method for monitoring and adjusting the slump and air content in a cement mix and mixing device

专利摘要:
SUMMARY MULTIVARIATED MANAGEMENT OF INCORPORATED AIR AND RHEOLOGY IN CEMENTITIOUS MIXTURES The invention relates to a method and system for monitoring and adjusting both the properties of air content and rheology (for example, slump / bottom, slump flow / laying) of a mixture of hydratable concrete contained within a concrete mixer (rotary concrete mixer). The system simultaneously monitors / controls the dosage of both rheology modifying additives (for example, polymeric polycarboxylate cement dispersant) and air-controlling agent or "ACA" (for example, air-incorporating agent), in function of at least four nominal response dose ("NDR") curves or profiles, in which at least four NDR profiles are based on the respective behaviors of each ACA and rheology modifying agents in air content and rheology.
公开号:BR112014014186B1
申请号:R112014014186-0
申请日:2011-12-12
公开日:2020-07-07
发明作者:Eric Koehler；Mark F. Roberts
申请人:Verifi Llc；
IPC主号:

专利说明:

FIELD OF THE INVENTION
[001] The present invention relates to the manufacture of concrete, and in particular, a method for monitoring and adjusting the properties of incorporated air and rheology (for example, slump / slump, slump / slump flow) in fresh concrete contained in a concrete mixing drum using a process control system. BACKGROUND OF THE INVENTION
[002] In US Patent Application Serial No. 11 / 834,002, Sostaric etal.disclosed that plasticizers and air-entraining agents can be dosed into the concrete contained in the mixing drum of a mixer truck using a process control system. However, it has not been explained how rheological properties, on the one hand, and air properties, on the other hand, could be controlled simultaneously.
[003] It is known, however, that the "slump" or fluidity can be individually monitored and adjusted using a process control system. This is done by measuring the energy required for the concrete to rotate in a mixing drum with several sensors; the correlation of the energy values with the abatement values (using a standard Cone Trunk Abatement Test); and storing that information in memory so that a central processing unit ("CPU") can correlate energy and slump values. See, for example, US Patents 4,008,093 and 5,713,663. Since the concrete hardens over time, due to hydration, evaporation, and / or other factors, more energy is needed to rotate the drum and the CPU can be programmed to activate devices that inject water or chemical dispersant into the mixture. concrete.
[004] Numerous patents have stated that various properties of concrete mixtures can be monitored and adjusted, through the use of sensor devices that are connected to a CPU. For example, in US Patent No. 5,713,663, Zandberg et al. implemented sensors to measure the amount of mix water and particulate ingredients, the moisture content of the sand, the weather, and other factors (See, for example, col. 8, lines 3-14). In US Patent Publication No. 2009 / 0.037,026, Sostaric et al. referred to the sensors for detecting the mixing drum temperature, rotation speed, 'acceleration / deceleration / tilt', vibration, and other properties. These and other prior art publications contain the common suggestion that the data collected by sensors can be listed in "search" graphics.
[005] However, for all prescriptions regarding the usefulness of data derived from sensors, the monitoring and control of rheology (for example, slump), as well as the incorporated air content, have not been achieved or integrated with precision or certainty in practice. Although it is well known that the change in air content affects the slump and vice versa, the concrete industry is unable to predict how the slump of a concrete mixture may be, for example, when doubling or multiplying levels built-in air. In other words, although the abatement can be increased, as a general proposition, by increasing the air content, the exact extent to which the abatement is increased has not yet been reliably predicted based on the amount of air incorporating mixture. ("AEA") that is introduced into the concrete mix. As a result, prior art devices have focused only on adjusting the rebate or other rheological property in the truck.
[006] For concrete without AEA, the addition of cement dispersant normally has an insignificant effect on the air content and the prior art devices were designed only to adjust the slump. However, in concrete with incorporated air, the present inventors realized that the alteration of rheology, by the addition of cement dispersing agents, substantially affects the air content. They believe that an integrated approach is needed to control both rheology and air content in such cases.
[007] The problem is that there is no coherent or linear correlation between rheological properties, such as slump and the use of AEAs in concrete mixtures. This is due in large part to the nature of the concrete, which is inconsistent from batch to batch, and even overnight. Many factors lead to this contradiction: including variability in the blend mix composition, quality and origin of the ingredients, processing conditions (eg temperature, humidity, cycles required for specific mixing drums), and the nature of the dispersant and AEA employed . As explained later, chemical dispersants and AEAs can have adverse and unpredictable effects on each other's performance.
[008] The state of the art lacks precise lessons on how to manage AEAs and dispersants using an integrated approach in a concrete mixer (rotary concrete mixer). The present inventors believe that the number of problems created by AEAs for ready-mix producers, contractors and owners far exceeds those created by all other additives. Almost everything influences the performance of AEAs: for example, environmental and concrete temperatures, travel time from plant to site, mixing time, type of cement, as well as the nature and variability of cement dispersants (particularly, polycarboxylate superplasticizers).
[009] There are different types of air in concrete: trapped air and incorporated air. The "trapped air" results from the mixing process, where the air is mechanically involved (usually 1.5% by volume of concrete) through the agitation of the aggregates or the movement of the blades inside the mixing drum. Such trapped air is visible to the naked eye as irregularly formed spans when viewed, for example, in a sawn cross-section of the hardened concrete. On the other hand, the "incorporated air" takes the form of microscopic voids of a spherical shape; which makes it easier to distribute throughout the mixture. The dimensioning and spacing of the incorporated air bubbles are important for increasing the durability of the concrete subjected to freezing / thawing conditions. Incorporating air mixtures are used to form and stabilize these microscopic voids in the concrete.
[010] The complicating factor is that the typical measurement of air incorporated in concrete involves reading as a percentage of the total amount of air, which means both "trapped" and "incorporated" air. When the percentage reading is 6% air, for example, this means that approximately 1.5% of the total air is trapped, while 4.5% is incorporated air.
[011] To further complicate matters, the fact that the concrete mixing drum and the movement of the concrete mixer, which is jolted (Jostled) during the journey due to roads and uneven surfaces, can increase the relative amount of "trapped" air. . On the other hand, the longer the concrete is transported in the truck, the greater the decrease in the free water content in the concrete due to evaporation and hydration. Since water is necessary for the formation of air bubbles, the percentage of total air, including the incorporated air, may decrease.
[012] A further complicating factor is that different types of AEAs have different effects on the formation of bubbles in the concrete mix and can be influenced differently, depending on the type of dispersant used.
[013] A wood-derived salt type AEA, such as Vinsol resin, is often used in concrete mixtures with low water levels in order to obtain a good bubble structure. When a superplasticizer is added, in order to obtain a greater reduction in dumping, the levels of incorporated air tend to decrease. This continues the more the concrete is mixed in the truck. The addition of the air incorporating mixture is therefore necessary for this situation.
[014] On the other hand, a synthetic resin type AEA (for example, fatty acid or tall oil salts) works differently as it tends to incorporate more small bubbles as the slump increases. Thus, if water is added to the concrete mix at pouring, the amount of air that enters can potentially increase to excessive levels in some situations.
[015] In view of the above, the present inventors believe that a new method and automatic process control system is necessary to simultaneously integrate the monitoring and adjustment of both air and rheology properties, using separate component additions. an additive component of air control and an additive component of rheology control that, until now, have shown unpredictable and adverse effects on each other and on the resulting concrete mixture. SUMMARY OF THE INVENTION
[016] In order to overcome the disadvantages of the prior art, the present invention provides a process control management method and system for the control and regulation of air and rheology (for example, abatement, abatement flow, the limit of elasticity) in hydratable cementitious mixes, such as concrete in a mixing drum.
[017] The system and methods of the invention are suitable for adjusting the properties of concrete in a mixing drum, by means of automatic control and controlled addition of additives, including at least one cement dispersing agent comprising water, dispersant polymer, or mixture thereof; and including at least one air-controlling blend (ACA), such as an air-incorporating blend (AEA), an air-disintegrating blend (ADA), or a mixture thereof (AEA / ADA).
