TABLE - 1 of product analysis. EXAMPLE-2 a) Calcined bauxite 800 gms. b) Ordinary Portland Cement 600 gms. c) Fine quartz 300 gms. and d) Silicafume 100 gms. are mixed together with 09% water in a planetary mixer; e) mixing the product of steps (a) to (d) in a in a high intensity mixer while slowly adding to the mixer aqua sol of herein defined super plasticiser such as ligno- sulphonate and the like 60 gms. and processed further and cured in the manner described in Example- 1 attains: Compressive strength 2000-2500 Kg/cm.Sq. Flexure strength 180- 200 Kg/cm.sq. while retaining other product characteristics given in hereinbefore stated TABLE- 1. EXAMPLE- 3 In this example high alumina cement having specif¬ic area in the range of 4500-5000 cm.sq./gm is used instead of Ordinary Portland Cement and wherein other ingredients used are similar to composition of Example- 1 which when cured in herein Example 1 attains Compressive strength 2800-3000 Kg/cm.Sq. Flexure strength 250- 280 Kg/cm.sq. while retaining product characteristics given in hereinbe¬fore stated TABLE- 1. EXAMPLE- 4 In this example instead of alitic high early strength gain sulphoaluminate cement having specific surface area in the range of 4500 - 5000 cm.sq./gm. is used wherein the composition, particle size and processing of admixed materials and curing is carried out as stated in Example- 1 to attain : Compressive strength 1800-2000 Kg/cm.Sq. Flexure strength 160- 180 Kg/cm.sq. while retaining other product characteristics given in hereinbefore stated TABLE- 1. EXAMPLE-5 In this example : a) separately mixed aggregates such as fused alumina, brown tabular alumina, white tabular alumina, and calcined bauxite 650 gms. are mixed with : b) Ordinary Portland Cement 750 gms. c) fine quartz 300 gms. d) Silicafume 100 gms having hereinbefore stated particle size and processing is carried out in hereinbefore stated Example- 1 and which when laid on asphalt / concrete road top of pre- dressed potholes and cured at ambient temp, in open air for 4 hours to 1 day and extended upto 28 days attains : Compressive strength 1150-2000 Kg/cm.Sq. while other product characteristics given in hereinbefore stated TABLE- 1 are retained. EXAMPLE- 6 In this example instead of using calcined bauxite steel or stainless steel powder particle is used to form rock hard wear resistant strength to the cured top layer of 'ACCMarg' composite while retaining other aggregates and process condition same as stated in Example-1 and which when laid on asphalt / concrete road top on pre-dressed potholes and top layer of asphalt / concrete />cobbble stone road top and cured at ambient temp, in the manner stated in Example-1 attai ns : Compressive strength 2500.-3000 Kg/cm. Sq. Flexural strength 250- 280 Kg/cm.Sq. having product characteristics given in hereinbefore stated TABLE- 1. EXAMPLE- 7 Repairing potholes and relaying worn out top layer of old asphalt or cobble stone road surfaces with "ACCMarg' composite is carried out by following steps wherein : 1) sweep clean dust and other particles deposited in pot holes and on top layer of asphalt road to be resurfaced followed by applying cationic emulsion forming a binder; 2) applying layer of herein stated metallised polym¬er plasticiser wherein the void ratio of said plasticiser is around 25-30% on said emulsion coated layer of step 1; 3) laying a coat of 'ACCMarg' light fluid/coherent consistency layer on the product of step (2) and uniformly spreading firmly with rubber scrappers and compacting by rolling a smooth roller to remove any residual air pockets left therewithin behind and form a sandwich pack between base of said dressed pot holes and said plasticiser layer before being allowed to get cured for 4 hours to 1 day and Extending upto 28 days depending on the rock hardness de¬sired to be attained by said 'ACCMarg' surface complying with BS and IS specifications to attain herein before stated TABLE- 1 of product characteristics. Example- 8 For filling up pot holes formed in and/ or resurfacing cement concrete road tops anionic emulsion is used as binder and followed by steps given in Example 7 to attain product characteristics given in herein stated in TABLE- 1. Example- 9 For giving high skid resistance to 'ACCMarg' laid top layer