Concrete based composite material and method of making a structural element therefrom

A method of forming a structural element including a composite material, the method comprising:

• providing a filler material comprising:
• a cementitious component;
• a sand component including iron rich particles;
• an aggregate component;
• a water component;
• forming a composite material including:
• mixing the cementitious component, the sand component, and the aggregate component to provide a mixture;
• hydrating the mixture with the water component to form the composite material;
• wherein the sand component has an iron rich particle content of at least 60% by weight of the sand component;
• wherein the iron rich particles have an iron content of at least 60% by weight of the iron rich particles;
• wherein the composite material has an iron content greater than 17% by weight of the composite material;
• and
• wherein the iron rich particles are an iron rich by-product recovered from an iron slag material;
• inserting the composite material into a mold cavity defined by a mold;
• and
• curing the composite material to form a structural element.

A method of forming a structural element including a composite material, the method comprising:

• providing a filler material comprising:
• a cementitious component;
• a sand component including iron rich particles;
• an aggregate component;
• a water component;
• forming a composite material including:
• mixing the cementitious component, the sand component, and the aggregate component to provide a mixture;
• hydrating the mixture with the water component to form the composite material;
• wherein the sand component has an iron rich particle content of at least 60% by weight of the sand component;
• wherein the iron rich particles have an iron content of at least 60% by weight of the iron rich particles;
• and
• wherein the composite material has an iron content greater than 17% by weight of the composite material;
• inserting the composite material into a mold cavity defined by a mold;
• curing the composite material to form a structural element;
• demolding the structural element from the mold;
• and
• applying a polyurea-based material on a surface of the structural element, such that the polyurea-based material encapsulates the structural element and defines a coating on the surface of the structural element.