[018] An example of a system and method of the invention for monitoring and adjusting the incorporated air level and the rheology of a hydratable cementitious mixture, comprises: (a) supplying a concrete mixture in a concrete mixer (rotary concrete mixer), where the concrete mixture comprises hydratable cement, aggregates and water for the hydration of said cement, and the concrete mixture has a total volume, when mixed uniformly, from 0.765 m3 to 11.47 m3 (1.0 to 15.0 yards cubic); (b) introducing in a central processing unit (CPU) and storing in the computer accessible memory the performance of the desired concrete, which varies in relation to: A target rheology or target range (hereinafter referred to as "RT"), in which a desired concrete abatement or abatement range is specified within a range of 0 to 27.94 cm (0 to 11 inches) (for example, the abatement that is determined based on the standard Cone Trunk Abatement Test, according to ASTM C143-05 or other standard test); and a target air content or target range "AT", where a desired air content in the concrete or range of the desired air content is within a range of 1% to 10% (which can be determined according to the tests standards set out in ASTM C138-10, C173-10, and / or C231 -10 or other tests); (c) operate said concrete mixture in said concrete mixer (rotary concrete mixer) and obtain at least one rheology value in the current time (hereinafter referred to as "RCT") and at least one air content value in time current (hereinafter referred to as "ACT"); (d) comparing, using the CPU, said RCT with said RT, and said ACT with said AT, until the CPU detects a non-compliance event, in which said RCT does not conform to said RT and / or said ACT does not comply with said AT; and (e) introducing into the concrete mixture contained in said mixer (rotary concrete mixer), one of at least two different types of additives, comprising: at least one additive to modify the level of air incorporated in the concrete mixture ( hereinafter referred to as "ACA"), in which at least one said ACA comprises at least one Incorporating Air Mix (hereinafter referred to as "AEA"), Disincorporating Air Mixing ("ADA"), or a mixture thereof, and at least one cement dispersant to modify the rheology of the concrete mixture, where at least one said cement dispersing agent comprises a polymeric cement dispersant, water, or a mixture thereof; said introduction of at least one said ACA and a cement dispersant to be obtained by the valve system controlled by the CPU according to the memory device accessible by the CPU which has at least four data correlation sets: or that is, (i) the effect of said cement dispersant on rheology (for example, slump); (ii) the effect of said ACA on the air content; (iii) the effect of said ACA on rheology (for example, the rebate); and (iv) the effect of said cement dispersant on the air content. The present invention can be used to monitor and control rheological properties, such as slump flow, slump, and yield strength of the fresh hydratable cementitious composition.
[019] Thus, the systems and methods of the invention involve the introduction of AEAs (air-entraining additives), ADAs (air-entraining additives, or "anti-foam agents), or combinations of AEAs and ADAs. Preferred embodiments involve introduction of AEA and polymeric polycarboxylate cement dispersant in a concrete mixture, these combinations of chemical blends are the most problematic to manage.
[020] In the preferred systems and processes of invention, each of the aforementioned correlations described above, in paragraph (e) (i) to (e) (iv), is based on a data set in which the respective values of at least at least one ACA (as mentioned in steps "(e) (ii)" and "(e) (iii)") and at least one cement dispersant (as mentioned in steps "(e) (i)" and "(e) (iv)") are determined using the nominal dose response profiles ("NDR"). The NDR profiles are based on an average of at least two, and preferably a plurality (more than three) of dose / effect curves, as will be explained in detail below. These NDR profiles do not require long compilations to be placed in "query tables" of the parameters by the operator. These NDR profiles minimize the task of introducing various parameters at the beginning of each preparation or mixture preparation. A dose response curve represents a correlation between the amount of water and / or additive or chemical mixtures and a concrete property that is modified by the effect of water and / or chemical mixtures. The dose-response curve can be represented in one of a number of ways, for reasons of clarity and convenience, and to facilitate CPU programming. For example, a dose response curve for a chemical mixture that modifies the slump can be represented as the dose administered to the slump of the concrete. In addition, the dose-response curve can be represented as the change in the dose of the chemical mixture (or water) necessary to change the decrease in an increment unit, for example, the dose required to change the decrease in 2.54 cm ( one inch) (for example, to change the rebate by 5.08 cm to 7.62 cm (2 inches to 3 inches)).
[021] For the purposes of this application, a dose-response curve for a given set of materials, under a given set of conditions, which can be used later to select the appropriate dose during concrete production, is referred to here as the nominal dose response curve ("NDR"). Because the dose-response curve is a function of a large number of variables (material properties, temperature, etc.), it is impractical to develop dose-response curves that specifically involve considerations of all relevant variables to program a CPU with tables of query or similar that lists these specific variables; measure all of these variables, and then select the appropriate dose of the rheology modifying agent (for example, chemical mixtures) in order to achieve the desired response. Thus, preferred methods and systems of the invention will employ the use of NDR profiles or curves based on data correlations.
[022] It is yet another objective of the present invention to provide a means for an efficient and accurate update of the nominal dose response curve ("NDR") data of both the incorporated air level and rheology data (for example , rebate). This will solve the problems of specific external variables, avoiding having to explicitly consider those variables. Surprisingly, the present inventors realized that when the NDR curves are generated for the incorporated air level and the rheology level, for each additive to be incorporated into the concrete, then both rheology and air properties could be controlled. , simultaneously and adaptively, by a new, highly inventive, yet elegant control methodology, which is the object of the present invention.
[023] The present invention arises from two surprising discoveries: first, that concrete mixtures have different parameters (for example, temperature, mix composition, water levels, hydration levels, humidity, different trucks) and exhibit " dose response "that vary in amplitude, but somehow have similar behaviors where their dose response curves do not cross; and, second, that the aforementioned "dose response" profiles of the four correlations in paragraph (e) (i) to (e) (iv) can be monitored and adjusted so that the target incorporated air and the target rheology can be achieved in an integrated manner. For example, if an architect or work supervisor requests the delivery of a fresh concrete mix with a target slump (rheology) of, for example, “10.16 to 15.24 cm” (4 to 6 inches) (in reference to Standard Cone Trunk Felling Test) and a target air content incorporated, for example, "4 to 6 percent", the systems and methods of the present invention can be deployed to achieve these performance targets based on known fills and known equipment for monitoring air content and chemical mixtures. This capacity has not been previously achieved or suggested in the concrete industry.
[024] Other advantages and specific features specific to the invention are described below. BRIEF DESCRIPTION OF THE DRAWINGS
[025] Other advantages and features of the present invention can be more easily understood when the following detailed description of the preferred embodiments is carried out in conjunction with the attached drawings, in which:
[026] Fig. 1 is a graphic illustration of an example of the method of the present invention, in which, for a given concrete mixture, the current air content and slump (rheology), designated as "1", are determined and compared with the target air content (range) ("AT") and the target slaughter ("ST"), together represented by the rectangle designated in "2"; and, when non-conformity is determined, air and slump are adjusted by adding the air-entraining agent and / or cement dispersant based on at least four sets of data correlations: where the respective effects on air content and slump are correlated with each dose increase of the air-entraining agent (as illustrated by the arrow designated in "3") and each dose increase of the cement dispersant (as illustrated by the arrow designated by "4" ). The cumulative effects of these are illustrated by the arrow designated as "5" (indicating that the incorporated air and the slump of the concrete mixture were brought into the target ranges for AT and ST);
[027] Fig. 2 is a graphic illustration of the current slump (inches) of concrete plotted as a function of the amount of rheology modifying agent (for example, a cement dispersing agent referred to as a high-range water reducer or "HRWR") required to change an allowance per inch;
[028] Fig. 3 is a graphical illustration of the incorporated air content (%) of the concrete, as a function of the amount of Air Controlling Additive (for example, an air incorporating agent or "AEA") needed to change the air content by one percent;
[029] Fig. 4 is a graphical illustration of the current slump (inches) of the concrete plotted as a function of the amount of AEA needed to change the slump by one inch;
[030] Fig. 5 is a graphical illustration of the incorporated air content (%) of the concrete plotted as a function of the amount of HRWR needed to change the air content by one percent;
[031] Fig. 6 is a graphic illustration of the alternative method of the present invention in which the current concrete slump (inches) is measured as a function of the ratio of quantity to the amount of change in the incorporated air content (%), divided by the amount of the change in slaughter (inches) for a given dose of a chemical mixture;
[032] Figs. 7 and 8 are graphical representations of other dose-response curves for concrete mixtures in which the initial slump (horizontal axis) is expressed in relation to the dose required to increase the slump in one unit (vertical axis); and
[033] Fig. 9 is a graphic illustration in which it is perceived that the values of abatement change measured at the current moment (shown by points) correspond to the theoretical values of abatement change, according to the curves or profiles of response to nominal dose, and based on the tests of the cement dispersant in the abatement of the concrete mixture. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[034] The term "cementitious" refers to Portland Cement and / or cement substitutes (fly ash, blast furnace slag, limestone, pozzolan, etc.) which, when mixed with water, bind to fine aggregates, such as mortar sand, and in addition to coarse aggregates, such as gravel or concrete gravel. These materials are "hydratable" as they harden when mixed with water to form building materials and engineering structures.
[035] It is considered that conventional cement dispersants and air-controlling additives ("ACA") can be used in the present invention, as well as other optional additives to modify the rheology and the incorporated air of cement compositions, such as mortars and concrete. In addition, any mixture that results in a change in rheology or air content, even as a main effect or non-main effect (for example, secondary), can be administered using the methodology described here.
[036] For purposes of illustration, the property of rheology, known as "abatement", will be discussed and illustrated here. However, it is understood that the rheological properties, known as "slump flow" and "yield strength" are the related properties of fresh cement materials (eg concrete) that can also be monitored and controlled using the teachings of present invention.
