Computer-implemented methods for re-designing a concrete composition to have adjusted slump

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 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 for each 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.    
   
   
       2 . A computer-implement method as defined in  claim 1 , the computing system further determining a revised quantity for each of the components used to manufacture the revised concrete composition in order to produce a desired quantity of the revised concrete composition.  
   
   
       3 . A computer-implement method as defined in  claim 1 , wherein the ratio of cement paste to aggregates is increased so that the revised concrete composition has increased slump compared to the existing concrete composition.  
   
   
       4 . A computer-implement method as defined in  claim 1 , wherein the ratio of cement paste to aggregates is decreased so that the revised concrete composition has decreased slump compared to the existing concrete composition.  
   
   
       5 . A computer-implement method as defined in  claim 1 , the computing system further altering a ratio of fine aggregate to coarse aggregate so that the revised concrete composition has a desired cohesiveness.  
   
   
       6 . A computer-implement method as defined in  claim 1 , the computing system further altering a ratio of fine aggregate to coarse aggregate so that the revised concrete composition has a desired durability.  
   
   
       7 . A computer-implement method as defined in  claim 1 , the computing system determining how the revised ratio of cement paste to aggregates affects slump by accounting for a change in water content relative to other components in the concrete composition.  
   
   
       8 . A computer-implement method as defined in  claim 1 , further comprising manufacturing a concrete composition having a design slump, detecting a difference between actual slump and the design slump, and the computing system revising the ratio of cement paste to aggregate so that the revised concrete composition has a revised slump that more closely correlates to the design slump.  
   
   
       9 . A computer-implement method as defined in  claim 1 , further comprising manufacturing different batches of the existing concrete composition, monitoring changes in slump between the different batches, and when a change in slump is detected the computing system revising the ratio of cement paste to aggregate in order to maintain a substantially constant slump between the different batches.  
   
   
       10 . 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 and altering slump without altering strength, 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;    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 for the given set of raw materials;    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;    the computing system comparing the predicted strength for each concrete mix design with the target strength to identify an initial concrete mix design that is optimized with respect to strength; and    the computing system identifying a modified concrete mix design having altered slump by altering a ratio of cement paste to aggregates.    
   
   
       11 . A computer-implement method as defined in  claim 10 , the computing system further determining a quantity of each component used to manufacture concrete from the modified concrete mix design in order to produce a desired quantity of the concrete.  
   
   
       12 . A computer-implement method as defined in  claim 10 , wherein the ratio of cement paste to aggregates is increased so that the modified concrete mix design has increased slump compared to the initial concrete mix design.  
   
   
       13 . A computer-implement method as defined in  claim 10 , wherein the ratio of cement paste to aggregates is decreased so that the modified concrete mix design has decreased slump compared to the initial concrete mix design.  
   
   
       14 . A computer-implement method as defined in  claim 10 , the computing system further altering a ratio of fine aggregate to coarse aggregate so that the modified concrete mix design has a desired cohesiveness.  
   
   
       15 . A computer-implement method as defined in  claim 10 , the computing system further altering a ratio of fine aggregate to coarse aggregate so that the modified concrete mix design has a desired durability.  
   
   
       16 . A computer-implemented method of modifying an initial concrete composition having a predetermined ratio of fine aggregates to coarse aggregates in order to adjust slump, comprising: 
 identifying an initial concrete composition having a predetermined ratio of fine aggregates to coarse aggregates, an initial ratio of cement paste to aggregates, and an initial slump;    inputting into a computing system data relating to particle size and particle packing density for the fine aggregates and coarse aggregates;    the computing system designing a revised concrete mix design having a revised ratio of cement paste to aggregates in order to yield a revised concrete composition having an altered slump without substantially altering the strength of the revised concrete composition compared to the initial concrete composition; and    the computer system determining a quantity of each component used to manufacture the revised concrete composition in order to produce a desired quantity of the concrete    
   
   
       17 . A computer-implement method as defined in  claim 16 , wherein the predetermined ratio of fine aggregates to coarse aggregates is in a range of 40:60 to 60:40 parts fine aggregates to coarse aggregates.  
   
   
       18 . A computer-implement method as defined in  claim 16 , wherein the ratio of cement paste to aggregates is increased so that the revised concrete composition design has increased slump compared to the initial concrete composition.  
   
   
       19 . A computer-implement method as defined in  claim 16 , wherein the ratio of cement paste to aggregates is decreased so that the revised concrete composition design has decreased slump compared to the initial concrete composition.  
   
   
       20 . A computer-implement method as defined in  claim 16 , the computing system further altering the predetermined ratio of fine aggregate to coarse aggregate so that the revised concrete composition has a desired cohesiveness.