COMPUTER-IMPLEMENTED METHODS FOR REDESIGNING A PRE-EXISTING CONCRETE MIX DESIGN
First Claim
1. 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 at a given slump and at lower cost compared to the pre-existing concrete mix design, the method comprising:
- identifying a pre-existing concrete mix design that has a design strength, yields concrete having an initial ratio of hydraulic cement, water and air, and has an apparent design K factor based on the design strength and initial ratio of hydraulic cement, water and air;
inputting into a computing system a revised design K factor that is selected based on the design strength and that more closely corresponds to an optimal K factor corresponding to the design strength compared to the apparent K factor of the pre-existing concrete mix design; and
the computing system designing a revised concrete mix design having a revised ratio of components using a revised design K factor that is selected based on the design strength, wherein the revised concrete mix design guarantees a specific minimum strength at a given slump and at lower cost compared to the pre-existing concrete mix design.
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Accused Products
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.
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Citations
20 Claims
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1. 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 at a given slump and at lower cost compared to the pre-existing concrete mix design, the method comprising:
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identifying a pre-existing concrete mix design that has a design strength, yields concrete having an initial ratio of hydraulic cement, water and air, and has an apparent design K factor based on the design strength and initial ratio of hydraulic cement, water and air;
inputting into a computing system a revised design K factor that is selected based on the design strength and that more closely corresponds to an optimal K factor corresponding to the design strength compared to the apparent K factor of the pre-existing concrete mix design; and
the computing system designing a revised concrete mix design having a revised ratio of components using a revised design K factor that is selected based on the design strength, wherein the revised concrete mix design guarantees a specific minimum strength at a given slump and at lower cost compared to the pre-existing concrete mix design. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A computer-implemented method for redesigning a pre-existing concrete composition manufactured at a concrete plant from a set of raw materials so as to yield better optimized concrete that guarantees a specific minimum strength at a given slump and at lower cost compared to the pre-existing concrete composition, the method comprising:
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identifying a pre-existing concrete composition manufactured by a manufacturing plant from a set of raw materials and that has a design strength;
inputting into a computing system data relating to particle size and particle packing density for a plurality of solid components used by the manufacturing plant to manufacture the pre-existing concrete composition;
determining, based on the design strength for and an initial ratio of hydraulic cement, water and air within the pre-existing concrete composition, an apparent design K factor for the pre-existing concrete composition;
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 design strength from among a plurality of different design K factors that vary with concrete strength for the set of raw materials, the design K factor more closely corresponding to an optimal K factor for the design strength compared to the apparent design K factor of the pre-existing concrete composition;
the computing system designing a plurality of concrete mix designs having varying quantities of raw materials;
the computing system determining an amount of water that will yield or approximate a predetermined slump for each of the concrete mix designs;
the computing system determining, based on the selected design K factor and the amount of water determined to yield or approximate the predetermined slump, a predicted strength for each of the concrete mix designs; and
the computing system comparing the predicted strength for each concrete mix design with the design strength to identify one or more concrete mix designs that are better optimized with respect to strength compared to other of the plurality of concrete mix designs, wherein the one or more revised concrete mix designs yield one or more revised concrete compositions that guarantee a specific minimum strength at a given slump and at lower cost compared to the pre-existing concrete composition. - View Dependent Claims (13, 14)
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15. In an existing concrete manufacturing plant that manufactures a plurality of pre-existing concrete compositions having different design strengths, a method of redesigning the pre-existing concrete compositions so as to have actual strengths that more closely correlate with their respective design strengths compared to the pre-existing concrete compositions, the method comprising:
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identifying a plurality of pre-existing concrete compositions of the concrete manufacturing plant in need of better optimization, wherein at least two of the pre-existing concrete compositions have differing design strengths;
selecting a plurality of different design K factors for use in designing better optimized concrete compositions, wherein the different K factors correlate with and vary based on the differing design strengths;
designing, using the plurality of different design K factors, a plurality of revised concrete compositions having or revised ratios of components compared to the pre-existing concrete compositions, the revised concrete compositions having actual strengths that more closely correlate with their respective design strengths compared to the pre-existing concrete compositions previously manufactured at the concrete manufacturing plant, wherein the revised concrete compositions guarantee a specific minimum strength and slump at lower cost compared to the pre-existing concrete compositions. - View Dependent Claims (16, 17, 18, 19, 20)
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Specification