[037] Known cement dispersants, which can be used in the present invention, include conventional plasticizers (including superplasticizers). These include lignosulfonates, naphthalene sulfonates, melamine sulfonates, hydroxycarboxylic acids, oligosaccharides, and mixtures thereof. Other known cement dispersants include plasticizers with oxyalkylene groups (for example, ethylene oxide, propylene oxide, or mixtures thereof), groups of polycarboxylic acids (or their salts or esters); or their mixtures. Many of these types of cement dispersants, some of which contain thickeners and other viscosity modifying agents to improve stability or other attributes, are available from Grace Construction Products (Cambridge, Massachusetts) under various trade names, such as DARACEM ®, WRDA ® , ADVA ®, and MIRA ®, and these are all considered to be suitable cement dispersants that can be used in the present invention.
[038] The term "cement dispersing agent" and "cement dispersing agent", as used herein, is understood to refer to water and plasticizing agents, which facilitate the dispersion of hydratable cement particles within an aqueous suspension . In this context, it is understood that the term "plasticizer" refers to "water-reducing" agents that allow hydratable mortars or concretes to be made using less water. "Superplasticizers" are so called because they allow 12% or more of water to be replaced in the portion of the cement paste. Such plasticizing agents are conventionally known.
[039] In addition, for the purposes of the present invention, conventional cement dispersants can be employed, containing one or more air-controlling additives ("ACA") pre-mixed with the product formulation. The methods and systems of the present invention are considered to include commercially available cement dispersant formulations for use as the "cement dispersant" component, in combination with the dose of an additional and separate ACA component. For example, US Patent 7,792,436, owned by WR Grace & Co.Conn., Discloses a polycarboxylate cement dispersant formulated with air-controlling additives, and it can be administered in the concrete mixture, as the "cement dispersant" component. , and the same or different air-controlling additives (incorporators and / or disincorporators) can be administered separately, as the ACA component.
[040] In other examples of methods and systems of the present invention, it may be advantageous to use cement dispersants that have comparatively fast mixing dispersibility to accelerate the monitoring and adjustment of the properties of the concrete mixture. In US Patent 8,085,377 B1, for example, Goc-Maciejewska et al. discloses that phosphate-containing polycarboxylate dispersants have oxyalkylene groups, acrylic acid groups, and ester groups to achieve rapid mixing dispersibility when using concrete mixing equipment.
[041] Air-controlling additives ("ACAS"), suitable for use in the present invention, include conventional air-entraining agents ("AEAs"), as well as conventional air-disintegrating agents ("ADAs") (sometimes referred to as agents anti-foam). Conventional AEAs include water-soluble salts (usually sodium) of wood resin, rosin / rosin, or gum rosin; nonionic surfactants (for example, such as those commercially available from BASF under the trade name Triton X-100); sulfonated hydrocarbons; proteinaceous materials; or fatty acids (for example, tall oil fatty acids) and their esters.
[042] AEAs suitable for the purposes of the present invention are believed to be available from Grace Construction Products, under the trade names DAREX ®, DARAVAIR ® and AIRALON ®.
[043] Air disincorporating additives ("ADAs") that are useful in the invention are believed to include tributyl phosphate, propoxylated amines, silicone, and mixtures thereof.
[044] The term air control additives "ACA", as used herein, encompasses active surface agents and combinations thereof, and may involve both incorporation and disincorporation properties; or otherwise, components with different effects on air properties. For example, US Patent 7,792,436, as previously mentioned above, discloses a combination involving (a) a first active surface agent, comprising betaine, an alkyl or aryl or alkylaryl sulfonate group, or a mixture thereof, for the purpose of increasing the air content in the concrete; and (b) a second surface active agent comprising a non-ionic polymer surfactant containing oxyalkylene to provide a uniform and fine air gap distribution (with some disintegration properties), within an appropriate range of 3 to 20 percent. percent based on the volume of the concrete. Thus, the present inventors consider that examples of ACA can be used having both the incorporation and disincorporation properties, such as to control the quantity and quality of the incorporated air (for example, size and spacing) with the concrete matrix (eventually hardened) .
[045] The "ACA" component, similar to the cement dispersant component, may comprise a portion of one or more cement dispersing agents, in addition to the AEA and / or ADA. In fact, additional conventional concrete additives can be incorporated into either one or both "ACA" and "cement dispersant" components for aggregate performance values, and these include defining accelerators, retarders, and the like.
[046] Concrete mixer delivery trucks, with monitoring of the slump control and control equipment, such as hydraulic and / or electric sensors that measure the energy to rotate the mixing drum, speed sensors that measure the rotation speed, temperature sensors that monitor the atmospheric temperature, as well as the temperature of the mixture, and distribution equipment, as well as central processing unit (CPU) units to monitor the signals from the sensors and trigger the distribution equipment are, until now , relatively well known in the industry. For example, such dampening control systems, which can optionally be used in conjunction with wireless communication systems, are described in US Patent 5,713,663; US patent 6,484,079; US Serial No. 09 / 845,660 (Publication No. 200210015354 A1); US Serial No. 10 I 599,130 (Publication No. 2007 I 0185636 A1); US patent 8,020,431; US Serial No. 11 1834,002 (Publication No. 200910037026); and WO 2009/126138.
[047] An example of a system for monitoring and control using wireless communications, in combination with sensors to monitor various physical properties of the concrete mixture, is taught in US Patent 6,611,755, to Coffee. These teachings, as well as the patent references, as previously mentioned above in the background section of the invention, are expressly incorporated herein by reference.
[048] Sophisticated methods for monitoring and obtaining information about the quantity and / or characteristics of the cementitious material in the mixing drums (including abatement and air content) are also known to the industry (although to a lesser extent), by analyzing the energy waveforms (for example, hydraulic pressure), and preferably by converting waveforms in the time domain into frequency spectra in the time domain, through which more information can be obtained and evaluated. Such teachings are found in WPO No. WO 2010/111204 (entitled "Mixer Waveform Analysis for Monitoring and Controlling Concrete") by Koehler etal., Incorporated herein by reference.
[049] Thus, it is believed that examples of concrete mixing drums, suitable for use in the present invention, are those that are rotationally mounted on ready-mix delivery trucks, as mentioned above, or on stationary mixers, such as those that can be found in commercial mixing plants. The inner surfaces of the drum, in particular of mixing truck drums, tend to have at least one mixing blade that mixes aggregates within the concrete.
[050] It is believed that a number of examples of embodiments of the invention can be practiced through the use of commercially available automated concrete mix monitoring equipment, with little or no modification to the hardware, as would be evident from the invention. disclosed here. Such concrete mix monitoring equipment is available from VERIFI LLC of West Chester, Ohio, under the trade name VERIFI ®.
[051] The concept of "dose response", as used herein, should mean and reference the effect of a particular additive, as a function of the administered dose of cement dispersant (for example, water and / or chemical mixtures) and of an ACA (chemical mixture) on the property of rheology (for example, slump) and the property of air incorporated in a hydratable cementitious mixture, such as concrete. This concept is of particular relevance to Figs. 1 to 5, which illustrate how the present invention works to allow rheology (eg, abatement) and target air content to be prescribed by the end user (eg, contractor, customer, truck operator, or other customer) and are obtained by the system (for example, hardware / software mounted on a mixer truck with ready mix, or connected to the stationary concrete mixer of the plant, etc.).
[052] As illustrated in Fig. 1, the methods of the present invention allow an operator to specify a target rheology for the CPU of a mixing process control system (such as the rebate, which will be expressed in this section, for illustrative purposes, in terms of slaughter in inches, and the target slaughter being, in most cases, expressed as a range), called "ST"; and a target air content (for example, in percentage terms based on the volume of concrete, usually expressed as an interval), called "AT". The point designated as "1" represents the current slump and the current air content of the concrete mix to be mixed in the mixer (rotary concrete mixer), while the Air-Slump targets (ST and AT) are illustrated as a rectangle, designated as "2". Air-Abatement targets are defined, respectively, in terms of abatement in length (for example, inches or mm) and incorporated air content as a percentage of the volume of concrete. The CPU is programmed to retrieve from the memory accessible by the CPU (which can, for example, be stored in the concrete mixer truck with ready mix of concrete or accessed electronically and / or wirelessly from a dispatch center or control center) at least four sets of data containing the correlations. At least these four correlations refer to data sets on the effects of ACA and cement dispersant on concrete, including: (i) effect of cement dispersant on rheology (for example, slump, where ST was specified ); (ii) effect of ACA on air content; (iii) effect of ACA on rheology (for example, abatement, where ST was specified); and (iv) the effect of said cement dispersant on the air content.
[053] Thus, Fig. 1 represents by the arrow designated as "3", the change, both in the air content (incorporated) and in the slump, for the increase in the dosage of the air controlling additive component; while the arrow designated as "4" represents the change in air content and slump to increase the dosage of the cement dispersant component. The arrow designated as "5" represents the combined effect on air and slump with the increase in dosage of the two components.
