One example of correlating energy to mix well cement slurry under laboratory conditions to field conditions can be implemented as a method to determine energy to mix cement slurry. Electrical power supplied to an electric mixer in mixing a specified well cement slurry is measured. An energy to mix the specified well cement slurry is determined from the measuring. The determined energy to mix the specified well cement slurry and specifications of field equipment for use in mixing the specified well cement slurry at a well site are compared. The field equipment is a different configuration than the electric mixer. Based on the comparing, it is determined whether the well cement slurry needs redesigning according to capabilities of the field equipment.

A system for delivering and applying a flowable mixture to an article (311-313) is disclosed. The system includes a mixture delivery system (200) and a skinning system (300). The mixture delivery system (200) includes a mixer (220) configured to mix a dry material and a fluid to produce the flowable mixture, and a pump (235) configured to pump the flowable mixture to a delivery line. The skinning system (300) receives the flowable mixture from the mixture delivery system (200) through the delivery line. The skinning system (300) includes a skinning pipe (310) configured to apply the flowable mixture to the article (311-313) and a manifold (305) that supports the skinning pipe (310). The skinning system (300) also includes an article feeding mechanism (315) configured to push the article (311-313) into the skinning pipe (310). The skinning system (300) includes a transfer system (320) configured to hold the article (311-313) and move the article (311-313) out of the skinning pipe (310).

A method and system for initiating a majority percentage of chemical admixture dosage into a delivered concrete load preferably just before arrival of the concrete delivery truck at the delivery pour site, such that a maximized slump (or slump flow, or other slump characteristic) increase occurs just before discharge/pour. The invention employs a concrete slump management system having a processor that is programed to consider time of pour (discharge) and stored data that includes dosage response (change of slump characteristic) of the concrete mix due to past additions in the same type of concrete mix, and thus maximizes pre-pour increase in slump characteristic while minimizing or avoiding the risk of overshooting the slump target as well as limiting the time required for adjusting concrete to attain the target slump value at the jobsite.

A computer-implemented method and a computer-based product and monitoring system for contactless assessment of rheological properties of a fluid cement-based product, the method performing a first analysis which obtains the rotation speed of the mixing blades (31) of a truck-mounted concrete mixer drum (30) and detects the variation of the speed constituting a first parameter, performing a second analysis which obtains at least a sequence of images of the fluid product contained within the mixer drum (30), identifies particles, shapes, groups of particles, contours, and/or slope of the fluid product within the collection of sequential images, detects variations of speed and displacement direction of the particles and shapes, constituting a second parameter, performing a third analysis that detects a correlation between each first and second parameters from which the system calculates at least one parameter of rheological properties of the fluid product.

Volume of a concrete mix load in a rotatable mixer drum is determined using an in-and-out sensor probe system wherein the probe submerges into and exits from the concrete during mixer drum rotation and provides data to a processor used in the system for calculating volume of the concrete mix load based on the data. To take into consideration any concavity, convexity, and/or cascading surface flow effects that can hinder accurate determination of the concrete load volume, the processor is configured to compare original batch volume and rheology of the concrete load monitored during drum rotation. The calibration of load volume involves a comparison between real-time data and historic data stored in processor-accessible memory, and further take into account the speed and tilt of the mixer drum (such as caused by roadway conditions), the concrete mix design, and other factors.

A method and system for concrete monitoring calibration using truck-mounted mixer drum jump speed data selectively assimilated from previous deliveries. In preferred embodiments, the invention surprisingly employs data obtained using different concrete mix designs, as well as jump speed data obtained from high speed mixing after the trucks arrive at the construction delivery site and before pouring the concrete into place at the site. The method involves measuring energy (E) in terms of pressure or force associated with mixing the concrete (“E1”) at a first drum speed (“V1”) and measuring energy (E2) after a speed jump of +/- 2.5 RPM or more to a second drum speed (V2). Slump is calculated using low speed energy/speed/slump curve data, or pre-stored equation wherein slump (S) is derived as a function of slope of the line defined by E1,V1 and E2,V2 and intercept of the plotted relationship (at E axis where V is zero). The E/V/S relationship in the provided concrete is compared to at least two pre-stored data curves across drum speed ranges of 0.5 RPM - 6 RPM and 6 RPM - 20 RPM, to ascertain whether the provided concrete matches any of the stored curve data (i.e., previous concrete E/V/S profiles); and either activating the monitoring system for all drum speed ranges where a match is confirmed or allowing the monitoring system to calculate slump only at low drum speeds (below 6 RPM) and alerting a system user or operator that the system is only active for low speed monitoring

Some aspects of what is described here relate to analyzing a well cement slurry. In some aspects, a well cement slurry is mixed in a mixer under a plurality of conditions. The plurality of conditions correspond to a plurality of distinct Reynolds number values for the well cement slurry in the mixer. Power number values associated with mixing the well cement slurry in the mixer under the plurality of conditions are identified. Each power number value is based on an amount of energy used to mix the well cement slurry under a respective one of the plurality of conditions. Values for parameters of a functional relationship between power number and Reynolds number are identified based on the power number values and the Reynolds number values for the plurality of conditions.

A concrete composition having an optimized formulation and suitable for 3-D printing is provided. The composition may include a hydraulic cement composition, aggregate, cement and/or aggregate by-product dust, one or more rheology modifiers, a plasticizer, fibers, and a sufficient amount of water to effect setting of the composition. Optionally the concrete composition may include a setting agent. A method for 3D printing multiple layers of the concrete composition is also provided.

Exemplary methods and systems of the invention minimize errors in the manufacture or management of aggregate-containing construction materials such as concrete. Aggregates used for making concrete are stored or weighed in dry bulk bin type hoppers, and conveyed from these hoppers into mixer drums which batching or mix the concrete. The hoppers or conveyor belts may contain sensor probes for measuring moisture levels in the aggregate. These sensor probes require calibration from time to time, but time and expense are required for proper calibration, leading to habitually erroneous moisture level data used in the industry on a daily basis. The present inventors believe that the smallest inaccuracies in aggregate moisture level readings can have profound effects on the properties of the resultant concrete product. To confront this long suffered problem, the present inventors surprisingly discovered that the inaccuracy of these aggregate moisture sensors, as used for evaluating the aggregate as a dry bulk material, can be detected and even addressed through the use of slump monitoring systems during delivery to evaluate the concrete slurry mix prepared from the aggregates.

A system for a concrete mixer having a drum receiving fresh concrete therein. The system generally has: a sensor measuring a set of measurand values indicative of a measurand associated with at least one of the fresh concrete, the drum and components of the concrete mixer; and a controller communicatively coupled to the sensor, the controller performing the steps of: accessing the set of measurand values generated by the sensor; using a trained data processing engine stored on the non-transitory memory, at least one of determining a property value indicative of a property of the fresh concrete, determining a parameter value indicative of a parameter of the drum, and determining that the set of measurand values are indicative of some operating conditions of the concrete mixer; and outputting a signal based on said determining.