Patent Application
20250058497
One or more aspects of the present invention pertain to the technical field of construction. More particularly, one or more aspects of the present invention pertain to the field of structural concrete cast in-situ for walls and such. More particularly the present invention pertains to creating and using a structural concrete mix.
One aspect of the present invention pertains to methods of making zero slump pumpable concrete. Another aspect of the present invention pertains to apparatuses for placing and using zero slump pumpable concrete. Another aspect of the present invention pertains to systems for forming concrete structures.
It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description. The invention is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification. All numeric values are herein defined as being modified by the term “about,” whether or not explicitly indicated. The term “about” generally refers to a range of numbers that a person of ordinary skill in the art would consider equivalent to the stated value to produce substantially the same properties, function, result, etc. A numerical range indicated by a low value and a high value is defined to include all numbers subsumed within the numerical range and all subranges subsumed within the numerical range. As an example, the range 10 to 15 includes, but is not limited to, 10, 10.1, 10.47, 11, 11.75 to 12.2, 12.5, 13 to 13.8, 14, 14.025, and 15.
“Admixture” is a term of art in concrete construction that has the meaning of an additive that is typically used in minimal doses to affect the concrete properties. In this application it has a specific meaning to describe the additive compositions utilized to modify the concrete to provide the zero-slump-pumpable properties. These modifications include use of thixotropes for an improved rheology allowing placement of the concrete without forms, whereby it has a high static shear with shear thinning upon displacement, beyond what cement can provide, and to provide thickening in general as required for achieving zero-slump, and set-accelerators as preferred to allow rapid stacking of the concrete.
“Liquid-mixture” is a term used to describe the entire liquid supplied to the concrete mix in lieu of water, to impart the same properties described above, in the context of batching concrete with a volumetric mixing process where the water for that concrete is replaced entirely with the liquid-mixture.
The term “pumpable” as used herein is defined as the ability of confined concrete to flow under pressure while maintaining its initial properties.
The term “zero slump” as used herein is essentially as defined by the ASTM for concrete.
Concrete according to one or more embodiments of the present invention is termed “zero-slump-pumpable” concrete, to distinguish it from “no-slump” or “zero-slump” concrete which generally means a very stiff concrete mix that primarily includes less water as a means to create that stiffness. Concrete termed no-slump or zero-slump is intended for placement methods such as slip forming, dry packing, roller forming, or extruding; where attempting to pump the mix with a common concrete or grout pump is out of the question. However this use of the term “zero-slump-pumpable” refers to a new type of a concrete that can be pumped with a low-powered concrete or grout pump, yet is sufficiently stiff as it initially comes out of the pump hose to be placed in subsequent layers, building a vertical dimension of concrete without the need of forms; and is also sufficiently pliable and workable so that irregularities in the just-placed wet concrete can be corrected manually, allowing consistent placement with trued surfaces. “Zero-slump-pumpable” concrete as used herein is relatively soft and resembles a fluid having the consistency (i.e. viscosity), of something akin to what comes out of a soft ice cream dispenser. It is preferrably highly thixotropic having high shear strength in the static condition, but it responds well to dynamic forces with significant shear thinning allowing manipulation. It behaves as if it were a lighter weight substance even though it is normal weight concrete and it retains its shape, and quickly solidifies sufficiently to support additional layers placed over it.
According to one or more embodiments of the present invention, the zero slump pumpable concrete that can be pumped with a low powered concrete or grout pump can be pumped using a concrete or grout pump having a maximum power capacity of 50 horsepower or less.
According to one or more embodiments of the present invention, the zero slump pumpable concrete that can be pumped with a low powered concrete or grout pump can be pumped using a concrete or grout pump having a maximum power capacity of 75 horsepower or less such as the Mayco C30HDG Concrete Pump which has an engine output of 65 hp (51 kW).
According to one or more embodiments of the present invention, the zero slump pumpable concrete that can be pumped with a low powered concrete or grout pump can be pumped using a concrete or grout pump having a maximum power capacity of 100 horsepower or less such as the Mayco C30HDG Concrete Pump which has an engine output of 65 hp (51 kW).
According to one or more embodiments of the present invention, the zero slump pumpable concrete that can be pumped with a low powered concrete or grout pump can be pumped using a concrete or grout pump having a maximum concrete pressure performance of 600 pounds per square inch or less such as the Mayco C30HDG Concrete Pump which has a maximum concrete pressure performance of 500 pounds per square inch (35 bar).
Various embodiments of the present invention may include any of the described features, alone or in combination. Other features and/or benefits of this disclosure will be apparent from the following description.
The order of execution or performance of the operations or the processes in embodiments of the invention illustrated and described herein is not essential, unless otherwise specified. That is, the operations or the processes may be performed in any order, unless otherwise specified, and embodiments of the invention may include additional or fewer operations or processes than those disclosed herein. For example, it is contemplated that executing or performing a particular operation or process before, simultaneously with, contemporaneously with, or after another operation or process is within the scope of aspects of the invention.
The following patents are hereby incorporated by reference herein, in their entirety, for all purposes: U.S. Pat. Nos. 9,061,940, 9,266,969, 9,260,734, 9,238,591, 9,802,864, 9,643,888, 9,416,051, 9,266,969, 9,056,932, 8,882,907, 7,294,194, 5,753,036, 4,654,085, 8,864,905, 8,828,137, 8,764,273, 8,648,120, 8,491,717, 8,268,927, 6,221,152, 5,175,277, 9,505,658, 9,574,076, 9,199,881, 8,430,957, 8,545,620, 8,349,960, 9,040,609, 9,181,130. These patents disclose information about various agents that modify concete rheology to impart properties of thixopropy, where the at-rest shear strength is sufficient to allow vertical stacking of the concrete, with a shear thinning allowing pumping and manipulation of the zero-slump mix.
The one or more embodiments of the present invention comprises a system to produce a zero-slump pumpable concrete and to define and create vertical or sloped planar surfaces for placement of the concrete by means of a pump, where forms are not utilized, and consolidation of the concrete by vibration can also be accomplished as an option. Most any common concrete or grout pump, as is typically deployed at large or small construction projects, can connect to this system with the most universal concrete hose connection fittings. Concrete that would typically be batched at typical batch plants and delivered by typical concrete trucks can be used with that concrete pump, and one or more embodiments of the present invention modifies the concrete in the pumping line so that it can be placed and hold vertical dimension without the use of forms.
One or more embodiments of the present invention enable fast and easy real-time definition of a concrete vertical surface from pumped concrete as the concrete is being pumped; and it allows vibrating the concrete for consolidation during that placement of the concrete, while maintaining the vertical surface, without the usual forming process.
An embodiment of this geometry-definition system is to place the concrete against rigid foam panels that define the other surface of the concrete, so creating insulated concrete walls without undertaking the typical concrete forming process. Other embodiments of the present invention may include placement of concrete for retaining walls, foundation walls, or elevator shafts, where the concrete is placed directly against the effectively vertical surface of the excavation-or a waterproofing assembly positioned between finished concrete and the earth, etc. Or embodiments of the present invention can be used to construct freestanding plain concrete walls, which may include defining the surfaces of each side of the walls.
Embodiments of the present invention can replace processes such as shotcrete. Any of the backing methods used for shotcrete construction, such as wire lath or drywall panels, can be used with embodiments of the present invention. Embodiments of the present invention can place concrete at full thickness in one pass. Embodiments of the present invention can may also define the finished concrete surface while the concrete is being placed.
One or more aspects of the present invention pertain to providing in-situ structural concrete that does not need forming, yet can be pumped into place with any pump meant for normal concrete or grout. This concrete is suitable for walls of multi-story buildings, or civil engineering projects that would normally require forming, and so on. This type of concrete generally contains normal-weight aggregates, which makes a zero-slump-pumpable mix design more challenging than with light-weight aggregates. In general this type of concrete should not contain such things as excess lime (calcium hydroxide), and should routinely be able to reach in-place strengths of at least around 4000 psi (27.6 MPa) per the ASTM C-90 standard. This mix design must also be able to have the impermeability to survive unfavorable environments with the durability one expects of contemporary structural concrete.
One or more embodiments of the present invention inject and mix into the line of pumped concrete, an admixture that provides the desired zero-slump yet pumpable and workability properties for the resulting concrete, and at a rate that is proportional to flow rate of the concrete. One or more exemplary admixture compositions is disclosed herein. The point of injection is located an effective distance from the discharge end of the line of pumped concrete, to provide mixing benefit, so intermixing the admixture sufficiently with the concrete inline to give it these new properties, but at a length of line that has lower pumping pressure and one that can be removed, replaced and/or cleared of any blockage created from accelerated concrete. Various means of metering the injection of admixture flow rate to proportionally correspond with the concrete flow rate are disclosed. One variation is where the concrete mix water is replaced entirely with a liquid-mixture in the onsite volumetric mixing process, so taking advantage of the short time period between concrete mixing and placement to include agents that allow a rapid set of the modified concrete mixture.
Also disclosed are various methods and apparatus to define and control the geometry of surfaces of the pumped-in-place concrete, and to provide a method of temporary confinement of the concrete allowing further consolidation by vibration. These devices include passive and active means to minimize or prevent a sticky, cement-rich concrete from adhering to their geometry-defining surfaces. These devices are not related to the means and method of making or placing the concrete. Any type of concrete mix with suitable rheology and set rate to satisfactorily hold shape to suit one's need for rate of placement will work. The placement means does have some limitations in that the rate of placement cannot exceed the concrete material properties to hold form, given whatever amount of temporary confinement may be present. For example, if concrete were to be conveyed into place with a large bucket suspended by a tower crane, the discharge rate of concrete from the bucket could not exceed the ability to at least temporarily confine that amount of concrete into the desired geometry. Conveyance by chute, auger, belt, wheelbarrow, shovel etc can all be as acceptable to these geometry definition methods as is placement by pump.
The various elements of any of these devices disclosed herein can advantageously be combined with other devices in many different permutations. Generally, for the present disclosure, only a single example of each feature is given, and any of the other combinations of the features is not also shown, as it is typically apparent that these other combinations of the features can be made by persons of ordinary skill in the art in view of the present specification.
Reference is now made to
The concrete mixing truck 1 can be a conventional drum-mixing truck that is normally supplied with conventional concrete materials at a concrete plant with bulk material dispensing equipment, or it can be any other means of batching concrete, such as an onsite volumetric mixing system. According to one or more embodiments of the present invention, this concrete can be entirely conventional in every respect. According to one embodiment of the present invention, the resulting zero-slump-pumpable mix, combined with a minimum amount of subsequently-added admixture (described below) will have a higher proportion of ultra-fine binders. This would most often be a higher proportion of portland cement or fly ash, or both, or similar. These can be substituted with other binder materials, such as natural pozzolans, ground rice hull ash or blast slag, limestone powder, silica fume, et cetera. As the jobsite-added materials are typically more expensive than the batch plant constituents, and because they do not necessarily add strength, it is more economical to start with a type of concrete mix design that can be modified to a zero-slump-pumpable mix with a minimum of the jobsite-added admixture. The slump of this unmodified concrete mix is preferably low, in the range of 2 to 4 inches, but it needs to be pumpable by the given concrete or grout pump 2. This initial low slump is not essential, but it does reduce the amount of admixture subsequently required to bring the concrete to zero-slump-pumpable, and of course the lower water/cement ratios usually makes for stronger concrete. More on the mix design follows the explanation of the drawing figures.
The concrete or grout pump 2 can be any meant for this purpose, and if a cementitious mortar is used, it can be a pump meant for that media. Experiments for one or more embodiments of the present invention were done with a 1970's Mayco C30 HD grout pump, a relatively small and not very powerful concrete pump. The Mayco C30 grout pump (and the essential identical copies of it made by competitors) is likely the most common concrete pump model in the world, assuming one considers grout to be a variation of concrete having smaller aggregate and typically a higher slump. A stronger, more powerful concrete pump will provide more success with less-pumpable and stiffer concrete mixes, so the range of mix designs and amount of admixture disclosed here will work with most any functioning concrete or grout pump, and less jobsite modification to the concrete can be used if a stronger concrete pump 2 is available. The concrete mix used here because of the limits of the smaller ball valve concrete pump used; commonly referred to as grout pump, as the maximum aggregate size capacity is ⅜″ (9 mm). The larger aggregate size, such as ¾″ (18 mm) of “real” concrete, does not negatively affect the vertical stacking ability of the zero-slump-pumpable concrete, and it does allow for less of the binders and ultra-fines to be utilized while still having the desired zero-slump-pumpable properties. The concrete is pumped in normal concrete pumping hose of the diameter preferred; for a grout pump this would normally be a 2″ (50 mm) minimum diameter hose; for this lower slump mix a 2½″ (72 mm) diameter hose is preferred. A larger diameter hose allows more latitude in the fluid performance of the mix design. Larger concrete pumps would use 3″ (75 mm) and larger hoses.
The metering pump 3 can be part of a system where the pumping rate is adjusted and set manually as shown in
There are many options for the metering pump 3. One limiting criterion is the composition of the admixture. If it is low in suspended solids and of a viscosity and composition suitable for a common “airless” pump system designed for applying latex paint, such a pump can economically serve the purpose of metering the admixture proportionally to concrete flow where a relatively low proportion of admixture will suffice. In this case the admixture will need to be filtered as latex paint would need to be filtered. If the admixture contains abrasive or larger suspended solids, or is of a higher viscosity, that will cause problems with an airless paint pump system, then an airless pump system meant for applying texture finishes can be utilized. If the admixture is of a composition that contains substantial solids and/or that will cause problems for an airless texture pump, then a high-solids slurry pump such as a peristaltic pump (hose pump) or a progressive-cavity pump (rotor-stator pump) would be required. The peristaltic pump is typically limited by maximum pressure, where 200 psi (1400 kPa) is typically at the high end, and the progressive cavity pump is typically limited by output volume for reasonably-sized (affordable) pumps. The peristaltic and progressive-cavity pumps have the benefit of commonly being set up with small 3-phase motors with inverter/controllers that allow them to be run at variable pump rate on a single-phase 115-volt power supply. A suitable peristaltic pump is the Vector model 4004, by Wanner Engineering, Inc, of Minneapolis, MN. As this particular pump is capable of only 110 psi (750 kPa), its use requires the hose tail 6′ to be no longer than about 15 feet (4.5 M) depending on the fluid properties on the modified concrete; other Vector pumps will reach 200 psi (1380 kPa), but are a lot more expensive. A suitable progressive-cavity pump is the H-15 “Spray Buddy” (either version) by Hy-Flex Co, Knightstown, IN. This has variable speed and a built in hopper suitable for a high-solids admixture. Air powered industrial diaphragm pumps, such as those made by Graco, are also entirely suitable for most any required makeup of the admixture and flow rate.
If the admixture composition is suitable for an airless paint pump, then such a high pressure pump, as one typically used by a Painting Contractor, can be modified for this purpose, providing the range of flow rate can be adjusted to match that which is needed. Most airless paint systems have a pressure adjustment that also effectively adjusts flow volume for the line pressure present in this use as a proportional metering system. Essentially all airless paint pumps have high enough pressure to achieve injection into the concrete pump line. For example, a Graco Ultra Max II 595 PC Pro paint pump is sufficient to inject the admixture into a line of concrete, in that it achieves a very high pressure of 3300 psi (227 bar), and produces a flow rate of up to 0.70 gallons per minute (2.6 Lpm). If a 1:40 ratio of admixture to concrete is required, then this would allow the concrete to
The metering pump 3 flow rate must of course correspond to the concrete or grout pump 2 flow rate, according to the required admixture ratio, unless other metering methods are utilized as disclosed further on. For example, if pump 3 is capable of 0.70 gallons per minute, and a 1:40 ratio of admixture to concrete is required, then the concrete could be pumped at 28 gpm, which is about 8.3 cubic yards (6.3 cubic meters) per hour. A mix ratio more like 1:80 is preferred, and would allow up to doubling of this concrete pump rate using the same metering pump 3.
A container 31 is used to contain admixture as it is pumped to the concrete line. For a smaller airless pump, this can be as small as a 5 gallon (20 L) pail for lower admixture ratios, and where a higher admixture ratio is warranted, than this container would preferably be larger.
A flow meter 8 is optional to be able to know the instantaneous flow rate of the admixture, where such a device is in not built into the metering pump 3. Many airless paint pumps now have material flow information in a digital readout format, which can be used to determine flow rate. This can be done with a magnetic inductive flow meter, such as the model SM6004 made by IFM Efector, inc. with a USA office at 1100 Atwater Drive Malvern, PA 19355.
The material flow is as follows: From the concrete or grout pump 2, the concrete is pumped along a concrete pump hose 6 where it reaches the inline mixer 4. Simultaneously, the admixture is pumped by the metering pump 3 along an admixture hose 9, and through a control valve 10, and then also to the inline mixer 4. The combined concrete/admixture mix is then run through an optional reducer 7 and through the hose tail 6′. The reducer 7 can be a standard part such as is used in concrete pumping. It would typically have an HD flange connection at each end, and it would typically be long enough to avoid blockages per usual concrete pumping practices. The activation of both the concrete and admixture pumping systems can be controlled by a pump switch 11. The switch 11 can be the two different power switches taped together and operated by the same person, or the control wires for the concrete pump 2 and the metering pump 3 can be wired together at switch 11. This can be located adjacent to the location of concrete placement per common practice, and of course it can be wireless. Where an automatically proportional admixture meter system is used (discussed below), it will shut off admixture flow when the concrete flow stops. Other embodiments disclosed omit the need for switch 11. When it is possible that the admixture line pressure would be momentarily lower than the concrete line pressure, a check valve 78 is warranted where the admixture line enters 9 the inline mixer 4. This needs to be a high pressure device, such as a FLCV100T by Fluid Controls Inc, 10050 South 33rd West Avenue, Tulsa, OK 74132, distributed by Dultimeier Sales, 13808 Industrial Rd, Omaha, NE 68137. This is a check valve for pressure-wash systems that has a large enough orifice size to function with the admixture liquid containing suspended solids.
One way or another, the metering pump 3 rate needs to correspond proportionally to the concrete pump 2 rate, within the required limits of the ratio of the admixture design utilized. Where the admixture mix design allows flexibility in mix ratio with concrete, the admixture pumping rate can be measured and set to correspond to a normal concrete pump rate. The normal concrete pump rate is adjusted by setting and locking that motor throttle for the speed to run when the control switch is in the “pump” position, per usual practice. Where the admixture proportion needs to be, or is preferably held to, a stricter degree of accuracy, several devices for proportionally metering the admixture are disclosed further below.
The admixture hose 9 must be rated for the pressure created by the metering pump 3 of course, and normal airless paint hose will work perfectly well for an admixture that works with that pump. Otherwise, the high pressure hoses meant for shotcrete admixtures will work. The valve 10 is an optional and primitive means of adjusting the flow rate of the admixture into the inline mixer 4, and where the metering pump 3 allows, it can be used as the means of shutting off admixture flow rather than the switch 11. Of course it can be located at metering pump 3. Alternatively valve 10 can be set to divert admixture flow, when concrete modification is not required, or during clean up.
The concrete/admixture blend leaves inline mixer 4 through a length of a concrete pump hose tail 6′, which can be identical to normal concrete pump hose 6, except that the specific length of hose tail 6′ is critical because it determines the amount of pumping pressure that will be present at inline mixer 4, and how much further mixing will occur with the concrete/admixture blend after leaving the inline mixer 4. A long enough hose tail 6′ can intermix the concrete and admixture sufficiently without the inline mixer 4 present. This length requirement will vary considerably according to the concrete and admixture compositions, and the rate of concrete material stacking that is required.
The specific length of the hose tail 6′ is associated with the intermixing effectiveness of the inline mixer 4 and the attainable injection pressure of the admixture. In tests, an effective length has shown to be a minimum of approximately 10 feet (3 M) to sufficiently complete the mixing process, and this is effectively the minimum practical length necessary to provide flexibility to facilitate concrete placement while keeping the inline mixer 4 intermittently stationary, and a 15 foot (4.5 M) length is more practical from this perspective. Longer hose tail lengths are attainable with higher injection pressure, and will ensure complete mixing, but the concrete going though the hose tail 6′ is now very stiff and possibly very highly accelerated, so this length of hose is more vulnerable to inline blockages, should there be any delays in concrete placement. Accordingly, keeping it short enough to be cleared out with a length of rebar (typically 20 feet) is very beneficial, and this length has not shown to be not problematic for the injection of admixture with an airless paint pump, for example, but it can be a problem for pumps that reach only around 100 psi (0.7 MPa), depending on fluid properties of the mix. This down line injection system is a real advantage to the inline mixing process for creating zero-slump-pumpable concrete, in that none of the concrete pumping line other than the hose tail 6′ contains stiffened and accelerated concrete, so the entire pumping process is easier and less exposed to catastrophic blockage.