[054] The four sets of data correlation, mentioned above, are generally illustrated in Fig. 2 to Fig. 5, where each, for reasons of simplicity, shows "two" curves. In Fig. 2, the current slump (in terms of inches of concrete) is plotted versus the cement dispersant ("HRWR" refers to the high-reach water reducer) needed to change the slump by an inch. In Fig. 3, the incorporated air content (in terms of percentage based on the volume of concrete) is plotted versus the AEA required to change the air content by one percent. Likewise, Fig. 4 illustrates the allowance (inches) plotted versus the AEA required to change the allowance by one inch. Finally, Fig. 5 illustrates the incorporated air content plotted versus the cement dispersant ("HRWR") needed to change the air content by one percent.
[055] In each of Figs. 2 to 5, two examples of curves are shown. In Figs. 2 and 4, each curve can represent different current air contents. In Figs. 3 and 5, each curve can represent different current rebates.
[056] In preferred methods and systems, each of these data correlations, as illustrated in Figs. 2 to 5, should be based on a plurality of data sets. An example is given in the case of the effect of the cement dispersant on the slump, as shown in Figs. 7 and 8. Fig. 7 illustrates a plurality of data curves for various cement dispersants in different concrete mixtures. Fig. 8 shows that the average or median value can be obtained or generalized from the data set and used to adjust and dose the concrete mixes. This approach is applicable to each of the correlations of the data sets that have been graphically illustrated in Figs. 1 to 4, and, therefore, employed in the implementation of the method of monitoring and adjusting air and slump, which was illustrated in the Figure. 1.
[057] Fig. 6 is a graphic illustration of the alternative method of the present invention in which the current slump (inches) of concrete is measured as a function of the ratio between the amount of change in the incorporated air content (%), and the abatement change value (inches) for a given dosage of a chemical mixture. This shows that, for a current abatement value, air and abatement will change when a particular mixture is used. The amount of this change can be plotted. This chart can be updated as additional data is collected.
[058] The present inventors would like to register, at this point, that Figs. 7 and 8 are derived from related US Patent Serial No. 12 / 821,451, filed around June 23, 2010 (entitled "Method for Adjusting Concrete Rheology Based Upon Nominal Dose-response Profile '}. In 451, Koehler et al.described an unexpected dose-response behavior that appeared when different concrete mixtures, in which a cement dispersant (polycarboxylate) was mixed, demonstrated similar dose-response curves, in which slump was shown as a function of dose quantity ( ounces of mixing per cubic yard of concrete) needed to change the churn in one unit (such as churn 5.08 cm to 7.62 cm (2 inches to 3 inches), and 7.62 cm to 10.16 cm (3 to 4 inches), and so on. The calculation of a nominal dose response profile ("NDR") was illustrated in Fig. 2 (and in this application as Figure 7.) where at least two curves profile profiles (labeled "maximum dose" and "minimum dose" as a reference) are convenient to provide an NDR profile.
[059] As discussed in US Serial No. 12 / 821,451, the significance of the non-intersecting behavior of the nominal dose response curves (See, for example, Fig. 7 here) led Koehler et al. to realize that you can adjust the rheology of the concrete using a profile or NDR curve based on the same curve obtained from a single data set, although the use of at least two curves is better (See, for example , Fig. 2 here), and the use of a plurality of curves (See, for example, Figs. 7 and 8 here) is even better from the point of view of precision. The NDR profile can be adjusted by sizing only one parameter, that is, a ratio that reflects the current performance of the additive and that predicted by the NDR curve. Thus, an adaptive control methodology can be used to update the NDR curve information based on the current performance of the additive. Each additive dose is selected using the NDR curve adjusted by the scale factor of previous additive additions for the same concrete load. Thus, the selected doses are adjusted to the current conditions associated with the concrete load, without the need to explicitly measure and adjust these parameters. In such a case, the second and each subsequent dose of additive within a load is likely to be significantly more accurate than the first dose. This eliminates a long trial-and-error process where the past performance of the additive in the concrete load is not considered. (Note that the term "additive", as used herein, can refer to water and / or chemical mixtures, in the case of cement dispersant).
[060] The following explanation is made from US Serial No. 12 / 821,451, by Koehler et al., Which describes only as a concrete property (eg slump, air content) at a given time , can be evaluated. Koehler et al. they do not teach or suggest how rheology and air content could be monitored or controlled, simultaneously, through an integrated approach, as in the present application. The rheology of a given concrete mix can be adjusted by inputting into a computer processing unit (CPU), only the amount of concrete (load size) and the target rheology value (eg slump, slump flow) , or elasticity limit), and comparing the current rheology with the NDR profile, adding a percentage of the nominal dose of the chemical mixture that would be (theoretically) necessary to change the current rheology in the target rheology, measuring the resulting change in the value of rheology and compare it to the NDR value that theoretically would have been obtained using the nominal percentage dose, and then adjusting the rheology by adding a subsequent dose, which takes into account the deviation measured as a result of the first percentage addition . Therefore, a "learning" step can be taken into account to be incorporated into the methodology, without having to consider numerous parameters, such as temperature, mixture composition, humidity and other factors.
[061] In US Serial No. 12 / 821,451, an example of a method for controlling rheology, in a concrete mixer, in which the energy required for the operation of the mixer is measured and correlated with a nominal rheology value, and in that a rheology modifying agent (cement dispersant) is added to the cementitious composition to modify its rheology, comprises: (a) introducing into a central processing unit ("CPU") a target rheology value ("TRV") and the charge size of a hydratable cementitious composition containing or intended to contain a particular rheology modifying agent or a combination of rheology modifying agents; (b) obtain a current rheology value ("CRV") of the hydratable cementitious composition contained within a mixer; (c) compare, using the CPU, the current rheology value, obtained in step (b), with the nominal dose response profile ("NDR") stored in the memory accessible by the CPU, in which the referred NDR is based on at least one data set, where various dose quantities of a particular rheology modifying agent or combination of rheology modifying agents and their correlative effect on the rheology value (such as abatement, abatement flow, or elasticity limit) is stored in a recoverable manner, and determining the nominal dose of said rheology modifying agent or the combination of rheology modifying agents necessary to change the CRV obtained in the TRV specified in step "(a)"; (d) dosing the hydratable cementitious composition in a mixer with a percentage of said rheology modifying agent, or combination of rheology modifying agents that is selected or preselected from 5% to 99% based on the nominal dose determined in step ( c) necessary to change said CRV obtained to said TRV as specified in step (a); (e) obtaining a subsequent CRV of the hydratable cementitious composition after the percentage of the nominal dose of the rheology modifying agent or combination of rheology modifying agents selected or pre-selected in step (d) is added to and uniformly mixed with said hydratable cementitious composition; compare the dose selected or pre-selected in step (d) with the dose according to the NDR profile for the same change in the rheology value from step (b) to step (e), and to determine the scale factor ( "SF"), through which to adjust the dose from the NDR profile, where SF is defined as the actual dose of step (d) divided by the nominal dose to achieve the same change in the rheology value indicated by the NDR profile; and (f) mixing in the hydratable cementitious composition the rheology modifying agent or combination of rheology modifying agents in an amount calculated in terms of SF multiplied by the dose of the indicated NDR profile to convert the current CRV measured in step (e) to the TRV specified in step (a). If the target rheology value, such as abatement, is not reached after completing the steps, (which may be due to a number of factors, such as temperature or humidity variation), then the process steps ( e) and (f) can be repeated as needed. In addition, the rheology of concrete changes over time.
[062] Each time the rheology value decreases by a certain amount, a rheology modifying agent (for example, chemical mixture) must be added to restore the rheology value. Steps (e) to (f) can be repeated to adjust the rheology value.
[063] Thus, NDR profiles are calculated based on the average of at least two values of the dose-response curves (see, for example, Fig. 8), and, more preferably, an average of a plurality of values of the response curves. dose response obtained from tests of the rheology modifying agent or combination of rheology modifying agents (see, for example, Fig. 7).
[064] In addition, it was taught in US n912 / 821,451, that the system CPU can be programmed to assume a learning mode, in which batch stories can be incorporated into the NDR profile, which is then stored in the accessible CPU memory , and / or the scale factor can be reset so that the dosage can be processed more accurately. In other words, changes in the rheology value made by doses of the rheology modifying agent administered during a concrete mix delivery operation are incorporated into the nominal dose response (NDR) curve or scale factor, whereby the NDR curve or scale factor (SF) is modified; and changes in the rheology value in a subsequent concrete mix operation or delivery operations are made based on the modified NDR or modified SF curve.
