Methods and systems for redesigning pre-existing concrete mix designs and manufacturing plants and design-optimizing and manufacturing concrete

• US 20060287773A1
• Filed: 06/19/2006
• Published: 12/21/2006
• Est. Priority Date: 06/17/2005
• Status: Abandoned Application

• Current Assignee: iCrete LLC
• Original Assignee: E. Khashoggi Industries, LLC
• Inventors: Andersen, Per Just, Hodson, Simon K.
• Application Number:
  US11/471,293
• Publication Number:
  US 20060287773A1
• Time in Patent Office: Days
• US Class Current: 700/265
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 24/12 Nitrogen containing compounds organic derivatives of hydrazine hydrazine C04B22/00
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0096 Provisions for indicating condition of the compositions or the final products, e.g. degree of homogeneous mixing, degree of wear
• CPC Class Codes: G06F 2111/02 CAD in a network environment, e.g. collaborative CAD or distributed simulation
• CPC Class Codes: G06F 2111/06 Multi-objective optimisation, e.g. Pareto optimisation using simulated annealing [SA], ant colony algorithms or genetic algorithms [GA]
• CPC Class Codes: G06F 30/13 Architectural design, e.g. computer-aided architectural design [CAAD] related to design of buildings, bridges, landscapes, production plants or roads
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Design optimization methods can be used to design concrete mixtures having optimized properties, including desired strength and slump at minimal cost. The design optimization methods use a computer-implemented process that is able to design and virtually “test” millions of hypothetical concrete compositions using mathematical algorithms that interrelate a number of variables that affect strength, slump, cost and other desired features. The design optimization procedure utilizes a constant K (or K factor) within Feret'"'"'s strength equation that varies (e.g., logarithmically) with concrete strength for any given set of raw material inputs and processing equipment. That means that the binding efficiency or effectiveness of hydraulic cement increases with increasing concentration so long as the concrete remains optimized. The knowledge of how the K factor varies with binding efficiency and strength is a powerful tool that can be applied in multiple circumstances. A concrete manufacturing process may include accurately measuring the raw materials to minimize variation between predicted and actual strength, as well as carefully controlling water content throughout the manufacturing and delivery process.

Claims

1. A computer-implemented method for designing, for a given set of raw materials, an optimized concrete mix design having a desired strength and slump at lower cost than a non-optimized mix design, the method comprising:

inputting into a computing system data relating to particle size and particle packing density for a plurality of solid components;

inputting into the computing system a target strength and slump;

inputting into the computing system a selected design K factor for use in determining a predicted strength for each of a plurality of concrete mix designs generated by the computing system, the design K factor being selected based on the target strength from among a plurality of different K factors that vary with concrete strength;

the computing system designing a plurality of concrete mix designs having varying quantities of raw materials;

the computing system determining, based on the selected design K factor, a predicted strength for each concrete mix design;

the computing system determining a predicted slump for each concrete mix design; and

the computing system comparing the predicted strength and slump for each concrete mix design with the target strength and slump to identify one or more concrete mix designs that are better optimized with respect to strength and slump compared to other of the plurality of mix designs.

2. A method as defined in claim 1, further comprising:

inputting into the computing system data relating to raw materials cost; and

the computing system identifying one or more mix designs having a lower cost compared to other of the plurality of concrete mix designs.

3. A method as defined in claim 1, wherein the selected design K factor accounts for an effect on concrete strength of including an amine strengthener.

4. A method as defined in claim 1, wherein the selected design K factor accounts for an effect on concrete strength of including at least one of fly ash or silica fume.

5. A method as defined in claim 1, wherein the selected design K factor accounts for an effect on concrete strength of using a specific mixing apparatus.

6. A method as defined in claim 1, further comprising:

preparing a concrete test sample based on a selected concrete mix

determining a strength for the concrete test sample; and

the computing system generating a new concrete mix design that yields a concrete composition having a strength that more closely correlates to the target strength compared to the selected concrete mix design.

7. A method as defined in claim 1, further comprising:

preparing a concrete test sample based on a selected concrete mix design;

determining a slump for the concrete test sample; and

the computing system generating a new concrete mix design that yields a concrete composition having a slump that more closely correlates to the target slump compared to the selected concrete mix design.