The composition of the admixture can vary considerably and the mix ratio with the concrete would correspondingly vary as well, according to the particular specific properties of a given admixture design and the properties of the constituents of the concrete and those mix ratios. The examples disclosed here may not correspond to a given or preferred admixture design that could be by others, and the method here is designed to work with any type of admixture that imparts the thixoptropy necessary to allow the concrete to be stacked vertically, and/or the set acceleration to allow the same thing; or to work with any other new chemical technology that affects a concrete mix to give it the necessary stiffening effect. For example, this can be agents that cause a “false set” of the concrete, which is a premature set that can be relaxed by agitation, typically caused by an excess of gypsum or an agent having the same effect in promoting the development if ettringite crystals. Other examples of thixotropes would be emulsions of Vinyl Acetate Ethylene copolymer (VAE), or of Poly Vinyl Alcohol (PVA), or of a highly fibrillated processed attapulgite clay or the like such as is untilized in well-sealing cements; or reinforcing fibers; or an Alkali Swellable Emulsifier, etc. Any of these agents that are activated by the high pH of concrete or the ionic strength of the portland cement solution, can be made to have an extreme thickening effect upon introduction, by injection, to the portland cement environment. This concept of utilizing complementing components, each maintained in separate routes of conveyance until intermixing together, where the reaction can be made to have significant beneficial effect on the concrete rheology. Set accelerators, such as aluminum sulfate, that are utilized with shotcrete can be used in the same manner with this injected admixture system, and many of the sulfate-metal salts also have beneficial effect on concrete rheology.
In addition to the concrete rheology disclosed in the documents incorporated by reference, many concete rheology modification improvements are being made, and it can be assumed that improved compositions will have potential to improve the effectiveness of the systems disclosed here. An example of this is the rheology modification found by cardon dioxide injection into a concrete mix, developed by CarbonCure Technologies Inc, 60 Trider Crescent, Dartmouth, NS B3B 1R6, Canada. This type of carbon dioxide gas introduction can be used in combination of the following disclosed devices, or can be a constituent of a liquid admixture composition.
For the admixture, constituents beneficial to concrete rheology consist of pulverous and/or liquid defoaming agents, wetting agents, alkyl polysaccharide ethers, hydroxyalkyl polysaccharide ethers and/or alkyl hydroxyalkyl polysaccharide ethers such as cellulose ether, starch ether and/or guar ether, the alkyl group and hydroxyalkyl group typically being a C.sub.1- to C.sub.4-group, synthetic polysaccharides such as anionic, nonionic or cationic heteropolysaccharides, in particular xanthan gum or wellan gum, cellulose fibres, dispersing agents, cement superplasticisers, setting accelerators, early strength accelerators, setting retarders, air entrainers, polycarboxylates, polycarboxylate ethers, polyacrylamides, completely and/or partially saponified and, where required, modified polyvinyl alcohols, polyvinyl pyrrolidones, polyalkylene oxides and polyalkylene glycols, the alkylene group being typically a C.sub.2- and/or a C.sub.3-group, which includes also block copolymers, dispersions and foam forming dispersion powders redispersible in water based on copolymers containing emulsion polymers such as e.g. those based on vinyl acetate, ethylene vinyl acetate, ethylene vinyl acetate vinyl versatate, ethylene vinyl acetate (meth)acrylate, ethylene vinyl acetate vinyl chloride, vinyl acetate vinyl versatate, vinyl acetate vinyl versatate (meth)acrylate, vinyl versatate (meth)acrylate, all (meth)acrylate, styrene acrylate and/or styrene butadiene, hydrophobing agents such as silanes, silane esters, siloxanes, silicones, fatty acids and/or fatty acid esters, thickening agents, fillers such as quartzitic and/or carbonaceous sands and/or flours such as quartz sand and/or powdered limestone, carbonates, silicates, layer silicates, precipitated silicic acid, light-weight fillers such as hollow microspheres of glass, polymers such as e.g. polystyrene spheres, aluminosilicates, silicon oxide, aluminium silicon oxide, calcium silicate hydrate, silicon dioxide, aluminium silicate, magnesium silicate, aluminium silicate hydrate, calcium aluminium silicate, calcium silicate hydrate, aluminium iron magnesium silicate, calcium metasilicate and/or volcanic slag as well as pozzolanic materials such as metakaolin and/or latent hydraulic components.
More rheology benefiting constitutents consist of polysaccharides and polysaccharide ethers soluble in cold water such as cellulose ethers, starch ethers (amylose and/or amylopectin and/or their derivatives), guar ethers and/or dextrins are polysaccharides and their derivatives are preferably used. It is also possible to use synthetic polysaccharides such as anionic, nonionic or cationic heteropolysaccharides, in particular xanthan gum or wellan gum. The polysaccharides may be chemically modified, but need not be so, e.g. with carboxy methyl groups, carboxyethyl groups, hydroxyethyl groups, hydroxypropyl groups, methyl groups, ethyl groups, propyl groups and/or long-chain alkyl groups. Further natural stabilising systems consist of alginates, peptides and/or proteins such as e.g. gelatine, casein and/or soya protein. Dextrins, starch, starch ethers, casein, soya protein, hydroxyalkyl cellulose and/or alkyl hydroxyalkyl cellulose are particularly preferred.
Synthetic stabilizing systems may also consist of one or several protective colloids. As an examples, there is/are one or several polyvinyl pyrrolidones and/or polyvinyl acetals with molecular weights of 200 to 400,000, completely or partially saponified and/or modified polyvinyl alcohols with a degree of hydrolysis of preferably approximately 70 to 100 mole %, in particular approximately 80 to 98 mole %, and a Hoppler viscosity in 4% aqueous solution of preferably 1 to 50 mPas, in particular of approximately 3 to 40 mPas (measured at 20.degree.C. according to DIN 53015) and melamine formaldehyde sulphonates, naphthalene formaldehyde sulphonates, block copolymers of propylene oxide and ethylene oxide, styrene maleic acid copolymers and/or vinyl ether maleic acid copolymers. Higher molecular oligomers may be nonionic, anionic, cationic and/or amphoteric emulsifiers such as e.g. alkyl sulphonates, alkyl aryl sulphonates, alkyl sulphates, sulphates of hydroxyl alcanols, alkyl sulphonates and alkyl aryl disulphonates, sulphonated fatty acids, sulphates and phosphates of polyethoxylated alcanols and alkyl phenols as well as esters of sulphosuccinic acid, quaternary alkyl ammonium salts, quaternary alkyl phosphonium salts, polyaddition products such as polyalkoxylates, e.g. adducts of 5 to 50 mole ethylene oxide and/or propylene oxide per mole of linear and/or branched C.sub.6- to C.sub.22-alcanols, alkyl phenols, higher fatty acids, higher fatty acid amines, primary and/or secondary higher alkyl amines, the alkyl groups being preferably a linear and/or branched C.sub.8- to C.sub.22-alkyl group in each case. Synthetic stabilising systems, in particular partially saponified, where required, modified, polyvinyl alcohols are particularly preferred, it being possible for one or several polyvinyl alcohols to be used together, where required with small quantities of suitable emulsifiers. Preferred synthetic stabilising systems are, in particular, modified and/or unmodified polyvinyl alcohols with a degree of hydrolysis of 80 to 98 mole % and a Floppier viscosity as 4% aqueous solution of 1 to 50 mPas and/or polyvinyl pyrrolidone. Water-soluble organic polymeric protective colloids with a higher content of carboxylic acid groups are, however, less preferred, in particular if they are produced by means of free radical polymerisation. Thus, the content of monocarboxylic acids and dicarboxylic acids and their anhydrides should be less than 50 mole %, preferably less than 25 mole % and in particular less than 10 mole %. Water-soluble organic polymeric protective colloids consisting of aromatic sulphonic acid condensates are, moreover, also less preferred.
The guidance to define the surfaces of the concrete wall 5 can vary, and for clarity are not shown in
For experiments performed using one or more embodiments of the present invention, concrete placement for a wall height of 8 feet (2.5 m) has been obtained within three minutes of elapsed time. This corresponds to a vertical rate of wall concrete placement at 2.67 feet (812 mm) per minute. For example, where a plane of support is provided behind placed concrete, the concrete can be pumped into placed at full thickness of a wall that is in the range of 4 inches (100 mm) thick or more, and hold this vertical orientation and shape, as fast as it can be pumped by the concrete or grout pump used for this testing, for walls as narrow as 2 ft (0.6 m) wide.
The inline mixer 4 is a device that provides a means to inject the admixture into the concrete as it is being pumped, and to intermix that admixture with the concrete in line. The inline mixer 4 provides inline mixing for two liquids within a pressure line, where one liquid is injected into the other. Mixer 4 has the same benefit for any of the proportional metering devices disclosed, and has various useful embodiments. As such, adjacent to an inline mixer casing 12, is an admixture injection assembly 17, which injects admixture into the pressure line of concrete upstream of the inline mixing process.
As one can see on
This design shows two sets of mixing vanes, which allows sequentially increased mixing. One can see a that each of the mixing vane 14 is skewed to force flowing concrete off the projecting edge, so creating a vortex toward the center of the concrete flow as is possible without creating blockages, and to maximize mixing as possible. Each mixing vane 14 is effectively clamped into place between a pair of a vane connection flange 15, and the clamping force created by at least 2 of a bolt assembly 16, or the equal, which can be any machine screw with hex nut preferably of ¼ inch (6 mm) diameter, that passes through a slot 24 in the mixing vane 14 and though a hole in each vane connection flange 15. The slot 24 can be an oblong hole or a notch, with a length sufficient to provide required beneficial adjustment. This type of attachment makes the positioning of each mixing vane 14 adjustable with respect to the amount of its projection into the inline mixer 4. This adjustment is necessary to accommodate different concrete mixes and aggregate sizes without creating blockages, yet maximizing the amount of mixing. The size of and resulting intrusion of each vane 14 can vary as shown in
In this embodiment each mixing vane 14 is skewed at 15 degrees from the inline mixer 4 longitudinal axis, and is of ⅛″ (3 mm), or thicker, stainless steel or plain carbon steel, and at the furthest projections, and given varied sizes, adjusts from 0.75″ to 1.5″ (18 to 37 mm) dimension into the casing 12. Each of the vane connection flange 15 is of ⅛″ (3 mm) minimum thickness and is welded to the casing 12. This arrangement is to make the vanes 14 easy to adjust as they wear, and inexpensive to replace when worn out. The length of each of the vane 14 must match each corresponding slot opening in casing 12, with minimal clearance, to avoid concrete and liquid leakage under pressure. Of course there are many options to affixing these vanes. Minimal leakage where they penetrate casing 12 is not a problem.
Each of the pairs of the vane connection flange 15 is preferably sloped at least approximately degrees from perpendicular to the average tangent of the surface of the casing 12—on average over the mixing vane 14 length-thereby sloping each of the mixing vane 14 in the direction that the concrete flow pushes on it. This slope prevents aggregate in the concrete from getting stuck in the crevasse at the upflow side of any of the mixing vane 14. Of course this slope can vary considerably with successful results.
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The admixture injection ring 20 has a number of an injection orifice 21, that surround the line of concrete flow. Each can have a corresponding injection shield 22, but these are optional. Each of the shield 22 is located partially over each of the orifice 21 in a manner creating a shield cove 23 corresponding to each orifice 21. The purpose of the shields 22 is to effectively create a small vortex and region of low pressure at each orifice 21, and in provide a path for the admixture to enter the concrete and penetrate it further, facilitating a more complete mixing of the two fluids. The same type of benefit can be provided to a lesser degree by sloping each orifice 21 in the direction of concrete flow, in lieu if including shields 22. This low pressure effect created by the shields 22 also has the benefit of allowing the use of a weaker metering pump 3, and helps with to draw admixture into the concrete as it flows, and not draw admixture in when the concrete flow is stopped, so assisting in the proportional metering process. There is no magic to the total number of orifices required; more is better except that the totality of the shields 22 creates the potential for blockage of concrete flow. A commercially available “water ring” commonly has 12 orifices. This should be considered a practical minimum for efficient intermixing; more orifices being better for intermixing. Testing showed that typical water ring orifices 21 are of a diameter too small for reliably passing admixture with suspended solids-such a water ring will immediately clog up with the preferred admixture composition for zero-slump-pumpable concrete.
The admixture injection ring 20 requires each of the orifice 21 to be of a diameter suited to the material making up the admixture. Suspended solids can create blockages; their makeup and concentration, along with the viscosity and lubricity of the admixture, determines the required size of each orifice 21. Assuming a viscosity of around 500 cP—which is around 66% of the way to latex paint from water—and a mix with suspended solids of soft, milled clays, each orifice 21 should be in the range of 3/32″ (2 mm) diameter. For higher viscosities and suspended solids in higher concentrations or of harder materials such as silica particles, the orifice 21 diameter would need to be increased to around ⅛″ (3 mm). Experimentation may be the only way to make this determination for a given admixture formulation, more on that follows in the admixture disclosure below. Making the orifices too large has the effect of increasing admixture seepage into the concrete line while all pumping is paused, and causes over consumption of admixture. In any case, while pressurized concrete is within mixer 4, admixture should be present under equal or greater pressure at the orifices 21, to avoid having the concrete material push into the orifices 21 and clog them up.
The shield 22 experiences aggressive conditions. It needs to be as abrasion resistant as possible, so is appropriately of manganese steel, or the equivalent, that is either hard-faced or hard-chrome plated; or each of the shield 22 can be entirely of weld-on hard-facing material. The exact size and shape will vary as it wears down, and fortunately it serves the required purpose at varied geometries and size. The inline mixer 4 functions without the shields, but the mixing is then less complete, at least within the inline mixer 4; and the demands on the metering pump 3 are greater. The preferred geometry for each shield 22 is a split, truncated cone that is located primarily up-flow of each orifice 21, where the split face is at the down flow side, aligned perpendicular to concrete flow and with orifice center. So the orifice 21 is effectively also partially bored into the shield 22, so creating a shield cove 23 at each shield 22. Each of the shield cove matches the corresponding orifice 21 and projects at least that diameter in distance outward from the inner surface of ring 20. The projection of the shield 22 is ideally around 5/32″ to 3/16″ (4 to 5 mm) from the surface of ring 20, and the truncated top is ideally around ⅛″ (3 mm) diameter, with each cone side surface sloped at around 25 degrees from vertical; and the leading edge slope is at approximately 45 degrees. This creates a base width of around ¼″ to 5/16″ (6 to 8 mm) transverse to the flow, with the split face taking around 3/16″ (4 mm) off of the down flow side of this base. In the direction of flow, the shield base dimension is approximately ⅜″ (9 mm). This dimension can be increased significantly to increase wear resistance. All of these measurements can vary considerably and the shield 22 can still provide the stated benefits to assist in mixing the admixture into the concrete, and of course the stated shape can and will have a smoothed and rounded form after use, as depicted in
This shows one example means of defining cast-in-situ concrete wall geometry, such as would be done for an insulated building. As the zero-slump-pumpable concrete mix makes building custom walls of concrete easier, it is anticipated that home construction will begin to adopt various versions of this concrete wall construction method. This wall has the solid concrete all on the interior side to provide thermal mass where it benefits comfort and energy efficiency, and has all of the insulating foam on the outside where it belongs, with some type of a stucco type finish over that. This arrangement is chosen for this example as it is optimal for energy-efficient construction, but it can vary of course, as for some climates insulating foam is not required, or it can be replaced with a layer of zero-slump-pumpable insulating concrete placed by this same method.
Assuming a conventional concrete foundation with cast-in-place vertically-projecting reinforcement is already built (not shown in this drawing figure), a number of a rigid foam panel 26 is erected in place, and each of a perimeter screed guide 27, is affixed. These are anticipated to be removed later. Temporary bracing to hold the wall plane vertical is not shown. After windows and doors et cetera are located, each of an interior screed guide 28 is affixed. These guides can be permanent or temporary. Both the perimeter screed guides 27 and the interior screed guides 28 are positioned in order serve to define a concrete vertical surface 25.
Numbers of a reinforcing bar 38 are tied in place per usual practice, and with excellent access as no forms or building blocks are in the way. Any of an electrical box recess 30 is located as required, simply using the electrical box itself as a blockout means. It can be attached to the face of the rigid foam panel 26, and spaced from it as required. Any such similar plumbing and mechanical blockout can be easily accomplished by the same means, along with any necessary associated carving out of the rigid foam panel 26. The zero-slump-pumpable concrete is then pumped into place via the concrete pump hose 6′, in subsequent passes beginning at the bottom of a section of wall and working upwards in subsequent passes of concrete being placed 36. As sufficient concrete material is pumped into a given section of the wall, the concrete vertical surface 25 is screeded off with a screed board 29, in the same manner as conventional concrete slab surfaces are defined. The exterior side of the rigid foam panel 26 is clad with a cementitious coating 39 such as stucco or a proprietary fiberglass-reinforced acrylic finish. Stucco is preferable for fire resistance, and it would typically have wire ties through the foam to attach it to the cast concrete wall.
Of course this is just one example of the many ways to exploit the benefits of zero-slump-pumpable concrete for home construction. It is so much nicer, cleaner, pleasant, economical, less wasteful, and quieter than is using the shotcrete process for building concrete walls. Unlike swimming pools and skateboard parks, building construction projects are not at all conducive to the extensive concrete rebound material mess left in front of vertical surfaces being sprayed with shotcrete.
This is an example of how to define a concrete foundation wall without the need for pre-situated vertical panels or surfaces. In this case, the concrete wall will be built it right up to a stay-in-place mudsill of appropriate material, something that cannot be accomplished if forms are in the way of the concrete placement, but this geometry is optional. This method can be particularly useful for retrofit foundations under existing buildings. The soil surrounding this portion of foundation is stripped away and not shown for clarity; the footing concrete is indicated to be normal concrete placed in a dug trench or with forms per usual practice, but of course it can always be zero-slump-pumpable concrete.
A continuous concrete footing 32 is placed in-situ, either at an earlier concrete placement, or at the same placement as the foundation wall. If both are at the same placement, conventional low-slump concrete can be used for the continuous concrete footing 32, if desired, and then the admixture can be introduced to produce the zero-slump-pumpable concrete for the wall, during the same concrete placement as the continuous concrete footing 32. If both are of the same concrete placement, it is beneficial to make that switch before the concrete for the curb atop the footing is placed so that it will have zero-slump. Of course the curb can always be defined with a single conventional form board, each side, as part of a separate conventional concrete placement. Either way, each of the reinforcing bar 38 is typically first tied in place per usual practice, if such reinforcing is required.
A mudsill guide 33 can be a permanent or temporary member. It is staked into place, if any such affixing is required, with a number of a bracing stake 34. A number of an anchor bolt 37 is pre-attached as required for building anchorage, where the mudsill guide 33 is to be left into place for subsequent wood-framed construction. A vertical screed board 35 is fashioned for each side of the wall, sized to allow a clear path of travel as possible. Handles are helpful but are optional. The concrete pump hose 6′ is directed to the wall plane, to create the concrete being placed 36, and each concrete vertical surface 25 is defined with the guided movement of each vertical screed board 35.
As the zero-slump-pumpable concrete with normal-weight aggregates is so easily pliable while holding a vertical shape, this type of minimalistic technique for defining the finished concrete geometry is sufficient. Of course these types of methods really facilitate the construction of more complex shapes using concrete, because the finished concrete geometry can be defined without building the heavy formwork. For example, a cylindrical shape can be defined by a vertical screed that is physically attached to a fixed pivot point; or where precision is not important, the top edges of a garden wall can even be defined by setting the zero-slump-pumpable concrete to a pair of strings set onto batter boards.
The geometry definition means disclosed herein are not at all required for placement of this modified concrete into a geometry having significant vertical dimension; the modified concrete can be stacked over itself to build up the vertical dimension, while that concrete can be pumped into place. Placement by other means can be also done. The various guidance means disclosed herein provide various ways to define where the finished concrete surfaces will be, and they allow that to be done in a rapid manner so as to keep up with a preferred rate of concrete placement, and they can provide a temporary confinment of the concrete allowing consolidation by conventional vibrational means.