[065] The CPU is programmed to dose the hydratable cementitious composition in the mixer using a selected or preselected percentage of the ideal amount of the rheology modifying agent (cement dispersing component) that would be determined by the NDR profile to change the current rheology value to the target rheology value that was previously entered. This percentage can be 50% to 95% of the ideal (or nominal) amount, and more preferably it will be about 50% to 90%; and more preferably it will be 50% to 80%. Generally, the lowest percentage in these ranges is preferred for this first dose until confidence is obtained.
[066] The CPU can also be programmed to obtain a subsequent current rheology value (eg slump) of the concrete after the percentage of the nominal dose of the specific rheology modifying agent (eg cement dispersant) has been added to the concrete. . The CPU can compare the nominal (or theoretical) effect on the rheology value of the percentage of the selected or pre-selected dose to the subsequent rheology value and determine the scale factor, through which to adjust the dose of the NDR profile. The scale factor is thus defined as the actual dose divided by the nominal dose, to achieve the same change in rheology, as indicated by the NDR profile.
[067] The CPU can also be programmed to mix the mixing dose to the concrete. The amount of this subsequent dose would be calculated by multiplying the scale factor (SF) by the amount theoretically necessary, according to the NDR profile, to change the current measured rheology value to the target rheology value previously specified by the operator.
[068] The steps programmed in the previous CPU can be repeated whenever the current property of the concrete is detected as being less than or greater than the target property of the concrete, when compared to a given threshold (introduced or pre-programmed). This can be done automatically, for example, by programming the CPU to repeat the steps, when the difference between the current and target values exceeds a predetermined quantity and, therefore, are determined in non-compliance with the others. If the difference between the current and target values is less than the predetermined value, the CPU can also be programmed to activate an alarm to indicate to the operator that the concrete mixture is ready to be discharged and poured.
[069] Thus, an NDR profile or curve can be derived from an average of at least two curves that represent the behavior of a given concrete mixture, as illustrated in Figs. 2 to 6, and more preferably the NDR is established using an average of a plurality of dose response curves for the particular chemical mixture (s), as illustrated in Fig. 7. The dose curves Figure response. 7, in particular suggest, by varying the amplitudes of the curve, that several parameters, such as the concrete mix composition, temperature, degree of hydration, water / cement ratio, and aggregate quantities may be varying slightly (or even significantly) ) from batch to batch. Furthermore, the fact that the various dose-response curves do not cross led the present inventors to realize that these other various parameters do not necessarily need to be kept constant in order to establish a response profile to the nominal dose (NDR), because the average of these dose-response curves would behave similarly in terms of calculating the quantities of mixture needed to change the property of the concrete mixture from (eg, slump) one value to the next (eg, slump from 2 inches to 5 inches) ).
[070] Another way to view NDR profiles is to realize that they involve data sets that have at least one non-homogeneous parameter, such as the composition of the concrete mixture, concrete temperature, degree of cement hydration, water / cement ratio, and quantity of aggregates or cement / aggregate ratio. These can be varied from batch to batch in the data sets that make up the NDR profile composition (See, for example, Fig. 1).
[071] US No. 12 / 821,451 discloses many of the chemical cement dispersants as mentioned above can be used, and emphasize that, while the same rheology modifying agent or combination of rheology modifying agents is being used as previously tested for create the profile response to the nominal dose (NDR), then other variables, such as composition of the concrete mixture, amount of water or cement or water / cement ratio, composition or selection of aggregates, degree of hydration, do not necessarily need to be into the CPU and remain optional.
[072] The present invention is believed to be a patentable improvement over document no. 12 / 821,451, in that it allows targets in rheology and the properties of the incorporated air to be simultaneously specified and integrated in the monitoring / processing system, and also allows the separate addition of a rheology modifier (for example, cement dispersant with or without incorporation of air and / or disintegration of air) and separate addition of air control agents (for example, incorporation of air and / or disintegration of air), despite the fact that the relationship between the effects of incorporation of air and dispersing effects (abatement) have been non-linear and historically unpredictable.
[073] In order to achieve this goal, the present invention provides a "multivariate control" capability that has not been achieved, disclosed, or even suggested before. As summarized above, an example method of the present invention for monitoring and adjusting the levels of incorporated air and rheology in a concrete mixture, comprises: (a) supplying a concrete mixture in a concrete mixer (rotary concrete mixer), said concrete mixture comprising hydratable cement, aggregates, and water for the hydration of said cement, and said concrete mixture having a total volume, when mixed uniformly, from 0.765 m3 to 11.47 m3 (1.0 to 15, 0 cubic yards); (b) inserting into a computer processing unit (CPU) and storing the desired concrete performance ranges in a computer accessible memory, in relation to: a slump target (rheology) or target range (hereinafter referred to as "ST" ), in which a concrete slump or desired slump range is specified within a range of 0 to 27.94 cm (0 to 11 inches); and a target air content or "AT" target range, where a desired air content in the concrete or range of the desired air content is within a range of 1% to 10%; (c) operate said concrete mixture in said concrete mixer (rotary concrete mixer) and obtain at least one slump value in the current time (hereinafter referred to as "SCT") and at least one air content value in time current (hereinafter referred to as "ACT"); (d) comparing, using the CPU, said SCT with said ST, and said ACT with said AT, until the CPU detects a non-compliance event, in which said SCT does not conform to said ST and / or said ACT does not comply with said AT; and (e) introducing into the concrete mixture contained in said concrete mixer (rotary concrete mixer), one of at least two different types of additives comprising: at least one chemical mixture to modify the air content in the concrete mixture (hereinafter referred to as as "ACA"), where the at least one ACA comprises at least one Incorporating Air Mix (hereinafter referred to as "AEA"), at least one Disincorporating Air Mix ("ADA"), or a mixture of at least one AEA and at least one ADA; and at least one cement dispersant to modify the rheology of the concrete mixture, said at least one cement dispersing agent comprising at least one polymeric dispersant, water, or a mixture of at least one said polymeric and water dispersant; said introduction of said at least ACA and cement dispersant being obtained by the valve system controlled by the CPU according to the memory device accessed by the CPU which has at least four data correlation sets: (i) effect of said dispersant of cement on rheology (for example, abatement); (ii) the effect of said ACA on the content of the incorporated air; (iii) the effect of said ACA on rheology (for example, abatement); and (iv) the effect of said cement dispersant on the incorporated air content.
[074] It should be understood that, in the description of the steps from method (a) to (e) above, the abatement is given as an example of rheology, and that the monitoring and adjustment of other rheological factors, such as abatement flow , DIN flow, yield stress, etc., can be replaced by slump targets and the current slump values designated, respectively, as ST and SCT.
[075] As described in step (b), operator adds at least two types of information to the central processing unit ("CPU"): a target rheology value (for example, abatement, abatement flow, DIN flow, yield voltage, etc.) and a target air content. The operator may also be asked to enter the load volume for the concrete that will be placed in the mixer (and therefore, examples of methods involve inserting the load size). The entry of these prescribed data points or targets can be performed by the person responsible for the batch in the mixing plant, by the truck driver, or foreman at the construction site. In fact, this entry can be performed by anyone responsible for delivering the concrete, and who does not require the insertion of other parameters, such as temperature, humidity, and other factors that are optional.
[076] In addition, as mentioned above, the target rheology value can be any of the rheology factors whose measurement in units of values is commonly used, such as: slump (usually measured in terms of units of length, for example, inches); slaughter flow (length, for example, inches); yield stress (usually measured in terms of yield, for example, pounds per square inch or Pascal); viscosity (Pascals.seconds); flow (length); and thixotropy (Pascal / second). The size of the load can be entered into the CPU in terms of weight or total volume of the concrete batch (for example, cubic yards), including all components. If the target rheology value (or interval) is defined in terms of abatement, then the abatement measurement can be made according to any number of standardized measurements (see, for example, ASTM C 143-05, AASHTO T 119 or EN 123502). If the target rheology value is defined in terms of the slaughter flow, this measurement can be made in accordance with ASTM C1611-05. If the target rheology value is defined in terms of the flow table test, it can be done according to DIN EN 12350-5 (sometimes referred to as "DIN flow").
[077] It is important that "at least four data correlation sets", mentioned in step (e), include the same or similar chemical blend components as those used for dosing into the concrete, as well as the same or similar concentrations of such components. For example, if the "cement dispersant" component to modify the rheology of the concrete mixture, as mentioned in step (e), comprises one or more specific polymeric cement dispersants (which, optionally, can be formulated with other additives, such as AEAs, ADAs, accelerators, and / or retarders), then it is important that the data correlation set mentioned in step (e) includes the identical or similar polymer cement dispersant (s) as formulated , with any other additives that may be present in the formulation of the product such as those used for dosing into the concrete. The same applies to the additive (s) or chemical mixtures that modify the incorporated air level ("ACA"), as mentioned in step (e). Identical or similar AEAs and / or ADAs should be used for the data correlation set, such as those used for concrete dosing.