8. A method as defined in claim 1, further comprising:

identifying a pre-existing mix design used by a manufacturing plant to manufacture a concrete composition;

determining, based on a design strength for and a ratio of components within a concrete composition made using the pre-existing mix design, an apparent design K factor for the pre-existing mix design; and

the computing system designing, according to claim 1, one or more new mix designs having a design K factor that is greater than the apparent design K factor for the pre-existing mix design.

9. A method as defined in claim 8, further comprising:

upgrading and/or recalibrating equipment used by the manufacturing plant in manufacturing concrete so that concrete manufactured by the manufacturing plant using the upgraded and/or recalibrated equipment has an actual strength that more closely correlates to design strength compared to previous equipment prior to upgrading and/or recalibrating.

10. A method as defined in claim 1, further comprising:

for a given concrete mix design that yields a concrete composition having a slump, strength, and ratio of cement paste to aggregate, the computing system designing a modified mix design having a modified slump, but a substantially similar strength, by altering the ratio of cement paste to aggregate.

11. A method of manufacturing a concrete composition using a concrete mix design that is optimized according to the method of any of claims 1-10, the concrete composition having a substantially optimized ratio of raw materials.

12. A concrete composition having a substantially optimized ratio of raw materials manufactured according to the method of claim 11, wherein the concrete composition has a signature design K factor that is unique as compared to an apparent design K factor for a less optimized concrete composition made using the given set of raw materials.

13. A concrete composition having a substantially optimized ratio of raw materials manufactured according to the method of claim 11, wherein the concrete composition has a signature K factor that is unique to the given set of raw materials as compared to a K factor for concrete having similar strength but manufactured from a different set of raw materials.

14. In a computing system for design-optimizing a concrete composition, a method for designing, for a given set of raw materials, an optimized concrete mix design having a desired strength and slump at lower cost than a non-optimized mix design, the method comprising:

receiving by the computing system data relating to particle size and particle packing density for a plurality of solid components;

receiving by the computing system a target strength and slump;

receiving by the computing system a selected design K factor for use in determining a predicted strength for each of a plurality of concrete mix designs generated by the computing system, the design K factor being selected based on the target strength from among a plurality of different K factors that vary with concrete strength;

the computing system designing a plurality of concrete mix designs having varying quantities of raw materials;

the computing system determining, based on the selected design K factor, a predicted strength for each concrete mix design;

the computing system determining a predicted slump for each concrete mix design; and

the computing system comparing the predicted strength and slump for each concrete mix design with the target strength and slump to identify one or more concrete mix designs that are better optimized with respect to strength and slump compared to other of the plurality of mix designs.

15. A method as defined in claim 14, further comprising:

the computing system receiving data relating to raw materials cost; and

the computing system identifying one or more mix designs having a lower cost compared to other of the plurality of hypothetical mix designs.

16. A method as defined in claim 14, wherein the selected design K factor accounts for an effect on concrete strength of including at least one of an amine strengthener, fly ash, or silica fume and/or using a specific mixing apparatus.

17. A computer program product containing executable instructions for implementing the method according to any of claims 14-16.

18. A computer-implemented method for redesigning a pre-existing concrete mix design so as to yield a better optimized concrete mix design that guarantees a specific minimum strength and slump at lower cost compared to the pre-existing concrete mix design, the method comprising:

identifying a pre-existing concrete mix design having an initial ratio of components, a design strength, and an apparent design K factor that varies based on strength; and

the computer system designing a revised concrete mix design having a revised ratio of components using a revised design K factor that is higher than the apparent K factor of the pre-existing concrete mix design and that more closely corresponds to an optimal K factor corresponding to, and selected based on, the design strength.

19. A method as defined in claim 18, wherein concrete compositions made using the revised concrete mix design have actual strengths that more consistently correspond to the design strength compared to concrete compositions made using the pre-existing concrete mix design.

20. A method of manufacturing a concrete composition using a concrete mix design that is redesigned according to the method of claims 18, the concrete composition having a better optimized ratio of raw materials compared to concrete compositions made using the pre-existing concrete mix design so as to have the specific minimum strength and slump at lower cost compared to concrete compositions made using the pre-existing concrete mix design.

21. A concrete composition manufactured according to the method of claim 20.

22. A concrete composition as defined in claim 21, wherein the concrete composition has a signature design K factor that is higher than the apparent design K factor of a concrete composition made using the pre-existing concrete mix design and that more closely correlates with an optimal K factor corresponding to the design strength.