This shows the simplest means of directly proportioning the admixture and concrete flow rates. A positive displacement pump 40 is linked directly to a flywheel 41 of a mechanical concrete or grout pump. This is in contrast to a hydraulically-powered concrete pump which typically has no flywheel. The flywheel 41 is supported by a drive axle 43, typically in pillow block type bearings, not shown, and connects to a power source with a drive belt 47. The rotational axis of the pump 40 is coupled with a hub connector 42 to the flywheel 41 with a sufficient number of machine screws tapped into the flywheel 41 hub, or equivalent. The hub connector 42 is a ⅜″ (9 mm) minimum thickness piece of steel plate fitted to accept, or welded to, a shaft coupling that mates with the pump 40 shaft and keyway. A shaft coupling or the equal is necessary to provide the directional flexibility to allow for misalignment of both shaft axes, per usual machine practice. A shaft coupling, such as the “L Series” manufactured by Lovejoy Inc, 2655 Wisconsin Ave, Downers Grove, IL, 60515, USA, is a suitable shaft connection here, to avoid problems of axis misalignment. The pump 40 is supported and aligned in place by a number of a support member 45, each of which is typically fastened to a chassis member 44 of the concrete pump trailer structure. This connection will vary with each concrete pump model, as the trailer structures vary. The arrangement for each of the support member 45 is determined by the fastening elements and requirements of the pump 40 selected. This is all known art. A configuration that allows the concrete pump hood, unmodified, to close, is the best way, and some of the pump 40 arrangements disclosed here to allow that with the Mayco C 30 HD. The hood can always be modified as required.
Pump 40 must be of an essentially positive displacement type, in that the flow must be reasonably proportional to shaft rotation, within limits, given anticipated line pressure and admixture viscosity. Accordingly, acceptable pump types include dual gear pumps such as the oval gear, dual impeller, lobe displacement, et cetera; and include the progressive cavity and peristaltic pump types, as well as the rotary vane or rotary piston pump, and so on. The selection of pump 40 size is determined by the proportional quantity of admixture it pumps per rotation in relation to the amount of concrete that the concrete pump displaces per rotation of the flywheel. This relationship must match the preferred proportion of admixture to concrete, or the admixture can be formulated to match the proportional pump rates.
The Mayco C30 HD concrete/grout pump displaces roughly around 0.03 gallons (0.1 L) of concrete per flywheel 41 rotation. The corresponding pump 40 should effectively displace an appropriate volume of liquid per rotation, under the line pressure conditions present. The actual effective output will vary from the published values, depending on the pump type, because the very low rpm in this application-typically less than 500 rpm-which is below the design parameters for most pumps. The only sure answer is to install a particular pump with a given admixture design and prove performance. Very good results with the direct drive setup have been obtained with a positive displacement dual gear pump, such as the Dayton 4KHG4, providing the admixture has sufficient viscosity but does not have solid particles that are not compatible with such a gear pump. The model 4KHG4 displaces around 0.0009 gallons (0.0034 L) per rotation into a line pressure of 60 psi. This translates roughly into a 1:30 admixture: concrete ratio, which is well within the acceptable range of admixture ratio. For lower proportions of admixture a drive speed reducer of appropriate reduction ratio is suitable, such as one of the “Raider” worm-gear reduction series by Morse, Inc. If the admixture composition has solid particles and so is incompatible with a gear pump, then a peristaltic pump can be used in this direct drive configuration. However the peristaltic pumps are commonly designed for a much lower rpm than is typical for flywheel 41, so the direct drive installation would need a such a gear reduction system as is common for such pumps. The drive speed to suit any pump can be changed with use of a belt drive system.
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Attached to the flywheel 41 is a drive pulley 46. A drive belt 47′ connects that pulley to a driven pulley 48, which is attached to the shaft of pump 40′. Pump 40′ is affixed to chassis member 44 in a manner that provides for appropriate alignment, adjustment and tightening of drive belt 47′ as would be normal for driving a pump such as this, all well known arts. This actual speed will vary with concrete pump speed, but the more important proportional speed does not vary unless pulley changes are made.
Existing technology can be used for making any required adjustment to the proportional speeds of belt driven pumps. This can be as simple as mounting different diameter pulleys. Fine adjustment can be made by utilizing an adjustable-diameter version of driven pulley 48 on the shaft of pump 40′. This can be one manufactured by Lovejoy Inc, 2655 Wisconsin Ave, Downers Grove, IL, 60515, USA. Their model 27828 will adjust in diameter from 1.72 to 4.65 inches (44 to 118 mm), providing a 270% adjustment in proportional speed ratio. Of course any pulley change also requires tension adjustment of belt 47′. To avoid the readjustment of pump 40′ mounting, a spring loaded belt tensioning system with an idler pulley, such as is found on “ride on” lawn mowers, is an appropriate arrangement. Proportional adjustment during pumping operation can be implemented with technology such as British patent GB2526675 “Continuously Variable Transmission” of April 2015 by Pattakos, and other available variable-drive-rate technologies for belt-drive systems that are adjustable while running, with applications ranging from drill presses to automobile transmissions.
This is a simplified diagram of an electronic control system for proportional metering of admixture that is based on the flow rate of a hydraulic fluid system powering a concrete pump. A hydraulic line 53 that is the source of pressure for driving the concrete delivery pistons, and is beyond any return line loop or relief valve system, will have a flow of hydraulic fluid that corresponds proportionally to the flow rate of concrete within a particular piston drive system. That is, for the typical dual piston concrete delivery system, line 53 is tapped with a flow meter transmitter 54, at a location between an actuator that pushes a cylinder of concrete and is beyond any return line or relief valve. For both a single acting and double acting fluid system, the flow of pressure-side hydraulic fluid during the forward stroke driving the piston will be proportional to the outward flow of concrete in that corresponding cylinder. At this same location for the line, in the retraction stroke, the flow of hydraulic fluid in the opposite direction will be proportional to the outward flow of concrete in the other cylinder. Thus for this purpose, the flow meter and transmitter 54 must be reversible and send an identical signal for either direction, or the signal must pass through a rectifier circuit to send a single polarity variable signal for opposing directions of hydraulic fluid flow.
A flow meter and transmitter 54 that serves this purpose is one such as that made by UK Flowtechnik Ltd, 1 Central Park, Lenton Lane, Nottingham, NG7 2NR, UK. The model series “Hysense QT 100” are turbine meters built for high pressure hydraulic fluid lines such as this, and have electronic circuit attachments that are built for this type of a control system. There are many other such meters of various technologies, and when included with proper electronic components and a DC power source and ground, that will send a flow control signal 55 that corresponds to the positive or negative flow rate in hydraulic fluid line 53, and is proportional to the total concrete flow rate.
A variable power inverter 56 is utilized as a speed controller. This can be one such as the TECO FM50, by TECO-Westinghouse Motor Company, 5100 North IH-35, Round Rock, TX, 78681. This inverter requires an AC power supply 57 of 115V at 60 Hz, and provides a modified 3-phase 230V power source 60 at a frequency determined by low-voltage inputs. This inverter requires an enclosure to provide protection from the moisture and contamination found at jobsites, with ventilation to prevent overheating. The flow control signal 55, and a potentiometer 58 that creates a control signal 59, are each connected to the proper low-voltage terminal of the variable power inverter 56, whereby their signals then modify the frequency of the 3-phase power source 60, and control an admixture pump system 61. The potentiometer 58 is typically part of a remote control box that includes other motor control signals for the inverter 56, such as “stop” and “reverse”. In this embodiment an admixture pump system 48 is powered by a 3-phase 230/460V motor designed for variable frequency power, such as the “Black Max” model HH 56H1 7E5303B P, by Marathon Electric Motors, 100 E. Randolph Street, Wausau, WI 54401-8003, USA. Where this motor is connected to a high torque pump such as a peristaltic pump, it is supplied with a direct-drive speed reducer, such as a type RF37AM56 by SEW-Eurodrive, Inc, P.O. Box 518, Lyman, SC, 29365, USA.
This shows an ultrasonic flow meter and transmitter 62 that is linked to the concrete pump hose 6, or any line of a concrete delivery system, and sends a flow control signal 55′ which corresponds to the concrete flow rate. The region of measured flow would need to be a length of straight rigid pipe with smooth transitions, per the flow meter manufacturer's requirements. A type of ultrasonic meter that measures concrete flow rate accurately enough for this purpose is the “DXF” meter series with the model DT-94 clamp-on transducers, now manufactured by Badger Meter, PO Box 245036, Milwaukee, WI, 53224, USA. This flow meter system operates by measuring the Doppler Effect on solids within the moving fluid. In combination with the other disclosures, a working example is given for a set of components that serves the purpose of measuring hydraulic fluid flow rate, or concrete flow rate, in order to meter admixture injection proportionally to the concrete flow rate by an electronic means to produce a zero-slump pumpable concrete mix. There are many other variations of these components that will serve the same function.
Of course the admixture pump can be hydraulically-driven from the same pressure system running the concrete pump, using the flow meter and transmitter 54, or flow meter and transmitter 62, to provide flow control signal 55. This simplified hydraulic schematic shows only the signal 55 controlling a proportional hydraulic valve 67, which could alternatively be a servo valve or the like; where valve 67 controls the hydraulic fluid flow rate to a hydraulically-driven admixture pump system 61′.
Valve 67 could be one such as a SP08-20 by Hydraforce Inc, 500 Barclay Blvd., Lincolnshire, IL 60069. This specification depends on the onboard voltage and the concrete pump size. Valve 67 may require amplification of signal 55 to operate within range of required flow, or a larger valve may be required. The hydraulic motor powering the admixture pump, making up the admixture pump system 61′, can be one such as the NorTrac Bi-Rotational Pump/Motor Model #CBS6-F2.1SS, marketed by Northern Tool Inc, 2800 Southcross Drive West, Burnsville, Minnesota 55306.
This schematic does not show any necessary check valves, pressure compensation system, feedback loop, manual control overrides, etc, that would be determined by the concrete pump manufacturer in the design of the comprehensive hydraulic system. The component sizing for optimized operation and stall prevention would be related to the specific properties of the onboard hydraulic system and the concrete pump rate.
Mixer 4′ differs from mixer 4 in that it has modified mixing vanes 14′, preferably of stainless steel, or hardened or wear-resistant materials per
The increased projection of each vane 14′ is possible, without causing blockage to concrete flow, by shaping each vane 14′ to be narrower than vane 14, and by staggering the location of each vane along the direction of flow. These features allow each vane in turn to create maximum disruption without creating blockage, and so this type of design provides efficient intermixing of admixture. This staggered layout allows larger aggregate to flow though mixer 4′ having the same diameter body 49 as mixer 4, even though each of the vanes 14′ project most of the way to the center of the body 49. This stagger allows the body 49, of 3 inch (75 mm ID) pipe, to pass ¾″ (18 mm) aggregate, providing the stagger distance is sufficient to avoid the combination of any two vanes to create a blockage. This prototype provides about 2″ (50 mm) of stagger between any 2 vanes, and with a total of 8 vanes, each is rotated 45 degrees from the previous one—with that polar axis being the center of the body 49. A more random pattern, or a staggered double helix pattern, not depicted, would create less tendency to block flow between any two vanes, and the entire unit could be of a shorter length than this prototype and have a similar mixing effect.
The width of vane 14′ can vary from about ¾″ (18 mm) to 1.5″ (150 mm) or more, with the portion projected entirely into the concrete flow tapered in width, all or partially. This taper length and angle is unimportant, and no taper simply poses an increase in the possibility of a blockage. As one can see in
Inline mixer 4′ prototype is primarily fabricated from materials, primarily aluminum or steel material, rather than starting from existing hardware or equipment. The admixture plenum 18′ is created from pipe and plate material. Each orifice 21′ is made by creating a notch in a seal plate 52, the notch being about 1.5 mm to 2 mm wide by 1.5 mm to 2 mm deep, but this can vary considerably. They may have to be larger to avoid blockage if the admixture contains large solids; though larger sizes will weep more when not desired, wasting some admixture. Plenum 18′ is sealed by the fit of a cylindrical flange 51 and the fit of a cylindrical insert 50 into the receiving end of mixer 4′, with matching pipe threads or an acme thread with a gasket, etc, made for the several-hundred psi plenum 18′ pressure. The outside diameter of insert 50 closely matches the inside diameter of seal plate 52 to minimize the seepage of admixture through this gap, which is the range of a few thousandths clearance (0.1 mm), but the precise clearance distance is generally not critical. The seepage through this gap is acceptable and is part of the intended flow of admixture injection into the concrete, as it literally spreads the distribution of admixture around more. The purpose of the array of each orifice 21′ is to direct most of the admixture toward each corresponding vane 14′. The Cylindrical insert 50 is of stainless steel or hardened or wear-resistant materials per
HD flange 13′ is welded to body 49, if body is steel pipe. Flange 13′ has attached pipe threads or the like to fit threads or a threaded fitting of body 49, if it is aluminum. A logical arrangement of the geometry of mixer 4′ results in the discharge flange 13′ being a larger size than inlet flange 13, such as 3″ (75 mm) verses 2.5″ (63 mm), and hose tail 6′ for maneuverability is generally preferred to be of a smaller diameter than hose 6. Therefore a reducer is typical at the connection to 13′; this may be from 3″ (75 mm) to 2″ (50 mm), for example.
A central idea of this embodiment is to replace the all of the water constituent of concrete made by the volumetric mixing process with a water-based liquid-mixture that provides the desired zero-slump yet pumpable and workability properties for the resulting concrete; and in combination to take advantage of this short time period between mixing and placing concrete that is made possible by the volumetric mixing process, to allow the addition of set-accelerators in the concrete. Alternatively, the water supply for the volumetric mixing process can be modified inline, by injection and intermixing of an admixture, so modifying the water to become a similar liquid-mixture before it is mixed in with the other concrete constituents.
A delivery system is built to supply the liquid-mixture into the volumetric mixing process at the rate of delivery required to match the continuous batch rate of the volumetric system. The onboard water delivery system is already designed to meter water in this manner, but this system is not designed for the viscosity and suspended solids of the liquid-mixture, and does not provide for the liquid-mixture mixing process. This disclosure shows a separated mixing and delivery system, but of course it can be entirely onboard a volumetric mixing truck, in addition to the water delivery system.
A shorthand description of this process is the following: The liquid-mixture blending process takes place in a mixing tank 63, then is transferred to the fluid metering system 64, where the liquid-mixture is metered into a volumetric concrete mixing truck 66 where it is mixed with cement and aggregates in replacement of plain water, and a resulting zero-slump-pumpable concrete is directed into the concrete or grout pump 2, and then is pumped into place at the concrete wall 5.
A non-specific depiction of a volumetric concrete mixing truck 3 is presented because this invention is not about the existing volumetric mixers or the trucks. Any volumetric concrete mixing system, with or without a truck, can be utilized with this process of creating zero-slump-pumpable concrete on a continuous basis.
On this embodiment of the concrete mixing process, the volumetric concrete mixing truck 66 is unmodified and in normal operation, except that the water delivery to the concrete mix is shut off or redirected back to the water tank. As each cubic meter of this concrete needs roughly 75 gallons (284 L) of the liquid-mixture, depending upon the amount of suspended solids etc, there is a material handling issue with this process. The mixing tank 63 is required for blending the constituents of the liquid-mixture. It should preferably be a vertical cylindrical shape to facilitate mixing, and at least around 80 gallons (303 L) capacity, if a cubic meter's worth of concrete is the preferred amount per mixed batch of liquid-mixture.
A water supply 68 is required, as is each liquid-mixture constituent 69 that is to be used, all of which are described further below. A paddle mixer 70 with a vertical shaft and a one-half horsepower 1750 rpm motor will suffice. This has a low-shear mixing propeller suitable for mixing paint, or the like. Preferably it has multiple 3″ (75 mm) minimum diameter propellers. A disclosure of the liquid-mixture design follows below, but here is information relevant to the mixing process: It is best to add the liquid-mixture constituents 69 that are surfactants or emulsifiers or plasticizers first, to help with, or at least not hurt, the wetting of the other dry constituents. Any alkali swellable emulsifiers (ASEs), super absorbent polymers (SAPs), or cellulosic or gum thickeners would preferably go in after the other constituents, as they bind up available water for wetting dry ingredients, slowing down this mixing process. The mixing time required is usually no more than 5 minutes beyond the time it takes to dispense and blend the various constituents into the water. That is 5 minutes beyond the time when the last liquids are added or the last solids are wet out by visual observation. Extra mixing is not a problem.
Once the mixing of the liquid-mixture is completed it could be batched into concrete directly, and a holding tank 65 could be omitted. However to continue mixing concrete to amounts beyond the mixing tank 63 capacity, a two tank system is required. This system allows liquid-mixture mixing and concrete batching to proceed simultaneously, where completed liquid-mixture is held in the holding tank 65 while it is metered into the concrete with the fluid metering system 64.
With the two tank system, the holding tank 65 should be at least the same size as the mixing tank 63, so its entire contents can be emptied into the holding tank 65. Bigger is better, so that the mixing tank 63 contents can be emptied before the holding tank 65 liquid-mixture is consumed into concrete. Of course a transfer pump 71 and fluid line 72 is required between the tanks. This pumping rate can be low and variable, and the total volume is relatively small, so many different pump types, not specifically meant for abrasives that may be in this liquid-mixture, will work OK. To suit any variation of the liquid-mixture, the transfer pump 71 would ideally be a small peristaltic pump, meant for slurry mixes, such as a Vector model 2002 with a ¼ hp motor minimum. For a mobile liquid-mixture delivery system on board the volumetric concrete mixing truck 66, this pump would preferably be hydraulically driven as is the normal water pump on such a truck.
Metering the liquid-mixture into the concrete mixing process is very important, in that an adjustable yet precise rate of flow must be achieved to control concrete slump with a slim margin of error, and the flow must be able to start and stop simultaneously with the concrete mixing. Also, this rate of flow must be relatively high, because the volumetric concrete mixing truck 66 typically makes concrete at a rate of up to or over a cubic yard a minute (cubic meter per 78 seconds), and so this liquid-mixture must correspondingly meter out at a rate of up to around 60 gallons per minute (227 L/min), to match the normally preferred rate of the volumetric mixing truck 66.
The fluid metering system 64 has these elements: the holding tank 65, a delivery pump 73, an actuated valve 74, a toggle switch 75, a flow meter 76, and a flow control valve 77. All elements of the fluid metering system 64 must be capable of delivering a fluid that is the liquid-mixture disclosed below
Regarding the delivery pump 73: A preferred version of the liquid-mixture is technically a slurry with suspended solids at such a concentration, that the industry associates this slurry with the need for special pumps that are designed for the density and abrasiveness of these types of suspended solids, such as peristaltic pumps. As these types of pumps having acceptable rates of flow, such as 60 gpm (227 L/m), are large, heavy, and have electrical power requirements that are not available at most jobsites. More economically, residential sewage pumps work well for the liquid-mixture, both in terms of flow rate and durability. These are available as 120-volt versions. An example is the Zoeller N282 sewage pump that can pump 63 gpm (238 L/m) at a dynamic head of 15 feet (4.6 M). Another example is the Grindex Solid Pump, part number 81232810005. The sewage pumps have the disadvantage that they do not self prime and so must be located below the holding tank 65, and they need an inlet to be plumbed into them rather than their normal configuration as a sump pump. These pumps are designed for high viscosity but not specifically for abrasive solids; however as the pumping run time is only during the overall concrete mixing process, so they can hold off the negative effects of the abrasive solids for a sufficient number of jobs before the seals start to leak.
For a mobile liquid-mixture delivery system, the delivery pump 11 would preferably be hydraulically driven. A peristaltic pump, such as the Vector brand noted above, or progressive cavity pump such as those made by Netzsch, Seepex, or Moyno is preferred for long-term reliability such as for a stationary installation of the fluid metering system 64; but these types of pumps that have the required rate of flow will have electrical power demands that are difficult to meet at a typical jobsite. Alternatively, they can be hydraulically driven, and this is suitable for such mobile applications.
Regarding the actuated valve 74: A three-way solenoid-type valve is installed to direct the liquid-mixture to the volumetric mixing truck 66 when needed, and to redirect it back to the holding tank 65 for the periods when the concrete mixing process is paused. This type of valve system allows continuous flow of the fluid allowing instantaneous starting and stopping at the high flow rate, and it avoids forcing the delivery pump 73 to work against a dead head. Also while directing flow to the return line it agitates the liquid-mixture preventing settling of the solids, and in fact it can be switched to this direction occasionally just for this reason. A “CO-AX” brand model 5-VSVM-50-DR will work. This has 24-volt controlled, pneumatically driven switching of the valve. A 24-volt power supply is required. This valve allows nearly instantaneous redirecting of the fluid. The wired-remote toggle switch 75 for the 24-volts is operated along with the similar toggle switch connected to a volumetric mixing control panel 84. These two toggle switches are operated simultaneously. Of course these switches are preferably combined into one toggle switch for operational purposes, but the dual switch operation diagramed in this embodiment requires no modification to the volumetric concrete mixing truck 66.