[078] It is preferable that each of the "at least four correlation sets of data" mentioned in step (e), be based on a plurality of nominal dose response (NDR) curves or profiles obtained from the same component to be dosed into the concrete. Thus, one will have to generate new NDR profiles for a cement dispersant packaging component, as it is observed that the addition or elimination of a particular active ingredient, from the chemical additive (s) formulation (s) ), affects rheology and affects air content. If, for example, a desired exchange in the cement dispersant packaging component affects both the rheology and the incorporated air levels, it is necessary to generate new NDR profiles for each of the rheological behaviors, as well as the incorporated air behaviors.
[079] Among the advantages of using NDR profiles is that they are self-correcting, and that they can eventually allow high precision, even when the cement dispersion polymer is different and where other active ingredients may be different in nature and amount. However, when using the method of the present invention, it is preferable to start with the same cement dispersants and the same ACA to compensate for any differences in their concentrations.
[080] In steps (c) and (d) of the example method of the present invention, described here, it is necessary for the CPU to determine the current state of the rheology and the current value of the air content of the concrete contained within the mixer. This is stored in memory accessible by the CPU, because it will provide a reference point for later steps.
[081] In step (d) of the method example, the CPU compares the current state of the rheology and the current value of incorporated air obtained in step (c) with target values that were introduced in step (b). If there is a difference, such as when the current value of incorporated air falls outside the range specified in step (b), then the CPU will access one or more data correlation sets (i) through (iv) referred to in “ step (e) ".
[082] Methods and systems of the present invention employ at least four different sets of data correlation, each of which is preferably generated using a plurality of data sets (e.g., curves or profiles). In other words, as described in step (e), a plurality of NDR profiles must be generated and stored in relation to: (i) the effect of the cement dispersant on rheology (for example, slump); (ii) the effect of the ACA on the incorporated air content; (iii) the effect of ACA on rheology (for example, abatement); and (iv) the effect of the cement dispersant on the incorporated air content.
[083] As mentioned earlier, the "cement dispersant" component can comprise water, one or more chemical mixtures, such as a polymeric polycarboxylate additive, or even both, and this cement dispersant component can further comprise an AEA, ADA, or mixture thereof; while the "ACA" component may comprise the same or similar AEA, ADA, or mixture thereof.
[084] In many cases, it is expected that the adjustment of the current rheology value or the actual air content of the concrete mixture, such that they are within the targets, can be performed using any of the dispersant components of cement or ACA component, or a combination of both.
[085] In this sense, this may be evident in Fig. 1, as this illustrates the situation where the current air content (as illustrated by the point designated as "1") is expected to be below the target air content ("AT"), such that an AEA will need to be added to the concrete to raise the air content in order to reach target "2" (rectangle). In most cases, the present inventors expect the point ("1"), which represents current air and slaughter, to be located below and to the left of the rectangle, in most cases. And it may be possible that point 1 may be located on the left, but also located above, of rectangle 2. In this case it would be necessary to introduce an Air Disintegrating Agent (ADA) in the concrete to reduce the incorporated air content in order to reach target "2" (rectangle).
[086] It is also evident that Fig. 1 illustrates the situation where, based on the data that are graphically illustrated by the incorporated air curve "3" and the slump behavior curve "4", both an AEA and a dispersant of cement will have to be added to move the air and slump properties of the concrete mixture into target "2" (rectangle). If the current air or slump properties (shown as point "1" in Figure 1.) are closer to target "2", it might be possible to introduce either the ACA or the cement dispersing component alone into the concrete mix in order to to hit target "2".
[087] In cases where both ACA and cement dispersant need to be added to the concrete mix in order to reach target "2", the CPU can be programmed to specify whether the components are favorable in terms of the amount of volume to be introduced into the concrete. Other examples of methods and systems of the present invention, therefore, include the additional step of introducing a preferred addition order or the percentage of the ACA or cement dispersant component. If the cement dispersing component is composed only or mainly of water, it may be desirable to introduce an ACA component to reach target "2" (since a large water content in the concrete mix could potentially decrease the strength properties of the concrete ). On the other hand, if economy is the main objective, the CPU can be programmed to make a cost / benefit determination, in such a way that the least expensive component is used to make the necessary adjustment to reach target "2".
[088] However, it is generally expected that, if it is determined that the current slump is outside the target slump range, the cement dispersant would be used to make an adjustment such that the current slump of the mixture is brought back to within the target slaughter range. If both the current slump and the current incorporated air content are determined (step (d)) as being in non-compliance with the target ranges entered in Step (b), then the CPU will access the stored data correlation sets in the memory accessed by the computer, and will send a signal to a valve for injecting a certain amount of cement dispersant into the concrete mixture (where the NDR profiles predict that the adjustment of the mixture to the target slump and incorporated air content has be done using the amount of cement dispersant alone); or the CPU will send signals to the two valves, one for the introduction of the cement dispersant in the concrete mixture, and the other for the introduction of ACA in the concrete mixture, where the use of the cement dispersant, by itself, does not it would be sufficient to adjust the current incorporated air content so that it conforms to the target range of the air content (as introduced in step (b)).
[089] It could also be the case that the CPU could select ACA injection alone in the concrete mix, where both the current air content and slump were determined to be non-compliant with the target air content and rheology, and could predict that a certain amount of ACA would be sufficient to adjust both the current rheology and the incorporated air content, so that they could be made to conform to the target range (as introduced in step (b)).
[090] In other examples of methods and systems of the invention, NDR curves are preferably based on at least four sets of data correlations involving at least one inhomogeneous parameter selected from the concrete mix composition, source of the concrete mixture ingredient, temperature, degree or extent of hydration, water / cement ratio, and quantity of aggregates. As more NDR curves are used to establish a profile, at least two or three, or even more, of these non-homogeneous parameters can occur without impairing the reliability of the use of NDR profiles to adjust the air and slaughter the concrete mixtures.
[091] In other examples of methods and systems, data about changes in the incorporated air and in the rheology of the concrete mixture, effected by the doses of ACA and cement dispersant administered during a concrete mixture delivery operation, and incorporated the nominal dose response curve (NDR) and the scale factors, on which the NDR curves and scale factors (SF) are modified; and subsequent changes in air and rheology, in the same or in a subsequent concrete mix delivery operation, are performed based on data from the modified NDR curves and / or the modified SF.
[092] Still in other examples of methods and systems, the CPU communicates electronically and / or wirelessly with the database memory accessible by the CPU that has the data about the referred changes in the incorporated air and in the rheology about the mixtures of concrete, effected by the doses of ACA and cement dispersant administered during a delivery operation of the concrete mixture, and incorporated in the referred response curve to the nominal dose (NDR) and in the scale factors, on which the referred NDR and scale factors (SF) are modified, as well as data related to changes in air and rheology, in the same or in a subsequent concrete mixture delivery operation, which were carried out based on the modified NDR curves and / or the Modified SF.
[093] For example, the inventors of the present invention consider that at least the four sets of data correlation can be transmitted by cable or wireless transmission (for example, a flash drive, Internet, radio frequency, etc.) to a central computer database (such as those located at dispatch / dispatch centers or another office) from which it can be accessed by individual CPUs within the mixer truck fleet.
[094] In other examples of methods and systems of the present invention, it is possible to understand the use of NDR profiles derived from at least four defined data correlations (see step (e) (i) to (e) (iv), where each of which involves concrete mixing operations involving at least two non-homogeneous parameters, and even more than two non-homogeneous parameters, selected from different concrete mix compositions, origins of the concrete mix ingredient, temperatures, hydration, water / cement ratios, different amounts or proportions of aggregates, and concrete mix compositions, so long as the specific mix components (eg water and / or additive or combination mixes) concrete), used to create NDR profiles and to obtain current values of current incorporated air and rheology (abatement), whether / be identical (s) or substantially similar (s), the behavior The slope of the NDR curves is similar from one unit of air value or rheology value to the other. In fact, even if two or more additives vary in composition, but are similar in performance, it may be possible to use the same NDR profile for all these additives.
[095] In yet other examples of embodiments of the invention, the process of monitoring changes in the incorporated air and rheology may involve the use of more than one type of ACA and more than one type of cement dispersant, with each type of additive component having its own scale factor, NDR profile, or both. For example, NDR profiles can be established for combinations of ACA components and cement dispersant components with each of these further comprising one or more additional additives, such as: viscosity modifying agents (eg thickeners, thixotropy modification); accelerators, retarders, or a mixture thereof; corrosion inhibitors, water repellents, resistance-increasing agents; and other additives and mixtures thereof.
[096] In yet other examples of methods and systems of the invention, more than one target air and / or rheology can be specified and covered by the same concrete mixture delivery operation. For example, multiple target air and / or rheology can be used, such as air rebates and / or target rheology (s) during transport (from batch production or operation at the plant to the job site) and during placement (after the truck arrives at the job site where the mixture is to be poured). As another example, it is possible to define two different targets that the concrete mixture will have in the same delivery / process operation and at the same time, such as the slump flow and plastic viscosity. It is possible, in other words, to have a rheology modifying agent, or combination of agents (for example, additive packages), to modify the slump flow (characterized by the spread of concrete from a removed slump cone) and have another rheology modifying agent or combination of plastic viscosity modifying agents (characterized by shear stress divided by shear speed).