23. In a concrete manufacturing plant that manufactures concrete from a given set of raw materials and/or processing variables, a composition of matter comprising an optimized concrete composition manufactured by the manufacturing plant, the optimized concrete composition having a minimum slump and strength that are achieved by mixing together an optimized combination of hydraulic cement, aggregates, water, and one or more optional components, which optimized combination is determined using an optimization process in which a pre-existing mix design previously used by the manufacturing plant is redesigned and optimized utilizing a design K factor for use within Feret'"'"'s strength equation that corresponds to a design strength of the optimized concrete composition and that is selected from a plurality of K factors that vary based on strength for the given set of raw materials and/or processing variables, the design K factor of the optimized concrete composition being a signature that differentiates the optimized concrete composition from a less optimized concrete composition manufactured using the pre-existing mix design.

24. A composition of matter as defined in claim 23, the optimized concrete composition being unique as compared to concrete compositions manufactured by any other manufacturing plant having its own unique set of raw materials and/or processing variables.

25. In a concrete manufacturing plant that manufactures concrete from a unique set of raw materials and/or processing variables, a composition of matter comprising an optimized concrete composition manufactured by the manufacturing plant, the optimized concrete composition having a minimum slump and strength that are achieved by mixing together an optimized combination of hydraulic cement, aggregates, water, and one or more optional components, which optimized combination is determined using an optimization process in which an optimized mix design is designed utilizing a design K factor for use within Feret'"'"'s strength equation that corresponds to a design strength of the optimized concrete composition and that is selected from a plurality of K factors that vary based on strength and correspond to the unique set of raw materials and/or processing variables, the design K factor of the optimized concrete composition being a signature that differentiates the optimized concrete composition from any other concrete composition manufactured using raw materials and/or processing variables that differ from the unique set of raw materials and/or processing variables employed by the manufacturing plant.

26. In an existing concrete manufacturing plant that manufactures a plurality of different concrete compositions having different design strengths, a method of manufacturing improved concrete compositions that have actual strengths that more closely correlate with their respective design strengths, the method comprising:

identifying a plurality of pre-existing concrete mix designs of the concrete manufacturing plant in need of better optimization, wherein at least two of the mix designs have differing design strengths;

selecting a plurality of different design K factors for use in designing better optimized concrete mix designs, wherein the different K factors correlate with and vary based on differing selected design strengths;

designing, using the plurality of different design K factors, a plurality of new or revised concrete mix designs having new or revised ratios of components compared to the pre-existing mix designs; and

manufacturing, based on the new or revised concrete mix designs, revised concrete compositions having actual strengths that more closely correlate with their respective design strengths compared to pre-existing concrete compositions previously manufactured using the pre-existing mix designs,

wherein the revised concrete compositions guarantee a specific minimum strength and slump at lower cost compared to the pre-existing concrete compositions.

27. A method of manufacturing optimized concrete compositions as defined in claim 26, further comprising making slump adjustments to one or more of the revised concrete compositions by adding or altering an amount of an admixture within the one or more concrete compositions.

28. A method of manufacturing improved concrete compositions as defined in claim 26, further comprising upgrading and/or adjusting production equipment utilized by the manufacturing plant so that each component is weighed or otherwise measured with an accuracy of about ±

2.0%.

29. A method of manufacturing improved concrete compositions as defined in claim 26, further comprising monitoring moisture content of solid components and altering measured amounts of solid components and added batch water used to manufacture a concrete composition based on detected changes in the moisture content of the solid components.

30. A method of manufacturing improved concrete compositions as defined in claim 26, further comprising delivering a concrete composition using a concrete mixing truck that includes a vessel containing an admixture that alters slump and metering a selected amount of the admixture into a mixing drum carrying the concrete composition in order to alter slump in a desired manner.

31. A concrete composition manufactured according to the method of any of claims 26-30.

32. In a concrete manufacturing plant having a given set of raw material components, a method of manufacturing optimized concrete compositions having actual strengths that more closely reflect their predicted or design strengths compared to less optimized concrete compositions made from the given set of raw material components, the method comprising:

providing a plurality of optimized concrete mix designs having different design strengths that were designed using different design K factors, wherein each different design K factor was selected at least in part based on its respective design strength; and

manufacturing a plurality of optimized concrete compositions based on the optimized concrete mix designs, each optimized concrete composition having an optimized ratio of components so as to have an actual strength that more closely reflects its predicted or design strength compared to a less optimized concrete composition made from the given set of raw material components.