Regarding the flow meter 76: The high flow rate, with a slurry of such potentially high-density, justifies the use of an electromagnetic type of flow meter, as this will not interfere with flow, and does not have any concerns of impellers getting fouled with the suspended solids. An Anderson-Negele IZMAG series, with a 50 mm diameter port will work. The plumbing from the holding tank 65 to this point is all 2″ (50 mm) diameter, with smooth radius bends, to minimize flow resistance. This reduces dynamic head and maximizes the achievable flow rate from the delivery pump 73. The dynamic head loss at the required flow rate for a given pump will of course determine the required line size.
Regarding the flow control valve 77: This is simply a manual valve that can be incrementally adjusted to restrict the flow rate, allowing the rate to match the liquid/binder ratio that is required for the zero-slump-pumpable concrete. The resulting concrete fluid properties are compared to the flow meter 76 reading to establish the desired setting of the valve. This is the same simplistic technology that is presently used with the volumetric concrete mixing systems. A stainless steel ball valve is preferred.
The liquid-mixture must then be dispensed with the sand, aggregate, and cement in an auger mixer 80, shown cut away to reveal the auger. A fluid line 72′ can attach to the same sprinkler head 79 that is normally used for water dispersion, and so reduced to the proper connecting diameter before this point of course, as these may be as small as 1¼″ (32 mm) pipe. This sprinkler head 79 typically has large enough orifices to accommodate all the liquid-mixture ingredients contemplated here. Alternately, a separate sprinkler head for the liquid-mixture can be located and affixed appropriately at the top of the auger mixer 18.
A check valve 78 can be installed at the end of the fluid line 72′ just before the sprinkler 79, so that liquid-mixture does not dribble out when concrete mixing is paused. As the liquid-mixture must be assumed to contain suspended solids, a one-way valve meant for sewage, also known as a “backwater” valve is preferred in this application for continued operation without blockage. If the existing sprinkler 79 is used, the line here would typically reduce down to 1¼″ (32 mm), a Zoeller 30-0181full-flow check valve is an appropriate choice.
As the concrete is dispensed from the auger mixer 80, it is directed into the intake hopper 81 of the concrete or grout pump 2. As the concrete is near to zero-slump at this point, a resulting problem is that it does not go down to the bottom of the intake hopper 81 without some help. This can accomplished with either be a conventional concrete vibrator, which is not shown, and is vibrated per usual practice; or the intake hopper 81 itself can be made to vibrate with a vibrator attachment 82, which can be clamped or fastened onto the side of the intake hopper 81. If a grating (not shown) is to be used at the top of the hopper, the attached vibrator must be located to also vibrate the grating in order to help the concrete to get through that. A high frequency vibrator in the range of 10,000 VPM, such as the Vibco US-450 electric vibrator is suitable for moving concrete. To prevent possible over-consolidation of the concrete, a suitable variable-frequency vibrator is the OLI Vibrator MVE.0021.36.115 external electric vibrator with the intensity controlled by the TruePower Electronic Stepless Speed Controller model 09-0123.
The concrete mix at this point does not need to be at zero-slump, and preferably is not at zero slump, yet. This is because the pumping process will reduce the slump, depending on the initial moisture level and porosity of the aggregates, and on the amount of distance and pressure incurred in pumping; adjustments must be made for these factors, on the order of about an inch or more of slump in most common situations. An initially very stiff mix made from dry porous aggregates will likely lock up very quickly and become totally unpumpable.
At this point the zero-slump-pumpable concrete is pushed by the concrete or grout pump 2 through a concrete pump hose 6, to be placed at the concrete wall 5 which has a number of a reinforcing bar 38 installed per building code or structural requirements. There is no limit to the aggregate size with regard to the performance of the zero-slump-pumpable concrete. The type of concrete pump 2 and size of the concrete pump hose 6 are the limiting constraints. Up to 150′ (45M) lengths have been used successfully in tests with the 2″ (50 mm) line using ⅜″ (9 mm) aggregate.
The alternative method whereby a system is in place to inject admixture into the water supply, so creating a liquid-mixture for making a zero-slump-pumpable concrete mixture could otherwise be identical to the primary embodiment disclosed. The admixture must be metered accurately proportional to the water flow rate, at a proportion that can vary according to the admixture composittion and concentration. This metering can be accomplished with any of the rate control means associated with the volumetric mixing system, or as disclosed per
This shows an overview of the major components to show how they work as a concrete placement guidance system. A surface guide channel beam 111 is located and supported by a pair of a climbing bracket 85, the version shown here being a roller bearing climbing bracket 85B corresponding to beam version 111. Each bracket 85 of the various disclosed versions 85A, 85B and 85C, utilizes a similar frictional connection for vertical positional attachment to each of a vertical guide post 110. The beam 111 is generally transverse to each of the post 110.
Each post 110 is prepositioned at a predetermined distance from the proposed finished concrete surface 25′; those attachments and any bracing are not shown. Each bracket 85 is self-connected about each post 110, thus providing a frictional connection which can support the necessary weight, yet can slip upwards as needed for more concrete guidance, simply by lifting beam 111. Each bracket 85 then holds that new elevation by frictional contact with post 110, unless that friction is released to allow beam 111 to move back down. Concrete is typically placed in successive horizontal passes. The presence of beam 111 provides temporary containment of concrete fluid pressure allowing vibration of the concrete during placement, as needed for consolidation. For this, the concrete mixture must have the proper rheological properties to allow sufficient localized consolidation by vibration of the placed concrete, without unwanted displacement of the previously-placed concrete below it.
Beam must 111 be able to span without too much deformation between each post 110, in its weak axis, for loads from vibrating concrete confined by it. This prototype version is a cold-formed steel joist section having a beam web 112 that is 10″ (25.4 mm) tall, and having a top and bottom beam flange 113 that is 3″ (76 mm) wide, each having a flange lip 114 that is typically about 0.625″ (16 mm) tall. This steel design thickness is typically at least 0.068″(1.73 mm), referred to as “14 gage”, and will typically be of material specification ASTM A1003 Type H Grade 33 or 50, with an electrogalvanized finish per ASTM A653. This beam section will normally have a weak axis deflection of no more than 0.25″ (6.5 mm) with a span of 14 feet (4.3M) between posts 110 while confining concrete being vibrated.
Beam 111 will slide horizontally through each bracket 85B, allowing it to cover more surface area horizontally beyond a given post 110, or to slide though to a third bracket 85B installed at a third post 110, allowing the concrete placement to continue uninterrupted. Bracket 85B allows this lateral movement in that the primary contact with beam 111 is by ball-bearing rollers that are arranged to run along the interior surfaces of the beam section. More specific detail of this assembly is disclosed in
As the relative movement of bracket 85B requires the inside of lower flange 113 to remain mostly free of debris such as spilled concrete, allowing passage of the rollers, a flexible closure 90 is fitted to lower lip 114 by an inner flexible flange 106 and an outer flexible flange 107, both tightly fitting around lip 114. Bracket 85B has a main body 86 that creates a gap between a spine plate 91 and a connecting plate 92, allowing closure 90 to extend further upward along beam web 112. Closure 90 is preferably an extrusion of a soft vinyl compound, such as the material used in manufacture of vinyl base molding. It is preferably imparted with a camber curving toward, and so pressing against, beam web 112, and has the flexibility to clear each spine plate 91 where present.
Each post 110 can be a length of lumber 2×4 or 2×6 or similar laminated material or the like. Metal posts will also work; more discussion on this follows below. Post is not required to be vertical of course; it can also define a sloped planar surface. Each bracket 85 has a quick disassembly means to allow removal and reinstallation at a new post 110. Bracket 85 allows for tilting relative to post 110, allowing beam 111 to be out of horizontal, and so that the lifting of beam 111 need not be simultaneous at both posts. Subsequent drawing figures illustrate these design features. These systems define the surfaces of in-situ concrete independently of the means of placement of the concrete and they work with any means of placement. Conveyance of the concrete to its final placement can be accomplished by chute, wheelbarrow, overhead lift, conveyor belt, pneumatic means, etc, as well as by pump. In a preferred embodiment, the invention allows pumping and placement of a cementitious mix including aggregate intermixed with an admixture onto a surface without employing compressed air or other pneumatic assistance methods and apparatus and does not utilize the introduction of a pressurized gas into the cementitious mix.
The beam 111 can slide laterally relative to each bracket 85 and so be shifted from one pair of the post 110 to another pair, or from any pair of posts to a third one then paired with one of the original two posts. The ease of this movement is made possible by the low friction elements and travel systems disclosed at the interface between the various embodiments of beam and bracket, allowing manual movement to be made during the time of concrete placement or shortly afterward. The short time period required for adequate set of the concrete as provided by the dislosures herein, allows movement of the beam before the concrete has hardened, making this movement possible by manual means. This includes the vertical movement that is performed as the beam is lifted, corresponding to the increasing height of concrete, whereby the state of thixotropy of the concrete allows the manual movement. Low friction devices can be included at the interface between post 110 and bracket 85, where this may be required for conditions of bigger and longer beams, that can benefit from the addition of such low-friction surfaces. In the test projects, these low-friction surfaces were not required for manual vertical movement of beam; the pliability of the set concrete was sufficient to allow the movement.
This embodiment of box beam 109 is of 0.120″ (3 mm) wall thickness extruded aluminum, as a practical minimum, and is preferably type 6061-T6 temper, if available in the size preferred. The extrusion thickness is 2″ (50 mm) minimum for a suitable span between posts at around 8 ft (2.5M) apart, or 3″ (75 mm) thickness for a suitable span of up to 12 ft (5.4M) apart. A beam depth of around 10″ (250 mm) is suitable, but this can vary. A steel box beam would be similar, but with a wall thickness of around 0.060″ (1.5 mm) or even down to 0.040″ (1.0 mm) at minimum, depending on the beam size, span, and steel grade.
The major component of bracket 85A is a U-body 91 that is made by splitting a length of tubular steel such as a 3″×3″ by 0.187″ wall tube. Two of an edge plate guide 152, that are of 0.25″ steel plate, are welded to fit top and bottom of beam 109; and to their outer edges is welded a keeper sheet 153, that is a piece of 16 gage (0.056″) stainless steel, so creating an aperture to fit box beam 109. Keeper sheet 153 is preferably of minimal thickness as it protrudes into the defined concrete surface 25′. Beam 109 must be able to slide through this receptacle with minimal binding as bracket 85A tends to twist etc under lateral force, due to the eccentricity between the center of beam 109 and post 110 as beam 109 is pushed along its longitudinal axis. Thus to prevent binding, receptacle typically needs to be of a longer length aperture than thickness of beam 109, and preferably is of a length over twice the beam thickness. Aperture should be of a finished dimension that is at least 0.020″ (0.50 mm) larger than maximum finished surfaces of box beam 109, all around, depending on surface finish materials. The sliding surfaces of beam are preferably all of a non-stick cladding 115, and the mating surfaces of bracket 85A are preferably of a similar non-stick cladding 115′. Cladding reduces binding friction and prevents hardened cement from adhereing, but it is not required for the device to function. Cladding can be a self-adhesive-backed ultra-high molecular weight polyethylene (UHMWPE) or polytetrafluoroethylene (PTFE) plastic sheet. Such a UHMWPE, part number TC 312-10 having a thickness of 0.010″ (0.25 mm), is made by TapeCase Ltd, 150 Gaylord St, Elk Grove Village, IL 60007. An example of a PTFE adhesive cladding is TC1821 PTFE Film Tape, also made by TapeCase Ltd. This has a 0.008″ film of “Rulan” PTFE that is made for improved abrasion resistance. Thicker non-stick cladding surfaces can be fastened in place with flush-set screws or rivets. Thicker non-stick cladding that is reliably adhesive-bondable without fasteners is suitable for cladding 115′ installed on bracket 85; disclosure for this material is given at
Non-stick surfaces are necessary on box beam 109 to allow concrete and cement residue and particles to easily break loose of these surfaces as box beam 109 slides through aperture in bracket 85A. The non-stick property can be accomplished many other ways, such as with a non-stick epoxy-paint, or graffiti-proofing paint, meant for this purpose. One suitable example is “Wearlon Super F-6M”, made by Plastic Maritime Corp, PO Box 2131, Wilton, NY, 12831. With all working surfaces of steel, a temporary non-stick coating can be reapplied as required, but this is not sufficient with plain aluminum surfaces. Other non-stick surface examples follow at
Bracket 85 must allow sliding fit of post 110, and also be designed to clamp tightly enough to post 110 to support necessary weight. The chosen dimensions of post 110 are critical to the making of the pinching mechanism of bracket 85. Two of a rotating arm 94, that are each pinned to body 151, are welded to a pinching bar 95. Both arm 94 and bar 95 are of 0.25″×0.75″ steel bar, or the equivalent. Where arm 94 is perpendicular to body 151 there is sliding clearance for post 110. When arm 94 rotates upward to where pinching bar 95 makes contact with post 110, any subsequent movement downward of bracket increases that pinching action. Providing that the coefficient of friction between the surface of body 151 or edge of pinching bar 95, and post 110, is greater that the tangent of angle “b” shown in
In this example a 10 degree angle of contact “b” has a tangent of 0.176, and the unlubricated kinetic coefficient of friction between wood and steel is between 0.2 and 0.5. Using a typical width for an unseasoned 2×4 for the design of bracket, which is around 3.563″, and adding 1/16″ more for clearance, the change in size at 10 degrees is 3.625*[1-cos (10)]=0.055″, which is that same 1/16″ original clearance. This is tight tolerances for lumber, but in practice it works very well. For a seasoned 2×4, the post width should be about right at 3.5″; that same bracket design with an opening of 3.625″ would then make contact at 15 degrees, a less-advantageous angle. The tangent of 15 degrees is 0.268, and the lowest end of the kinetic friction coefficient is 0.2, meaning that there is a theoretical chance that this bracket could slide if pushed downward. However this has never happened in practice, and the tendency for wood to physically indent where pinching bar 95 makes contact, makes this loss in functionality unlikely. The contacting surface of body 151 could be given appropriate relief to make unwanted slippage even less likely. However too much relief can make lifting bracket 85 difficult, and in fact practice has shown that a non-stick type of surface here can be preferable, as unwanted sliding has not been a problem. Use of a 2×6 for post 110 makes the geometry easier in that the proportionally longer arm 94 will open a larger space for movement. A 2×6 member for post 110 is not a usually required size for strength, but is generally straighter than a 2×4.
A very nice benefit of bracket 85 design is that the often-repeated upward motion is so easy. Simply push beam 109 (or 111 of
Guide post 110 could be of steel or aluminum. These coefficients of friction are generally higher than it is with wood. However there is really not a tendency for much physical indentation from pinching bar 95, so for these harder materials maintaining a target pinching angle of about 10 degrees from 90 is appropriate. As dimension tolerances are much tighter for metal verses wood, it is easier to maintain this more consistent design angle of contact with a given size of post.
As there may not be access to either end of any given post 110, bracket 85A must be able to disassemble and reconnect about a post. So each hinge pin 96′ is removable, in this case is a ¼″ diameter clevis type pin having a shoulder at the outer end, held in place with a retaining pin 98, which is known as a “spring pin” or a “hitch pin clip” in the US. Retaining pin 98 is located near the head of hinge pin 96′ to stay at the exterior portion of body 151 for better access. A pin hub 97 is welded to body 151 as a means to provide a place to lock hinge pin 96′ with retaining pin 98 at the exterior side of body 151. Hub 97 is preferably of about 0.120″ (3.0 mm) wall thickness steel, or equal, and of a length that allows easy manual insertion of locking pin 98. The hole for this in both hub 97 and hinge pin 96′ is oversized to facilitate the pinning process, as hinge pin 96′ must be in the proper rotation to make the hole. To reduce friction in the motion of arm 94 and avoid interference with the fillet at the inside corner of body 151, a washer 99 is used as a spacer between body 151 and arm 94. Washer 99 should be tack-welded to either body or arm, so it does not get lost on the job, as bracket 85A will be disassembled frequently. Accordingly, retaining pin 98 can have a lanyard for that same purpose.
A spring 101 is utilized to make sure that pinching bar 95 makes contact with post 75 at all times unless bar 95 is pressed downward. It attaches with end hooks through holes drilled very near the corner of body 91 and bar 95. Spring 101 is necessary so that the pinching action of bar 95 is immediate; it is not meant to provide the all the friction to hold beam 74 up, but it helps engagement when load is very low, so that bracket 73 does not ever start to slide. Spring 101 should provide at least around 15 pounds of force when bar 95 is making contact with post 75. Springs used for this purpose are stainless steel with a spring constant of around 1 pound per 0.038″ extension; this can vary considerably. Spring 101 must be durable in that it is the element that keeps arm 94 and pinch bar 95 assembly attached to body 91 when hinge pins 96′ are removed; and the attachment hooks at each end of spring 101 should each be a durable mostly-closed loop, to stay in place. Hot-melt glue placed at the holes where spring 101 attaches is helpful to keep parts from separating when disassembled.
To help prevent snags with spring coils, and more importantly, to prevent unsafe snap-closing of arms 94 into body 151 when bracket 85A is slid off the end of a post 110, spring 101 is placed inside a hose shield 102, shown only in
This model of bracket uses existing gate trolley roller-bearing assemblies, top and bottom, generally of stainless steel, and having also horizontal load resistance. Where the spine plate 91 mates with each of a trolley body 87, those are milled and machined as required to locate each pair of a vertical roller-bearing 88 at the inside face of beam flanges 113, top and bottom. Slotted holes are provided in plate 91 to allow vertical adjustment for best fit within beam 111; those holes preferably tapped in body 87 for tight frictional fastening. Each pair of the vertical roller-bearing must be held firmly in place to maintain stability in vertical of support of beam 111 as it is pushed laterally. Typically 0.25″ (6 mm) stainless steel fasteners are used.
Concrete confinement pressure onto beam 111 is supported by four of a horizontal roller-bearing 89 that rolls on beam web 112. Stability of the horizontal support system is provided by each of a retainer block 103, that is fastened with adjustability into the far edge each trolley body 87, by slots in block 103 with tapped holes in body 87, so that block 103 is aligned to match the surface of each flange lip 114. As bracket 85B is twisted from a lateral force on beam 111, the distance between resulting horizontal contact points between bracket 85B and beam 111 is what provides support stability. The distance along the beam 111 axis, between the loaded horizontal roller-bearing 89 and corresponding the retainer block 103, is beneficial to reducing those torsion-resisting point loads when beam 111 is pushed laterally. That distance must be at least the width of flange 113, and twice that distance is better. Block 103 is preferably of UHWMPE for lubrication and abrasion resistance, and has a beveled edge at the point of contact with lip 114, making the contact point closer to flange 113, so that variations in bend angle of lip 114 will minimize problems with horizontal fit of bracket 85B in beam 111.
The mechanism shown on bracket 85B that clamps onto post 110 is mostly the same as that of 85A, so the disclosure of
Cladding 115 is shown at the face of beam 111 presented to the concrete placement, and at the top flange 113. To minimize sticking to fresh concrete, this cladding can be of silicone-oil-filled UHMWPE such as “Duro-Glide”, either “#319 VT Purple” or “354 Red Hot”, both made by TSE Industries Inc, 370 112th Terrace North, Clearwater, Florida, 33762. A means of securely bonding such UHMWPE to the beam 111 without fasteners can be done if the material is modified by a process developed by LinkTech, Inc, 59648 M-43 Highway, Bangor, Michigan, 49013-9617. This is where a composite-bondable material, such as fiberglass cloth, is effectively “welded” to the UHMWPE surface, allowing it to subsequently be bonded with adhesive, such as a suitable epoxy, to other substrate material, per the recommendations of Link Tech.
Bracket 85C provides relative lateral movement by sliding on a set of rails in side of beam 111′. Bracket 85C geometry is arranged to generally provide clearance from the lower flange 113, so that small amounts of concrete falling inside of beam 111′ will not impede that relative lateral movement. Lower flange 113 can also have a series of a flange hole 137, to help in removing the spilled concrete. Each flange hole 137 would be preferably centered within the weak neutral axis of beam 111′, and kept within this zone enough to have minimal effect on that weak axis flexural resistance, such as ⅙ of the flange 113 width in each direction from the neutral axis. These design factors allow an open channel section to be utilized as beam 111′ without a need for closure 90.