[097] In another example of an embodiment, the scale factor is calculated as a weighted average of all dose responses at a given load or mix composition. In other words, in a series of delivery operations, in which various scale factors are derived, the scale factor used in the current delivery operation can be based on the average of all calculated scale factors, but mainly based on the data obtained from the most recent delivery operation.
[098] The correlations between the effect of the ACA additive component and the rheology modifying additive component, for the respective properties of the concrete mixture (for example, air and slump), can be calculated using various methodologies. The four data correlations that can be stored in computer-accessible memory for CPU use (for example, the effect of cement dispersant on slump, the effect of cement dispersant on air, ACA's effect on slump, and the effect of ACA on air) can be calculated, for example, using the following representative function:
where a, b, c, d, e, f, m, n, o, p, q, er are the empirical regression values determined from the previous data and "Sp" represents the amount of slaughter modifier additive (for example, volume), "ACA" represents the amount of Air Controlling Additive, "SCT" represents the rheology at the current time (for example, the allowance that can be determined, for example, according to ASTM 143), " ACT "represents the air content at the present time in terms of a percentage of the total volume of concrete; "ST" represents the target slump (ASTM 143), "AT" represents the target incorporated air content in terms of a percentage of the total concrete volume. During a concrete delivery, all parameters, except Sp and ACA, are known. Empirical regression values are determined from the latest concrete data. The values of S and A are determined by the measuring equipment on the truck. The ST and AT values are programmed in the CPU. Therefore, it is necessary to resolve the values of Sp and ACA. This can be done using known nonlinear optimization techniques. As there are two unknown variables, additional restrictions must be defined. These could include, for example: minimizing Sp, minimizing ACA, or minimizing cost. In addition, all SP and ACA values must not be negative.
[099] In yet other examples of embodiments, it is considered that more than four different sets of data correlation can be stored in memory accessible by the CPU for the purpose of adjusting the properties of the concrete mixture that uses more than two chemical blends. For example, methods and systems of the present invention may allow the adjustment of air and / or rheology in the concrete mixture using three or more different additive components, such as: (1) cement dispersing agent (water and / or chemical mixture); (2) air-entraining agent, and (3) air-disrupting agent. In this case, the database will have six sets of data correlation (or curved NDR profiles) based on the effect of each of these three components, respectively, on the incorporated air and the rheology (slump) of the concrete, as well as the scale factor data to adjust the concrete values through controlled additions of the three components.
[0100] In other embodiments, the database memory accessible by the CPU contains information or data stored about one or more concrete mix compositions, origin of the concrete mix ingredient, concrete temperature, water / cement ratio , and time since the production of the batches for each data point related to the changes in the incorporated air and in the rheology of the concrete mixtures as a function of the doses of ACA and cement dispersant administered during the concrete mixture delivery operation.
[0101] In still other embodiments, the data memory accessible by the CPU contains information or data related to one or more concrete mix compositions, origin of the concrete mix ingredient, temperature of the concrete, water / cement ratio, and time since batch production, and one or more of these data are used to select the nominal dose response curve or scale factor.
[0102] It is expected that the methods of the invention will be used to measure and adjust any characteristic of concrete rheology, including slump, slump flow, and yield strength. The measurement and adjustment of the abatement are probably of great concern, but the inventors believe that other rheological characteristics, such as the abatement flow or DIN flow, could be monitored and adjusted using the methodologies of the present invention.
[0103] In still other examples of methods of the invention, the method of the invention in which both the ACA and cement dispersant components are fed into the mixer, when the concrete mixture is controlled and, upon checking that it does not conform with the target slump and air content, it can be suspended for part of the delivery path, where the CPU can be programmed simply to add the concrete dispersing component in order to achieve the target rheology (or targets), and possibly also to reach the target air content. It may be possible, after the concrete ingredients (eg cement, aggregates, water) are loaded into the mixer to make the concrete mix, that only the cement dispersant component (water, water reducing mix, such as a superplasticizer), must be added until the concrete mixture reaches RT and AT and the concrete can be maintained using only the water reducing mix to keep both RCT and ACT inside RT and AT. After that, when the delivery mixer truck approaches and / or enters the construction site, the CPU can be programmed to activate the use of both water reducing additives and ACA, in order to keep both the RCT and the ACT inside the RT and AT.
[0104] In yet other examples of methods, the concrete must be mixed with a prescribed amount to ensure that the cement dispersant or AEA is fully distributed throughout the mixture. For example, if the cement is mixed in a rotating mixing drum, the number of rotations required for mixing can be defined based on the identity of the cement dispersant and / or added ACA. This complete mixture must be supplied before the concrete is unloaded or step (c) must be repeated. The following examples are provided for illustrative purposes only, and are not intended to limit the scope of the present invention. EXAMPLE 1
[0105] The following section describes how to generate a dose response curve or profile for a given mixture, in this case, a cement dispersant used to generate a slump profile. A concrete mix is carried out in a laboratory mixer without any chemical mixtures added. The slump is measured by removing portions of samples from the concrete and inserting them in a slump cone, according to the ASTM C143-05 standard. The air content is also measured. When this test is finished, the tested mixture is discarded. Immediately afterwards, another concrete mixture, which has the same concrete mixture composition, is made in the same laboratory mixer, but this time with a chemical mixture (for example, polymeric polycarboxylate cement dispersant). The slump and air content are measured again. When this test is finished, the mixture is discarded. A number of other successive samples, based on identical mixing factors (for example, temperature, type of cement, the amount of air and water, the water / cement ratio, etc.), can be done in the laboratory mixer, but each varying only in the dosage value of the additive. Except for the dose of the additive, all other variables must be kept constant. Each successive mixture must be discarded after the test. The resulting data, if represented graphically, will resemble one of the plotted lines shown in Figs. 2 e5.
[0106] The above process is then repeated, but for each reiteration, one of the mixing factors varies, while all other mixing factors are kept constant. Varied mixing factors may include: the temperature of the materials, the amount and type of cement, the type of fine aggregate, the type of coarse aggregate, the amount of air in the concrete, the amount of water, and the water / cement ratio . The data relating to these concrete mixtures having a varied mixing factor are also represented as the various lines shown in Fig. 1.
[0107] Surprisingly, when the above method was performed, it was found that the dose response curves, as shown in Fig. 7, do not intersect. The property of the concrete mixture (slump, for example) can be adjusted depending on the behavior of any curve or an average of all such dose-response curves, and the behavior of such curve or plurality of curves can serve as a curve of reference or nominal response dose during real production-operation time.
[0108] (As explained earlier, Fig. 8 is a simplified version of Fig. 7 showing the "minimum", "maximum", and average dose response curves. The average dose response curve, shown in Fig. 7. can serve as a response curve to the nominal dose during the real production-operation time). EXAMPLE 2
[0109] The NDR profile or curves, based on the polycarboxylate cement dispersant mentioned in Example 1 above, were field tested using a mixer truck having an automatic monitoring and dosing system, provided by Verifi LLC of Ohio, available under the trade name VERIFI ®. This monitoring system measured the slump based on the hydraulic pressure and the speed of the mixing drum. This system can also inject dispersing cement additive into the mixing drum from a small chemical storage tank mounted on the fender. (See also US Patent Publication 2009/0037026, by Sostaric et al.). Over the course of months, a variety of concrete mixes were prepared on the mixer truck. A nominal dose response profile was obtained, similar to that described above in Example 1, and this was used as a reference profile or "nominal" reference dose ("NDR").
[0110] A series of tests was performed using the example method of the invention for different delivery operations of the concrete mixture, in which the NDR was used by the central processing unit of the automatic monitoring and dosing system for each successive sample of the mixture of concrete prepared in the mixing drum. The mixtures produced in the drum, over the following weeks, experienced natural variations in terms of temperature, raw materials, mixing ratios (eg water / cement ratio, water / aggregate ratio, fine / coarse aggregate ratio, etc.) . And the water-reducing mixture (polycarboxylate cement dispersant) was dosed according to the NDR profile.
[0111] The use of the NDR profile as a reference to adjust the current slump resulted in changes in the concrete mix similar to those suggested by the NDR profile. When the NDR curve is applied first, the abatement change is then used to develop the scale factor (SF), which is then used in the next additive addition.
[0112] In other examples of methods of the invention, the concrete is mixed in the mixer, after step (e), for a number of rotations of the rotating concrete mixer according to the identity of the cement dispersant introduced in the concrete and / or the ACA . This is done both before the concrete is discharged from the mixer and before step (c) is repeated. In yet other examples of methods, steps (c) to (e) are repeated at least once, and preferably more than once, until the cement is discharged from the mixer.
