Computer-implemented methods for redesigning a pre-existing concrete mix design

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.

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.    
   
   
       2 . A method as defined in  claim 1 , 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.  
   
   
       3 . A method as defined in  claim 1 , the revised design K factor being selected from among a plurality of different K factors that vary with design strength for a given set of raw materials.  
   
   
       4 . A method as defined in  claim 1 , further comprising inputting into the computing system data relating to particle size and particle packing density for at least two differently-sized aggregate components and the hydraulic cement.  
   
   
       5 . A method as defined in  claim 1 , further comprising: 
 the computing system designing a plurality of concrete mix designs having varying quantities of solid 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.    
   
   
       6 . 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.    
   
   
       7 . 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 an amine strengthener, fly ash or silica fume.  
   
   
       8 . 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.  
   
   
       9 . A method as defined in  claim 1 , further comprising: 
 preparing a concrete test sample based on a selected concrete mix design;    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 with the target strength compared to the selected concrete mix design.    
   
   
       10 . 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 with the target slump compared to the selected concrete mix design.    
   
   
       11 . A method as defined in  claim 1 , 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.    
   
   
       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: 
 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.    
   
   
       13 . A method as defined in  claim 12 , 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.    
   
   
       14 . A method as defined in  claim 12 , 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.    
   
   
       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: 
 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.    
   
   
       16 . A method as defined in  claim 15 , wherein at least some of the selected design K factors account for an effect on concrete strength of including at least one of an amine strengthener, fly ash or silica fume.  
   
   
       17 . A method as defined in  claim 15 , 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.  
   
   
       18 . A method as defined in  claim 15 , further comprising upgrading and/or adjusting production equipment utilized by the manufacturing plant to manufacture the revised concrete compositions so that each component is weighed or otherwise measured with an accuracy of about ±2.0%.  
   
   
       19 . A method as defined in  claim 15 , further comprising upgrading and/or adjusting production equipment utilized by the manufacturing plant so as to monitor moisture content of solid components and alter measured amounts of solid components and added batch water that are used to manufacture the revised concrete compositions based on detected changes in the moisture content of the solid components.  
   
   
       20 . A method as defined in  claim 15 , further comprising upgrading and/or adjusting production equipment utilized by the manufacturing plant so that the revised concrete compositions are delivered using concrete mixing trucks that include a vessel containing an admixture that alters slump and that meter a selected amount of the admixture into a mixing drum carrying the concrete composition in order to alter slump in a desired manner.