Guidance for beam 111′ relative to bracket 85C is provided by an internal rail 129, top and bottom, and a flange rail 130, top and bottom. These rails are all of UHMWPE or Polyoxymethylene plastic material or the like. They can all be the UHMWPE material modified for epoxy bonding as disclosed at
Bracket 85C provides vertical and confinement support for beam 111′ with four of a sloped bearing block 125, which is preferably of silicone-oil-filled UHMWPE or PTFE or the like, and has an edge with a milled groove to fit exposed corner of inner rail 129. Block 125 is of sufficient thickness to provide strength at projections of that milled edge to sustain design loads without material failure. If the width of the milled grove is around ¼″ (6 mm), then the total thickness of block should be at least ½″ (12 mm) to provide this strength at those edges. Each block 125 is affixed to bracket 85C by means of a sloped flange 124, that is steel plate of about ¼″ (6 mm) thickness that is welded to both if a connecting plate 92′ and stiffened with both of a welded on gusset plate 123, all of similar material. Block is clamped in place with a clamping plate, of ⅛″ (3 mm) steel or similar and four of a hex bolt or the like to provide alignment and clamping force. Block has slots at bolt locations allowing position adjustment for fit to rails of beam 111′.
A flange bearing plate 126 is of the same UHMWPE or PTFE material or the like, and is clamped to a face plate 93′ with a clamping plate 127′ and four flat head machine screws or the like, so that the surface of face plate 93′ remains flat for post 110 to be in contact at any point of face plate 93′. Bearing plate 126′ at the bottom flange lip 114 has two of a beveled edge 128, angled to clear residual spilled concrete from the face of flange guide 130, allowing passage of bearing plate 126′ though such debris. Bearing plate 126′ has horizontal adjustment by use of a compressible shim 154 so the fit to face of flange rail 130 can be adjusted by relative tension of those machine screws. These screws can preferably be replaced by threaded studs welded to face plate. Shim 154 is sized for fit to flange rail 130 as it is fixtured in location, and is of a rubber material having a durometer Shore A hardness of around 70 or so, to allow required minor position adjustment.
An optional mud scraper 133 is attached to angled plate with fasteners also for angled bearing block 125, with a mounting flange 135. Scraper 133 has a curved blade 134 that functions as a snowplow blade in removing fresh concrete debris from that portion of beam web 112 and the top of inner rail 129, as beam 111′ slides by bracket 85C. Scraper 133 would be of injection molded polyethylene or the like, of durometer Shore A hardness of over 90. It is easily replaceable if damaged. Alternatively, bearing block 125 can have a ‘protruded” or beveled portion near corner of rail 129, similar to the beveled edge 128 of bearing plate 126’, to help clear concrete debris from rail 129. Scraper 133 would be at each outer side of both lower angled bearing blocks; it is shown one side for clarity.
In that the zero-slump-pumpable concrete mix can be problematically very sticky in temporarily sticking to most any non-stick surface, beam 111′ has an active non-stick surface built integrally into its face that defines the concrete surface 25. A cellular chamber 117 is adhered to the outer face of beam web 112. The chamber 117 is an extruded plastic cellular sheet product such as the polypropylene copolymer “Corroplast” made by the Coroplast company, 201 Industrial Park Rd, Vanceburg, KY 41179; or the polycarbonate “Polygal” made by Polygal Inc, 1100 Bond St, Charlotte, NC 28208. Each or these products contain a series of linear rectangular cells between two continuous surfaces, which can serve as channels for conveyance of the liquid “form release”. These channels are oriented vertically, transverse to the axis of the beam. The thickness of cellular chamber 117 can range from 2 mm to 10 mm. The thickness need not be more than allows free flow of “form release” at a very low pressure. This may preferably be 3 mm or 4 mm for Corroplast. The thinnest Polygal is 6 mm, which also works.
The outer wall of the cells, at the outer surface of the cellular sheet, is perforated at regular close intervals to allow passage of a liquid that serves as “form release”; this can for example be 1/16″ (1.5 mm) diameter holes at ¼″ (6 mm) maximum on center, with the size and pattern dependant on the effective viscosity of the “form release” and other factors. Adhered over chamber is a permeable non-stick cladding 117. This can be a sheet of UHMWPE that is produced by sintering of the plastic particles, at a particle size and pressed density that allows porosity of the sheet; and the surfaces are skived, or the equivalent, to avoid any manufacturing surface effect that seals over the material pores. Many other porous thermoplastic materials will serv the purpose of cladding 117. The preferred thickness of permeable cladding 117 depends on its porosity, in that liquid of a given viscosity must pass through it at very low pressure. A UHMWPE prototype is made of ⅛″ (3 mm) thick “DW 402P” made by DeWAL of 15 Ray Trainor Dr, Narragansett, RI, 02882. This product has nominal void volume of 30%, and a “torturous” pore structure with a pore size distribution of 5 to 50 microns, is hydrophobic, oleophillic, and maintains a high abrasion resistance despite the porosity. Used with an oil-based or otherwise “phillic” liquid, this material will tend to absorb that liquid and repel the water-based concrete, so for example, that the material soaked with an oil-based “form release” under minimal fluid pressure from behind, will actively shed sticky concrete and cement. The effectiveness of this came as a surprise. This system has beneficial utility for many other of surfaces involved in concrete placement where cement sticking to those surfaces causes problems, delays, or additional labor.
Assembly of the non-stick surface system is preferably by use of permanent “adhesive transfer tape” resistant to whatever liquid may be used as form release. This could be a 468 MP or a VHB 4952, both made by 3M Company, St. Paul, MN, 55144; either installed per the manufacturer. The tape needs to be attached to the outer surface of chamber 117 before the series of perforations are made in it. Chamber 117 top and bottom edges stop short of each flange 113, and cladding 116 wraps onto the outer side of each flange, and is adhered with the same type of tape or with a suitable adhesive compound. Fabricating the bends in this type of plastic is a known art. This layup creates an edge plenum 120 at each corner of the beam, allowing horizontal distribution of the liquid in order to reach all the perforated cells of chamber 117. The ends of each plenum are plugged with urethane caulking or the like, or a suitable orifice can be created to fit a removable plug of the various types that will work for this very low pressure, allowing drainage of the liquid if necessary.
A route of access for the liquid to reach the plenums can be created with a number of a check valve 121′ that is also a common zerk fitting, with its internal spring of a cracking pressure of below 1 psi (7 kPa), threaded into a hole that is tapped through both beam web 112 and the top inner rail 129. To prevent delamination of the cladding 116 from internal pressure, at least one pressure relief valve 122 is installed. This can be something like a model #317400, with a cracking pressure from 0.25 psi to 1 psi (2 to 7 kPa), made by Alemite LLC, 5148 N. Hanley Rd, St. Louis, MO 63134. Relief valve 122 can be installed the same way as valve 121′. Plumbing the liquid to valve 121′ can be done by the equivalent of a common grease gun, except that the pressure capacity of this type of tool is far too high, so a pressure-relief mechanism would need to be involved. For temporary slight localized overpressure, valve 121′ can be accompanied by a number of fasteners that have flush heads helping to hold cladding tight at that area. As the pressure system is very low, a simple length of vinyl tubing that fits over valve 121′ will suffice as a liquid delivery means, as shown in
When the member defining a concrete surface is a channel profile, such as the surface guide channel beam 111 or 111′, a significant advantage is provided in making the means of vertical and planar support, and lateral translation means, all internal to the member. This support and guidance system, being internal for this type of member, can then be away and significantly protected from the surfaces necessarily exposed to contact with hardening concrete, so avoiding that concrete material interfering with the functioning of these dynamic support systems.
Adequate pressure to pass a “form release” liquid though the permeable non-stick cladding 116 can be achieved by elevating the liquid above the beam 111′ with a gravity feed bag 143 or the like. For water, 1.2 feet (0.35 M) of head is 0.5 psi (3.4 kPa), so such a bag held a couple of feet above the beam, with a length of plastic tubing 146 connected to the check valve 121′ of
Alternatively, an “on board” pressure tank 139, which is the same as a common polyethylene “garden sprayer”, with a hand pump 140, a fill port 141, and a manual relief valve 142, but is made of a size to fit between the beam web 112 and the bracket 85C (
Beam 111′ can also have a means of oscillation to help prevent it from sticking to fresh concrete, as opposed to the usual higher frequency vibration used for concrete that may tend to slump freshly placed concrete that is already below the beam, causing unwanted distortion of that concrete wall surface. This oscillation would preferably be in the frequency range of 10s to 100s of VPM, contrasted to concrete vibrators that operate in the 1000s of VPM. The object here being to simply move the beam slightly back and forth along its axis-even a small amount, so breaking adhesion with the concrete while minimizing disturbance of it. There are many suitable electric and pneumatic oscillators available for this, but they generally do not fit between beam web 112 and bracket 85C, so would need to be removable for when the beam is moved. A pneumatic inline sander 147 can be made to fit in this space by cutting down the width of a normal inline sanding pad 148, and then the pad is securely fastened to beam web 112. A variable speed version of the inline sander, item #13747 marketed by the Eastwood Company, 263 Shoemaker Road, Pottstown, PA 19464, will allow the VPM to be optimized for minimizing sticking and unwanted settlement of concrete. The relative amplitude of beam oscillation can be adjusted by adding a number of a lead weight 150 to sander 147, each preferably sized to fit inside of bracket 85C. A pneumatic hose 149 runs out to an air supply. The sander position is shown relatively low in
A drip system for dispensing “form release” over the surface of cladding 116 is created by making a gap 157 between a top cladding 115′ having a continuous notch near the edge, and the cladding 115 or permeable cladding 116, having an upper edge that is held back from connecting with top cladding 115′, so creating a gap 157. Cladding 115 or 116 can also have a notch along the top edge, if it facilitates fit of a length of perforated tubing 158. Tubing 158 can be the same as the tubing 146 attached to bag 143, except that it has a plurality of small perforations, as would a “soaker hose”, but more frequent. Tubing 158 can alternatively be of an extruded section of Polyethylene or the like, shaped to fit a particular slot between the two cladding members. The “form release” leaks out at a rate controlled by its viscosity, pressure, and also by choices made for the size and number of perforations in tubing 158. “Form release” then seeps down the surface of cladding 115 or 116 from gravity. The continued upward movement of beam 111 against concrete also has the effect of drawing the “form release” down the face of the cladding. This cladding is given the two numerical references in that it can be preferable to be the hard smooth UHMWPE or the like, or to be a porous hydrophobic and oleophillic, sintered, skived UHMWPE. The latter material will absorb and become saturated with an oil-based “form release” and so will tend to repel any water-based cement material. This application applies to all variations of beam, 109, 111, 111′, etc. The top cladding 115′ is highly preferred to protect tubing 158 from damage by the concrete hose tail 6′ (
There is a wide range of degree of porosity in thermoplastic materials such as UHMWPE, and an effective amount of porosity can appear deceptively solid and imprevious. For example, the base material for snow boards etc has differing porosity related to a preferrence for hot wax absorption. Rental skis for beginners tend to have a smooth solid UHMWPE base material that does not significantly absorb wax, and performs satisfactorily for most of those skiers without any wax. Racing skis and higher performance snow boards have a sintered porous UHMWPE base that absorbs and holds ski wax very well, so that their performance can be tailored optimally for specific snow conditions. An example of this is the “Durasurf” 2001 or 4001 base material; both made by Crown Plastics CO. Inc, 116 May Drive, Harrison, OH, 45030. It is an almost indiscernable difference between solid and porous ski base materials; they both seem to be a very solid non-prorous plastic base, but the Durasurf type of material will act as a membrane or as a substrate that disperses “form release”. As its porosity is less than the DW 402P UHMWPE disclosed above, the permeability is less, or the thickness would need to be less to have similarly behavior as a membrane. The permeability (wax absorption) of Durasurf is kept as a trade secret. The material is typically “flamed” on one side-which is to seal the porosity to improve bonding to the snow board. This reduces permeabilty; so for this purpose unflamed material is preferable and if the material is post-process skived that will increase permeability benficially.
Perforated tubing 158 is preferably replaceable. Blockages can occur, created from particles in the “form release”, or from back-pressure of concrete confinement pushing cement back into the gap 157. If perforated tubing 158 is easily removed, this allows the clearing of gap 157 of cement particles etc with an appropriate bladed tool or one shaped to match the tubing-fit void; and then tubing 158 can be replaced by either sliding a length in from one end, or pressing a length in through the gap 157, providing it is sized to fit the compressed tubing. Tubing 158 can be normal irrigation drip line, such as the common ¼″ (6 mm) diameter polyethylene tubing, except that perforations meant for drip emitters are simply perforations, and they are at much more frequent intervals, such as 1″ (25 mm) on center. Perforations can preferably have spacings over a spectrum that decreases as distance from liquid source increases, to provide more uniform distribution of “form release” over length of beam at the low pressure system. The range of spacings can be from about ½″ or 2″ (12 mm to 50 mm) at the supply end, to as close as about ½″ to ¼″ (12 mm to 6 mm) at the terminal end, and spacings between that in between both ends. Experimentation is necessary for a given “form release” viscosity and liquid head. Normal drip irrigation barbed fittings are typically suitable for joining or plugging these types of hoses.
The term “form release” has been in quotes because it may or may not be a form release agent; more generally it is a liquid non-stick agent. For some conditions it is preferably a cement retarding agent to give the concrete surface a longer working time, such as those agents used with sculpting decorative concrete surfaces; or as the concrete placed in this way is exposed to sun and air, and so it benefits from the use of a liquid curing agent formulated to minimize evaporation at the exposed surface. There are suitable form release agents meant for traditional forms, and other suitable ones meant for use with polyurethane stamps or rollers for texturing concrete surfaces. Plain water can serve these types of purposes in hot and dry conditions, or just because the surface of this zero-slump low water/cement ratio concrete mix becomes more workable with more water. In this case one simply needs connect a water supply 68 to a garden hose in order to supply the active non-stick system. A pressure regulator 161 may be preferable or required rather than simply turning the water flow rate very low; and in most cases it is necessary with the channel chamber 117 system (
When plain water or a water-based non-stick agent is used, and that agent has saturated the porous cladding 116, the cement at that surface, which is a very concentrated solute, will draw the less concentrated solvent-mostly water in this case-out of the cladding 116, by the process of osmosis. This osmotic pressure tendency will continuously separate the cement from the cladding, providing that a continuous source of water is available. This process works to prevent cement from sticking whenever cladding 116 has the continuous supply of water or water-based agent, whether the water or agent is available to saturate the cladding, with or without the chamber 117 of
Where the cladding 116 is of an oleophilic porous material, and the non-stick agent is oil-based, there is a tendency for the cladding to selectively absorb the oil-based agent and repel the water-based cement. This effect of selectively absorbing a preferred agent and repelling the water-based ionic cement solution will also work with lipid and polyol liquids, such as glycerol, as they are non-polar. So a continuous source of this type of agents is made available for absorbing into the porous cladding, and so then causing a sacrificial non-stick mechanism. Or a continuous source of this type of agent is made avainable via the chamber 117 on the backside of the cladding 116, which then acts as a selective membrane allowing the agent to pass though toward the concrete, again causing a sacrificial non-stick mechanism.
When the water supply 68 is used, a more concentrated version of a cement retarder or a curing compound or a non-stick agent or the like can be included in solution with the supplied water, with use of an inline proportional doser 159, such as a “Minidos” model 112602 or 112620. The doser 159 choice depends upon the preferred water flow rate, dose ratio and pressure capacity of the active non-stick system, etc. These dosers use source water pressure to power the proportional dosing, so typically the pressure regulator 161 would then best be downstream. There are many other varied makes, types and models of dosers to select from; however the venturi types would tend to be adversely affected by backpressure related to the active non-stick system. The preferable size of a concentrate container 160 depends on the dose proportion, etc. A common five-gallon (19 L) pail is typically fine. All elements of this system need protection from solid particles that can get into the concentrate or even the water supply. Necessary inline filters and check valves etc are not shown, but should be in place per usual practice as needed at any stage of the system, and per the recommendations of the manufacturer of the flow control hardware selected.
The use of a relatively low dose of the admixture is preferable in terms of a reduced amount of material handling outside of the traditional concrete batching process. As concrete batching methods are generally very cost efficient in terms of cost per unit of material relative to retail or online types of material distributions, it is generally much more cost efficient to rely as much as possible on concrete delivery systems, whether by batching plant or volumetric mixer. Given these cost factors, a primary benefit of the admixture is to be as effective in thickening as possible at a low dose, and to achieve this, the thickening agent in the admixture is preferably as concentrated as possible. With respect to cement accelerators, a high concentration can be easily included in a liquid form, and this technology is developed by the shotcrete industry in use with both liquid and dissolved-salt accelerators. This list includes dissolved salts of aluminum sulfate, calcium nitrate, calcium chloride, etc.
With respect to a thickener, thoxotrope, rheology modifier, or similar agent that effects aqueous compositions such as concrete, there is a problem in that the admixture cannot be very quickly intermixed within a line of pumped concrete unless it is in liquid form. An aqueous admixture with a high concentration of such a thickening agent, which is in an active state of effect, the effect within the admixture itself will create a problematic viscosity for delivering that admixture. So it is preferable that the thickening effect within the admixture does not take effect until introduction to the concrete. This mechanism can be one such as a thickening effect that is based on environmental conditions. For example, use a low viscosity alkali swellable emulsion (ASE), or a hydrophobic alkali swellable emulsion (HASE), where an extreme thickening effect is activated by introduction to a higher pH environment, such as a pH of 8 or higher. Low doses of such an agent within an aqueous environment like concrete, where the pH is generally above 11, can have a significant thickening effect. An example of such a powerful alkali swellable agent is “Tychem 68710”, an anionic carboxylated styrene butadiene copolymer alkali swellable thickener, made by Mallard Creek Polymers, 2800 Morehead Road, Charlotte, NC, USA, 28262. It provides extremely high thickening of aqueous solutions when the pH exceeds 8.0; the admixture composition using this mechanism must of course have a native pH lower than that. Another mechanism for thickening action upon introduction to portland cement is a thickening agent that activates upon introduction to such an ionic aqueous solution. An example of such a concentrated thixotrope is “Acti-Gel 208”, a highly purified hydrous magnesium aluminum-silicate attapulgite clay, made by Active Minerals International, Inc, 6055 Lakeside Commons Drive, Suite 315, Macon, GA, USA, 31210. This product is available in a slurry form that is particularly activated by the ionic aqueous solution of portland cement, immediately providing thixotropy. These examples are types of rheology control agents utilized in oil-drilling fluid-control and well-cementing; many of these various types of rheology control agents also have useful application to this invention.
A novel thickening regime for an injectable admixture such as this, is to take advantage of water-miscible liquids that will accept high amounts of water-activated thickeners without reacting with them. The miscible liquid acts as a fluid carrier of the thickener, to deliver it into the concrete. This allows very a high concentration of a very powerful thickener, such as a dispersible powder thickener, to be stable and unreactive at a very high concentration, to be in a liquid form and remaining so at a low enough viscosity to be deliverable into the concrete mix by means of the metering technologies disclosed herein. This type of a composition allows a more reliable and durable means of thickening to be delivered to the concrete, in that this regime develops a more robust type of thickening, for any so injectable composition. The thickening developed in this way will have less effect of viscosity loss from over mixing, or hysteresis, than with thickening based on pH or ionic solution strength, it will have sustainability with increased thickening as initial cement hydration proceeds, and it can have a broader range of dose ratio where the resulting concrete will be both zero-slump and pumpable.
Very pronounced thickening of large amounts of concrete can be developed with very low doses of an injected liquid admixture of this type of composition. As very powerful thickeners can be effectively “hidden” or “masked” within a liquid carrier, this allows their injection, intermixing, and dispersement more thoroughly throughout the concrete mix. As the powerful thickeners are also provided with a means of delay in their effect, in that their suspension within the miscible liquid is increasingly penetrated by the concrete mix over time per that liquid miscibility, during intermixing, pumping and placement. Without this masking or powerful thickeners, an immediate and pronounced thickening would prevent a thorough enough intermixing, in that an immediate thickening action prevents further disbursement; and the resulting concrete mix will be lumpy and inconsistent, and the strength and hydration will also be inconsistent, negatively affecting strength. The combination of these mechanisms, masking and delay, allows a much stronger and more consistent thickening effect to be imparted into the concrete. The miscible liquid as a carrier provides both a masking of the thickener, and a delay of the thickening effect. Without the masking, such very powerful thickeners could not be successfully introduced by injection, and without the delay, a preferred amount of thickening would not be possible without causing blockage of the pumping line and other negative effects.