[0113] Fig. 9 shows that the abatement change values measured at the current moment (shown by the points) coincide with the theoretical abatement change values. EXAMPLE 3
[0114] The present inventors consider that NDR profiles can be generated from the curves based on at least four different data correlations, such as the effect of said cement dispersant on rheology (for example, slump) ; effect of ACA on incorporated air content; effect of said ACA on rheology (for example, abatement); and the effect of the cement dispersant on the incorporated air content. Preferably, NDR profiles are based on a plurality of different delivery operations, involving heterogeneous parameters (for example, selected from various concrete mix compositions, origins of concrete mix ingredients, temperatures, degrees of hydration, water / cement ratios, quantities of aggregates). Each of the four sets of data correlation (as illustrated in Figures 2 to 5) was expected to have the characteristic without intersection equal to or similar to the NDR curves in Fig. 7. In preferred embodiments, data can be transmitted from each individual CPU unit (for example, in each process control system for the delivery mixer truck, or stationary concrete mixer of the plant) to a central database for future access by the CPU units to allow the use of updated NDR profiles.
[0115] The principles, preferred embodiments and modes of operation of the present invention have been described in the previous specification. The invention, which is intended to be protected here, however, is not to be interpreted as being limited to the particular forms disclosed, since these are to be interpreted as illustrative, rather than restrictive. Those skilled in the art can make variations and alterations without departing from the spirit of the present invention.

权利要求:
Claims (19)
[0001]
1. Method for monitoring and adjusting the abatement and air content in a cementitious mixture, CHARACTERIZED by the fact that it comprises: (a) providing a concrete mixture in a concrete mixer, said concrete mixture comprising hydratable cement, aggregates, and water to hydrate said cement, and said concrete mixture having a total volume when mixed uniformly inside the concrete mixer 0.765 m3 to 11.47 m3 (1.0 to 15.0 cubic yards); (b) inserting into a computer processing and storage unit, in the memory of the computer's accessible processing unit, the concrete performance ranges in relation to: the target slaughter or the target slaughter range; and a target air content or a range of target air content, wherein an air content or a range of air content in the concrete is within a range of 1% to 10%; (c) mixing the concrete mixture in the mixer and obtaining at least one slump value at the current time and at least one air content value at the current time; (d) comparing, using the computer's processing unit, the at least one abatement value at the current time against the target abatement or the abatement range and the at least one value of the air content at the current time against the air content target or target air content range until detection by the computer processing unit of a non-conformity event, where the at least one abatement value at the current time does not conform to the target abatement or abatement interval target and / or at least one air content value at the current time does not conform to the target air content or the target air content range; and (e) introducing into the concrete mixture contained in said concrete mixer, one of at least two additives of different compositions comprising: at least one chemical mixture to modify the air content in the concrete mixture, in which at least one chemical mixture for modifying the air content in the concrete mixture comprises at least one air-entraining mixture, at least one air-disarming mixture, or the mixture of at least one air-entraining mixture and at least one air-disarming mixture; and at least one cement dispersant for modifying the abatement of the concrete mixture, said at least one cement dispersant comprising at least one polymeric dispersant, water, or a mixture of said at least one polymeric and water dispersant; said introduction of at least one chemical mixture to modify the air content in the concrete mixture and / or at least one cement dispersant being achieved by the valve system controlled by a computer processing unit according to the accessible unit memory of the computer processor having at least four correlated data sets comprising: (i) the effect of said cement dispersant on the abatement of the concrete mixture; (j)) the effect of at least one chemical mixture to modify the air content in the concrete mixture on the air content; (k) i) the effect of at least one chemical mixture to modify the air content in the concrete mixture on the slump of the concrete mixture; and (l)) the effect of said cement dispersant on the air content of the concrete mixture.
[0002]
2. Method, according to claim 1, CHARACTERIZED by the fact that said at least one chemical mixture to modify the air content in the concrete mixture is an air incorporating agent.
[0003]
3. Method, according to claim 1, CHARACTERIZED by the fact that said at least one chemical mixture to modify the air content in the concrete mixture is an air disintegrating agent.
[0004]
4. Method according to claim 1, CHARACTERIZED by the fact that said at least one chemical mixture to modify the air content in the concrete mixture comprises both an air-entraining agent and an air-disembedding agent.
[0005]
5. Method, according to claim 1, CHARACTERIZED by the fact that said at least one cement dispersant is a polycarboxylate polymer.
[0006]
6. Method, according to claim 5, CHARACTERIZED by the fact that said at least one chemical mixture to modify the air content in the concrete mixture is an air disintegrating agent.
[0007]
7. Method, according to claim 1, CHARACTERIZED by the fact that, in step (e), said at least four sets of correlations identified in (i), (ii), (iii) and (iv) are based at an average or average value calculated from at least two response curves to the nominal dose.
[0008]
8. Method, according to claim 7, CHARACTERIZED by the fact that, in said step (e), said four sets of data correlations identified in (i), (ii), (iii) and (iv) are based on an average or average value calculated from a plurality of nominal dose response curves.
[0009]
9. Method, according to claim 8, CHARACTERIZED by the fact that, in said nominal dose response curves, said at least four sets of data correlations involve at least one non-homogeneous parameter selected from the group consisting of a model of concrete mixture, source of concrete mixture ingredient, temperature, degree of hydration, water / cement ratio, and added value.
[0010]
10. Method, according to claim 9, CHARACTERIZED by the fact that, in said nominal dose response curves, said at least four sets of data correlations involve at least two non-homogeneous parameters selected from the group consisting of a model of concrete mixing, source of concrete mixing ingredient, concrete temperature, degree of hydration, water / cement ratio, and added value.
[0011]
11. Method, according to claim 1, CHARACTERIZED by the fact that changes in the air content and dejection of the concrete mixture as affected by doses of chemical mixtures to modify the air content in the mixture of concrete and cement dispersant administered during a concrete mixture distribution operation are incorporated in said nominal dose response curves and the scale factors in which said nominal dose response curves and scale factors are modified; and the subsequent changes of air and slump in the same or a subsequent operation of distribution of the concrete mixture are carried out on the basis of said modified nominal dose response curves or said scaled factors.
[0012]
12. Method according to claim 11, CHARACTERIZED by the fact that the computer's processing unit communicates wirelessly with the database memory of the computer's accessible processor unit having data relating to said changes in air content and abatement of concrete mixtures due to doses of chemical mixtures to modify the air content in the mixture of concrete and cement dispersant administered during the concrete mixture distribution operation and incorporated in the said response curves to the nominal dose and scale factors in which the said response curves to the nominal dose and the scale factors are modified, as well as data related to changes in air and slump of the same or a subsequent operation of distribution of the concrete mixture carried out based on said response curves to the modified nominal dose or modified scale factors.
[0013]
13. Method according to claim 12, CHARACTERIZED by the fact that the computer processor's accessible memory unit database stores information about one or more concrete mix model, source of concrete mix ingredient, concrete temperature, water / cement ratio, and time since dosing for each data point in relation to said changes in the air content and abatement of concrete mixtures depending on doses of chemical mixtures to modify the air content in the mixture of concrete and cement dispersant administered during the concrete mix distribution operation.
[0014]
14. Method according to claim 13, CHARACTERIZED by the fact that one or more of the concrete mix model, source of concrete mix ingredient, concrete temperature, water / cement ratio, and time since dosing are used to select the modified nominal dose response curve or scale factor.
[0015]
15. Method, according to claim 1, CHARACTERIZED by the fact that said cement dispersant comprises water and a water reducing mixture.
[0016]
16. Method, according to claim 15, CHARACTERIZED by the fact that water is the cement dispersant added after the ingredients are loaded into the mixing drum until reaching the target slump or target slump and the target air content or the target air content range, and water reducing or superplasticizer mix is the cement dispersant used to maintain at least one abatement value at the current time and at least one air content value at the current time at the target abatement or in the target slaughter range and in the air content or in the target air content range.
[0017]
17. Method, according to claim 1, CHARACTERIZED by the fact that after step (e), concrete is mixed in a rotating mixing drum a number of revolutions which is based on the identity of the cement dispersant and / or the mixture chemical to modify the air content in the added concrete mixture before the concrete discharge or repeat step (c).
[0018]
18. Method, according to claim 1, CHARACTERIZED by the fact that steps (c) to (e) are repeated until the concrete is discharged from the mixer.
[0019]
19. Mixing device CHARACTERIZED by the fact that it has a computer processing unit and an accessible computer processing unit memory, the computer processing unit and the accessible computer processing unit memory being programmed to carry out the method as defined in claim 1.

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法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2019-09-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|

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2020-05-19| B09A| Decision: intention to grant|

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2020-07-07| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/12/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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PCT/US2011/064333|WO2013089663A2|2011-12-12|2011-12-12|Multivariate management of entrained air and rheology in cementitious mixes|

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