surface of asphalt, concrete or cobble stone roads the green 'ACCMarg' fluid / consistency layer is spread with quartz particles before being cured followed by steps given in Example- 1 to attain desired rock hard wear resistant top surface having product characteristic given in herein before stated TABLE- 1. Example- 10 For giving smooth road top surface to the ~ACCMarg' layered top surface on asphalt, concrete or cobble stone roads herein stated curing compound such as .Rtt;e C\if€ - .Al¬and the like or combination thereof is sprayed on said top "ACCMarg' layer to retard its rapid drying and wherein the other ingredients of said composite and which when cured as stated in Example- 1 attains hereinbefore stated TABLE-1. Example- 11 While said ~ACCMarg' composite is being converted into light fluid / coherent consistency in a pan mixer it is i impregnated with any colour fast dye mixed with water for being impregnated with giving eye pleasing smooth coloured dust and water repellent road top surface. Example- 12 For rehabilitation and extension of service life of old asphalt / concrete / cobbled road tops where apart from sub-grade soil properties, soil moisture - where mainly pavement thickness matters - its cross sectional thickness is in¬creased and in such cases the 'ACCMarg' overlays are thinner in cross section yet having higher load bearing capacities than bituminous overlays. According to this invention the mixing of the various ingredients stated in any of the herein before stated Examples 1 to 12 forming cementitious composite is carried out in any known mixers such as ordinary mixer, ball mill mixer, planetary mixer or high intensive mixer comprising a high speed rotor wherein rotation of pan is opposite to said rotor direction and is capable of producing a moisture free high density composite having TABLE-1 of herein stated product characteri sties. While we have described and illustrated a particular embodiments of our process of manufacturing cementitious material, it is intended to illustrate the process rather than to limit it. It is to be expressly understood that this process is susceptible to such changes and modifications which may be made by any person skilled in the art to suit individual job requirement specification and any such changes or modification so made therein by such skilled person shall define no material departure from the salient features of the process of present invention herein described and illustrated in the accompanying set of working examples. WE CLAIM: 1. A process of manufacturing a low porosity, ultra high density, cementitious composite comprising amongst others of: a) Preparing a homogenous admixture by dry mixing the following : i) 10 to 60 % crushed men or reactive aggregates containing alumina, having a particle size of 0.5 mm to 10 mm. ii) 10 - 80 % water soluble alitic and/or non alitic cement, having a particle size varying from 15-30 microns (3500 -5000 cm sq.gm) iii) 5-50 % of one or more varieties of crushed, sieved, wet ground and pulverized silicious material as filler, having particle size of less than 10 microns; iv) 10 - 60 %of organic and/ or inorganic fibers, of .05 to 10mm size ; v) 5 - 40% of ultra fine metallic particles of 50A° to 5 microns size vi) optionally adding 0-5 % of pigment dye to give color to composite b) Preparing a moisture free homogenous mass by adding to admixture water reducing aqueous solution of super plasticizers capable of eliminating locking forces between admixture particles, to obtain desired consistency and air drying the same. c) Adding water to the homogenous mass, to prepare a light, fluid, uniform, plastic consistency homogenous composition and setting the same, by pouring on predressed substrate and subsequently spreading and leveling composition to have a void ratio of less than 30 % with or without external skid resistant layer, and compacting the same to remove air pockets, and curing at ambient temperature to form a ultra high density, cementitious composite. 2. A process as claimed in claim 1, where in the substrate are pot holes in roads or asphalt road surfaces are predressed with a coating layer of cationic or anionic emulsion followed by a coat of 1-5% metallised polymer coated aggregates, to form a binder composition, between substrate and cementitious • composite. 