The thickening powder carried by the miscible liquid can be a cellulose ether, such as methylcellulose or hydroxypropyl methylcellulose, or the like. It can be a processed-cellulose rheology modifier manufactured for cement-based adhesives intended for vertical surfaces, such as the EBM, EBS, RHEMO, BCM, or MT series, by Akzo Nobel Functional Chemicals LLC, 281 Fields Lane, Brewster, NY 10509-2676, USA. The powder can be a Vinyl Acetate-Ethylene copolymer (VAE) or Poly Vinyl Alcohol (PVOH) or Poly Vinyl Acetate (PVA) or the like. An example is “DA-1120” VAE redisbursible powder, by Dairen Chemical Corp, 9th Floor, No. 301, Song Kiang Road 104, Taipei, Taiwan. Or it can be another organic compound such as one of the ELOTEX series, also by Akzo Nobel. An example is FX 5300, which is a vinyl acetate, vinyl versatate, acrylate and ethylene based redispersible binder that is used for adding thixotropy to cement-based tile adhesives. The thickener can be a polysaccharide, such as whelen gum, diutan gum, guar gum, alginic acid, xanthan gum, etc. An example is “Kelco-Crete”, a diutan gum made for cement-based products, by CP Kelco, Cumberland Center II, 3100 Cumberland Boulevard, Suite 600, Atlanta, Georgia, 30339, USA. The thickener can be starch based, such as those from arrowroot, cornstarch, katakuri starch, potato starch, sago, cassava, etc. An example of a suitable starch thickener manufactured for cement products, is one of the ELOSET series, variations of carbohydrate starch ether disbursible powders, such as ELOSET 393 or 542, also by Akzo Nobel. Also, many different super absorbent polymer (SAP) powders can be used with very effective thickening effect at a low dose, along with more refined versions of the polyacrylic acid (PAA) thickeners can also be used with great success, such as Carbopol 940 NF polyacrylic acid made by The Lubrizol Corporation, 29400 Lakeland Boulevard, Wickliffe, Ohio, 44092, USA. The SAP thickeners also have the benefit of providing internal hydration that improves the curing of concrete. Variations of SAP used for this purpose include those made of a poly-acrylic acid sodium salt, polyacrylamide copolymer, ethylene maleic anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, or starch grafted copolymer of polyacrylonitrile. The most common variation utilized for internal curing of concrete is the poly-acrylic acid sodium salt, and as this type of polymer will absorb hundreds of times its weight in water, very small doses are required for thickening as a component of this admixture.
Another type of thickener that can be used is a fine-milled clay, such as the dry version of the Acti-Gel 208 mentioned, or a similar processed attapulgite, palygorskite, sepeolite, metakaolin, bentonite, or similar type of clay, such as is used by the oil industry for controlling rheology of drill lubricating fluids, or by the coating and adhesives manufacturers, or by the shotcrete industry. One property of the thickener that may be preferred, is that it will not react to some proportion of water within the miscible liquid of the admixture, where such an amount of water may be necessary to pre-dissolve a mineral-salt-based cement set-accelerator, should that be desired. Two or more types of thickeners can be appropriately be combined in this composition, as a combined effect can have a greater robustness of the thickening action, and in fact using these products in combination is often recommended by the manufacturers. And any of the other thicker regimes disclosed or incorporated by reference can also be viable in combination the miscible liquid thickening regime. Such compatibilities must be investigated; for example the Acti-Gel 208 slurry will tend to activate in the presence of mineral salt cement accelerators, and the resulting admixture may become too thick to inject and intermix as a liquid. The polyacrylic acid thickeners will tend to swell, at least slowly, if any amount of water is present in the admixture.
The liquid carrier must be compatible with the selected powdered thickener, in that it allows smooth and thorough dispersement throughout the carrier, and it must be miscible enough with water to immerse the carried thickener into the aqueous cement solution of the concrete, for thorough thickening effect. Also, the carrier must not seal the thickener in a manner so preventing thickening reaction at the subsequent exposure to the aqueous cement solution. Many of the miscible alcohols can be suitable carriers depending upon the thickener(s) selected, and other factors mentioned. Suitable monohydric alcohols would include methanol, ethanol, propan-2-ol (isopropyl alcohol), butan-1-ol, (butyl alcohol). Suitable polyhydric alcohols would include ethane-1,2-diol (ethylene glycol), propane-1,2-diol (propylene glycol), and propane-1,2,3-triol (glycerol), except that the toxicity of ethylene glycol makes it undesirable. Suitable unsaturated aliphatic alcohols would include prop-2-ene-1-ol (allyl alcohol) and prop-2-yn-1-ol (propargyl alcohol). Suitable carriers include more complex organic compound variations such as dipropylene glycol (DPG), 4-oxa-2,6-heptandiol, 2-(2-hydroxy-propoxy)-propan-1-ol, and 2-(2-hydroxy-1-methyl-ethoxy)-propan-1-ol; and polyethylene glycol (PEG), H—(O—CH2—CH2) n-OH, with the variations of PEG being the water-miscible ones such as the low molecular weight variation, PEG 400; and even some emulsifiers such as the polysorbates, such as polysorbate-20. The compatibility of the liquid carrier with the preferred thickeners is essential, and this needs to be tested. Specifically, the composition stability needs to be verified for the time period needed for use; and the effect in concrete needs to be tested to determine the dose, to establish the relative metering rate, and determination of any negative effects.
As an example, the admixture can be as simple as one thickener in one miscible liquid. This can be most any of the starch-based rheology modifiers by Akzo Nobel listed above; the choice for this example is ELOSET 393. The miscible liquid choice for this example is propylene glycol, even though it does have a retarding effect on the cement hardening. Some other miscible liquids have better rheology effect with less retardation effect, such as the polyethylene glycols or the dipropylene glycols; however propylene glycol is very inexpensive and it serves this miscible-carrier purpose well, and like the others, it serves beneficially as a shrinkage reduction agent for concrete. Measured by weight, an example of a most simple admix in this regime can be one that is 30% ELOSET 393 and 70% propylene glycol. This very simple composition will have pronounced thickening of concrete when injected and intermixed at around 1% to 4% of the concrete by weight, with 2% addition being a good target value. The 2% addition is in the range of around 40 pounds per cubic yard (24 kilos per cubic meter), but this depends significantly on the concrete mix factors and weather conditions. This admixture has the robustness to provide an acceptable range of thickening with a relatively wide range of dose ratios. As this admix has a retarding effect on the cement hardening, the build-up of taller walls, or situations where the placed concrete requires early strength development, a change to this admixture is warranted. However, for walls where early strength is not important or for decorative and sculpted faux-stone walls, a retardation effect is generally preferred to allow time for the continued manipulation, and this simple admixture also provides that benefit. For these and other applications, any negative effect of propylene glycol on strength development can be offset with a polymer resin, such as a styrene butadiene or acrylic resin, as is typically used for strengthening or bonding of concrete and cement products, and is commonly utilized for such decorative walls. These types of resins can be included in this admixture. Like any constituent, the capability with the other constituents should be tested. Also, there can be benefit in replacing some of this type of starch-based thickener with another type of thickener, such as a cellulose-based thickener. For example the 30% total of ELOSET 393 can be reduced by half, to 15% or so, with another 15% or so of RHEMO 500, also by Akzo Nobel. This blend can be expected to have greater robustness with respect to dose ratio, amount of intermixing provided, and consistency of effects over more extended time periods; although the first admix composition is really good enough in these respects. The starch-based thickeners tend to separate from the liquid more than the cellulose-based, but remixing will remedy this. The cellulose-based tend to react with propylene glycol to thicken, but less so with other carriers such as PEG 400, or DPG, or even polysorbate 20.
Where faster hardening of the concrete is preferred, as will often be the case, the simple admixture can also include a set accelerator such as a solution of aluminum sulfate in water. In this case, the aluminum sulfate is first dissolved in water at a ratio of 1 part, or 33%, aluminum sulfate to 2 parts, or 67%, water. The precise ratio is not important; the goal is to achieve a near maximum concentration solution at room temperature. After complete dissolution, this solution is then added to the original admixture composition at proportions up to around 33% of final admixture. A useful amount is 10%. At 10%, the mix would be 63% propylene glycol, 27% ELOSET 393, and 10% aluminum sulfate solution, by weight. With that solution breakdown, the water is around 6.7% and the aluminum sulfate is about 3.3% of the total admixture, by weight. For this composition, the presence of water with many of these thickeners may cause a slow thickening reaction with the admixture. The increasing thickening, if it is an issue, can be eliminated where the aluminum sulfate is replaced by use of an organic or non-aqueous accelerator such as Diethanolamine or Triethanolamine, or the like, as they are utilized by admixture manufacturers to offset retardation caused by high range water reducers. The possible permutations of carrier and thickener combinations disclosed herein is into the many hundreds of possibilities, and not all of them have been tested. It is the case that most of the combinations tested work to make a composition that allows thickening and rheology control of concrete may the means of injection and intermixing. Where the combination of these components does not work, it is typically a case of the thickening agent reacting with the carrier causing the admixture to thicken too much for a fluid delivery means. The other most common compatibility problem is where the thickening agent will react with any amount of water in the mix, and so an aqueous accelerator cannot be used, such as PAAs typically cannot be used with any water in the admixture. The other thickener types, such as those that react to pH and ionic solution strength, will often have premature thickening reactions with various mineral salts, etc.
Charts are presented for simple examples of the thickening admixture. These show only the use of propylene glycol as the liquid carrier. This is not the best performing liquid to add to a portland cement mix in that it retards the hardening of the cement and does not add strength, but it is significantly less expensive than some of the other choices, and it does also serve as a shrinkage reducer. The starch-based thickener is shown here because it tends to be more compatible than a cellulose-based is with propylene glycol, while the organic thickeners tend to be more expensive or may not be compatible with water or a mineral salt in the admixture.
Another effect that can be imparted with the injected admixture is one of a pronounced false set of the concrete. A false set is a condition where there is rapid growth of ettringite crystals shortly after hydration begins, causing a rapid stiffening of the concrete mix. The effects of a false set are eliminated by manipulation of the concrete, such as with pumping or vibration, but they can reestablish upon leaving the concrete static, so inducing a false set can be very beneficial to a zero-slump-pumpable concrete mix composition. Most often the tendency of portland cement to have a false set is where the amount of added gypsum is too high, or the gypsum is more dehydrated by conversion to the hemi-hydrate and anhydrous forms of calcium sulfate during the cement kilning process. In the case of the present means of injection and intermixing of the concrete, only gypsum, the calcium sulfate dihydrate form, is practical for use as a constituent to induce a false set where water is present in the admixture, in that the other forms (plaster) will rapidly set up within the admixture having water. However with this new type of admixture composition where water-reacting agents are masked with an alcohol or the like, and in the case where the admixture composition has no water in it, the dehydrated forms of calcium sulfate can be utilized for greater effect to induce a false set, and at a smaller dose than can be done with the gypsum. The smaller dose of calcium sulfate will have less tendency for concrete brittleness and for any sulfate-related deterioration later on. To induce a degree of a false set, the example admixture above that includes the aluminum sulfate can have around 12% of gypsum included; and the first example that is just carrier and thickener, can have 6% or so calcium sulfate hemihydrate.
These amounts can be increased significantly, but the compatibility in terms of the admix setting up can become more of an issue. The admixture compositions containing some water can actually remain stable, without setting up, with the addition of calcium sulfate hemihydrate at a low dose, providing the mineral saturation of the water is sufficient, and the amount of water is low enough, to prevent hydration of the calcium sulfate hemihydrate. Products marketed as “paster of paris” can be a dry-mix castable composition of calcium sulfate hemihydrate combined with calcium carbonate and crystalline silica. Plaster of paris can substitute for calcium sulfate hemihydrate, but testing for compatibility needs to be performed.
Methods, systems, and devices, are developed for creating a means of in-situ placement of a concrete mix that can have the thixotropy to hold vertical dimension without containment, while maintaining pliability to be pumped into place and manipulated to a desired shape, and can be combined with concrete set accelerators, allowing subsequent layers of this concrete mix to be continuously stacked in place to build tall walls and such without the use of forms. Concrete without these special properties is pumped toward the point of placement where it is modified by injecting and mixing, into that line of pumped concrete, an admixture containing thixotropes, thickeners and/or set accelerators or other modifiers to provide these properties and other improvements. This method allows conventional plant batching with commonly available constituent materials for batching an economical concrete that is delivered to a jobsite and then is pumped most of the way to a point of placement, before inline modification; allowing minimal conveyance and pumping of a zero-slump and set-accelerated concrete mix, avoiding difficulties and risk associated with pumping such a modified concrete mix. Various means of metering the injection of the admixture flow rate to correspond proportionally to the concrete flow rate are also disclosed. Alternatively a means for modifying a volumetric concrete batching and mixing system to achieve the same result is disclosed. A system is disclosed for defining a vertical or sloped concrete surface utilizing a movable beam attached to guide elements with sliding brackets, with the beam contact surface optionally having an active non-stick system.
The flow of concrete in a pump line is not typical fluid flow. Concrete consists mostly of solids, generally in the form of hard aggregates. It is preferably of an aggregate gradation filling out a spectrum of sizes specifically designed to maximize the solids content, while still being pumpable, though perhaps barely. Thus, pumped concrete should be considered more to be an almost solid extrusion of tightly compacted aggregates, that is only able to flow because of a lubricating layer, sometimes called a ‘slip layer’, that develops at the surface of the pipe or hose containing the pressurized concrete (and that must develop to allow pumping). Aggregates can be of any material, and if of lightweight material such as particles of foam or pumice, the concrete volume may still be mostly of such aggregate, the mass may not be mostly aggregate, because of the light weight.
While pumping, the fresh concrete does not remain homogenous, due to the formation of the lubrication layer near the pipe wall. Accordingly, coarse aggregates move slightly away from the periphery, with the shear rate gradient over the pipe radius as a driving force. As a consequence, cement paste and a fraction of finer material move towards the pipe wall, forming the lubrication layer. As peripherally injected admixture tends to reside in the lubrication layer, a primary objective of intermixing with concrete is to direct that admixture away from the periphery, but without precipitating a blockage.
Concrete pump operators are constantly concerned about the possibility of a disrupting line blockage, because it can take such a minimal amount of an obstruction to precipitate a partial blockage, which can immediately lead to total line blockage. Increased pumping pressure tends to simply lock the blocking materials more tightly together, while squeezing out the water, making the blockage worse. Accordingly, any design for a static mixer that works in concrete has to carefully balance constant risk of line blockage with given intermixing/modification requirements. This is why, that until the present invention, there were no static mixers for pumped concrete. It was not even considered feasible, until the present inventor, after many failures, has ultimately proven designs that can do it reliably and surprisingly well.
Shotcrete processes enjoy the benefit of a significant volume of an additional driving fluid, which pumped concrete does not. Flowing shotcrete is primarily air by volume. It is actually a process of high-volume pumping of air, and is not necessarily any pumping of concrete. Shotcrete flow consists of such a majority of air volume within the hose or pipe line, that the “concrete” part of it can actually be entirely dry material at rest, picked up into the passing air flow and transported solely by the air flow. The design of mixing nozzles for shotcrete are based on high velocity air flow, which serves as the driving force for both the cement and the aggregates, and so can use fluid flow principles such as those of Bernoulli or Venturi, to create low pressure areas for injection of other components into the shotcrete. These types of effects do not occur in pumped concrete to any sufficient degree to utilize them for injection or intermixing. Accordingly, shotcrete inline mixing technology will never work for pumped concrete, which is typically many times denser, is moving much more slowly, and behaves like a solids extrusion-because that's what it is.
The process of intermixing a high-solids high-density clay slurry, such as the clay slurries used for stabilizing excavations, benefits from the present mixer designs, particularly in that jobsite controls do not necessarily prevent inclusion of aggregates in such slurries. Though even an aggregate-free cementitious or clay slurry, or an aerated cementitious mix, generally will not pass through a conventional ribbon static mixer, because of the high solids content of the cement, other solids-binder, suspended mineral, or clay. Most of the time, a conventional ribbon static mixer, under pressure, will become immediately blocked by the suspended solids, even in a very wet slurry, largely because of the very high density of cement or mineral particles themselves. While a “high-solids” type of static mixer, meant for high-viscosity food or sewage processing, will pass a very wet and highly-aerated cement slurry, these designs will have a lower shear intermixing action than any version of the present invention, and so will not intermix a cementitious mixture or mineral slurry well enough for purposes such as rheology modification. The designs disclosed herein, are the opposite, in using the dense solids of cementitious mixes or other slurries as an advantage to further the intermixing process, by repeatedly introducing them to high shear forces, and so providing the necessary intermixing action, but without inducing significant blockages or unacceptable pressure drop, in that these designs provide sufficient clear space and stagger between single high-shear mixing elements. So, these static mixers are preferable, if not necessary, for cementitious and other high-solids high-density slurry applications, with or without included aggregates. These designs will be sought after for such inline modification purpose, as the other static mixer options that can pass such a slurry are so much less effective.
Existing active (motorized) inline mixers will work for cement slurry and mortars with small aggregates, however these are excessively expensive. These systems presently utilized for inline modification of 3D printing mortar, have costs that can be 100× higher than those of the present invention, making them inaccessible to the average contractor or tradesman.
This shows the system and process of
Mixer 200 is one option of these new types of inline static mixers allowing passage of concrete material that is primarily solids in the form of aggregates, and without benefit of the flow of additional fluid, such as the airflow of shotcrete, while providing intermixing of the concrete with an admixture or other component. Modification within a pumping line is essential where concrete without that modification is necessary for purposes of batching, mixing, or pumping the concrete, such as where the modification component(s) creates a very rapid set, an extreme thickening, or causes any other behavior that can make placement of concrete too difficult, particularly after more time has passed after batching the concrete. Even for concrete made instantly with a volumetric mixing system, a very reactive component may need to be delayed introduction into the concrete, in order to first allow conveyance to the point of placement.
Unmodified concrete can be delivered to the point of inline modification at the end of a pumping line or at any point along the pumping line, where highly reactive components can then be intermixed. This avoids unwanted and counterproductive reactions in the concrete batching process because this inline intermixing system can defer the introduction of highly reactive components to a point literally past the batching process, because it allows component introduction during the placement process. This inline modification of concrete allows new a means of volume production of Roman Concrete activated with quicklime (or other variations of self-healing concrete enabled by an agent that reacts to future cracking of the concrete). This new process facilitates the inclusion of highly reactive shrinkage compensating agents, and makes possible rapid additive-manufacturing methods with low cost conventional delivered concrete. Low-carbon concrete can be batched with less-reactive binding materials, or only supplementary cementitious materials, such as fly ash, slag, or metakaolin, so that a very non-reactive or entirely non-reactive concrete can be stable for long periods, such as hours or days or indefinitely, even in hot weather, and then be activated inline with an alkali, or quicklime, or any other appropriate activating agent. That is, a dormant mix (that is not hydraulically setting) can be modified in line to become a hydraulically setting mix. For example, a mix that utilizes a binder that is essentially inert and not hydraulically-setting without activation, such as metakaolin, fly ash, or blast furnace slag, can be modified inline to become a hydraulically-setting binder by inclusion of the appropriate activator, such as an alkali silicate, a carbonate, a high-pH activator or a reactive organic compound. Very rapid setting geopolymers and alkali-activated-binder concretes, and other low-carbon concretes compositions not invented yet, can be made more practical and less expensive for use in high volume production for large construction projects by using this inline activation system, because the inline introduced agents do not necessarily need to be made to react to a given specific cement chemistry, instead they can react to the presence of water, for example. This can be used to activate an otherwise dormant concrete mixture, as it is being placed by pump.
Mixer 200 is a replacement of the inline mixer 4, such as previously disclosed or any version now disclosed herein, and is combined with an additional mixer. Inline mixer version 4.1 is shown here, which has a single helix of mixing vanes and admixture injected at a single point directed at those vanes, discussed below. Beyond that is a mesh mixer 202, which is a length of rigid pipe conduit, having effectively roughened interior surfaces, to provide further intermixing action by forcing agitation and rotation of the concrete aggregates as the concrete is pumped. Alternatively, the hose tail can be eliminated by extending either of these mixer designs with sufficient mixing elements to complete the required intermixing action for the concrete modification application at hand.
The amount of required intermixing between concrete and a modifying admixture can vary by the application and admixture type. In the case where concrete does not need the admixture other than for temporary viscosity or rheology modification, an intermixing process that satisfies that modification but is otherwise incomplete, can be sufficient. That is because in some cases, much or even most of the concrete can avoid direct contact with modifying admixture, while enough concrete does react directly, to serve the purpose of allowing additive layering vertically, without forms or shotcrete. Where the admixture is a liquid composition that will migrate into concrete, a given level of intermixing requires less physical mixing action. So, a sufficiently functioning inline mixer can by itself allow building without forms without, need of subsequent intermixing action of an attached mesh mixer or a hose tail. However, a more complete intermixing is more beneficial or necessary where the admixture composition is one that imparts permanently beneficial properties to the concrete, such as shrinkage reduction, waterproofing, chemical resistance, strength increase, self-healing effect, etc. For this, the combination of the inline mixer with high-aspect disrupting elements—of various embodiments having geometry disclosed below, and the mesh mixer with conduit surficial disrupting elements, allows a more thorough intermixing process.