33. A method of manufacturing optimized concrete compositions as defined in claim 32, further comprising making slump adjustments to one or more of the optimized concrete compositions by adding or altering an amount of an admixture within the one or more concrete compositions.

34. A method of manufacturing improved concrete compositions as defined in claim 32, further comprising weighing or otherwise measuring the components of each concrete composition with an accuracy of about ±

2.0%.

35. A method of manufacturing improved concrete compositions as defined in claim 32, further comprising monitoring moisture content of solid components and altering a measured amount of solid components and added batch water used to manufacture a concrete composition based on detected changes in the moisture content of the solid components.

36. A method of manufacturing improved concrete compositions as defined in claim 32, further comprising mixing one or more of the optimized concrete compositions using a concrete mixing truck that includes a vessel containing an admixture for adjusting slump and metering a selected amount of the admixture into a mixing drum carrying the concrete composition in order to alter slump in a desired manner.

37. A concrete composition manufactured according to the method of any of claims 32-36.

38. In a concrete manufacturing plant that manufactures concrete from a given set of raw materials, a concrete building system comprising a plurality of optimized concrete compositions manufactured by the manufacturing plant, at least two of the optimized concrete compositions having different design strengths, each of the plurality of optimized concrete compositions having a guaranteed minimum slump and strength that is achieved by mixing together an optimized combination of hydraulic cement, aggregates, water, and one or more optional components, which optimized combination is determined using an optimization process for designing optimized mix designs used by the manufacturing plant to manufacture the optimized concrete compositions, each optimized mix design being designed using a design K factor for use within Feret'"'"'s strength equation that corresponds to a design strength of the optimized mix design and that is selected from a plurality of K factors that vary based on strength, each optimized concrete composition having a signature design K factor that differentiates it from at least one other of the optimized concrete compositions having a different design strength.

39. A concrete building system as defined in claim 38, the signature design K factor of each optimized concrete composition differentiating the optimized concrete composition from less optimized concrete compositions manufactured from the given set of raw materials.

40. A concrete building system as defined in claim 38, the signature K factors for the optimized concrete compositions differentiating the optimized concrete compositions from concrete compositions manufactured from raw materials that differ from the given set of raw materials used by the manufacturing plant.

41. A method of determining whether an existing concrete composition having a given design strength and given ratio of components is overdesigned without having to (i) prepare a concrete test sample, (ii) allow it to harden, (iii) test its actual strength, and (iv) compare the actual strength of the test sample with the given design strength, the method comprising:

determining an apparent design K factor for the existing concrete composition based on the given design strength of the concrete composition and the given ratio of components within the concrete composition; and

comparing the apparent design K factor with a more optimal K factor that corresponds to the given design strength and which is selected from among a plurality of different K factors that vary with varying concrete strength.

42. A method as defined in claim 41, further comprising determining how much the existing concrete composition is overdesigned by determining a deviation between the apparent design K factor of the existing concrete composition and the selected K factor.

43. A method as defined in claim 41, further comprising redesigning the existing concrete composition by means of an optimization procedure that utilizes a revised design K factor that more closely correlates with an optimal K factor for the given design strength, wherein the optimization procedure yields a revised concrete composition having an actual strength that more closely correlates with the design strength compared to the existing concrete composition.

44. A method as defined in 41, further comprising manufacturing the revised concrete composition.

45. A revised concrete composition manufactured according to the method of claim 44.

46. A revised concrete composition as defined in claim 45, wherein the revised concrete composition has a signature design K factor that differentiates it from the existing concrete composition.

47. A computer-implemented method of modifying a concrete composition made from a given set of components in order to adjust slump without significantly altering strength, comprising:

identifying an existing concrete composition that is manufactured according to an optimized mix design that specifies a specific ratio of components, including a ratio of cement paste to aggregates, so as to achieve a desired strength and slump;

inputting into a computing system data relating to particle size and particle packing density of one or more types of aggregates; and

the computing system designing a revised concrete mix design having a revised ratio of cement paste to aggregates that yields a revised concrete composition having a desired slump without substantially altering the strength of the revised concrete composition compared to the existing concrete composition.

48. A computer-implement method as defined in claim 47, the computing system further adjusting an amount of each of the components used to manufacture the revised concrete composition in order to produce a desired quantity of the revised concrete composition.

49. A concrete composition manufactured according to the method of claim 47 or 48.