3. A process as claimed in claim 1 and 2 where in the water soluble cement consists of one or more among ordinary Portland cement, high early strength cement, sulphate resistant cement, low heat cement, Portland blast furnace slag cement, Portland pozzlona cement, white Portland cement, calcium sulphate aluminate cement, high alumina cement. 4. A process as claimed in claim 3, where in the silicious material consists of one or more in selective combination among the group consisting of quartz, sand, slag, alumina, calcium carbonate, dolomite, calcite, metakaoline metal powders, agate, quartzite, garret, sandstone, amorphous silica, colloidal silica. 5. A process as claimed in claim 4 wherein the fibers are organic fibers of one or more among the group of carbon black, kavelar and where such fibers are capable of forming a tangled mesh within the composite. 6. A process as claimed in claim 4, where in the inorganic fibers of one or more among metal, stainless steel, glass, high alpha alumina, micro silica, polycrystalline alumina. 7. A process as claimed in claim 5, where in the ultra fine particles include one or more among alumina, calcium carbonate, hydroxide, ash or rice husk, metakaoline, oxides such as AI2O3, SiO, ZrO and TiO, ground sieved flyash, quartz slag and micro silica or elemental silicon. 8. A process as claimed in claim 7 where in alumina containing aggregates include one or more among calcined bauxite, white/brown tabular alumina, and fused alumina. 9. A process as claimed in claim 8 where in the super plasticizers include one or more in selective combination among water soluble lignosulphonate, sulphonated melamine formaldehyde condensate or sulphonated naphthalene, formaldehyde condensate or modified carboxylic ether. 10. A process as claimed in claim 9 where in the coating layer of cationic emulsion consist of bitumen emulsion or polyacrylate solution.. 11. A process as claimed in claim 9 , where in the coating layer of anionic emulsion includes polyacrymalide anionic emulsion or asphalt emulsion 1.2. A process as claimed in claim 10 or 11, where in the curing at ambient temperature extends from 4 hours to 28 days depending on strength of composite to be obtained. 13. A process as claimed in claim 12, where in the external surface layer of composition is saturated with powdered quartz to render the asphalt road skid resistant. 14. A process as claimed in claim 1.3 where in. the external surface layer is sprayed with a curing compound to prevent rapid drying 15. A process as claimed in claim 14, where in the curing compound is Ritecure-Al by itself or in selective combination.. 16. A process as claimed in claim 1 to 15 where in mixing takes place in a planetary mixer or a high intensity mixer comprising of high speed rotor, with pan where in pan rotation is opposite to rotor direction generating a dense packing of powdered homogenous mass 17. A process as claimed in claims 1 to 16, where in the mixing first takes place in a planetary mixer followed by high intensity mixer. 18. A process of manufacturing a homogenous composition for a rapid setting , low porosity, ultra high density cementitious composite made by any one or more of the steps as described here in above and referred to in the examples. Dated this 31st day of October 2000 Usha A.Chandrasekhar Advocate and Patent Attorney For ACC Limited Applicants

Documents:

972-mum-2000-abstract(06-12-2004).doc

972-mum-2000-abstract(06-12-2004).pdf

972-mum-2000-cancelled page(06-12-2004).pdf

972-mum-2000-claim(granted)-(06-12-2004).doc

972-mum-2000-claim(granted)-(06-12-2004).pdf

972-mum-2000-correspondence(ipo)-(12-12-2005).pdf

972-mum-2000-correspondence1(13-08-2003).pdf

972-mum-2000-correspondence2(06-12-2004).pdf

972-mum-2000-form 1(14-12-2004).pdf

972-mum-2000-form 1(31-10-2000).pdf

972-mum-2000-form 13(02-12-2004).pdf

972-mum-2000-form 13(29-11-2004).pdf

972-mum-2000-form 19(14-08-2003).pdf

972-mum-2000-form 2(granted)-(06-12-2004).doc

972-mum-2000-form 2(granted)-(06-12-2004).pdf

972-mum-2000-form 26(15-07-2004).pdf

972-mum-2000-form 26(31-10-2000).pdf

972-mum-2000-form 3(29-11-2004).pdf

972-mum-2000-form 3(31-10-2000).pdf

972-mum-2000-form 5(31-10-2000).pdf