The sequence is shown with the high-aspect high-shear-disruption vane mixer applied before the casing-surface-disruption mesh mixer. In the depicted case, a single point of injection is directed to engage a series of mixing vanes, to intermix it as possible, before a mesh mixer further completes the intermixing process. This sequence can be reversed. That is, the mesh mixer, particularly that with circumferential injection of admixture, can force intermixing about the circumference of the line, before the vanes direct that intermixed material toward the center of the flow, for intermixing with that more extrusion-like core flow.
This shows a combo mixer 200 where, in this example, the inline mixer 4.1′ has a cross section that increases in area as concrete flows, such as according to the taper of a concrete line reducer fitting but installed in reverse direction, for purposes of reducing or eliminating the pressure increase caused by the presence of the mixing vanes 14′, and reducing the likelihood of a line blockage caused by the vanes, as the flow area is continually increased over the mixer. Also, as the conduit diameter changes relative to flow direction diverges the concrete flow streamlines, forcing relative motion between aggregates, providing additional intermixing. The body 49′ for this mixer can be a standard concrete reducer fitting but installed in reverse, to become an “increaser”. It can clamp to the concrete hose 6 and the mesh mixer 202 with typical HD couplers 192; or these can be any other pump line connector system, such as cam lock.
Mixer 4.1 has the admixture line 9 lead to a single point of injection via an injection quill 216, preferably aligned with the vanes, described further below. One reason for a single point of injection, rather than the circumferential injection of previous disclosures, is that a single point can better stop backflow action at moments where the admixture pressure is lower than the concrete pressure. A backflow action does not prevent continued function, but can cause some admixture reaction and temporary blockage, and so reduce certainty about where the admixture is injected at any moment, if any orifices are blocked. There is no uncertainty with a single injection point. However, the single point injection has less initial distribution than circumferential injection, so this must be addressed for an effective mixing vane arrangement. It should be noted that a means of additive injection is not a necessary feature of these mixer designs, in that they can be used for the further mixing of a given slurry composition where high shear action is necessary.
Another reason for a single point of an injection, particularly via a quill, is that this geometry can allow the injection of dry solid particles into liquid concrete under pressure, given a suitable miniature screw-auger delivery system, or the like, for feeding solids though the quill. And a means to prevent concrete water migration into the quill to the extent that would not allow discharge of the solids, as the present inventor, at least, has not found a check valve that works in this application. A solution can be to make the quill long enough, including primarily outside of the mixer, in order to to prevent water migration from reaching the dry solids delivery system, in lieu of any type of a check valve. This prevention can include use of the motion of the solids toward the mixer, and the stoppage of concrete pumping pressure whenever solids-admixture delivery is stopped. The solids within the quill would need to be of a type that can make contact with water, including the high-pH mix-water of concrete, without locking up material passage through the quill. This can be a reactive shrinkage compensator, for example, where the solids passage through the quill is faster than a migrating reaction that would block it. Or, this can be a relatively unreactive clay powder that kills the effect of a water reducer in the concrete, such as a polycarboxylate ether high range water reducer having a water reducing effect very sensitive to the presence particular clays. Injecting a small amount of such a clay powder, combined with the resulting absorption of some mix-water, can radically kill concrete slump. Intermixing of any dry solids into concrete usually requires more mixing action than does a liquid admixture, so of course the designs as shown here can include more vanes, etc. The migration of mix-water up the quill can be a beneficial process, facilitating the intermixing of the solids agent, by prewetting it.
The mesh mixer 202 is shown with a cylinder of wire mesh 204 welded to the inside of a casing 12, which can be a length of conduit such as schedule 40 steel pipe, or the like. Alternatively, it can also be of a standard reducer fitting for concrete, but preferably turned in reverse to be an “increaser” for reasons previously noted. Locating an increaser beyond the previous vane mixer provides more intermixing benefit, as the vane mixer has already transported admixture inward from the lubricating layer, where the aggregate agitation from diverging flow streamlines further intermixes it.
The wire mesh 204 can be described as a series of circumferentially linear obstructions. In one embodiment, it is oriented with longitudinal wires 208 against the casing, and transverse wires 206 exposed more directly to concrete flow (also shown in
A cross-section view shows the mesh 204 where longitudinal wires 208 are used for both attachment and spacing of transverse wires 206, which do the mixing. The casing 12 gross internal area, represented by distance Ag shown, would be π*Ag2/4 for a cylinder of diameter Ag, for example. And the net flow area, is represented by distance An shown. The benefit of mixer 202 is that it allows a significantly large unobstructed unrestricted concentric flow area for passage of aggregates, while also utilizing those aggregates for intermixing purposes, as they engage the periphery. An can be as much as 98% of Ag, and the mixer functions wonderfully-depending upon significant aggregate size, with more disclosure of the novel process given below. The ratio of An/Ag can be as low as one would like, providing that An is of a sufficient area to allow the aggregate flow. It is preferable that An does not step down in sized significantly, or even at all, from the upstream Ag, so as to avoid blockages. In a typical example, if 6 gage (4 mm) wire mesh is used inside a 4″ (100 mm) diameter pipe, then the net diameter would be approximately: 100 mm−(4*4 mm)=84 mm; then the ratio of areas would be proportional to (842/1002)=0.71 If the mixer 202 increases diameter from the mixer 4.1′ or the concrete line 6, then An can approximately continue that same cross sectional area, the ratio An/Ag can be very low, such as 0.5 (such as a 3″ inside diameter mesh cylinder centered in a 4.5″ inside diameter conduit), where spacers outside the wires 208 would be required (not shown), or wires 208 would need to be larger, or they would just not touch the casing (except at their connections, shown below). If the casing is of a rectangular section rather than a cylinder, such as can be the case for specific design of a 3D printing nozzle, for example, then the mesh and the remaining opening would still preferably be approximately concentric to it.
A detail section shows a portion of the casing 12 with a portion of the mesh 204 against it, to show one aggregate rock 217 as it rolls after engaging one of the transverse wires 206. The distance 205 of the transverse wire 206 from the casing can be sufficient to allow the lubricating layer, shown as arrow 207, to be able to flow outside of the transverse wires; and with peripheral injection of admixture, most of it still remains within the lubricating layer. Distance 205 can also be one that allows a wire to engage a given or preferred size of aggregate 217, in this case based upon the size of the longitudinal wires 208, noted previously. So, as the repeating series of an obstruction (206) is supported at a controlled distance from the casing, and the support allows fluid flow between the obstructions and the casing, each such obstruction is more likely to make direct contact with passing aggregates. Direct contact with aggregates temporarily stops them, and then other passing aggregates typically push them along. In order to clear the obstruction, the stopped aggregate rolls. This differentiates the movement of that aggregate from adjacent aggregates that do not make contact. The rolling action of the contacting aggregate creates intermixing action between the admixture and the concrete. The differential action of that aggregate causes more intermixing. The result is a very efficient means to intermix admixture, initially confined within the conduit periphery, with pumped concrete, under a typical pressurized concrete flow regime.
For example, to target primarily ½″ (12 mm) aggregate, the distance 205 can be about ¼″ (6 mm). For wire mesh of 4 mm wire (6 gage), distance 205 would be 6 mm (full-diameter of wire 208 plus half-diameter of wire 206). The wires do not need to be of a round cross section, any shape will do. To consistently allow flow of the solids, the significant interior cross-sectional area consists mostly of a concentrically-central obstruction-free area. The intended meaning of “significant” is defined at
It is important to note that the positioning of the obstacles 206 out to a distance 205 beyond the casing creates a condition where the obstacle is projected into the fluid flow outside of any surface boundary layer at the casing, or other confining surface. So, flowing material-fluid that can include small solids such as cement-without aggregates is also forced or allowed to flow between the obstruction and the casing, and so flows on both sides of the obstruction, which is to say that fluid is forced to flow around it. This condition forces direct impact onto the obstruction with resultingly higher shear forces, even without any aggregates present. This interaction allows high shear intermixing of a slurry, or an aircrete mixture, or the like, consisting of high-density particles, such as cement, without risk of blockages. Accordingly, this static mixer also provides very efficient intermixing of any such slurry needing inline rheology modification, or continued mixing of clay with water, such as for a slurry utilized for stabilizing excavations in areas of high ground water, as noted previously.
In a previous example given, of a 4 mm diameter wire mesh 204 in a 100 mm diameter pipe, the actual obstruction, in terms of the projected area in the direction of flow, presented by each transverse wire 206 is about 11 square cm, which is about 14% of the total pipe area. The friction resulting from this 14% obstruction will be greater than for a high aspect vane 14′ presenting the same amount of obstruction, because of interference with the lubricating layer about the periphery of the pipe. However, the risk of total line blockage is still low because the unobstructed concentric core is most of the effective pipe area, and such an embodiment of the mesh mixer is intended for use at or near the end of a pump line, where the line pressure is lowest. To reduce increased pressure effects upstream within the pump line (excessive pressure drop because of static mixer causing excessive flow resistance), the mixer diameter can be increased, or be of an increasing cross section, relative to the pump line. The resulting increase in weight does not hinder machine-controlled concrete placement.
Alternatively, the intended disruptions can be from any projections extending from the surface of the casing that disrupts the lubricating layer and intersects with passing aggregates. The circumferential mixer 201 is one that has a series of a circumferential step 213, in lieu of the mesh 204. In this case the lubricating layer is forced away from the casing at each step, which will also contact aggregates. This design induces more friction than the mesh, and so will be more likely to create blockage, but can be combined with a reverse taper casing to reduce blockage tendency. Also,C the steps do not have to be of a full circumference, but of partial circumference, and in a staggered pattern, so as to reduce blockage tendency while providing high shear forces, while still roughly concentric to the casing. These partial arcs can be cut from sections of concentric pipe and welded or screw-fastened to the casing. This design can be a more permanent intermixing surface, or it can be of other replaceable textures, such as expanded metal lath. The projections can be any form of transverse ridges, or that of a sufficiently roughened surface, machined into the casing, such that the lubricating layer is disrupted to the extent that aggregates roll, tumble, and agitate, et cetera, so having relatively differential interparticle motions, rather than slide along the surface uniformly.
These induced actions on aggregates significantly increase concrete pumping friction, however that increase is mitigated by using a relatively short length of the roughened surface, and particularly by the location at the termination of the pumping line, where fluid pressure against the surface is lowest, and so resulting frictional effects of agitated aggregates are the least. This type of a roughened surface can replace the hose tail 6′, to the extent where a short length, such as short as one foot (30 cm), of the mesh mixer can complete intermixing action otherwise needing a length in the range of 15 feet (4.5M) of hose tail.
The advantage of the wire mesh of some type for a roughened surface is that it is inexpensive and easily replaced, and can be secured into place with a clamp (rather than welding), such as shown in
The termination of mixer 202 at the discharge 194 can be the same circular cross section as is typical for the cylinder body. It can have a connection flange, so that a 3D print nozzle can attach, allowing extrusion of smooth surface concrete filaments, of any geometrical cross section, if preferred.
These show various views of a multi-helical design inline mixer 4.2, in this case with a staggered double helix arrangement of the mixing vanes 14′. These drawings show the mixer compressed in length for fit on the drawing sheet, where the distance between sequentially-encountered vanes would preferably be relatively much greater than shown. This preferred geometry is disclosed more specifically in
The double helix mixer 4.2 is shown from the exterior with mixing vanes, both near side and far side, drawn with dashed (hidden) lines. The admixture line 9 is plumbed to multiple ports through a controlled distribution system 218, discussed below. In this case, the two lines distributed are 9A and 9B, each going through a check valve 78 before into an injection quill, 216A and 216B respectively. The purpose of multiple helix vane arrangement is to shorten the necessary length of the mixer for a given amount of mixing action, as it staggers locations of sequential mixing vanes, allowing their distance in the line of flow to be shorter without increased likelihood of causing line blockage.
The reason for a controlled distribution system 218 rather than a simple manifold is that the shared injection system can be unstable. If one path, 9A or 9B should develop more line resistance than the other, the tendency is for all admixture to take the path of least resistance, so ceasing all flow to the more resistive path. This instability can be solved by providing controlled resistance to each line, so that one line cannot accept all of the necessary flow rate; or it can be solved by controlling relative flow into each line. Device 218 is of the latter, with the extreme case simply being two independent pumps that each pump equal amounts into lines A and B. Or device 218 can be a flow distributor consisting of a switching valve that alternates between A and B, such as a motorized rotating valve. Or device 218 can be a pair of solenoid valves that are activated alternately by an intermittent timer to feed A then B. With one valve NO (normally open) and the other NC (normally closed), a single power activation will alternate flow from previously unpowered valves. A power activation at a short interval, such as a few seconds on then a few seconds off, will force alternating the flow between lines A and B.
The section view of mixer 4.2 shows a projected average path 220A of admixture injected from quill 216A. The specific paths of portions and particles of admixture, not shown, will follow specific variations as induced by turbulence from each vane and the effect of each vane on the aggregates. The spiral path is induced by the twist (rotation) of the aggregate of the vanes, and redirection at each vane making the average of the admixture move away from the circumference. Having multiple spirals allows a shorter mixer design in that each set of vanes does not need to complete a full rotation, in order for the complete mixer circumference to provide intermixing engagement. For example, 3 staggered arrays can each be attributed to engage 120 degrees of the circumference. This is particularly beneficial where the average path of admixture does not spiral much, and so capturing the entire average path would require a mixer that would be 3 times longer. It is important to note that the other extreme of simply injecting admixture into a smooth cylinder or length of hose will result in it primarily providing circumferential lubrication with minimal intermixing, resulting in the need for a much greater length of pump line for sufficient intermixing. This very long mixing length creates a longer path of travel for modified concrete, leading to increased likelihood of blockages and a significant delay between and admixture dose change and opportunity to measurable effect.
The cross-sectional view shows a version for a double helix array of vanes that has extensive interaction with concrete throughout the entire cross section, with each array engaging 180 degrees of the mixer circumference, and showing projected average paths, 220A and 220B, corresponding to each injection quill. This example also shows an array of vanes optionally optimized in size for purposes of distributing admixture though the concrete, while causing less total flow resistance; where the vane closest to the point of injection projects less from the casing, while still extending enough to capture the flow of any admixture. As the flow of admixture spreads further from the periphery after engagement with each vane, each successive vane extends further from the periphery, or is sized larger, as needed to engage further-disbursed admixture. This arrangement reduces total combined area of line blockage and so total resistance to pumping action. In any case, these vanes are all adjustable in penetration depth, so that if any of them were to cause a blockage, that blocking area can be reduced.
A section view shows why any this new type of inline mixer works for mostly-solids concrete, in terms of providing sufficient intermixing while not creating blockages. That is, any single mixing vane 14′, even if the largest of a vane series, still has a small projected area, Av, of blockage relative to the total cross-sectional area of the concrete flow, Ac, contained within the casing 12 (πr2 for a cylinder), with examples of these relative areas given below. In this case, the vane is shown with no rotation or slope, so as to make the projected area of blockage visually clear, and this is a viable geometry of the obstruction created by a given vane. The point is to show that this a relatively small obstruction, and combined with sufficient stagger to any preceding or following obstruction, provides minimal total blockage to concrete overall flow. Yet these very disruptive high aspect and high shear obstructions, encountered one at a time at a sufficient distance in between, can avoid tendency to create a line blockage, while also providing sufficient intermixing action, as the design in entirely avoids any significant single restriction to the concrete flow. The proposed designs are primarily of vanes that can have both rotation and slope, so that the true engagement resistance at any given cross section of projected flow is actually less than depicted, though it must be acknowledged that the presence of aggregates, particularly coarse aggregates, increase the effect of a projected blockage by the diameter of the aggregates flowing around the obstruction at that moment. Alternatively, the vanes can be entirely perpendicular to the flow, though in this extremely disruptive case the area of any given vane should not exceed 5% of the total gross flow area, Ag.
For example, if Av is 5% of Ag, leaving a net area An of 95%. Considering all relevant factors, such as aggregate size, vane slope, rotation, taper, and spacing, that vane can create an effective flow blockage of up to about 10%, for example. Then, effectively 90% of the original unobstructed flow path is still available at all points of flow, and so, for example, literally 90% of the initial conduit cross section can remain unobstructed at all points of flow within the mixer. Depending upon the aggregate content and the fluidity of the concrete mix, the mixer can pass aggregates with as much as 25% of the original or initial cross sectional area (which can be considered the line size leading to the mixer) blocked, however this cannot be considered reliable in avoiding blockages for more typical, economical, and preferable concrete mixes, where generally as much aggregate volume as possible is preferred, and the water content is kept low to increase strength and reduce shrinkage. The greater proportion of obstruction, or conversely the unobstructed portion, that can be as low as 75%, would be suitable for specialty and highly fluid mixes-which can still be mostly aggregate by volume, but are not necessarily economical concrete that is optimized to carry as much aggregate as possible.
Yet with a number such vanes, such as ten, the entire array having a combined Av of, say, 50% of Ag, or an effective Av of 100% of Ag, given the effect of aggregate size, for example. In a polar array per
Where the casing cross sectional area is increasing, this can be true even where a given vane obstructs more than 20% or 30% of Ag, for example. In the example of
For a relatively fluid aggregate flow, assuming a relatively high slump, such as at least 6″ (15 cm), a maximum viable projected area for any given vane, having sufficient slope and rotation as noted, would be ¼ of the significant gross cross-sectional area, Ag, of the flow conduit. “Significant” is used to indicate the Ag leading up to the location of the particular vane, in the case of an cross-sectional area that is continually increasing to avoid blockage tendency (such as mixer 4.1′ of
The disadvantage to an increasing number of vanes is also increasing the required length of the mixer, assuming holding a given preferable distance between subsequently-engaged vanes, and also an increasing cost of mixer manufacture. The length advantage of the multiple helix array, such as the double helix of mixer 4.2, is that subsequently engaged vanes are not adjacent, rather are opposite, or at least at a greater transverse distance, so that the distance in the direction of flow between them can be shorter without increasing the likelihood of blockage, thus allowing a shorter mixer using overlapping vane arrays.
These drawings show layouts of some example vane arrays, where the casing 12 interior-cylindrical surface is laid flat, for ease of visualization and measurement definition of the vane array geometry. This practice has worked very well in communicating proposed geometry for mixer fabrication purposes of mixer prototypes, so why not also for patent applications? The flow direction is shown from right to left, parallel to the horizontal edges drawn, though the aggregate effect of the vane array can spiral the flow somewhat, such as shown as a non-horizontal line, 220A on
Two adjacent vanes 14′ of the inline mixer type 4.1 are shown on a portion of the casing 12 surface rolled out flat. Each vane is given a slope, S from normal to the surface; a rotation, R (previously noted as “twist”) from perpendicular to flow; a projected width, W; an average projected width, Wa; a projected height, H; a projected height to the centroid of the vane area, Hc, and an offset, O, between the two, all measured perpendicular to the flow axis of the cylinder; a taper, T, measured as a proportion or angle, which can be created by angling one or both edges; a spacing distance, D, between the two vanes, and a clear distance, C, both measured along the flow. A pitch, P, is the offset, O, divided by the spacing distance, D, expressed as the tangent or the angle. In the case of a specific injection point design, the pitch can be designed to match the estimated average path of admixture flow, such as line 220A of
Each vane 14′ preferably has a taper, T, or some type of width reduction toward the tip, though this can also be a tapered end of a rectangular vane. This is not essential; it is a means to reduce total resistance to aggregates while allowing the vane to project further toward the center of flow. A truncated or rounded tip is also functional, and as the abrasion from passing aggregates intense, any fine or relatively sharp tip will round it over soon anyway. The portion of the vane outside of the casing should have no taper, so that parallel edges can maintain sufficient closure to the opening in casing 12 (visible in
The taper is related to the aspect ratio, H/W, of the vane projected height, H, divided by the projected width, W; and the relative aspect ratio, Hc/Wa, is of the vane projected height to the centroid, Hc, divided by the average width, Wa. The relative aspect ratio is more relevant to compare with other non-triangular shapes. For example, where the vanes are truncated, rounded, or rectangular, the relative aspect ratio is a more useful measure to compare effect on aggregate flow. This mixer design benefits from directing flow primarily around the obstructions (vanes), rather than primarily over them, and for this purpose, and for vanes of most shapes, the relative aspect ratio is a good measure of determining whether that type of flow will occur. For any particular concrete mix, if necessary to prevent blockage, any vane, or all vanes, can be adjusted to be reduced in projection (height). As vanes wear down, then can be projected further, and also re-tapered, if necessary.
The testing has shown that, in general, a relative aspect ratio of ½ or greater, with the vane tip projecting most of the way to the center of the concrete flow, will generate the necessary high shear mixing action in aggregates, while allowing a mostly-aggregate concrete to pass by. This corresponds to a triangular vane that is higher than it is wide (H>W) as a minimum case meeting these criteria. Where the array of vanes are each staggered in height, some leading vanes may be of lower aspect out of convenience in keeping a constant width for all vanes, regardless of height, for interchangeability purposes. These vanes will still serve the purpose of the new mixer, as they will direct admixture from the periphery and toward subsequent higher-aspect vanes, and as they are relatively smaller, they will be less likely to cause blockages, even if spaced closer together.
Each vane 14′ is of a high enough aspect that it can be described to have two sides for which material to flow by, and material does flow around both sides of each vane. In other words, it has a high enough aspect ratio that it can be described that something flows “around” it. It will then also be the case that material flows by both sides of it.
Assuming that any vane is of a projected area, Av (
For high aggregate flow, a preferred minimum vane spacing in the direction of flow, Dmin, is about 8 times the projected area of the first vane of any pair. So, if a particular vane is 0.7 square inches (6.45 square cm) (10% of the area of a 3″ (75 mm) diameter conduit), then the preferred minimum spacing to the next vane would be about 5.6″ (142 mm). The minimum viable spacing for an aggregate-fluid flow, assuming a relatively high slump material (such as at least 6″ (15 cm) of slump), is twice the projected area of the first vane of any pair. So, for that same 0.7 square inch vane, the minimum spacing to the next vane would be about 1.4″ (36 mm). This minimum spacing also works for a non-aggregate, high-solids, high-density slurry flow.
The assumptions in all cases is that the offset, O, of each subsequent vane is sufficient to increase the intermixing action beyond the previous vane, and that each vane slope, S, rotation, R, and taper, T are all within certain preferable values, described below. Enough of such vanes in an array that affects most of the concrete, will generally sufficiently intermix a thickening admixture with the concrete, at least. For an extreme case, of vanes not having any slope, rotation nor taper, then the spacing distance requirement would preferably approximately double, that is, at least 8 times the large-aggregate diameter between vanes, in the direction of flow, and of twice that distance to further reduce likelihood of a blockage. While this will effect a high-shear mixing, a safer distance between vanes would be 6 inches (15 cm) for ¾″ (18 mm) aggregate. For an array of 10 vanes, this mixer would need to be at least 60 inches (1.5 m) long, which is excessive; whereas an array of vanes with preferable slope, rotation, and taper can be as short as half that length, which is acceptable, for the same aggregate size. So, there is a preferable balance between a vane design that is abrupt enough to induce higher shear, and one that generates sufficiently-high-enough shear while also having sufficient slope, rotation, and taper, to preferentially reduce chances of blockage.
There is the case of a type of vane that reaches across to the other side of the casing, such as a rod run through the pipe, where the relative aspect ratio of the projected area can be very high. Prototype testing has shown that this geometry generally has a less favorable mixing-to-blockage likelihood, as the concrete flow tends to develop as an extrusion of aggregates. Because of this effect, bridging across the conduit presents a much greater tendency to block the flow-particularly as the concrete becomes stiffer from previous intermixing with a thickening admixture, while providing relatively less action mixing where the admixture tends to initially congregate-along the periphery. So, while such a vane geometry is viable, it is not as robust in terms of avoiding blockages, as is simply projecting from one side with a high-enough aspect obstruction, so it is not discussed further.
The effect of vane rotation is to reduce resistance by offering one easier path for the concrete, and to direct most of the flow around one side. The assumption is that the vane is of a flat surface, such as of an adjustable plate—for purposes of keeping costs low, and that simply rotating that flat surface is the practical option, however the vane can be machined of a custom shape, or of a diamond shape (square bar rotated 45 degrees), or the like, to achieve this same purpose. In any case the relevant issue is that the leading surface is angled rather than perpendicular to flow. In terms of reducing resistance, it matters less what direction (gradient) that angle is, rather than how much net combined angle (rotation and slope) there is. For example, if the rotation is 40 degrees from perpendicular, and the slope is 20 degrees from vertical, the combined net angle from perpendicular is the same as if the rotation is 20 degrees and the slope is 40 degrees. Specifically, the combined net angle from perpendicular =asin(sinR)1/2+ (sinS)1/2)2.
There is a difference in rotation and slope in where the concrete is directed off of the vane, more toward the side or more toward the center of flow. A greater rotation still allows an abrupt impact by one edge of the vane, whereas a greater slope does not. Testing has shown that it is difficult to redirect admixture significantly toward the center of flow with any single vane without increasing the risk of blockage, while a series of smaller vanes can achieve this effect. So, for a series of vanes, each small enough to not cause a blockage, located along an average path of admixture; the vanes having a combination of slope to move admixture toward the center of flow, and rotation to direct admixture toward the next vane in succession, the total effect can be to direct more admixture away from the periphery, and to intermix it more with an extrusion type of flow, without causing a line blockage.
The rotation can vary from zero (perpendicular to flow), as an example is given, to 80 degrees from perpendicular, as in the case of vane 14 of mixer 4 (
Slope from perpendicular can range from zero (perpendicular to flow) to 60 degrees from perpendicular. A preferred range of slope is from 5 to 50 degrees from perpendicular, because slope beyond 50 degrees generally does not provide a high enough shear force on the concrete or solids-slurry. A preferred range of combined net angle (formula above) from perpendicular can be between 15 to 55 degrees, this angle being the result of the formula given above. The preferred target combined net angle for prototype vanes (to date) has been in the range of 25 to 45 degrees.
These factors of array, layout and relative-aspect are more important to the mixing functionality than is the specific shape of any vane. A rectangular vane of the same projected area, having an aspect ratio of 1.5 and projecting to the center of flow will function for this high shear mixing; the lack of taper will create a greater chance of blockage and will load up the vane in bending about 50% more—while also having a smaller section at the root. The vane would need to be about twice as strong in flexure at the root, to avoid failure (bending or breaking, depending on the material). For vanes at the beginning of a variable-sized vane series, a lower aspect ratio can function well as a lower amount of projection is also the case. In these cases, a relative aspect ratio as low as 1 can be beneficial. There is really no maximum aspect ratio in terms of mixing functionality (given enough vanes), other than the structural and practical limits of a very slender object holding up in concrete flow—a vane rotated 90 degrees will work structurally and provide high shear. A greater number of smaller, very slender, such as a relative aspect ratio of 10, mixing vanes is also a very effective array.
The pitch, P, between any two adjacent vanes of a series is the offset divided by the spacing distance, O/D, expressed as a ratio or the a tan (angle). The pitch will determine whether a following vane is affected by a previous vane. It is significant in this case where there is intention to direct a single injection point of admixture into a series of vanes (such as in
This is a schematic layout for a doble helix mixer 4.2, where each of two series of vanes corresponds to a point of injection of admixture. A series is aligned to an average flow line 220A, for purposes of intermixing admixture from quill 216A, and the same for quill 216B. the average path 220 is shown as if a single flow for drawing clarity only, where the admixture flow really is continually disintegrated into increasing numbers of tributaries, each of increasingly diluting flow. The flow also splits 215 about any high-enough aspect vane. The object of repeatedly directing admixture and surrounding concrete to a series of vanes is to repeatedly disrupt initial streams of pure admixture injected from a single point, so that the admixture is intermixed with enough of the concrete to impart a thickening effect for vertical buildup purposes. This array design is not for the most thorough intermixing of the concrete; it is for the best for dispersion of a concentration of admixture into a sufficient amount of concrete. For more thorough intermixing, subsequent vanes, or the mesh mixer, can follow these arrays. Counterintuitively, for some applications there is a better result with less intermixing, such as is the case with the use of a thickening admixture having a thickening structure that breaks down from the hysteresis of overmixing. This effect can be difficult to recognize and/or diagnose. The present invention, in its varied embodiments, can be adjusted to determine the most suitable intermixing action, and also tailored to intermix the ideal amount, and ideal sequence, for a given material application.
As multiple arrays, or sequential series, of vanes are overlapping by a stagger or partial-step of each original series, the distance (spacing) between subsequently-engaged vanes is, in this case, half the distance (spacing=D/2) between vanes of each series. This engagement sequence can shorten the required length of the mixer in that subsequent vane engagements alternate between the two series, and so alternate across to the far side of the mixer. This lateral distance between vanes allows a closer distance in the direction of flow, while allowing for the same degree of passage of aggregates.
This diagram has the same notation as
This schematic layout of a mixer type 4′, with peripheral injection of admixture, shows average flow lines, 220.1 and 220.2, coming from two of the array of orifices. The vane geometry can be that shown in
This schematic is of a double cascade array, where a leading perpendicular-rotation vane 14C is aligned with single injection point, so dividing the average admixture flow into two streams, 220R and 220L. Each of the pair of streams then cascades similar to the series shown for mixer 4.2 shown in
This is one example of a mixer where the direction of rotation (twist) of vanes alternates, so that no net rotation of flow is induced. This is also the case for an array of vanes having no rotation.
The combination inline mixer and screeding device 180 (“mixer-screeder”) that in this case combines an inline mixer 4.1 with a mesh mixer 202′ fastened to a screeder plate 182, which can be connected to each other with a coupler 192. Mesh mixer 202′ varies from 202 in having the screeder plate 182 rigidly attached, permanently or removably. The inline mixer and mesh mixer can be any version described in previous disclosures. The screeder-mixer combines the intermixing of admixture and concrete with a screeder plate that can define a vertical surface of concrete.
In this case, the discharge 194′ is rectangular in shape, as an integral extrusion nozzle. This allows the volume of discharged concrete to more closely conform with that of the additive layers being placed, with or without the plate 182. The cylindrical mesh mixer 202′ transitions to the rectangular cross section having smooth interior surfaces, so that smooth rectangular filaments can be extruded.
Mixer-screeder can be guided by machine control guidance 196. A swivel connector 190 allows rotation of the screeder plate without resistance from the concrete hose 6. In this case an asymmetrical plate 182 it is rotated for movement toward the viewer's right, so as to have more surface area for supporting a concrete surface as it moves horizontally. There is no limitation to the size or extent of plate 182, other than what may be too large to manipulate with given equipment.
The mixer-screeder 180, or the like, can reverse the sequence of mixing component types. That is, a screen mixer, such as mixer 202 of
This a version of a mixer-screeder 180′ that is shown utilized in combination with an excavator arm 184 or similar. The simplest version of this device provides no automated control of the screeding surface 182, so in this most primitive case the concrete surface being defined is entirely up to manual control by the equipment operator. This low-cost guidance system is suitable where a concrete wall-surface does not need to be precise, or where the surface is expected be re-screeded manually, or if it is to be a faux stone wall, etc, that can have surface irregularities. Device 180′ also serves well for the construction of sloped concrete embankments, in combination with a tilting bucket attachment, discussed below.
The device 180′ has a length of a rigid pipe conduit, that can be the mesh mixer 202, clamped into place between an excavator bucket 186, and a thumb device 188, which is a very common controllable attachment to excavator arms. The hydraulic controlling mechanisms for those elements are not shown, for clarity. These known mechanisms can vary according to the equipment manufacturer. Any similar or other known means of clamping or attaching the device 180′ to an actuating arm may be suitable. The mixer 202 is heavy-duty enough to not collapse while being pinched, so is of material such as 3″ schedule-40 steel pipe. It can be of an inside diameter of at least that of the inline mixer preceding it.
The inline mixer 4.3 shown here is with a number of adjustable mixing vanes 14′, disclosed previously, which in this case are combined with an elbow fitting, which can be of conventional concrete pumping hardware having typical connections at each end. The admixture injection design and vane array can be of any type. This elbow fitting can also be a reducer fitting, and it can be placed in reverse as an “increaser”, so that for example a 2.5″ pump line 6 can be increased to a 3″ or 4″ pipe to connect to the mesh mixer. As noted, this diameter increase is to reduce tendency of any line blockages related to the effects of the inline mixing modification to the concrete, and to provide additional intermixing, and because the device 180′ can be supported and guided by heavy equipment, so the increased weight resulting from a larger diameter pipe is not a problem.
As any significant turn in a line of pumped concrete causes relative motion between aggregates, as the concrete flow streamlines change direction. This effect alone creates intermixing action which can be exploited more effectively by locating vanes 14′ before the turn as practical. This sequence allows directing of admixture away from the periphery so that the aggregate agitation from the bend can provide further intermixing of admixture within the core of flow. The mixer 4.3 shown has an extended straight length (shown as vertical) before the bend to allow the vanes to significantly precede the bend. The same effect can be exploited by locating an elbow, or even any type of an “increaser”-which also changes relative direction of flow streams, beyond a straight inline mixer. Combining the mixing vanes with the elbow fitting allows a more compact assembly, and so is more practical where an elbow is preferred anyway, which is often the case for purposes of hose handling with automated placement systems
The connection of hose 6 to mixer 4.3, and from mixer 4.3 to mixer 202, can be typical concrete line connections, or cam lock type connections, but the placement device 180′ benefits from both of these connections being made by a swivel coupler 190. This allows two degrees of freedom for the motions of the screeder plate 182 that are not restricted by the hose 6. The multiple orientation of swivels in the pump line is preferred or essential for automated placement methods.
Between arm 184 and bucket 186, there can be an articulation attachment, not shown. This can be an attachment that allows multi-axis tilting of the bucket (or other attached device) relative to the excavator arm, known as a “tilt coupler”; or one that tilts and rotates the bucket, known as a “tiltrotator” attachment, or a “Steel Wrist”, and the like. Versions of the tilt coupler are made by Amulet Manufacturing Company, 6442 W. Boekel Rd. Rathdrum, ID 83858 and by Parker-Helac 225 Battersby Avenue Enumclaw, WA 98022, and many others. Tiltrotator attachments are manufactured by: Engcon, Industricentragatan 4, 833 93 Strömsund, Sweden, and Rototilt Inc, 22 Morton Avenue East, Brantford, ON N3R 7J7, Canada, and many others. These attachments allow articulation of the screeding plate 182 to align with a proposed concrete surface.
The plate 182 preferably has the active non-stick surface system disclosed in previous applications by the present inventor. It can have proportions such that there is a greater length in the direction it is being moved from—in this case moving right to left (from the viewer's perspective)-in that the trailing portion is temporarily supporting the just-placed concrete and so benefits from a greater surface area. The leading portion of the plate is shorter to allow visual inspection of the concrete placement, and to allow closer proximity to obstructions and perpendicular walls, etc.
A primary mesh mixer 203 has primary mixing action from a repeating series of transverse surface protrusions, per mesh mixer 202. Mixer 203 can be the only intermixing process, or it can be followed by a vane mixer 4′, or the like. The admixture injection can be peripheral as is mixer 4 of
Another double ring 222′ can be employed to secure a number of a duckbill valve 210′ of lower profile, so not needing a shield for protection from the flowing concrete. In this case, each orifice 21″ of ring 20.1′ can have a “sloped out” portion in the downflow direction, to enable the valve to open more easily with concrete debris lodged in the orifice area. The outer ring 20.2′ can have specific recesses for each valve centered at each hole 212 for locating and securing each valve. In either embodiment, the outer ring can be of elastic material, such as rubber or silicone, to allow system assembly, or if of a rigid material such as metal, then a break can be necessary to allow insertion of the valves.
The purpose of having a mini valve at each orifice is to prevent concrete liquid from reaching the plenum 18 at moments where the concrete line pressure is higher than the admixture line pressure. With a water-reactive admixture, this contact with concrete mix water will induce a reaction, gelling the admixture, which eventually can require a clean out. While the check valve 78 prevents significant amounts of this backflow, with multiple orifices, such as this periphery array, it is still possible that some will admit concrete mix water without a check valve. The mini valves do not need to stand up to high pressures if the main check valve 78 is installed, just the differential pressures that can exist and vary from one orifice to another, when the concrete line pressure is relatively higher. The mini valves do not need to be the duckbill style, they can also be of a conventional design check valve using a steel ball at the orifice that fits into a seat in the injection ring, and spring also fitted into the ring 222 or 20 (of
The mesh mixer 203 can have the same welded wire mesh 204 previously disclosed, where the transverse wires 206 do the mixing, though in this example where the longitudinal wires 208 connect to a pressed flange 209, where the wire ends can bend to become forged or pressed into a like metal flange that fits into the circumferential space between the casing 12 and the gasket 224, so that when the casing is screwed tight to the gasket, the mesh 204 is secured into place and can stay fixed as concrete pumping action is activated. This design allows easy installation, removal for cleaning, and replacement, without a need to involve replacement of other parts or of any welding, etc. If necessary, the flange 209 can be split at one location, so that a replacement mesh 204 can install from the discharge end, as would need to be the case for a reverse-tapered mesh mixer (such as 203′ of
Mixer 203 can be of a length sufficient to intermix an admixture for the need and application at hand. Or, it can combine with any other version of vane mixer disclosed, where the subsequent mixing purpose can be to direct admixture-intermixed concrete more toward the center portion of the flow, and to intermix that with remaining unmixed concrete. In either sequence of mixers, the presence of aggregates is utilized to further the intermixing process.
This shows a combination inline mixer 200′ where a mesh mixer 203′ precedes a vane mixer 4.4. Mesh mixer 203′, can be any of any mesh or deformed surface type, can have the reverse taper shown, and is connected to the hose 6 with a swivel coupler 190. Mixer 200′ is an example of a design that has both types of mixing elements, that can be combined in any manner; their distinct function is illustrated in
Alternatively, the mesh 204 (shown on
This shows a portion of a casing 12 interior surface with cartesian coordinates given from an origin inside a mixer, with the x-axis in the direction of flow. The rotation about the x-axis, 226, is motion typical of static mixers, and occurs in some of the present vane mixers when the same direction of rotation is given to an array. What is unique about embodiments of the present invention is having mixing elements, such as the transverse wire 206, that induce rotation 228 about the y-axis, the axis of rotation being substantially perpendicular to the material flow, and/or substantially parallel to the tangent of the arc of the casing. What is also unique about embodiments of the present invention is including mixing elements, such as the vane 14′, that induce rotation 230 about the z-axis, the axis of rotation being substantially perpendicular to the material flow, and/or substantially normal to the casing. The actual axis for rotation 228 and 230 is not necessarily perpendicular to the line of flow, but substantially away from parallel to the axis of rotation 226 to be a separate and distinct mixing action from the spiral that is common to static mixers. These rotations are induced by forcing material to go around these obstructions that are oriented in different directions. For the wire 206, this is shown for an aggregate in
The present mixer design can induce rotation about the multiple axes, that are substantially parallel or perpendicular to each or not. This combination of multiple axes or rotation, and multiple-directional axes of rotation, provide distinctly different mixing actions, more thoroughly completing intermixing action, and they can be combined in a static mixer, so optimizing inline static intermixing.
These new types of static mixers, particularly of varied function types used in combination, create an enormous improvement in the inline intermixing of concrete or cement slurry with an admixture, by static mixer, which was not previously possible, without combining a significant amount of air flow. These benefits apply to any type of cementitious mixture having a high-density-solids binder, such as portland cement, alternative hydraulic binders, supplementary cementitious materials, or minerals in suspension.
In the foregoing specification, the invention has been described with reference to specific embodiments; however, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification is to be regarded in an illustrative, rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments; however, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all of the claims.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “at least one of,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited only to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
The present application is a continuation in part of U.S. patent application Ser. No. 16/469,623, titled “APPARATUSES AND SYSTEMS FOR AND METHODS OF GENERATING AND PLACING ZERO-SLUMP-PUMPABLE CONCRETE,” to Michael George BUTLER, filed Jun. 13, 2019, which is a United States national phase application of International Patent Cooperation Treaty Application S/N PCT/IB18/00301, titled “APPARATUSES AND SYSTEMS FOR AND METHODS OF GENERATING AND PLACING ZERO-SLUMP-PUMPABLE CONCRETE”, filed Jan. 16, 2018, which claims benefit of U.S. Patent Application Ser. No. 62/446,443, titled “Method and System using a Volumetric Concrete Mixer to Make Zero-Slump-Pumpable Concrete,” to Michael George BUTLER, filed Jan. 15, 2017 and U.S. Patent Application Ser. No. 62/446,444, titled “Methods and Devices to Make Zero-Slump-Pumpable Concrete,” to Michael George BUTLER, filed Jan. 15, 2017. The contents of all of these applications and patents are incorporated herein in their entirety by this reference.
| Number | Date | Country | |
|---|---|---|---|
| 62446443 | Jan 2017 | US | |
| 62446444 | Jan 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16469623 | Jun 2019 | US |
| Child | 18372690 | US |
